CKSA12 - Air Compressors Direct
Contents
1. JAIN AIR ACTIVATION SYSTEM COMPACT ON BOARD AIR KIT INSTALLATION GUIDE 12 09 08 Copyright ee ted No liability is assumed for damages resulting the use of the information contained herein ARB Air Locker Air Operated Locking Differentials ARB Air Locker Air Activation System and Air Locker are trademarks of ARB Corporation Limited Other product names used herein are for identification purposes only and may be trademarks of their respective owners ARB 4x4 ACCESSORIES Corporate Head Office 42 44 Garden St Tel 61 3 9761 6622 Kilsyth Victoria Fax 61 3 9761 6807 AUSTRALIA 3137 Australian enquiries sales arb com au North and South American enquiries sales arbusa com Other international enquiries exports arb com au WwWwW arb com au 1 Introduction 1 1 Pre Installation Preparation 2 1 2 Tool Kit Recommendations 2 2 Installing the Compressor 8 2 1 Installing the solenoid s 3 2 2 Installing the Pressure Switch 3 2 3 Assembling Installing the Air Filter 3 2 4 Using an Air Filter Extension Tube optional 3 2 5 Mounting the Compressor 4 3 Connecting the Air System 3 1 Running and Securing the Air Line 7 3 2 Connection to the Air Locker Bulkhead Fitting 8 4_Mounting amp Connecting the Electrical System 9 4 1 Mounting the Actuator Switch es 9 4 2 Wiring the Actuator System 10 5 Testing amp Troubleshooting 5 1 Leak Testing 12 5 22. APPLICATIONS OTHER THAN ENGAGING AN AIR LOCKER WHEN THE ENGINE IS RUNNING NOTE Do not run the tube through areas where it will be exposed to elevated temperatures while the compressor is running as this will pre heat the air intake and reduce compressor performance E Assemble an extension tube with 1 4 NPT male fitting at one end and a 1 4 NPT female end at the other Install the tube inline with the air filter E Secure loose sections of the tube and the air filter 2 5 Mounting the Compressor Loosen the two motor mount screws so that the compressor can be freely pivoted in its mount while establishing a good mount position FULL 180 ROTATION MOTOR MOUNT SCREWS 2 Installing the Compressor O Identify a position on the vehicle or inside the cabin where the compressor can be safely and conveniently mounted NOTE The ideal position of the compressor should give consideration to all of the 10 11 12 13 14 15 16 following points Keep away from sources of heat e g too close to exhaust system components or directly behind the radiator etc The position should be safe from damage or abrasion caused by sand or gravel from the road surface Avoid any extended exposure to direct sunlight Keep away from excessive moisture e g directly exposed to road spray or rain runoff Mounting location should be above the highest
3. detected Proceed to STEP 6 Wiring fault between the isolating switch and the pressure switch Replace wiring Using a multimeter check for battery voltage approx 12V at the RED WHITE wire connected to the pressure switch installed into the compressor manifold while still connected Was battery voltage detected Proceed to STEP 7 Pressure switch fault or compressor not de pressurized Replace switch or drain pressure Disconnect the compressor motor from the wiring loom at the connector plug Using a multimeter check for battery voltage approx 12V at the RED WHITE wire on the loom side of the plug Was battery voltage detected Proceed to STEP 8 Wiring fault between the pressure switch and the compressor motor connector Replace wiring Using a multimeter check the continuity resistance between the SOLID BLACK wire on the loom side of the plug not on the compressor side and the negative terminal of the battery Did the resistance measure less than 1 Ohm Intermittent fault or internal compressor problem Contact ARB Wiring fault in the ground wire between the battery and the compressor motor Replace wiring 2 5 Testing amp Troubleshooting 5 4 Post Installation Check List Now that the compressor installation has been completed ARB recommends that you take the time to complete the following check list just to insure that you haven t missed any of the vital steps E The air
4. packed with each Air Locker differential HINT Only attach the cover plate to the face of the switch once the switch has been mounted and wired correctly as the cover plates are designed to be difficult to remove For reasons of safety and for ease of operation the Air Locker actuator switch es should be mounted in a location picked to best suit the operator Make sure you have taken the following points into consideration L Switch es MUST be mounted and should never be allowed to simply dangle from the wiring loom during vehicle use Switch es should be within easy reach of the driver Ideally any Air Locker switch should be able to be operated without physical effort or distraction to the driver compressor switch location is not critical Switch es should be mounted within the line of sight of the driver so that switch position ON or OFF can be visually determined by the rocker position and the illumination state The position of the switch es should best eliminate any possibility of accidental operation by the driver or one of the passengers Switch cutout position s must be located area with a minimum of 50mm 2 of clearance behind the face of the cutout L Switch es should not be mounted where they will be exposed to water e g in the lower section of an inner door panel L ARB recommends that you apply the Air Locker Warning Sticker ARB part 210101
5. system has been leak tested L The air filter position will not be exposed to moisture dust or dirt air lines and wiring have been securely cable tied to resist snagging Switch es been securely mounted within operator reach yet well away from danger of accidental engagement Switch es function properly and illuminate to indicate activation INSTALLATION PERFORMED BY DATE OF INSTALLATION ARB SERIAL No 6 Parts List 6 1 Exploded Assembly Diagram See itemized parts list overleaf A i 6 Parts List 6 2 Itemized Parts List See exploded diagram figure 8 AIR COMPRESSOR MODEL No CKSA12 ITEM QTY DESCRIPTION PART 01 4 MOUNTING BOLT M6 x 25mm 200405 02 1 BACKING PLATE 290603 03 4 MOUNTING NUT M6 locking 6151223 04 1 2 PNEUMATIC SOLENOID NOT SUPPLIED 05 1 PRESSURE SWITCH 5 06 2 PLUGS 170802 07 1 COMPRESSOR ASSEMBLY 501 08 1 FILTER CARTRIDGE 300502 09 1 AIR FILTER HOUSING 300501 1 WIRING LOOM 180408 1 ACTUATOR SWITCH 180209 i 1 SWITCH COVER COMPRESSOR ISOLATION 180212 1 INSTALLATION GUIDE 2102SA12 Not illustrated in exploded view
6. within close visual proximity of the switch location NOTE If no adequate position be found on existing dashboard panels a surface mounted bracket Fig 5 may be purchased from your ARB Air Locker distributor to suit 1 2 or 3 switches REAR AIR LOCKER 4 Mounting amp Connecting the Electrical System 4 2 Wiring the Actuator System When wiring an ARB compressor switch Air Locker pressure switch Air Locker actuator switch es and Air Locker solenoid s to an ARB Air Compressor all connections can easily be set up using only the supplied wiring loom ARB 180408 Fig 7 Consulting the wiring diagram Fig 7 for wire colors and the switch terminal illustration Fig 6 plug each of the female spade terminals onto their appropriate switch terminal IMPORTANT As a Safety precaution the SWITCH 2 position in the wiring loom will not activate unless SWITCH 1 is already activated Therefore if both front and rear Air Lockers are installed then the rear MUST be controlled by SWITCH 1 and the front by SWITCH 2 This serves to reduce the risk of accidental engagement of the front Air Locker If only one Air Locker is installed then it should be wired using the terminals for SWITCH 1 regardless of whether the Air Locker is mounted in the front or rear axle Using a multimeter or an automotive test light locate an accessory outlet or cigarette lighter port in
7. C motors e g compasses radio GPS antennas engine management sensors etc Where possible the compressor should be mounted close to the location of the Air Locker equipped axle in a single Air Locker system or halfway between both axles in a dual Air Locker system Never mount the compressor in a position where it would be considered unsprung mass e g mounted directly to the axle or the engine block 2 Installing the Compressor Using the compressor backing plate as a template referring to Fig 2 for exact sizes drill four mounting holes at a diameter of 6 5mm 0 267 NOTE Try to drill holes accurately Holes should never be drilled open more than 8mm 0 31 in size to compensate for misalignment 90 3 54 70 2 76 26 5 0 26 o N MOUNTING CENTER AXIS COMPRESSOR MOTOR lO N ee T Hold compressor in place and assemble bolts through the rubber vibration isolators in the compressor mount and into the newly drilled holes Assemble the backing plate onto the protruding bolts from the opposite side Install the locking nuts with the nylon locking flange facing away from the backing plate as shown in Fig 3 Tighten to a torque of approximately 3 5 Nm 2 5 10 Rotate the compressor motor the mount to its most desirable position and tighten the two mount screws to a torque o
8. See section 2 4 2 4 Using an Air Filter Extension Tube optional The air filter of the CKSA12 was designed so that it could be relocated to a more suitable location if required using an extension tube IMPORTANT The length and inside diameter of the extension tube can restrict the intake flow and negatively affect the performance of the compressor In severe cases this could result in overheating and or damage to compressor components Use the following chart to make sure that your extension tube will not restrict the intake flow 3 2 Installing the Compressor Measure the intended length of the extension tube Maximum Length of Tube Minimum Inside Diameter of Tube 300mm 11 8 8mm 0 32 800mm 31 5 10mm 0 39 1770mm 69 7 12mm 0 47 3430mm 135 07 14mm 0 55 6130mm 241 3 16mm 0 63 Consult the chart above for the recommended minimum inside diameter of the tube NOTE ARB does not recommend connecting your compressor intake to the air supply snorkel or other part of the air ducting for engine aspiration However if an extension tube is used to relocate the compressor intake to your engine intake supply then it must be understood that the negative pressure vacuum created by the engine when it is running will adversely affect compressor performance DO NOT RUN THE COMPRESSOR FOR
9. Testing the Air Locker Actuation 12 5 3 Electrical Fault Diagnosis 12 5 4 Post installation Checklist 12 6 Parts List 8S 6 1 Exploded Assembly Diagram 15 6 2 Itemized Parts List 16 1 Introduction IMPORTANT To assure the highest level of planning and reliability goes into this installation please read this quide in its entirety before attempting any modifications to the vehicle 1 1 Pre Installation Preparation Although your ARB Air Compressor comes complete with all the step by step instructions you will need to install your new air source ARB recommends that you have your ARB Air Compressor installed by a trained professional Many ARB distributors around the world have been fully instructed in Air Compressor installations by ARB and have gained a wealth of experience and skill from years of performing similar installations Make sure your Air Compressor kit is the correct model for your application and that it contains all of the parts listed on back cover of this booklet Also be sure you have appropriately equipped yourself with all the necessary tools parts and materials to complete this installation see section 1 2 Tool Kit Recommendations and minimize vehicle down time Please refer to your ARB Air Locker Operating amp Service Manual for information on operating servicing driving technique or trouble shooting your ARB Air Locker s HINT Place a V mark inside each of the symbols as you complete ea
10. air line around tight bends which may kink the air line and restrict or block the air flow Keep the air line well away from your vehicle s exhaust components Air lines will melt if subjected to extreme heat L Do not run more air line than necessary Excess line volume created when coiling the left over hose using unusually large diameter hose etc will increase drain on the compressor resulting in the compressor running more often than needed Support the air line by tying it back with cable ties wherever possible At the solenoid end of the air line always trim the line to length with a sharp knife to avoid distorting the tube where it plugs into the push in fitting To attach the air line to the push in fitting of the solenoid insert the line firmly into the fitting pull outward on the flange of the fitting while holding the line as far into the fitting as possible and then gently pull outward on the air line to clamp the line in place NOTE To remove the air line from the push in fitting while holding the flange of the fitting out push the air line into the fitting as far as possible then press the flange inward then pull the air line free of the fitting 3 Connecting the Air System 3 2 Connection to the Air Locker Bulkhead Fitting In the case of an IFS axle assembly or the case that the axle assembly has been completely removed from the vehicle the assembly wi
11. ch step It is very important NOT to miss any of the steps 1 2 Tool Kit Recommendations Below is a list of tools and supplies you may need to complete this installation 1 2 1 Tools L Standard automotive sizes metric and or imperial of sockets wrenches Alan keys and drills L A razor knife to cut the nylon tubing L A leak test gauge i e ARB ALTGO1 multimeter L A soldering iron 1 2 2 Supplies L Thread lubricant sealant compound for pressure fittings e g LOCTITE 567 Teflon paste or plumbing supply Teflon tape soap and water mixture to test for air leaks L Electrical tape L Solder and or automotive crimp fittings 2 installing the Compressor 2 1 Installing the Solenoid s IMPORTANT This step applies to the 12V solenoid that is packed with each ARB Air Locker differential If the compressor is to be used for an alternate purpose then skip this step and plug or terminate the ports as required by the application Remove one of the BSPT plugs from its port in the compressor manifold using a 5mm hex key Apply Teflon paste tape to one end of the nipple X BSPT insert into the port and tighten Apply Teflon paste tape to the free end of the nipple Assemble the inlet port side of the solenoid marked as port 1 onto the nipple and tighten The solenoid should be rotated into a position that does not
12. f approximately 2 Nm 1 5 ft lb 3 Connecting the Air System 3 1 Running and Securing the Air Line IMPORTANT The path taken by the air line from your compressor to your Air Locker is unique to your vehicle and the desired position of your compressor Plan ahead carefully when running the air line and always follow these guidelines NOTE The flexible 5mm air line described here is supplied with your Air Locker kit and NOT with your ARB compressor kit If you require air line to complete your installation then contact your Air Locker distributor Account for axle travel when running the line from the axle to a fixed point on the vehicle Leave enough slack in the air line to allow for maximum suspension travel in both directions Not necessary on IFS installations Avoid leaving large lengths of air line hanging underneath the vehicle where they may get tangled on rocks sticks etc HINT Cable tying the air line to one of your flexible brake lines will account for axle travel and should help keep your line from getting snagged E Run the air line all the way from the compressor to the differential before trimming either end of the line to length This will save complications that may arise if the air line has to be removed Make sure the line does not contact sharp edges or abrasive surfaces that damage the air line over time Do not run the
13. ll have to be remounted in order to position the bulkhead fitting in its correct location for air line access Trim the air line to length using a sharp knife C Insert the support spring over the end of the air line small end first Fig 4 O Insert the outer compression nut over the air line T Insert the 5mm 0 1977 ferrule over the end of the air line Leave approx 5mm of tubing between the ferrule and the end of the tube SUPPORT SPRING OUTER COMPRESSION NUT FERRULE 5 0mm 0 197 SUPPORT TUBE Insert the support tube all the way into the end of the air line HINT If the support tube is too difficult to insert place the end of the air line into a cup of boiled water to soften the tubing Insert the tube end all the way into the center compression nut of the bulkhead fitting Screw on the outer compression nut while supporting the center compression nut from turning and tighten The ferrule and support tube are now permanently attached Assemble the support spring over the outside of the outer compression nut Secure any loose sections of tube with a cable tie 4 Mounting amp Connecting the Electrical System 4 1 Mounting the Actuator Switch es ARB compressor and Air Locker actuator switch es can be easily panel mounted inside the vehicle in a 21mm x 36 5mm 0 83 1 44 rectangular cutout NOTE Air Locker actuator switches are
14. ne wheel by hand The wheel should rotate freely and the opposite wheel should be turning in the opposite direction without any resistance or mechanical noise from within the differential Turn the Air Locker switch to the ON position The symbol on the switch cover should light up Rotate the same wheel again and check that both wheel rotate together L Turn the switch off again Rotate the same wheel again The wheels should again rotate in opposite directions 5 Testing amp Troubleshooting 5 3 Electrical Fault Diagnosis The following describes an effective procedure for tracing an electrical fault in an ARB CKSA12 compressor which has been wired using a genuine ARB wiring loom All steps must be performed in the order listed here for an accurate assessment NOTE Before attempting to troubleshoot a malfunctioning compressor always make sure that the STEP 1 5 2 5 3 YES NO 4 YES NO 5 NO 6 YES NO 7 5 8 5 compressor manifold has been de pressurized all connections have been made according to the wiring diagram Fig 7 the vehicle s ignition is in the accessory power position and that the isolating switch has been turned ON Using a multimeter check the voltage at the battery terminals to make sure the battery is working and is fully charged Did the battery measure at lea
15. ntil the air system is fully charged NOTE With the Air Locker s disengaged the compressor should have to recharge over time Intermittent recharging without Air Locker use usually indicates a leak at the solenoid or pressure switch fittings Actuate the Air Locker s compressor should not again for a period of at least 15min Air system recharging within that time period would indicate that a leak is present in the system If a leak is found to be present spray a soap and water mixture onto all air fittings in the system while the compressor is fully charged Bubbles should appear at any leak points Check that leaky fittings have been adequately tightened If leaking persists then disassemble fittings clean threads and reapply thread sealant 5 2 Testing the Air Locker Actuation To test that your air system electrical system and your Air Locker differential is functioning correctly Support the vehicle such that the wheels are free to rotate e g on axle stands chassis hoist etc Leave the parking brake off the transmission in neutral and the Air Locker switch OFF Turn the ignition to the ON position leaving the motor off large symbol on the Air Locker switch cover should not be illuminated Turn the compressor on to charge the air supply to maximum pressure While supporting the drive shaft flange rotate o
16. obstruct any other ports on the compressor manifold NOTE The solenoid exhausts compressed air through the center of the black retaining cap when the Air Locker is disengaged Make sure this orifice cannot be obstructed Apply Teflon paste tape to the threads of the 5mm fitting and assemble it into the solenoid outlet port stamped 2 and tighten using a wrench spanner NOTE Do not tighten fittings more than hand tight If two Air Locker units being controlled with this air source then repeat this step for the second solenoid 2 2 Installing the Pressure Switch Remove the rubber dust plug from the middle port in the compressor manifold and discard Apply Teflon paste tape to the threads of the pressure switch and assemble it into the port and tighten with a wrench spanner NOTE Do not tighten any more than hand tight 2 3 Assembling Installing the Air Filter E Insert the foam filter cartridge into the air filter base Assemble the filter cover by aligning the 3 notches between the cover and the base and applying pressure until it snaps into place Screw the air filter assembly into the threaded hole in the front of the compressor NOTE If an intake extension tube is to be used then the extension tube will be screwed into the front of the compressor and the air filter will be screwed into the extension tube
17. possible waterline to avoid submerging during water crossings The position must allow free flow of dry cool air to the air filter assembly unless an intake extension tube is to be used in which case it is the filter assembly and the extension tube which must be located accordingly The position should allow access to the air filter assembly for filter disassembly and cleaning unless an intake extension tube is to be used If an intake extension tube is to be used then consideration should be given to the intake position so that the distance length of tube between the compressor mounting location and the actual air intake point can be kept to a minimum The position must allow the compressor motor mounting bracket to firmly secure the compressor using all 4 bolts The position must allow access to the opposite side of the mounting location so that the backing plate and locking nuts may be installed Parts of the compressor may get hot while running for long periods of time and therefore the compressor should be located away from where it could be touched by children or pets The position should permit a short protected and accessible route for the wiring loom to follow The compressor should not be mounted in a position where the running sound might be considered startling or irritating for vehicle occupants The compressor should not be mounted in close proximity to devices that are sensitive to the electromagnetic fields of D
18. st 11 5 volts Proceed to STEP 2 Insufficient battery voltage Recharge or replace the battery Disconnect the compressor motor from the wiring loom at the connector plug Run a wire directly from the negative terminal of the battery to the BLACK wire of the compressor motor Momentarily connect a wire from the positive battery terminal to the RED wire of the compressor motor Did the compressor activate when the wires were connected Remove the extra wires and reconnect the compressor motor plug Proceed to STEP 3 Internal compressor problem Contact ARB for assistance Using a multimeter check for battery voltage approx 12V at the RED YELLOW wire connected to terminal 2 of the compressor isolation switch i e the wire leading from the vehicle s accessor Was batiery voltage detected Proceed to STEP 4 Wire has not been connected correctly or accessory power has not been turned on Attach RED YELLOW wire to live accessory power power Using a multimeter check for battery voltage approx 12V at the SOLID RED wire connected to terminal 3 of the compressor isolation switch while still connected Was battery voltage detected Proceed to STEP 5 Switch fault or switch not turned ON Replace switch or toggle switch to ON position Using a multimeter check for battery voltage approx 12V at the SOLID RED wire connected to the pressure switch installed into the compressor manifold Was battery voltage
19. the vehicle NOTE The desired outlet should supply positive 12 volts DC be fused at 15 amps be live only when the vehicle ignition key is in either the ACC position or in the ON position Using a soldering iron or automotive quality crimp connectors splice the red yellow wire i e the red wire with a yellow stripe onto the positive wire of the accessory outlet pair Insulate the junction area well with electrical tape Using a multimeter or an automotive test light locate an active dash light supply wire NOTE The desired wire should supply 12 volts DC less if dimmed and react to the illumination level of the instrumentation dash light dimmer Using a soldering iron or automotive quality crimp connectors splice the blue white wire i e the blue wire with a white stripe onto the active illumination supply wire O Insulate the junction area well with electrical tape L Assemble the 4 male spade connectors on the loom into the supplied plastic connector housing so that each wire color matches up with the same color when the 2 halves of the housing are plugged together NOTE This connection has been supplied disassembled to assist in the routing of the compressor loom through a 10mm drilled hole e g through the firewall if necessary L Run the remainder of the loom to the compressor mounting position T Plug the 2 female spade terminals on
20. to any of the 2 compressor pressure switch terminals O Plug the compressor motor connectors together Plug the female solenoid connector with a yellow wire into the solenoid controlling the rear Air Locker or the front Air Locker if only a front Air Locker is installed Plug the female solenoid connector with a green wire into the solenoid controlling the front Air Locker if 2 Air Lockers are fitted Ground the black negative wire by bolting the 6mm 1 4 eye terminal where it can make direct contact with the body of the vehicle NOTE In vehicles that do not employ body ground such as aluminum bodied vehicles remove the eye terminal and splice this wire directly to an existing negative terminal capable of carrying 15 amps 4 Mounting amp Connecting the Electrical System RED RED YEL BLK BLU WHT pa 5 6 COMPRESSOR ISOLATION SWITCH YEL AIR LOCKER SWITCH 1 SWITCH TERMINALS BLU WHT AIR LOCKER SWITCH 2 FIREWALL PORT DISCONNECTION PLU BLK RED WHT RED WHT SOLENOID 2 PRESSURE CUTOUT SWITCH SOLENOID 1 COMPRESSOR MOTOR PLUG 5 Testing amp Troubleshooting 5 1 Leak Testing With the vehicle parked and the engine off turn the compressor and wait u
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