Air Compressor Kit - 4wheelparts.com Axle and Gear... · Read ntirsuu c uuoml tblltefpg uuc...

G 2 A X L E . C O M • 3 1 0 . 9 0 0 . 2 6 8 7 • 4 0 0 W . A r t e s i a B l v d . C o m p t o n , C A 9 0 2 2 0

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Read entire instruction manual before attempting G2 air compressor installation.

• G2aircompressorisdesignedtobeusedtoactuateG2CORElockers,DRSSwaybar,orotherlightdutyair-operatedaccessories.Itisnotintendedforcontinuoususeapplicationssuchastireinflationorairtools

• Forusewith12voltDCsystemsonly• Professionalinstallationrecommended• Donotdisassemble,attemptrepairs,ormodifythecompressorinanyway• Disconnectnegativecablefromnegativeterminalonbatterypriortoinstallation

BILL OF MATERIALS:

PART# DESCRIPTION QTY.

700-AC1-01 AIRCOMPRESSOR 1

700-AC1-02 WIREHARNESS(2PCS) 1

700-AC1-03 PRESSURESWITCH 1

700-AC1-04 MOUNTPLATE 1

700-AC1-05 COMPRESSORSWITCH 1

700-AC1-06 1/8"NPTPLUG 3

700-AC1-07 6MMHARDWAREPACK 1

700-AC1-08 1/8"NPTTHREADEDNIPPLE 3

700-AC1-09 ZIPTIEPACK 1

SPECIFICATIONS:

VOLTAGE: 12VDC

MAXAMPDRAW: 9AMPS

MAXWORKINGPRESSURE: 150PSI

PRESSURESWITCH: 105PSI/70PSI

DUTYCYCLE@72°F: 15MIN@40PSI

FLOWRATE@0PSI: 0.8CFM

AMPDRAW@0PSI: 5.5AMPS

REQUIRED TOOLS:

Basicmechanics’handtoolsSafetyGlassesRazorKnifeDrillw/1/4”BitThreadSealant(TeflonTape)ElectricalTapeWireCrimperSolderingIron(Optional)

Air Compressor Kit PART# 70-AC1

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Air Compressor Kit PART# 70-AC1

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For Technical Support/Warranty Information please contact us at 310-900-2687 or tech@g2axle.com

SOLENOID INSTALLATION:

1.IfinstallingG2DRSswaybarorlockingdifferentialkits,installtheairsolenoidprovidedwiththosekitsatthistime(followtheinstructionsprovidedinthosekits).NOTE: MULTIPLE SOLENOIDS CAN BE ATTACHED TO THE AIR COMPRESSOR MANIFOLD. WHEN ATTACHING FITTINGS OR ACCESSORIES, SUCH AS SOLENOIDS, TO THE COMPRESSOR MANIFOLD BE SURE THEY ARE SEALED PROPERLY USING THREAD SEALANT OR TEFLON TAPE.

2.Removethe1/8”NPTplugfromtheaircompressormanifold.

3.ApplythreadsealantorTeflontapetoboththreadedendsof1/8”NPTmalenipple.

4.Threadoneendofthe1/8”NPTmalenippleintothesolenoidandtheotherintothemanifoldofaircompressor.Tightenconnectionsapproximately1.5–3turnspastfingertight.IMPORTANT! DO NOT OVER TIGHTEN.

AIR COMPRESSOR INSTALLATION:

IMPORTANT!: BEFORE DRILLING ANY HOLES, BE SURE THE BACKSIDE IS NOT OBSTRUCTED AND THAT YOU ARE NOT DRILLING INTO WIRING, PLUMBING, ETC. NOTE: THE BACKSIDE OF THE MOUNTING SURFACE NEEDS TO BE ACCESSIBLE TO TIGHTEN MOUNTING BOLTS.

1.Findasuitablelocationonthevehicletomounttheaircompressorthatisfreefromexcessivedirt,moisture,heat,debris,ordirectsunlight.Forexample,JeepJKapplicationscanmounttheaircompressorontothefirewall,behindthedriversideinnerfenderliner.Makesurethereisadequateclearancebetweenthecompressorandinnerfenderliner,exhaustmanifold,oranyothervehiclecomponents.

CAUTION: THE COMPRESSOR MAY BECOME HOT IF USED FOR EXTENDED PERIODS OF TIME.

2.Theaircompressorcanberotatedbylooseningtheboltsthatclampthemountplatetothecompressormotor.(Figure3)3.Afterasuitablemountinglocationhasbeenfound,usethemountplateasatemplate,centerpunchanddrillthe(4)1/4”mountingholes.Usingthe(4)supplied6mmX25mmboltsandhardwaresecuretheaircompressortothevehicle.

FIGURE 3Loosen to rotate Air Compressor

FIGURE 2

FIGURE 1

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Air Compressor Kit PART# 70-AC1

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For Technical Support/Warranty Information please contact us at 310-900-2687 or tech@g2axle.com

SWITCH INSTALLATION:

1.Mounttheaircompressorrockerswitchinalocationeasilyaccessiblebythedriver,wheretheswitchcannotbeaccidentallybumpedorengaged.

2.Rockerswitchescanbepanelmountedina0.83”x1.44”rectanglecut-outorinasuitableswitchpanel.Ifmountingmultipleswitches,suchasthosesuppliedwithG2lockingdifferentialsorDRSunitkits,dosoatthistime.(Figure5)

3.Installtherockerswitchintothecut-outorsuitableswitchpanelbypressingitintolockintoposition.(Figure5)

NOTE: Be sure the rocker switch is in the correct orientation before installing it to the switch base.NOTE: Connect wiring harness to switch terminals before installation if the back side of the switch will not be accessible after installation. (Figure 6)

WIRING HARNESS INSTALLATION:

1.Themainwiringharnessprovidedcomespre-wiredforusewithupto(3)additionalswitchesandairsolenoidstooperateG2frontandrearlockersandDRSswaybar(KitsSoldSeparately).

2.Themainwiringharnessissuppliedintwopieces(shortsideandlongside)withtheconnectorshalvesuninstalledtoaidininstallationifpassingthewiringharnessthroughafirewallorbulkhead.Thespadeterminalswillneedtobeinstalledintotheconnectors.(Figure7)IMPORTANT!: BE SURE THE COLORS OF THE WIRES LINE UP WITH THE WIRES ON THE OPPOSING CONNECTOR HALF. A CROSSED WIRE COULD CAUSE A SHORT CIRCUIT. NOTE: IF NECESSARY, A PAPER CLIP OR SMALL SCREWDRIVER CAN BE USED TO REMOVE THE TERMINALS FROM THE CONNECTOR HALVES.

FIGURE 7

FIGURE 5

FIGURE 6

Wires shown are for representation only. Actual parts may differ in appearance.

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Air Compressor Kit PART# 70-AC1

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For Technical Support/Warranty Information please contact us at 310-900-2687 or tech@g2axle.com

IMPORTANT! AVOID CONTACT WITH SHARP EDGES, MOVING PARTS, EXHAUST, ANYTHING THAT CAN CAUSE DAMAGE OR WEAR.

WIRING HARNESS, SWITCH SIDE (SHORT):

1.Besuretodisconnectthenegativecablefromthenegativebatteryterminal.

2.Connectthefusedred/yellowstripedwiretoasuitablepositive(+)12voltDCpowersourceusingthesuppliedterminalendifneeded.Ifsplicingintoanexistingwire,besuretoproperlysolderandinsulatetheconnection.Itispreferredtoconnectthefusedred/yellowstripedwiretoacircuitthatisonlylivewheneithertheignitionkeyisintheONorACCposition.Besuretoproperlycrimpandinsulatetheconnection.(Figure11)IMPORTANT!:Theselectedcircuitneedstobecapableofprovidingthemaxamperagerequiredfortheaircompressorplusanyadditionalamperagedrawsalreadyontheselectedcircuit.

3.Connecttheblue/whitestripedswitchlightwiretothevehiclesdashboardillumination,dimmercircuitorheadlampcircuitusingthesuppliedterminalendifnecessary.Ifsplicingintoanexistingwire,besuretoproperlysolderandinsulatetheconnection.(Figure11)

4.Connecttheremainingterminalendstotheircorrespondingswitchterminals.(Figures6and11)

WIRING HARNESS, COMPRESSOR SIDE (LONG):

1.Connectthemainwiringharnessbulkheadconnectorhalves.Besurethecoloredwiresarecorrectlylineupwitheachotherbeforeconnecting.(Figures7and11)2.Routethemainwiringharnesstotheaircompressor.Usingthesuppliedzipties,securemainwiringharnessawayfromsharpedges,movingparts,exhaust,anythingthatcancausedamageorwear.NOTE:Gatherupexcesswiringandsecureusingzipties.3.Determineasuitablelocationfortheblackgroundwire,suchasthevehicle’sframe,body,orconnectdirectlytothenegative(-)batteryterminal.Usetheprovidedelectricalconnectorifneeded.Besuretoproperlycrimporsolderandinsulateconnection.(Figure11)4.Connectthewiringharnesstotheairpressureswitchterminalsusingtheredandthered/whitestripedwires.(Figures10and11)

IMPORTANT! NEVER BYPASS OR USE A AIR PRESSURE SWITCH NOT RATED FOR YOUR AIR COMPRESSOR.

5.Connectthewiringharnesstotheaircompressormotor.(Figures11)

6.IfinstallingadditionalsolenoidsforG2lockersorDRSunit,connectthemtotheircorrespondingswitchesinthewireharnessusingthewiringdiagramortheinstructionssuppliedwiththosekits.(Figures6and11)

7.Besuretosecurewiringharnesstokeepfromhangingortuggingonanyoftheconnectors.

FIGURE 10

FIGURE 9

FIGURE 8

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Air Compressor Kit PART# 70-AC1

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For Technical Support/Warranty Information please contact us at 310-900-2687 or tech@g2axle.com

AIR LINE ROUTING:

NOTE: G2 SOLENOIDS, NYLON TUBING, AND PUSH-TO-CONNECT FITTINGS ARE PROVIDED WITH DIFFERENTIAL LOCKER KITS AND/OR DRS KITS. 1.RoutethenylontubingfromtheG2solenoidsontheaircompressortotheG2solenoidsonthelockingdifferential(s)orDRSunit.NOTE: WHEN ROUTING THE AIR LINES FROM THE AIR COMPRESSOR TO THE LOCKING DIFFERENTIAL(S) OR DRS UNIT, AVOID CONTACT WITH SHARP EDGES, MOVING PARTS, HOT EXHAUST PARTS OR ANYTHING THAT CAN CAUSE DAMAGE OR WEAR. DO NOT KINK THE NYLON TUBING WHEN PLUMBING AROUND CORNERS.

NOTE: USE ONLY THE NECESSARY LENGTH OF TUBING TO REACH LOCKING DIFFERENTIAL(S) OR DRS UNIT. EXCESS TUBING LENGTH INCREASES THE VOLUME OF AIR THE COMPRESSOR MUST FILL WHEN ACTIVATING THE DIFFERENTIAL(S) OR DRS UNIT.

NOTE: BE SURE TO PROVIDE ENOUGH NYLON TUBING SLACK TO ALLOW FOR FULL TRAVEL OF THE DIFFERENTIAL. 1.Usingasharprazorknife,cutthenylontubingmakingsuretoleaveacleancut.Makesuretherearenoburrsorsnagsthatcoulddamagethesealsintheairpush-to-connectfittings.

2.Insertthenylontubingintothepush-to-connectfittings.Applypressuretoproperlyseatthenylontubing.Toremove,depresstheouterringoffitting,pushtubinginandthenpullouttoreleasetubing.3.Usingthesuppliedzipties,securethenylontubing.NOTE: IF PLUMBING A LOCKING DIFFERENTIAL, SECURE TO THE DIFFERENTIAL BREATHER VENT LINE THAT RUNS FROM THE VEHICLES BODY TO THE DIFFERENTIAL.

SYSTEM TEST:

NOTE: BEFORE TESTING THE SYSTEM, DOUBLE-CHECK THAT ALL PUSH-TO-CONNECT FITTINGS, ELECTRICAL CONNECTIONS, HARDWARE, AIR LINES, AND WIRING ARE PROPERLY SECURED, FULLY CONNECTED AND TIGHT.

1.Reconnectthenegativebatterycabletothenegativebatteryterminal.

2.TurnthevehicleignitiontoONorACCandengagetheaircompressorswitch.TheG2emblemontherockerswitchwilllightupandtheaircompressorwillbeginrunning.Theaircompressorwillautomaticallyshutoffoncethesystembuildsfullpressure.

3.AnylockerorDRSsystemcanbetestedatthistime.Thesolenoidwillopenwhentherespectiveswitchisengaged,releasingairtoactivatethecomponent.

4.Itisnormalfortheaircompressortoturnonmomentarilytobuildbacktheairpressurethatwaslostduringcomponentoperation.Whentheswitchisdisengaged,thesolenoidclosesandbleedsoffairpressuredownstream,allowingthecomponenttodeactivate.

5.Withallsystemsactivated,checkfittingsandconnectionsforairleaks.Sprayingamixtureofsoapandwaterontheconnectionswillaidinindicatingaleakingfitting.Re-tightenfittingsasnecessary.

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Air Compressor Kit PART# 70-AC1

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For Technical Support/Warranty Information please contact us at 310-900-2687 or tech@g2axle.com

TROUBLE SHOOTING:

CONDITION POSSIBLECAUSE/SOLUTION

AirCompressorWon’tTurnON • Check fuse. Replace if blown• Confirm system power• Compressor switch wired incorrectly or is faulty.

See wire diagram• Check pressure switch for continuity.

Switch should be normally closed• Crossed wires at bulkhead wiring harness connector.

See wire diagram

AirCompressorWon’tTurnOFForisslowtobuildpressure

• Air system isn’t building pressure. Check for air leaks.• Excessive system volume (i.e. additional air tank installed)• Confirm there is adequate voltage to compressor (12VDC)• Worn air compressor piston rings

BlowsFusesWhenSwitchisOFF • Electrical short in wire harness• Crossed wires at bulkhead wiring harness connector.

See wire diagram

BlowFusesWhenSwitchisON/Running

• Fuse not rated high enough for air compressor• Crossed wires at bulkhead wiring harness connector• Short in wiring harness• Excessive air usage / amp draw

ConstantlyCyclesOnandOff • Check for air leak in system• Worn compressor piston rings

ExcessiveNoise • Inspect for loose mount bolts or hardware• Worn compressor

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Air Compressor Kit PART# 70-AC1

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For Technical Support/Warranty Information please contact us at 310-900-2687 or tech@g2axle.com

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Air Compressor Kit PART# 70-AC1

G 2 A X L E . C O M • 3 1 0 . 9 0 0 . 2 6 8 7 • 4 0 0 W . A r t e s i a B l v d . C o m p t o n , C A 9 0 2 2 0

For Technical Support/Warranty Information please contact us at 310-900-2687 or tech@g2axle.com

NOTICE TO OWNER OPERATOR, DEALER AND INSTALLER:

Vehiclesthathavebeenenhancedforoff-roadperformanceoftenhaveuniquehandlingcharacteristicsduetothehighercenterofgravityandlargertires.Thisvehiclemayhandle,reactandstopdifferentlythanmanypassengercarsorunmodifiedvehicles,bothonandoff–road.Youmustdriveyourvehiclesafely!Extremecareshouldalwaysbetakentopreventvehiclerolloverorlossofcontrol,whichcanresultinseriousinjuryorevendeath.Alwaysavoidsuddensharpturnsorabruptmaneuversandallowmoretimeanddistanceforbraking!G2remindsyoutofastenyourseatbeltsatalltimesandreducespeed!Wewillgladlyansweranyquestionsconcerningthedesign,function,maintenanceandcorrectuseofourproducts.PleasemakesureyourDealer/Installerexplainsanddeliversallwarningnotices,warrantyformsandinstructionsheetsincludedwithG2product.Applicationlistingsinthiscataloghavebeencarefullyfitcheckedforeachmodelandyeardenoted.However,G2reservestherighttoupdateasnecessary,withoutnotice,andwillnotbeheldresponsibleformisprints,changesorvariationsmadebyvehiclemanufacturers.Pleasecallwheninquestionregardingnewmodelyear,vehiclesnotlistedbyspecificbodyorchassisstylesorvehiclesnotoriginallydistributedintheUSA.

Pleasenotethatcertainmechanicalaspectsofanysuspensionliftproductmayaccelerateordinarywearoforiginalequipmentcomponents.Further,installationofcertainG2productsmayvoidthevehicle’sfactorywarrantyasitpertainstocertaincoveredparts;itistheconsumer’sresponsibilitytocheckwiththeirlocaldealerforwarrantycoveragebeforeinstallationofthelift.

WARRANTY AND RETURN POLICY:

G2warrantiesitsfulllineofproductstobefreefromdefectsinworkmanshipandmaterials.G2’sobligationunderthiswarrantyislimitedtorepairorreplacement,atG2’soption,ofthedefectiveproduct.Anyandallcostsofremoval,installation,freightorincidentalorconsequentialdamagesareexpresslyexcludedfromthiswarranty.G2isnotresponsiblefordamagesand/orwarrantyofothervehiclepartsrelatedornon-relatedtotheinstallationofG2product.Aconsumerwhomakesthedecisiontomodifyhisvehiclewithaftermarketcomponentsofanykindwillassumeallriskandresponsibilityforpotentialdamagesincurredasaresultoftheirchosenmodifications.Warrantycoveragedoesnotincludeconsumeropinionsregardingridecomfort,fitmentanddesign.WarrantyclaimscanbemadedirectlywithG2oratanyfactoryauthorizedG2dealer. IMPORTANT! To validate the warranty on this purchase please be sure to mail in the warranty card.

CLAIMS NOT COVERED UNDER WARRANTY: •Partssubjecttonormalwear,thisincludesbushings,bumpstops,balljoints,tierodendsandheimjoints•DiscontinuedproductsatG2’sdiscretion•Bentordentedproduct•Finishafter90days•Productswithevidentdamagecausedbyabrasionorcontactwithotheritems•Damagecausedasaresultofnotfollowingrecommendationsorrequirementscalledoutintheinstallationmanuals•ProductsusedinapplicationsotherthanlistedinG2’scatalog•Componentsoraccessoriesusedinconjunctionwithothermanufacturer’ssystems•Warrantyclaimswithout“ProofofPurchase”•G2acceptsnoresponsibilityforanyalteredproduct,improperinstallation,lackofor

impropermaintenance,orimproperuseofourproducts.

WARRANTY REGISTRATION NUMBER PLACE HERE:

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