II Kits 25490, 25491 Automatic Self-Leveling System 3 Y fuse For mini (ATM) fuse doubles (011608) ECR 8403 ORDER OF INSTALLATON height 1. Install electronic magnet sensor and bracket. r and 2. Install compresso exhaust solenoid. harness 3. Route wiring through and air lines make all vehicle and s. connection wiring to 4. Connect battery. 4 1 2 To air springs E Ignition fuse box and relay or AC Connect to ignition source W or X K Z AA from Apply heat seal heat gun to butt splice. exhaust Compressor and air line can The compressor on either side be installed solenoid. of the exhaust Front view Q H T G 1-1½ R S Alternate magnet mounting bracket installation Side view L T A O P N M Leaf springs bracket in each The EHS can be mounted so that part of it hangs below the frame. Vehicle frame F Chamfered edge J 68 No more than and between EHS exhaust solenoid. To exhaust solenoid bags to scale. Air not Drawing not only and are are for reference SmartAir II. included with or CAUTION as close Mount the EHS the leaf of to the center It spring as possible. in front can be mounted axle. the of or behind REMOVE ALL FUSES WHEN TING FAILURE JUMP-STAR ON THE VEHICLE. EHS. THE OR WELDING COULD DAMAGE TO DO SO fig. C.1 5 Axle or of the magnet line Schrader valve/air kit bag included with 24 No more than solenoid between exhaust. and compressor sensor Electronic height D avoided. wiring air lines and air lines or Avoid routing edges. If passingframe, use near sharp holes in the and wiring through Support wiring rubber grommets. with zip ties or other 12 air lines every means. air lines. to Avoid kinking r in a location compresso the tires. Mount the splashing off avoid water solenoid B U Ground under compressor Afix ground frame. contacts the bracket so it that is the magnet The edge of cap for the socket of chamfered face the inside screw should EHS. toward the the vehicle, loose until the. Leave the magnet for adjustment system is ready Note locations NOTE: To keep within voltage drop industry standards, wires. do not extend wires Extending the could decrease life. compressor C Q Quick Installation Guide include: away from and air lines exhaust. Install Keep wiring such as the cannot be heat sources if heat sources heat shields Fuse box For blade (ATC) V Hardware COMPONENT n based on as may need modificatio should be used This layout ons. This guide the application Important considerati a general reference. + - AD 72118 Compressor...1 assembly 16060 ft. Exhaust solenoid...20 21984 Harness...1 26893 1/4 Air line... 20946 sensor bracket Smart Air II 11997...1...1 Pack Magnet bracket..12 10966 G Magnet mounting..2 10967 tie H 8 Black zip tee...1 10466 x 1/4 Union I 1/4 x 1/4 screw...1 Self-tapping 21838 J #14-14 x 3/4 cap screw...1 socket Flat 17173 K #10-24 x 1.25 U-bolt...1 18600 x 4.5 L 3/8 x 3.5...2 10583 M Clamp bar 2 lock nut 01426 N 3/8-16 Nylon...3 18435 O 3/8 Flat washer screw...2 18444 Self-tapping P 1/4-14 x 1.1 cap screw 17263 Flat socket Q #10-24 x 1...3 17925 R #10 Flat washer nut...1 18590 lock S 10-24 Nylon...1 18591 T 1 P-clamp...1 11269 adapter... U 14-16GA...1 ATM fuse tap.250 term 24561 V Insulated female.187 term 14-16GA...1 24594 W Insulated female...1 24524 adapter X ATC fuse tap...1 24542 ATM Y Fuse holder 14-16GA.1 24501 ble butt splice Z Heat-shrinka...1 Ring terminal 24661 AA 3/8 10-12GA..1 24748 AB Fuse ATM 3A terminal Ring 24503 AC 3/8 14-16GA 24681 AD A B C D E F * Dual system all quantities Wiring to the battery AB...1 LIST*...1 HARDWAREElectronic height sensor (EHS)..1 SUGGESTED LAYOUT SmartAIR II SmartAIR II 4 n Diagram C. Installatio Magnet option Pages 4-5 INSTALLATION GUIDE For maximum effectiveness and safety, please read these instructions completely before proceeding with installation. Failure to read these instructions can result in an incorrect installation.
TABLE OF CONTENTS A. Introduction... 1 Important System Information.... 1 Notation Explanation.... 1 B. Installing the SmartAir II System... 2 Choose a Mounting Location. 2 Choose How to Mount the Magnet Bracket.... 2 Mounting the Compressor and Exhast Solenoid... 3 C. Quick Installation Guide... 4 Hardware List... 4 Order of Installation.... 4 Suggested Component Layout.... 4 D. Installing the Air Lines... 6 Tips for Cutting Air Lines.... 6 Installing Air Lines.... 6 Checking for Leaks.... 6 Fixing Leaks... 6 E. Calibrating the System... 7 F. Troubleshooting Guide... 7 Limited Warranty and Return Policy... 9 Replacement Part Information 9 Contact Information... 9
SmartAIR II A. Introduction SmartAir II is an automated air management system. It is designed to keep the vehicle at the pre-programmed ride height without user input. The electronic height sensor (EHS) is mounted to the vehicle frame and the magnet/ bracket is mounted to the axle or leaf spring. When load is added to the vehicle, the magnet rises above the EHS centerline (as the suspension is compressed). If the magnet maintains this position for a minimum of 15-20 seconds, the EHS will turn on the compressor, adding air to the air bags. Air is added until the magnet is re-centered, restoring the vehicle to its pre-programmed ride height. When the load is removed from the vehicle, the magnet falls below the EHS and, after 15-20 seconds, will energize the exhaust solenoid. This allows the air to escape from the air bags until the magnet is re-centered, restoring the vehicle to its pre-programmed ride height. NOTATION EXPLANATION Hazard notations appear in various locations in this publication. Information which is highlighted by one of these notations must be observed to help minimize risk of personal injury or possible improper installation, which may render the vehicle unsafe. Notes are used to help emphasize areas of procedural importance and provide helpful suggestions. The following definitions explain the use of these notations as they appear throughout this guide. DANGER WARNING CAUTION NOTE INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH. INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH. INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE TO THE MACHINE OR MINOR PERSONAL INJURY. Indicates a procedure, practice or hint which is important to highlight. 1
B. Installing the SmartAir II System SmartAIR II See the Installation Diagram on pages 4-5 for detailed information about installing the SmartAir II system. CHOOSE A MOUNTING LOCATION The electronic height sensor (EHS) and magnet mounting bracket should be mounted as close to the center of the leaf spring as possible, and can be forward or rearward of the axle. The sensor should be attached to the frame rail and can hang down off of the frame rail if necessary to take full advantage of the range of the sensor (Fig. B.1). NOTE CAUTION KEEP ALL COMPONENTS CLEAR OF ANYTHING THAT MAY COME IN CONTACT WITH THEM WHILE THE SUSPENSION TRAVELS IN JOUNCE AND COMPRESSION. When choosing the mounting method, keep in mind that the center of the magnet must align with the height sensor when the vehicle is at ride height. The magnet and the height sensor must be between 1-1 1/2 apart. The EHS is shown with the bracket mounted partially below the frame. The magnet bracket is shown mounted under the clamp bar. fig. B.1 CHOOSE HOW TO MOUNT THE MAGNET BRACKET The magnet bracket can be mounted so it is between the clamp bar and the leaf springs or under one of the bolts holding the clamp bar to the leaf spring. CAUTION THIS MAGNET IS VERY STRONG. IT IS POSSIBLE FOR THE MAGNET TO PINCH FINGERS AND SKIN BETWEEN ANOTHER MAGNET OR METAL OBJECT. CARE SHOULD BE TAKEN WHEN HANDLING THE MAGNET. 2
SmartAIR II MOUNTING THE COMPRESSOR AND EXHAUST SOLENOID The compressor must be mounted no more than 24 inches from the exhaust solenoid. Mount the exhaust solenoid no more than 68 inches from the EHS (Figs. B.2 & B.3). The ground wire should be fastened below the compressor bracket so that it is in contact with the frame. Some paint may need to be ground off the frame to make good contact. fig. B.2 Compressor The compressor air line can be installed on either side of the exhaust solenoid. fig. B.3 Exhaust solenoid CAUTION LOCATE COMPRESSOR IN DRY, PROTECTED AREA ON VEHICLE. DIRECT SPLASH OR EXCESSIVE MOISTURE CAN DAMAGE THE COMPRESSOR AND CAUSE SYSTEM FAILURE. 1. Use the compressor as a template for mounting. 2. The compressor can be mounted in any orientation: sideways, upside down or top up. 3. Install the compressor using hardware supplied with the compressor. 4. Follow middle insert on pages 4-5 for wiring and location recommendations. NOTE Figures B.1, B.2 and B.3 show a completed SmartAir II installation on a Chevrolet Silverado. 3
C. Quick Installation Guide HARDWARE LIST* A 72118 Electronic height sensor (EHS)...1 B 16060 Compressor...1 C 21984 Exhaust solenoid assembly...1 D 26893 Harness...1 E 20946 1/4 Air line...20 ft. F 11997 Smart Air II sensor bracket...1 Hardware Pack G 10966 Magnet...1 H 10967 Magnet mounting bracket...1 I 10466 8 Black zip tie...12 J 21838 1/4 x 1/4 x 1/4 Union tee...2 K 17173 #14-14 x 3/4 Self-tapping screw...1 L 18600 #10-24 x 1.25 Flat socket cap screw...1 M 10583 3/8 x 3.5 x 4.5 U-bolt...1 N 01426 Clamp bar...1 O 18435 3/8-16 Nylon lock nut...2 P 18444 3/8 Flat washer.2 Q 17263 1/4-14 x 1 Self-tapping screw...3 R 17925 #10-24 x 1 Flat socket cap screw...2 S 18590 #10 Flat washer..1 T 18591 10-24 Nylon lock nut...3 U 11269 1 P-clamp...1 V 24561 ATM fuse tap adapter...1 W 24594 Insulated female.250 term 14-16GA...1 X 24524 Insulated female.187 term 14-16GA...1 Y 24542 ATC fuse tap adapter...1 Z 24501 Fuse holder ATM1 AA 24661 Heat-shrinkable butt splice 14-16GA...1 AB 24748 3/8 10-12GA Ring terminal..1 AC 24503 Fuse ATM 3A...1 AD 24681 3/8 14-16GA Ring terminal...1 2 4 3 Y V For blade (ATC) fuse or For mini (ATM) fuse To air springs E Q AD AA C AC Z SmartAIR II W or X K AB Wiring to the battery Ignition fuse box and relay Compressor and exhaust solenoid B U Connect to ignition source Apply heat from heat gun to seal butt splice. Ground Afix ground under compressor bracket so it contacts the frame. * Dual system doubles all quantities ORDER OF INSTALLATON 1. Install electronic height sensor and magnet bracket. 2. Install compressor and exhaust solenoid. 3. Route wiring harness and air lines through vehicle and make all connections. 4. Connect wiring to battery. 1 The edge of the magnet that is chamfered for the socket cap screw should face the inside of the vehicle, toward the EHS. Leave the magnet loose until the system is ready for adjustment. Alternate magnet mounting bracket installation Front view Note locations of the magnet bracket in each option or O N D P M Q T S H Leaf springs Electronic height sensor L G 1-1½ R Side view T A Axle F The EHS can be mounted so that part of it hangs below the frame. Vehicle frame Chamfered edge Magnet 4
SmartAIR II Fuse box - + NOTE: To keep voltage drop within industry standards, do not extend wires. Extending the wires could decrease compressor life. SUGGESTED COMPONENT LAYOUT This layout may need modification based on the application. This guide should be used as a general reference. Important considerations include: Keep wiring and air lines away from heat sources such as the exhaust. Install heat shields if heat sources cannot be avoided. Avoid routing air lines and wiring near sharp edges. If passing air lines or wiring through holes in the frame, use rubber grommets. Support wiring and air lines every 12 with zip ties or other means. Avoid kinking air lines. Mount the compressor in a location to avoid water splashing off the tires. Schrader valve/air line included with bag kit The compressor air line can be installed on either side of the exhaust solenoid. No more than 24 between exhaust solenoid and compressor. J No more than 68 between EHS and exhaust solenoid. or Mount the EHS as close to the center of the leaf spring as possible. It can be mounted in front of or behind the axle. Drawing not to scale. Air bags are for reference only and are not included with SmartAir II. To exhaust solenoid REMOVE ALL CAUTION FUSES WHEN JUMP-STARTING OR WELDING ON THE VEHICLE. FAILURE TO DO SO COULD DAMAGE THE EHS. fig. C.1 5
SmartAIR II D. Installing the Air Lines TIPS FOR CUTTING AIR LINES When cutting air lines, use a sharp knife or a hose cutter and make clean, square cuts (Fig. D.1). Do not use scissors or wire cutters because these tools will deform the air line, causing it to leak around fittings. Do not cut the lines at an angle. The minimum bend radius for 1/4" air line is 1". Do not bend the air line less than the minimum bend radius or side load the fitting connections. Air lines are to be installed straight into fittings. Inspect the air line for scratches that run lengthwise prior to installation. Contact Air Lift customer service at (800) 248-0892 if the air line is damaged. To watch a video demonstrating proper air line cutting, go to air-lift.co/cuttingairline fig. D.1 NOTE PUSH-TO-CONNECT FITTINGS Air lines should be pushed into the push-to-connect fittings firmly, with a slight sideto-side rotational twist. Check the connection by pulling on each line to verify a robust connection. To release the air line from the connection (Fig. D.2), first release all air from the system. Push in on the air line (step 1), push the collar in (step 2). With the collar depressed, pull the air line out of the fitting (step 3). Push-to-connect fitting Collar STEP 1 Air line STEP 2 STEP 3 fig. D.2 CHECKING FOR LEAKS 1. Inflate the air spring to 30 PSI using the Schrader valve. 2. Spray all connections and the Schrader valve with a solution of 1/5 liquid dish soap and 4/5 water. Spot leaks easily by looking for bubbles in the soapy water. 3. After the test, deflate the springs to the minimum pressure required to restore the system to normal ride height. 4. Check the air pressure again after 24 hours. A 2-4 PSI loss after initial installation is normal. Retest for leaks if the loss is more than 5 PSI. FIXING LEAKS 1. If there is a problem with the push-to-connect fitting, remove the air line as described above. Trim 1 off the end of the air line. Be sure the cut is clean and square (see Fig. D.1). 2. Reinsert the air line into the push-to-connect fitting as described above. 6
SmartAIR II E. Calibrating the System 1. Pressurize the air springs with 5 PSI using the Schrader valves with the vehicle unloaded. 2. Remove the screw in the magnet so you can see the sensor through the hole and center it on the white line. 3. Turn the ignition on. Release the pressure from the bags, wait until the compressor turns on and check to ensure it fills back up to 5 PSI. If vehicle doesn t rise, raise the magnet until it will maintain 5 PSI at ride height. F. Troubleshooting Guide Problem Cause Solution The system has a 15- to 20-second delay before the compressor and exhaust solenoid will function. Compressor doesn t run. System not exhausting properly. Compressor runs all the time. Vehicle does not maintain/reach ride height. Nothing happens when the vehicle is on. Blown 15-amp or 3-amp fuse, bad ground, poor connection, bad compressor or Electronic Height Sensor (EHS). Blown 3-amp fuse, bad connections, bad solenoid or EHS. Leak in air line, fitting or exhaust solenoid, bad relay or EHS. Bad/leaking exhaust solenoid or bad EHS. The vehicle could be overloaded. Blown 3-amp fuse, poor ground or connection. Bad EHS. Magnet may not be properly aligned (typically too high), may be backward or may be improper distance from EHS. Check fuses, grounds and connections. Ground terminal at relay to see if compressor runs. Unplug compressor and bench test. Check fuse and connection. Unplug exhaust solenoid from harness connection. Use jumper wires to vehicle power and ground to check operation by connecting one side of exhaust solenoid connector to power and the other to ground. If it functions, the EHS is bad or there is a bad connection. Locate leak, replace relay or check EHS. Unplug the solenoid and test by jumping power and ground to appropriate circuit in harness to ensure functions. If the air pressure in the system is at its max pressure of 100 PSI, the height the magnet/sensor was set at will not be achieved. Reduce the load to achieve level ride height. Check fuses, connections and grounds. Test individual components to verify function. Ground terminal to test compressor and harness. Check magnet alignment, distance, and ensure the chamfered side is facing EHS. 7
Notes SmartAIR II 8
SmartAIR II Limited Warranty and Return Policy Air Lift Company provides a 2-year limited warranty to the original purchaser of SmartAir II from the date of original purchase, that the products will be free from defects in workmanship and materials when used on cars and trucks as specified by Air Lift Company and under normal operating conditions, subject to the requirements and exclusions set forth in the full Limited Warranty and Return Policy that is available online at www.airliftcompany.com/warranty. For additional warranty information contact Air Lift Company customer service. Replacement Part Information If replacement parts are needed, contact Air Lift customer service. Most parts are immediately available and can be shipped the same day. Contact Air Lift Company customer service at (800) 248-0892 first if: Parts are missing from the kit. Need technical assistance on installation or operation. Broken or defective parts in the kit. Wrong parts in the kit. Contact Information Have a warranty claim or question. Contact the retailer where the kit was purchased: If it is necessary to return or exchange the kit for any reason. If there is a problem with shipping if shipped from the retailer. If there is a problem with the price. Mailing address P.O. Box 80167 Lansing, MI 48908-0167 Shipping address 2727 Snow Road for returns Lansing, MI 48917 Phone Toll free: (800) 248-0892 International: (517) 322-2144 Email Web address service@airliftcompany.com www.airliftcompany.com Air Lift Company reserves the right to make changes and improvements to its products and publications at any time. For the latest version of this manual, contact Air Lift Company at (800) 248-0892 or visit www.airliftcompany.com. 9
Need Help? Contact Air Lift Company customer service department by calling (800) 248-0892. For calls from outside the USA or Canada, dial (517) 322-2144. Register your warranty at www.airliftcompany.com/warranty Thank you for purchasing Air Lift products the professional installer s choice! Air Lift Company 2727 Snow Road Lansing, MI 48917 or P.O. Box 80167 Lansing, MI 48908-0167 Toll Free (800) 248-0892 Local (517) 322-2144 Fax (517) 322-0240 www.airliftcompany.com Printed in the USA BGL-0816