Air Lift 72000 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-681 • (05902) • ECR 6629
INSTALLATION GUIDE
Kit 72000
Automatic Leveling
Digital On-Board
Compressor System

Important:Avoiding Cold Weather Freeze-up ............2
Introduction.......................................3
ImportantSafetyNotice .............................................3
Notation Explanation ................................................3
Installation Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HardwareList .....................................................5
Tools List .........................................................5
Installing the WirelessAIR System. . . . . . . . . . . . . . . . . . . . . 6
Installing the Compressor ............................................6
InstallingtheManifold...............................................7
Installing the Electrical Components ....................................8
Attaching the Air Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Joining the Digital Controller to the Manifold..............................11
Rejoining and Options Menu ..........................................13
Things You Need to Know............................................13
Checking the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Joining Troubleshooting Flow Chart...................14
TroubleshootingGuide .............................16
Warranty and Return Policy ..........................17
Replacement Information ............................18
ContactInformation ................................18
Templates.........................................19
TABLE OF CONTENTS
1

2MN-681
WirelessAIR
How to Avoid a Freezing Condition
in 72000 Wireless Air Kits
Important
To avoid COLD WEATHER FREEZE UP:
Add 4 oz. (1/2 cup) of
“GUNK” Brand AIR BRAKE ANTI FREEZE
Directly into each ex member. Remove the air line and/or tting from
the air bag and ll directly. Gunk Brand Air Brake Anti-Freeze may be
purchased at an automotive parts store or truck supply store.
WARNING: DO NOT FILL THROUGH COMPRESSOR OR MANIFOLD
— DAMAGE WILL OCCUR.
CAUTION: DO NOT USE ENGINE ANTI-FREEZE
Check uid levels in ex member every year (add if needed).
1/2 Cup
Pour Here

3
MN-681
WirelessAIR
Introduction
The purpose of this publication is to assist with the installation, maintenance and
troubleshooting of the WirelessAIR 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, step-by-step installation information, 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] for the latest version
of this manual or nd it online at http://www.airliftcompany.com/wirelessair.htm.
SYSTEM INFORMATION
The WirelessAIR (Advanced Integrated Remote) is designed for automatic digital leveling of
the on-board compressor system. The kit includes a compressor, manifold, wiring harness,
and wireless digital controller. With the capability to control two air springs independently, the
system can be used in or outside the vehicle, for adjustments in full view of the vehicle.
The wireless digital controller is a compact, battery powered unit that features advanced
integrated diagnostic capabilities for increased safety and peace of mind. It also includes
a clip that can be attached to the vehicle’s visor. Two user-dened memory buttons are
provided for frequently used settings. As an added safety measure, minimum air pressures
are automatically maintained. The manifold is also weather resistant and waterproof up to
2 ft for maximum life expectancy.
IMPORTANT SAFETY NOTICE
The installation of this kit does not alter the Gross Vehicle Weight Rating (GVWR) or payload
of the vehicle. Check your vehicle’s owner’s manual and do not exceed the maximum load
listed for your vehicle.
Gross Vehicle Weight Rating: The maximum allowable weight of the fully loaded vehicle
(including passengers and cargo). This number — along with other weight limits, as well
as tire, rim size and ination pressure data — is shown on the vehicle’s Safety Compliance
Certication Label.
Payload: The combined, maximum allowable weight of cargo and passengers that the truck
is designed to carry. Payload is GVWR minus the Base Curb Weight.
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
denitions explain the use of these notations as they appear throughout 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

4MN-681
WirelessAIR
Installation Schematic
8787
8585
8686
3030
40 30 30 60 40 40 50 40
40 30 30 60 40 40 50 40
Fuse Panel
F
C
N
B
E
M
N
O (1 Amp fuse)
K or P
L
O (15 Amp fuse)
Inset A
Adapter Adapter #1
Adapter #2*
*Uses 3/16 (smaller) female push on connector Air springs are shown for
reference only. They are not
included in the kit. g. 1
Red/white (+12V KEYED) wire
Yellow (+12V BATT FUSED) wire
Yellow/red (+12V COMP) wire
Red wire
Black wire
Compressor’s red wire

5
MN-681
WirelessAIR
TOOLS LIST
Description.............................................. Qty
Hoist or oor jacks................................................ 1
Safety stands........................................................ 2
Safety glasses ...................................................... 1
Torque wrench...................................................... 1
Heavy duty drill..................................................... 1
#2 Phillips bit driver .............................................. 1
Description.............................................. Qty
7/32 & 1/8 Drill bits ............................................... 1
5/16 Driver............................................................ 1
Hose cutter, razor blade, or sharp knife ............... 1
Spray bottle with dish soap/water solution ........... 1
Digital volt meter................................................... 1
HARDWARE LIST
Item Part # Description................................Qty
A 72001 Wireless digital controller*...................1
B 72003 Wireless manifold................................1
C 16092 12V Compressor.................................1
D 20220 20 ft. hose ...........................................1
E 72003-004 Wireless manifold harness..................1
Harness Hardware Pack (34638)
F 21838 Tee 1/4 PTC .......................................2
G 24537 Quick splice 18-22 ga .........................1
H 24561 Adapter mini fuse................................1
J 24542 1/4 ATC/ATO tap in fuse.....................1
K 24594 1/4 Female spade 22-18 ga ................1
L 24661 Heat shrink butt 22-18 ga....................1
M 24748 Ring terminal 12 ga.............................1
N 24752 Heat shrink butt 16 ga.........................2
Item Part # Description................................Qty
O 24767 Barrel and spade fuse pack ................1
P 24542 3/16 Female spade 22-18 ga..............1
Q 21834 1/8” FNPT - 1/4” PTC..........................1
R 21839 1/8” MNPT - 1/4” PTC.........................1
Mounting Hardware Pack (34639)
S 17385 10-32” x 1/2” Screw.............................2
T 10466 8” Zip tie ............................................16
U 17263 1/4” x 1 Self-tapping screw .................1
V 18411 5/16” Lock Washer..............................1
W 17132 #8-18 x 1/2” Philips S-t screw (black) ....2
X 17386 #10 x 2.5 Self-tapping screw...............1
Y 10977 Magnet................................................1
Z 72001-004 Visor Clip.............................................1
* Batteries not included.
Missing or damaged parts? Call Air Lift customer
service at [phone] for a replacement part.
STOP!

6MN-681
WirelessAIR
Installing the WirlessAIR System
INSTALLING THE COMPRESSOR
1. Select a rigid mounting location on your vehicle’s frame or cross member that shields
the compressor from the elements and heat sources (g. 2).
2. Centerpunch and drill four 7/32” to 1/4” holes on the mounting location using the supplied
template on page 19.
3. Attach the compressor to the frame using the four supplied screws and washers from the
compressor box (g. 2).
4. Fasten the screws with the supplied nuts and lock washers from the compressor box.
5. Ground the ring terminal using the 1/4” x 1” self-tapping screw (U) and the 5/16” lock
washer (V) (g. 2).
6. Insert the male tting (R) into the compressor intake (g. 3).
7. Insert the hose into the male tting (R) (g.3).
8. Route the hose into the vehicle or into another clean, dry location.
9. Insert the compressor lter into the female tting (Q). Trim the hose and insert it into the
female tting (g.3).
10.Secure the hose and lter using the zip ties (T) provided.
Compressor
Frame
Ring terminal
g. 2
Male tting (R)
Compressor intake
Hose Female tting (Q)
Compressor lter
g. 3

7
MN-681
WirelessAIR
INSTALLING THE MANIFOLD
When mounting the manifold, it will be necessary to leave the screws loose until after you have
joined the manifold to the display controller using a magnet (see Joining the Digital Controller...).
There must be no pressure in the air bags when the manifold is powered on for the rst time.
1. The manifold can be mounted by using either the two 10-32” mounting holes on the bottom
or the thru hole with the locating protusion. If mounting by the bottom of the manifold, use
the supplied template on page 19 to drill two 7/32” holes into the mounting surface. Secure
using the 10-32” x 1/2” screws (S) (g. 5).
THE MANIFOLD MUST ALWAYS BE MOUNTED IN THE ORIENTATIONS SHOWN IN FIG. 4.
2. If mounting by the thru hole and protrusion, try to nd an existing hole into which the
protrusion will t. After you have joined the controller to the manifold in later steps, secure
using the #10 x 2.5 self-tapping screw (X) torqued to 77 in-lbs. If needed, drill a 7/32”
hole for the protrusion and a 1/8” pilot hole for the self-tapping screw using the template
supplied on page 19 (g. 6).
If torque exceeds 77 in-lbs, the screw (X) has a high probability of breaking.
CAUTION
The manifold must be installed in
one of these orientations.
Self-tapping
screw (X)
Protrusion
Screws (S)
g. 6
g. 5
g. 4
NOTE
NOTE

8MN-681
WirelessAIR
INSTALLING THE ELECTRICAL COMPONENTS
1. Once the manifold has been mounted, ground the white (-12V GND) wire with the serrated
ring terminal to the frame or other part of the vehicle that is grounded to the battery. Use
a #8-18 x 1/2” Philips S-t screw (black) (W) to attach (g. 7).
Ground the white
(-12V GND) wire
using screw (W)
Mounted manifold
g. 7
2. Mount the relay to a safe location on the frame or body within 10 inches of the manifold using
the #8-18 x 1/2” Philips S-t screw (black) (W) .
3. Locate a keyed +12 volt accessory source on the vehicle using a digital volt meter and
connect one side of the barrel fuse to it (g. 8) . It may be possible to tap into the fuse
box with the provided fuse taps, please note that the supplied fuse taps will t the majority
of vehicles, but may not t all.
Air Lift Company is not responsible for any damage to the vehicle due to splicing into the
wrong wire on the vehicle’s electrical system. If you have any questions regarding the proper
+12V keyed wire to tap into, please contact your local dealer.
4. Crimp one half of the heat shrink butt connector (L) to the other end of the barrel fuse.
Trim any access red/ white (+12V KEYED) wire and crimp to the other half of the heat
shrink butt connector (g. 8). Shrink the coating on the connector with a heat gun to seal.
To prevent failure, secure the wire away from all heat sources using zip ties.
Try to route the wire through an existing hole with a protective grommet. If none are available,
drilling a hole may be necessary. Once the hole is drilled use the grommet material provided
to protect the wire from sharp edges.
If the vehicle has an external fuse box, routing through the rewall may not be necessary.
NOTE
NOTE
Barrel fuse
Heat shrink butt
connector (L)
Female spades
(P) or (K)
g. 8
Red/white
(+12V KEYED) wire Red/white
(+12V KEYED) wire
NOTE