Air Lift Smart Air 25415 User manual

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.
MN-601 • (11610) • ECR 5863
INSTALLATION GUIDE
Magnetic
Height Sensor
No. 25415,
25430

2MN-601
SmartAir

1
MN-601
SmartAir
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Important System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Notation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installing the SmartAir System . . . . . . . . . . . . . . . . . . . 4
Installing the Compressor and Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Attaching the Height Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Attaching the Magnet and Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installing the Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Adjusting the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Checking the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warranty and Return Policy . . . . . . . . . . . . . . . . . . . . . . 9
Replacement Information . . . . . . . . . . . . . . . . . . . . . . . . 10
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TABLE OF CONTENTS
1

2MN-601
RoadTamer
Introduction
The purpose of this publication is to assist with the installation, maintenance and
troubleshooting of the SmartAir System.
It is important to read and understand the entire installation guide before beginning installation
or performing any maintenance, service or repair. The information here includes a hardware
list, tool list, step-by-step installation information, maintenance tips, safety information and
a troubleshooting guide.
Air Lift Company reserves the right to make changes and improvements to its products and
publications at any time. Contact Air Lift Company at [phone], ext. 1 for the latest
version of this manual.
IMPORTANT SYSTEM INFORMATION
The system is comprised of an Electronic Height Sensor (EHS), a bracket mounted magnet,
solenoid valve, relay, air compressor, and an interconnecting wire harness. This system is
combined with the previously installed air bags.
The EHS is mounted to the vehicle frame and the magnet 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 25
seconds, the EHS will turn on the compressor, via the relay, adding air to the air bags. Air
is added until the magnet is re-centered restoring the vehicle to its preset ride height.
When load is removed from the vehicle, the magnet falls below the EHS and energizes the
solenoid valve. This allows the air to escape from the air bags until the magnet is re-centered
and the reduction in load is accomodated.
An optional kneeling system can be purchased, which includes a dash mounted rocker
switch. This system works to manually exhaust air from the bags when a lower vehicle is
needed while parking.
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 througout this guide.
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.
DANGER
NOTE
WARNING
CAUTION

3
MN-601
SmartAir
Installation Diagram
fi g . 1
Compressor (-) (6)Compressor (-) (6)
Splice into
keyed on
ignition wire.
Splice into
keyed on
ignition wire.
Inside View of
Connector
Inside View of
Connector
5 AMP5 AMP
V Battery
(1)
V Battery
(1)
CompressorCompressor
Compressor (+) (5)Compressor (+) (5)
Valve (-) (4)Valve (-) (4)
AA
JJ
GG
PP
QQ
RR
FF
MM
NN
BB
CC
LLKK
SS
JJ
IITT
II
DD
EE
OO
20 AMP20 AMP
View of
magnet
from
other
side
View of
magnet
from
other
side
Side ViewSide View Back ViewBack View
GND
(2)
GND
(2)
(1)(1)
Solenoid + (3)Solenoid + (3)
Solenoid - (4)Solenoid - (4)
CompressorCompressor
3030
8686
8787
8585
Compressor mounting
hardware is included
with the compressor.
GroundGround
Optional Ring Terminal. Connect Wire to a 12V constant on power source. (Use terminal if connecting to battery.) Optional Ring Terminal. Connect Wire to a 12V constant on power source. (Use terminal if connecting to battery.)
This will not be
attached to anything
unless the kneeling
switch option is used.
This will not be
attached to anything
unless the kneeling
switch option is used.
Portion of Harness Inside Cab Portion of Harness Inside Cab
Enlarged View
THIS END UP
ALIGN DOTTED
LINEWITH CENTER
OF MAGNET
Orange dot will face the inside of the vehicle towards the height sensor.
Exhaust tube
Do not connect to system.
Must vent to atmosphere.
mount forward of axle
Item Part # Description.................................Qty A 24050 Electronic Magnetic Height Sensor.....1
B 16092 Compressor ........................................1 C 26238 Exhaust Solenoid................................1 D 26687 Harness...............................................1 E 20220 1/4” Air Line........................................20’
HARDWARE LIST Item Part # Description.................................Qty
F 10966 Magnet................................................1 G 10967 Magnet Mounting Bracket...................1 H 10466 8” Black Zip Tie..................................12 I 21838 1/4” x 1/4” x 1/4” Union Tee ................4 J 17173 1/4” x 3/4” Self-Tapping Screw ...........3 K 17185 #8 - 32 x 3/8” Washer Head Screw.....2 L 18417 #8 Lock Washer..................................2 M 17232 #10 - 24 x 1” Hex Machine Screw.......1 N 18498 3/16 - 24 Nyloc Nut .............................1 O 10583 3/8” x 3.5” x 4.5” U-bolt .......................1 P 01426 Clamp Bar...........................................1 Q 18435 3/8” - 16 Nyloc Nut ..............................2 R 18444 3/8” Flat Washer .................................2 S 17132 #8 - 18 x 1/2” Self-Tapping Screw ......1 T 26818 Pressure Release Valve Assembly.....1

4MN-601
SmartAir
3. Cut a length of air line and remove the compression nut in the end of the leader hose
and slip it over the air line. Insert the barb on the leader hose into the air line, seating
it completely against the leader hose fitting. Thread the nut onto the fitting and tighten.
Connect the other end of the air line to one of the push-to-connect fittings on the tee of
the pressure relief valve assembly (fig. 2).
4. Cut another length of air line and attach one end to the open push-to-connect fitting on
the tee of the assembly and the other end of the air line to the solenoid valve.
INSTALLING THE COMPRESSOR AND DEFLATE SOLENOID
1. Attach the filter to the fitting on the end of the compressor.
2. Select a rigid mounting location on your vehicle’s frame or crossmember that shields
the compressor from the elements and heat sources (fig. 2). Refer to chart below for
step-by-step instructions.
The compressor and deflate solenoid must be mounted within reach of the wires when the
wiring harness is plugged in.
Installing the SmartAir System
123
Compressor Centerpunch and drill four
1/4” diameter holes using
the compressor feet as a
template.
Attach using four
supplied screws.
Fasten using four
supplied nuts.
Solenoid Centerpunch and drill
two 3/16” diameter holes
using the template on the
back of the manual?
Attach using two
supplied lock washers
and bolts.
NOTE
CAUTION MOUNT THE COMPRESSOR AND DEFLATE SOLENOID AT LEAST 6” FROM ANY HEAT
SOURCES. DO NOT MOUNT THE COMPRESSOR OR THE MANIFOLD IN THE ENGINE
COMPARTMENT.
fi g . 2
Exhaust Tube
Do not connect to system.
Must vent to atmosphere.
To air spring Compressor mounting
hardware is included with
the compressor.
Ground
Exhaust
Solenoid Union Tee
Compressor
Pressure Relief
Valve Assembly

5
MN-601
SmartAir
It may be necessary to stabilize the pressure relief valve assembly. If so, use a tie strap
and attach it to the frame rail or a crossmember.
5. Attach the compressor and deflate solenoid to the frame rail or crossmember using fig.
2 as a guide.
6. Mount the solenoid as close to the compressor or air spring as possible (fig. 2). Use the
template on the back of the manual for mounting the solenoid.
MOUNT THE COMPRESSOR AND DEFLATE SOLENOID AT LEAST 6” FROM ANY HEAT
SOURCES. DO NOT MOUNT THE COMPRESSOR OR THE MANIFOLD IN THE ENGINE
COMPARTMENT.
ATTACHING THE HEIGHT SENSOR
1. Choose a mounting location along the frame rail for the height sensor.
Preferably mount the height sensor forward of the axle.
2. Using the provided screws and nyloc nuts, attach the height sensor to the chosen frame-
mounting location (fig. 3).
STAY CLEAR OF ANYTHING THAT MAY HIT THE HEIGHT SENSOR WHILE THE
SUSPENSION TRAVELS IN JOUNCE AND COMPRESSION.
ATTACHING THE MAGNET AND MOUNTING BRACKET
THE MAGNET HAS A STRONG PULL. USE CARE WHEN HANDLING AS NOT TO PINCH
FINGERS OR SKIN.
1. Place the supplied u-bolt around the leaf springs near the previously mounted height
sensor (fig. 4 and fig. 5).
2. Using the figures below as a guide, choose the best mounting method for your
vehicle.
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”- 1½” apart.
3. Attach the bracket to the u-bolt using the chosen mounting method using fig. 4 and fig. 5.
4. Loosely attach the magnet to the bracket using the supplied bolt and nyloc nut.
There is a small orange dot on the magnet that will face the inside of the vehicle towards
the height sensor.
5. Align the center of the magnet with the dotted line on the height sensor. Once the magnet
is in line, securely tighten the hardware.
THIS END UP
ALIGN DOTTED
LINE WITH CENTER
OF MAGNET
CAUTION
NOTE
CAUTION
NOTE
NOTE
CAUTION
fi g . 3
NOTE

6MN-601
SmartAir
fi g . 6
NOTE
INSTALLING THE ELECTRICAL COMPONENTS
1. Run the harness from the cab to the solenoid/compressor location.
It may be necessary to drill a hole so that the harness can easily pass through from the
cab to the vehicle frame. Place a grommet or silicone sealant around any holes that the
harness passes through to protect it from abrasive surfaces.
2. Connect single terminal connectors to connect the black compressor wire to the relay
wire (fig. 6).
3. Connect the double terminal connector from the solenoid to the double terminal connector
relay wires (fig. 6).
Axle
Magnet Bracket
(mounted between
the clamp bar and
leaf spring)
Nyloc Nut
Magnet
Frame
Electronic Height
Sensor (EHS)
There must be
1” - 1½” between
the magnet and
the EHS.
(orange dot
faces EHC)
fi g . 4 Axle
Magnet Bracket
(attached to u-bolt)
Magnet
Frame
Electronic Height
Sensor (EHS)
Nyloc Nut
There must be
1” - 1½” between
the magnet and
the EHS.
(orange dot
faces EHC)
fi g . 5
Compressor Wire
Solenoid Wires
Relay
Harness
Ground

7
MN-601
SmartAir
5. Using a butt connector, attach the 12 gauge wire from the terminal 30 on the back of the
relay to one end of the 20 amp fuse holder (fig. 8).
6. If choosing to use the ring terminal, attach it to the other end of the fuse wire (fig. 8).
7. Choose an appropriate 12+ volt source on the vehicle.
A direct connection to the battery is suggested.
NOTE
4. Splice the red wire with the 5 AMP fuse that is connected to the back of the relay to a
keyed on ignition wire (fig. 7).
fi g . 7
8. Attach the terminal end of the ground wire to a clean section of the framerail using the
provided self-tapping screw (fig. 9).
fi g . 8
fi g . 9
Inside View of
Connector
Splice into keyed
on ignition wire.
5 AMP
20 AMP
Back View
Optional Ring Terminal
Connect wire to a 12V
constant on power
source. (Use terminal if
connecting to battery.)
Ground
30
85 86
87

8MN-601
SmartAir
V Battery (1)V Battery (1)
BB
OONN
JJ
5 AMP5 AMP
Compressor (+) (5)Compressor (+) (5)
Compressor (+) (5)Compressor (+) (5)
Compressor (-) (6)Compressor (-) (6)
CompressorCompressor
GroundGround
CompressorCompressor
Valve (+) (3)Valve (+) (3)
Valve (-) (4)Valve (-) (4)
Valve (-) (4) (Not Used)Valve (-) (4) (Not Used)
IgnitionIgnition
Harness Magnetic
Height Sensor Connector
Harness Magnetic
Height Sensor Connector
20 AMP20 AMP
Back ViewBack View
GroundGround
3030
86868585
8787
Troubleshooting Guide
Template For Drilling Holes
CAUTION
ADJUSTING THE SYSTEM
1. Make sure that the distance between the face of the magnet and the height sensor is
between 1” and 1½”.
2. The bolt in the center of the magnet must be in line with the dotted line on the height
sensor when the vehicle is at ride height.
THIS MAGNET IS VERY STRONG. IT IS POSSIBLE FOR THE MAGNET TO PINCH SKIN
AND SMALL BODY PARTS BETWEEN ANOTHER MAGNET OR METAL OBJECT. CARE
SHOULD BE TAKEN WHEN HANDLING THE MAGNET.
CHECKING THE SYSTEM
1. Inspect all air line connections with a solution of 1/5 dish soap to 4/5 water. Should a
leak be detected in a push-lock-fitting, reinstall the air line to the fitting. Make sure air
line is cut off squarely and that the air line is completely pushed into the fitting.
2. If the compressor or the solenoid fails to function, check the 20 AMP fuse and ground
connection. Repair and replace as necessary.

9
MN-601
SmartAir
Air Lift Company warrants its products for the time periods listed on the next page, to the
original retail purchaser against manufacturing defects used on catalog listed applications
on cars, vans, light trucks and motorhomes under normal operating conditions for as
long as Air Lift manufactures the product. The warranty does not apply to products that
have been improperly applied, installed, used in racing applications or not maintained in
accordance with installation instructions furnished with all Air Lift products. The consumer
will be responsible for removing (labor charges) the defective product from the vehicle and
returning it, transportation costs prepaid to the dealer from which it was purchased or to Air
Lift Company for verification.
Air Lift will repair or replace, at its option, defective products or components. A $10.00
shipping and handling charge will apply to all warranty claims. Before returning any defective
product, you must call Air Lift [phone] U.S. and Canada for a Returned Materials
Authorization (RMA) number. Returns to Air Lift can be sent to: Air Lift Company • 2727
Snow Road • Lansing, MI • 48917.
Product failures resulting from abnormal use or misuse are excluded from this warranty. The
loss of use of the product, loss of time, inconvenience, commercial loss or consequential
damages is not covered. The consumer is responsible for installation/reinstallation (labor
charges) of the product. Air Lift Company reserves the right to change the design of any
product without assuming any obligation to modify any product previously manufactured.
This warranty gives you specific legal rights and you may also have other rights that may vary
from state-to-state. Some states do not allow limitations on how long an implied warranty
lasts or allow the exclusion or limitation of incidental or consequential damages. The above
limitation or exclusion may not apply to you. There are no warranties, expressed or implied
including any implied warranties of merchantability and fitness, which extend beyond this
warranty period. There are no warranties that extend beyond the description on the face
hereof. Seller disclaims the implied warranty of merchantability. (Dated proof of purchase
required.)
Warranty and Returns Policy
PROBLEM CAUSE SOLUTION
The system has a 25 second delay before the compressor and solenoid will function.
Compressor doesn’t run. Blown fuse, bad ground, poor
connection, bad compressor or
ECU.
Check fuses, grounds and connections. Ground
terminal 85 at relay to see if compressor runs.
Unplug compressor and test.
Solenoid doesn’t work. Blown fuse, bad connections, bad
solenoid or ECU.
Check fuse, connection, unplug solenoid and
jumper power and ground to check operation.
Compressor runs all the
time.
Leak in system, bad relay or ECU. Locate leak, replace relay or check ECU.
Vehicle does not maintain
ride height.
Bad/leaking solenoid or bad ECU. Unplug solenoid and test by jumping power
and ground.
Nothing happens when the
vehicle is started.
Blown fuse, poor ground or
connection.
Check fuses, connections and grounds.
Bad ECU. Test individual components to verify and ground
terminal 85 to test compressor and harness.
Magnet may not be properly
aligned, may be backward or may
be improper distance from ECU.
Check magnet alignment, distance, and insure
orange dot is facing ECU.

10 MN-601
SmartAir
Replacement Information
If you need replacement parts, contact the local dealer or call Air Lift customer service at
[phone], ext.1. Most parts are immediately available and can be shipped the same
day.
Contact Air Lift Company customer service at [phone], ext. 1, 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.
• 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.
Contact Information
If you have any questions, comments or need technical assistance contact our customer service
department by calling [phone], ext. 1, Monday through Friday, 8 a.m. to 5 p.m. Eastern
Time. For calls from outside the USA or Canada, our local number is [phone].
For inquiries by mail, our address is PO Box 80167, Lansing, MI 48908-0167. Our shipping
address for returns is 2727 Snow Road, Lansing, MI 48917.
You may also contact us anytime by e-mail at [email protected] or on the web at
www.airliftcompany.com.
Air Lift 1000*......................2 Year Limited
SureSet*.............................2 Year Limited
Super Duty*.......................2 Year Limited
Other Accessories............2 Year Limited
Ride Control*.....................2 Year Limited
SlamAir..............................2 Year Limited
Ride Control Plus*............2 Year Limited
Load Controller (I)*...........2 Year Limited
SmartAir*...........................2 Year Limited
Load Controller (II)*..........2 Year Limited
EasyStreet Systems.........1 Year Limited
RoadTamer Systems........2 Year Limited
*The purchase of an Air Lift Load Controller II, SmartAir Automatic Leveling System or SureSet Load
Controller System with a Super Duty, Ride Control, or AirLift 1000 extends the air springs’ warranty
from two years to a Limited Lifetime Warranty to the original purchaser of the covered systems. All
other above listed warranty requirements will apply. (PrimaryAir and EasyStreet air spring systems
are excluded from this offer.)

Air Lift Company • 2727 Snow Road • Lansing, MI 48917 or PO Box 80167 • Lansing, MI 48908-0167
Toll Free [phone] • Local [phone] • Fax [phone] • www.airliftcompany.com
Thank you for purchasing Air Lift products — the professional installer’s choice!
Printed in
the USA
Need Help?
Contact our customer service department by calling
[phone], ext. 1, Monday through Friday, 8 a.m.
to 5 p.m. Eastern Time. For calls from outside the USA
or Canada, our local number is [phone].