Accuair E-level User manual

Installation Manual

ACCUAIR: Rocker Switch

Congratulations!

Thank you for purchasing the revolutionary e-Level™ system by AccuAir.

This system manages the height of up to 4 Air Springs and offers never

before seen accuracy in all applications by constantly learning your vehicle’s

characteristics. Through the use of advanced height monitoring techniques,

this system automatically corrects for changes in load, whether driving or

parked, minimizing user input and maximizing accuracy throughout your

driving experience. To enhance the entire system’s performance and reli-

ability, the AccuAir e-Level™ also manages your Air Compressor(s) to keep

onboard air at an ideal pressure for your application.

To maximize functionality, the AccuAir e-Level™ allows you to select from

three distinct vehicle heights through a Rocker Switch:

1.) Ride Height (The height that you will typically drive your vehicle at).

2.) Low/Cruise (Typically set at 10% of your total suspension travel).

3.) High/Extra Clearance (Typically set at 90% of your total suspension

travel to increase mobility and clear driving obstacles).

THE SYSTEM

MUST BE

CALIBRATED

BEFORE USE

SEE Opp Man

PAGE 6.

Description Page Number

Table Of Contents

Terms & Conditions

Wiring Diagram

Installation Overview

Mounting & Wiring Instructions

Testing Mechanical & Electrical Hookup

Ride Height Sensor Installation

Setup Programming

Mounting Templates

4-5

7-12

14-20

22-26

- Page 3 -

Terms & Conditions:

AccuAir Control Systems, L.L.C. is hereby referred to as ACCUAIR. The Pur-

chaser, end-user, or installer is hereby referred to as CUSTOMER.

Warranty

ACCUAIR will repair or replace any failed components for the life of the vehicle

given that the components were installed and operated as intended by

ACCUAIR. Upon the return of a failed component(s), ACCUAIR will determine

the cause of failure. If it is due to improper installation, or misuse of the system,

a repair charge will be assessed and the customer will be contacted before

work is performed or replacement parts are shipped. If the failure is due to faulty

parts, then ACCUAIR will repair or replace the failed components at their own

discretion and in a timely manner.

Legal Disclaimer

•ACCUAIR’s products must be installed by a qualied professional installation

facility as recommended by ACCUAIR.

•System operation and installation is at the CUSTOMER’s own risk. ACCUAIR

accepts no liability for damage of property or persons caused by its products,

components, accessories, installation instructions or otherwise.

•ACCUAIR accepts no responsibility for systems, products or components

provided by other manufacturers for use with or around the ACCUAIR system.

For components other than ACCUAIR’s, follow the manufacturer’s instructions

for installation and operation.

WARNING: No part of the vehicle should be able to contact the

ground when all air is out of the air springs.

ECU

- Page 13 - - Page 14 -

- Page 2 - - Page 3 -

- Page 16 - - Page 17 -- Page 4 - - Page 5 -- Page 16 - - Page 17 -- Page 4 - - Page 5 -

BATT_12V

COMP_1

SENS_2

SENS_1

FRONT

SENS_4

SENS_3

P_SENS

V_GND

EC_GND

ECU

Compressor 2 (Optional)Compressor 1

Compressor(s)

Relay

(Main) 70Amp Fuse

(F2) 3 Amp

Compressor

Relay Fuse

(F1) 10 Amp

ECU Fuse

12 V Batt

3 4

IGN_12V

Position Select

Switch

OFF ON

IGN

Program

Button

IGN_12V

OFF ON

IGN

HEADLIGHTS

TouchPad™

Controller

When using other MFG’s

valves:

1.) Up 4 White/Black

2.) Up 3 White/Orange

3.) Up 2 White/Purple

4.) Up 1 White

5.) Down 4 White/Gray

6.) Down 3 White/Green

7.) Down 2 White/Brown

8.) Down 1 White/Blue

1 2 3 4

5 6 7 8

- Page 6 -

Installation Overview:

After your Air Springs and Suspension Components have been installed, you can

begin installing the AccuAir components in the following order:

1.)

2.)

3.)

4.)

5.)

6.)

7.)

8.)

9.)

Install VU4 (Valve Unit)

Install ECU (Electronic Control Unit)

Install Height Selection Rocker Switch

Install Tank Pressure Sensor

Install Air Compressor(s)

Install Wiring Harnesses

Test Wiring and Mechanical Components

Install Ride Height Sensors

CALIBRATE SYSTEM

WARNING: Make sure to disconnect the vehicle battery ground

terminal throughout the wiring process.

- Page 7 -

VU4 (Valve Unit) Mounting:

Valve Mounting Considerations

• These valves are 100% weather-proof and can be mounted under vehicle.

• You will need to mount the ECU near the valves, so make sure that there is

enough space for both items.

Step-by-Step

1.) Find a at location to mount the VU4. This should allow enough room for

the airlines to be inserted without too much bending.

2.) Transfer hole pattern from the VU4 Mounting Template on page 22.

3.) Drill holes with a 3/16” drill bit and bolt the VU4 down with the included #10-24

Allen head cap screws.

4.) Place the ground eyelet from the VU4 wiring harness under one of the cap-

screws and make sure that this screw has good contact to chassis ground.

(Remove paint or coatings to expose bare metal)

5.) You may use this same location to place the ECU ground, so do not tighten

yet.

V_GND

Ground Eyelet Installation

1 2 3 4

5 6 7 8

1.) Up 4 White/Black

2.) Up 3 White/Orange

3.) Up 2 White/Purple

4.) Up 1 White

5.) Down 4 White/Gray

6.) Down 3 White/Green

7.) Down 2 White/Brown

8.) Down 1 White/Blue

When using other

MFG’s valves:

Wire Color Description

- Page 8 -

ECU Mounting:

ECU Mounting Considerations

• The ECU is 100% weather-proof and can be mounted under vehicle next to

the valves.

• The ECU can be mounted upright or on its back as seen below. (If back

mounted, back tabs must be removed)

• The following diagrams illustrate both “Standard” and “Optional” mounting

congurations.

Bottom Mounting (Standard):

See ECU Mounting Template

on page 24.

Back Mounting (Optional):

See ECU Mounting Template

on page 26.

Step-by-Step

1.) Find a at location near the VU4 (Valve Unit) to mount the ECU.

2.) Plug-In the Valve Harness while nding the mounting position to make sure

that it reaches.

3.) Transfer hole pattern from the ECU Mounting Template on pages 24 & 26.

4.) Drill holes with a 3/16” drill bit and bolt the ECU down with the included

#10-32 Allen head cap screws.

For optional mounting,

remove back tabs with

diagonal cutters and a le.

- Page 9 -

Pressure Sensor Mounting:

Tank Pressure Sensor Mounting Considerations

• Mount the Pressure Sensor vertically with the threads aiming downward to avoid

moisture build up in the sensor.

• Mount the Sensor close to the ECU to connect the pre-terminated sensor

harness that is part of the Main ECU Harness.

Step-By-Step

1.) Coat the threads of the Sensor and any threaded tting or adapter used in the

air supply system with a thread sealer to help prevent air leaks. We recommend

a liquid thread sealer for best results but Teon tape will work also. We strongly

recommend an Anaerobic Thread Sealer such as Loctite’s (P/N: 565)

2.) After tightening the sensor wipe off the excess thread sealer.

Air Tank

Example 1:

Pressure Sensor Mounting.

(In the top of the tank)

WARNING: e-Level™ System is NOT compatible with any other Pressure

Sensor or Switch.

- Page 10 -

Installing & Wiring Air Compressor(s):

Air Compressor(s) Mounting Considerations

• There should be a fuse in between the Compressor(s) and the battery.

• The Compressor(s) get very HOT during operation. Make sure to leave space

between items that are susceptible to heat. (Wires, Nylon-Air Line, etc.)

Step-By-Step

1.) Find a location for the Compressor(s) to be mounted with good air

circulation.

2.) Transfer the hole pattern of the Compressor using the Air Compressor as

your template.

3.) Drill holes and bolt the Air Compressor(s) down.

4.) Install the Power Wire to the vehicle battery (12v+) with an inline fuse

(30Amps per Compressor) that is included with your Compressor(s) near the

vehicle battery (12v+).

5.) Install the Compressor Relay inline with the Compressor’s power line.

6.) Install the Ground Wire to vehicle/chassis ground. (Make sure to remove any

rust or paint to ensure a thorough ground)

- Page 11 -

Wiring Harness Installation Considerations

• The plugs that connect to the ECU will only t in the desired orientation. Do

not force the connectors into the wrong mating connector.

• Make sure to press all connectors on rmly until an audible “click” sound can

be heard from the lock.

• Route all wiring away from exhaust or other hi-temp areas.

• Use Rubber Grommets for areas where sharp metal could eventually wear

through the wire insulation.

Step-By-Step

•ECU Main Harness

1.) First connect the Main Harness at the ECU then route each section to each

component on the vehicle.

2.) Route the Rocker Switch sub harness (gray 7-wire bundle) to the inside of the

vehicle and leave until later in installation.

3.) Route the 3-wire Tank Pressure Sensor sub harness (green, red, and black

wires) labeled “P_SENS” to the sensor.

5.) Route the single yellow wire labeled “COMP_1” with a 3 Amp fuse to trigger

the Compressor Relay(s).

6.) Route the single red wire labeled “BATT_12V” with a 10 Amp fuse to the

vehicle battery.

7.) Mount the single black wire labeled “EC_GND” with the VU4 ground.

Install Wiring Harnesses:

See System Diagram

on pages 4-5.

CLICK !

- Page 12 -

Height Selection Rocker Switch Mounting

• Choose a mounting location that will allow the driver to operate and view the

switch from the driver’s seat. Once your target mounting position has been

found, use the template below to cut a hole in the panel.

• Once the Rocker Switch is mounted inside the vehicle route the single orange

wire labeled “IGN_12V” to the vehicle ignition. Check the manufacturer’s specs

for an ignition source inside the vehicle.

Rocker Switch Mounting:

Install switch so that

lock is DOWN.

Rocker Switch Cutout Template:

0.830”

1.450”

Push the Height Selection Rocker

Switch in from the front of the

panel until ush.

Mounting Panel

Now install the plug from the rear,

(make sure to press until

rmly seated).

Mounting Panel

Now connect the Orange wire labeled “ ”

to a 12 Volt Vehicle Ignition Source.

IGN_12V

- Page 13 -

Now that the majority of your system components are installed, plumbed, and

wired (Mechanical Air Suspension Components, Compressor(s), Tank(s), Tank

Pressure Sensor, Valves, Air Line, ECU, and Height Selection Rocker Switch), it

is time to test the system and begin the height sensor installation.

NOTE: This process can be done manually with jacks or electronically

using the following instructions.

To Begin Testing The System:

Turn the vehicle Ignition ON, or start the vehicle.

(You will need to be charging your electrical

system either by running the vehicle or by us-

ing a high amperage battery charger). The Air

Compressor(s) will turn ON and begin lling the

Tank(s). Wait until the system reaches max pres-

sure and turns the Air Compressor(s) OFF. This

process can take from 1-8 minutes depending on

the size of your Compressor(s) and Tank(s).

You can now Raise/Lower all 4 Air Springs by

simply pressing the “ ” or “ ” Buttons on

the Height Selection Rocker Switch.

As you consume air pressure by raising the

vehicle, the Air Compressor(s) will automatically

turn ON when necessary.

This is a good time to do some mechanical

system checking:

Look for mechanical interference throughout the

range of travel for the Air Springs and all moving

suspension components.

Test for air leaks at all ttings and pipe threaded

joints using a soapy spray bottle. To x any air

leaks rst lower the Air Springs “ ”, then turn

the ignition OFF and depressurize the Air Storage

Tank(s).

Testing Wiring & Mechanical Components:

OFF ON

IGN

- Page 14 -

Height Sensor Installation:

Understanding suspension movement is the key to sensor mounting. The term

“vertical travel” means the amount of up and down distance that a point on a

suspension arm moves as it rotates. Realize that there is no “vertical travel” at the

arm’s pivot point. If you mount a sensor very close to a pivot point it will barely

travel at all. If you mount a sensor too far out on an arm, it will travel too far and

damage the sensor. See the following diagram for an illustration of this theory:

DANGER: Sensor installation requires viewing suspension movement

from underneath the vehicle. This must be done on a lift with ramps for

safety. Do not attempt to get under the vehicle while it is on the ground

or on jack stands for this process!!!

Large Vertical Travel

Small Vertical Travel

Pivot Point

Rotation

- Page 15 -

Height Sensor Installation:

WARNING: Sensor travel is limited to 2.75”. Over extension

or over compression will damage the sensor.

2.75”

Under/Over Extension

- Page 16 -

Height Sensor Installation:

Step 1.) Choose a stationary mounting

point on the frame where you hope to

mount the sensor, (Mark an “X” here).

All of the following measurements will

be taken from this point.

Step 2.) Mark a Dot on the moving sus-

pension arm directly under the “X” from

step 1, (This will be your target ball stud

mounting point). With the vehicle at the

top of its travel (aired all the way up),

measure from your dot up to the center

of your “X”. We will call this distance

“A”.

Step 3.) While standing clear, exhaust

the vehicle to the very bottom of its

travel. Now re-measure from your dot

up to the center of your “X”. We will call

this distance “B”.

Calculate the sensor travel by subtract-

ing B from A, (Sensor Travel = A-B).

- Page 17 -

Step 4.) If your sensor travel is less

than 2.75” then move further away from

the pivot point of your suspension arm

and repeat steps 1 through 3. If your

sensor travel is more than 2.75” then

move closer toward the pivot point of

your suspension arm and repeat steps 1

through 3.

(We understand that getting the

sensor travel right on 2.7500” is not

possible, so make the travel less than

2.75” rather than greater that 2.75”

when you come to this point.)

Step 5.) Once you have established

your ball stud mounting point that yields

2.75” of sensor travel drill or weld to at-

tach the supplied ball stud at this exact

point.

Height Sensor Installation:

Ball Stud Mounting

Surface

Allen Bolt

Thin Washer

1” Stand-off

(Optional)

- Page 18 -

Height Sensor Installation:

Step 6.) With the sensor linkage

installed on the sensor arm and the

vehicle at the middle of the travel,

hold the sensor apparatus up as if it

were attached to the ball stud that you

installed in Step 5. Determine if you will

need to shorten the linkage. If not con-

tinue to step 8. If so unscrew the end-

links and cut the threaded rod, (Make

sure to restart the threads nicely). Then

cut the plastic tubing 5/8” shorter then

your new total rod length, (you want

5/16” worth of thread engagement

on each end). Then re-assemble the

rod. Note that the end links do not need to get tight on the rod, because once

installed the ball stud prevents them from rotating loose.

Step 7.) Attach the lower end-link to the

ball stud. With the vehicle about half

way through the travel, nd the exact

sensor mounting point that keeps the

mounting holes and linkage rod vertical.

Once established, trace the outline of

the sensor to the frame.

Metric

6 mm x 1.0

- Page 19 -

Height Sensor Installation:

Step 8.) With the vehicle at the very

bottom of the travel, hold the sensor at

the same location traced on the frame

in step 7. Either rotate the sensor slight-

ly, or adjust the linkage so that there is

about 1/4” of clearance between the

upper plastic stop and the rotating arm.

Visually note this amount.

Step 9.) With the vehicle at the very

top of the travel, compare the clear-

ance found in step 8, to the clearance

between the lower plastic stop and the

rotating arm. Repeat Step 8 and 9 until

the upper and lower clearance is ap-

proximately equal.

Step 10.) Use the nal sensor loca-

tion to mark the two mounting holes to

be drilled through the frame. Drill the

holes and install the sensor mounting

hardware. (BE CAREFUL NOT OVER

TIGHTEN!)

Step 11.) Now that the sensor is mount-

ed, repeat Step 8 and Step 9 to make

sure that the clearance is still equal.

Adjust the linkage if necessary.

- Page 20 -

Height Sensor Installation:

SENS_#

2.75"

ECU

NOTE: It is EXTREMELY important to wire the Ride-Height Sensors

correctly. Identify the number label on each sensor cable and route it to

the correct corner of the car based on the system diagram in the front of

this manual.

- Page 21 -

THE SYSTEM

MUST BE

CALIBRATED

BEFORE USE

SEE Opp Man

PAGE 6.

Setup Programming:

System Calibration

Refer to your OPERATION MANUAL for the System Calibration

Procedure.

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