Air Lift LoadController 25850 User manual

MN-750 • (071305) • ECR 7651
For maximum effectiveness and safety,
pleasereadtheseinstructionscompletely
before proceeding with installation.
Failure to read these instructions can result in an
incorrect installation.
INSTALLATION GUIDE
Kits 25850
and 25854
Single Gauge Analog
Compressor Systems
Kit #25850 with standard duty compressor
Kit #25854 with heavy duty compressor

Introduction ....................................... 2
Important Safety Notice .............................................2
Notation Explanation ................................................2
Installation Diagram ................................3
Hardware List......................................4
Single Analog Gauge Electrical Schematic .............5
Single Analog Gauge Mounting Options................6
Installing the Load Controller / Single System...........7
Getting Started ....................................................7
Recommended Compressor Locations ..................................7
Step by Step Installation .............................................8
Standard Duty Compressor Mounting ...................................8
Heavy Duty Compressor Mounting .....................................8
Air Line and Power Wires Routing for the Standard Duty Compressor..........9
Air Line and Power Wires Routing for the Heavy Duty Compressor ............10
Product Use Information.............................12
Frequently Asked Questions ..........................................12
Tuning the Air Pressure..............................................12
Guidelines for Adding Air.............................................13
Warranty and Returns Policy .........................14
Replacement Information ............................15
Contact Information ................................15
TABLE OF CONTENTS
1

2MN-750
Introduction
The purpose of this publication is to assist with the installation of the LoadController / Single
onboard air management system.
Itisimportanttoreadandunderstandtheentireinstallationguidebeforebeginninginstallation
orperforming any maintenance,serviceorrepair. The informationhereincludes a hardware
list and step-by-step installation information.
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] or visiti us online at
www.airliftcompany.com for the latest version of this manual.
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: Thecombined, maximum allowableweightof cargo andpassengersthatthe 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
highlightedbyoneofthesenotationsmustbeobservedtohelpminimizeriskof personal injury
orpossible improper installation whichmayrenderthevehicle unsafe. Notesareusedtohelp
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
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3
MN-750
Low Pressure
Sensor Firewall
Fuse Box
Air Springs
(previously installed)
(A1) Standard Duty Compressor
Harness
Analog Single Gauge
Power Wire
Power
Wire
Fuse Adapter
In Line
15 amp Fuse
Inflation Valve
Grommet
Ground
Harness
Relay
- OR -
(A2) Heavy Duty Compressor
Ground
Power wire
Filter Compression Fitting
Leader Hose
Installation Diagram
Adapter #1
Adapter #2
Adapter #3 *
Adapter
Fuse
* Uses 3/16 (smaller) Female Push On Connector
g. 1
NOTE: THIS IS NOT AN
ELECTRICAL SCHEMATIC
BUT A LAYOUT OF THE
CONTROL SYSTEM.SEE
PAGE 5 FOR ELECTRICAL
DIAGRAMS.
Load Controller / Single

4MN-750
Missing or damaged parts? Call Air Lift customer
service at [phone] for a replacement part.
Hardware List
Item Part # Description ............................... Qty
A1 16060 Standard Duty Compressor ................1
A2 16092 Heavy Duty Compressor.....................1
B25194 Analog Single Gauge..........................1
C26512 Harness, Single Analog Gauge...........1
D 21952 Tee, 1/8 FNPT X 1/4 PTC...................1
E24558 Sensor, 5 PSI......................................1
F 20946 1/4” Air Line, “DOT”........................... 25’
G 25196 Gauge Mounting Kit............................1
H 10463 Grommet.............................................1
I 24652 Spade Fuse, 15 Amp (ATC)................1
J 24539 Fuse Holder (ATC/ATO) .....................1
K 24752 Center Butt, 12-10 GA Shrink Tube....2
L24524 3/16” Terminal, FSpd ..........................1
M 24595 FSpd Terminal, 12 GA ........................1
N 24543 Fuse, AGC Tap In...............................1
O24561 Mini Fuse Adapter...............................1
P24542 ATC/ATO Fuse Tap In 1/4 ..................1
Q 24594 1/4” Terminal, FSpd 16 GA.................4
R10466 8” Zip Tie.............................................5
S 21838 Tee Union 1/4” X 1/4” PTC .................3
T 17441 #8-18X1” Tek Screw ...........................2
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MN-750
Single Analog Gauge Electrical Schematic
g. 2
AL004A
AL007
AL004C
AL006C AL005C
AL006A
AL005A
Load Controller / Single

6MN-750
Single Analog Gauge Mounting Options
g. 3
Single analog gauge mounting
hardware on bottom of gauge
g. 4
Single analog gauge mounting
hardware on top of gauge
g. 5
Back of analog gauge
AirlinePower Wires
g. 6 Optional Dashboard Mounting
(Exploded View)
Load Controller / Single

7
MN-750
Installing the Load Controller / Single System
GETTING STARTED
This part of the installation should be done after the air spring kit is installed.If you
have any questions, please call Air Lift customer service at [phone].
If you are adding this control system to an Air Lift LoadLifter5000 application, then no
modications to the low pressure sensor are necessary. If you are adding this control system
to an Air Lift 1000 or RideControl application, and if your specic application requires a
minimum of 10 p.s.i., then it will be necessary to adjust the low pressure sensor to 10 p.s.i.
To increase the pressure in the low pressure sensor, remove the rubber plug with pliers
(g. 7). Using an allen wrench, turn the screw clockwise 4 1/4 turns (g. 8). Push the rubber
plug back into the top of the low pressure sensor. Proceed with the step by step installation
instructions.
RECOMMENDED COMPRESSOR LOCATIONS
Important
LOCATE COMPRESSOR IN DRY, PROTECTED AREA ON VEHICLE.
DIRECT SPLASH OR EXCESSIVE MOISTURE CAN DAMAGE
THE COMPRESSOR AND CAUSE SYSTEM FAILURE.
Disclaimer: If you choose to mount the compressor outside the vehicle please keep in
mind the compressor body must be shielded from direct splash and the intake should be
snorkeled inside the vehicle. If the compressor does not include a remote mount air lter or
if mounting the compressor outside the vehicle, make sure to orient the compressor intake
lter so that all moisture can easily drain.
Please also remember...
•To avoid high heat environments
•To avoid mounting the compressor under the hood.
•To check to be sure the compressor harness #2 will reach the compressor and connect
to harness #1.
The compressor can be mounted in any position — vertical, upside down, sideways, etc.
(please refer to the instruction manual).
g. 7
Remove
rubber cap
g. 8
Turn allen screw 4 ¼
turns clockwise
Load Controller / Single

8MN-750
STEP BY STEP INSTALLATION
We recommend that you install the air spring kit rst per the instructions provided with the
air spring kit.
1. Install the gauge pod (gs. 3, 4 & 5). Select a convenient mounting location that has a
sturdy rigid surface. The bottom edge of the dash on either side of the steering wheel is
agood location. Attachthe gaugepod tothe selectedlocation withthe blackself-tapping
screws.
Optional dash mounting bracket and hardware also included (g. 6).
2. Connect the harness to the gauge pod.
a. Connect the color coded wires to the gauge harness as shown in the attached
schematic.
b. Connect the low pressure switch assemblies as shown in gures 2 and 9.
c. Do not connect the power wire at this time.
d. Thewiring harness also connects the gauge pod tothelowpressuresensorassembly.
The low pressure sensor protects the air springs from failure resulting from low
pressure in the unloaded condition. This sensor is preset to maintain a MINIMUM
pressure of 5 psi in the air springs unless the setting was changed in the “Getting
Started” section. The sensor measures the pressure in each spring and turns on the
compressor if the pressure falls below the set psi.
e. Screw ground eyelet to rewall or other electrical ground in the cab.
The sensor should be located under the dash inside the vehicle and secured with the
provided tie straps.
3. Install the compressor unit.
a. Hold the compressor in the recommended location (g. 10 or 11).
b. For box frames: In some cases the frame section will not be wide enough to mount
the compressor legs at to the rail. Refer to gs. 10 and 11 in this situation.
DO NOT DRILL ANY HOLES INTO THE FRAME OR THE FLOOR BOARD BEFORE
CHECKING FOR HYDRAULIC LINES, GAS LINES, AND/OR ELECTRICAL WIRES
THAT MAY NEED TO BE MOVED ASIDE. ALSO, WHEN ATTACHING TO THE FLOOR
BOARD, IT IS IMPORTANT TO CHECK WHERE THE SCREWS PROTRUDE THROUGH
THE FLOOR BOARD. IT MAY BE NECESSARY TO TRIM OR COVER THE TOP OF THE
SCREWS INSIDE THE VEHICLE. A SEALER SHOULD BE USED AROUND THE SCREW
TO PREVENT THE ELEMENTS FROM ENTERING THE CAB AREA.
STANDARDDUTYCOMPRESSOR MOUNTING (FIG.1-A1, 10)
In some cases the mounting area does not provide enough room to use a drill to drive in
the screws. It may be necessary to use the mounting brackets as a template to drill 13/64”
holes through the frame rst and then use a 7/16” nut driver to install the self tapping screws.
NOTE
NOTE
CAUTION
NOTE
g. 9
Compressor side
Gauge side Black (ground)
Gray
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MN-750
HEAVY DUTY COMPRESSOR MOUNTING (FIG. 1 - A2, 11)
Using the compressor as a template, drill holes and mount the compressor using the black
mounting hardware that comes in the box containing the compressor.
Attach the compressor ground wire to one of the mounting screws (g. 1).
AIR LINE AND POWER WIRES ROUTING FOR
THE STANDARD DUTY COMPRESSOR:
1. Push the air line onto the barb tting on the compressor. Make sure the air line covers
all barbs. A small amount of water or lubricant and pushing with a slight circular motion
will ease installation (g. 12).
g. 12
Air line
Ground Power (red) wires
Barbed tting/
check valve
NOTE
g. 11
Frame
Floor plan
g. 10
Floor plan
Frame
L-bracket
Supplied self
tapping screw
¼” Bolt and nut will need to be provided if the L-bracket is
fabricated. The L bracket is shown as an optional mounting
method and is not supplied.
NOTE
Load Controller / Single

10 MN-750
(A2) Heavy Duty Compressor
Ground
Power wire
Filter Compression Fitting
Leader Hose
AIR LINE AND POWER WIRE ROUTING FOR
THE HEAVY DUTY COMPRESSOR:
1. Remove the nut from the leader hose and install over air line from check valve assembly.
2. Push the air line from the check valve assembly into the barbed tting on the compressor
leader hose.
3. Slide the nut over the tting and tighten securely (g. 13).
4. Route the harness to the compressor.
a. Use existing grommets in the oorboard or rewall to route the harness from the cab
to the frame mounted compressor.
b. In some cases, a hole may have to be drilled to allow access for the harness. Drill
a 1” diameter hole and install the provided grommet (g. 14). It will be necessary to
seal any grommets or holes that have been cut, drilled or removed so as not to allow
elements to enter the cab area of the vehicle.
c. When routing the wiring harness, it should not be routed so as to lay on, or near,
the exhaust pipe/mufer/catalytic convertor of the vehicle. Routing along the top of
a crossmember or over a heat shield is recommended.
5. The next connection is between each air spring and the air line “T” tting.
a. With the air springs deated, use a hose cutter to cut the air line already installed
between the air springs and the ination valves.
b. Install the provided “T” ttings (g. 1) by pushing the air line into each leg of the “T”
until you feel a denite “click”. Each line should go in 9/16”.
c. Connect a single length of air line to the open leg of the “T”. Connect as shown in
the pneumatic schematic.
d. Route the air line across the chassis from the far side over the exhaust system heat
shieldsand along theframeup to thecompressor.Avoid heat sources,sharpedges,
and tight bends.
g. 14
After the hole is drilled and before
you route the harness to through the
rewall, insert the grommet and “walk”
the material around the inside edge of
the drilled hole. You may have to trim
the grommet to get an exact t.
(The exible grommet is in the sealed
parts package.)
g. 13
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11
MN-750
NOTE
CAUTION
e. Route air lines into cab from “T” tting and attach to pressure switch assembly as
shown in the pneumatic schematic.
f. Route air lines from low pressure switch to gauge barb.
g. Press air line over gauge barb. Water or lube may assist in securing air lines over
the barb. A circular motion will assist in installation.
6. Connect the power wire to fused ignition.
a. Route it to the vehicle fuse box.
b. Determine which open terminal (accessory, etc.) works only when the key is in the
“on” or accessory position (or refer to the owners manual for an available accessory
fuse). The terminal should have an amperage rating higher than the 15 amp in-line
fuse.
c. Connection to the fuse terminal will depend on what type of fuse your vehicle uses.
If your vehicle uses the barrel type fuse, use adapter #1. If you have the standard
spade type fuses, use adapter #2. Many late model vehicles use a smaller spade
type fuse which requires adapter #3 (g. 15). If adapter #1 or #2 are used, it will be
necessary to cut off the ¼” female connector attached to the power wire and crimp
the smaller 3/16” female connector supplied with this kit.
Connect adapter to “HOT” side of the fuse. With the ignition on, the compressor will turn on
and ll the system to 10 p.s.i. before shutting off.
7. Press the off/on button to inate both air springs and use the small deate button to
adjust the pressure. Inate to 30 p.s.i. (20 p.s.i. for Air Lift 1000 kits). Check all ttings
and ination valve cores with a solution of 1/5 dish soap to 4/5 water in a spray bottle
for leaks.
IMPORTANT: If the compressor runs continually or often, then there is a leak. Disconnect
the compressor at the fuse box and test for leaks with a soapy water solution.
NEVER RUN THE COMPRESSOR LONGER THAN FOUR MINUTES CONTINUOUSLY.
ALLOW AT LEAST FIVE MINUTES FOR COOL DOWN BEFORE STARTING THE
COMPRESSOR AGAIN.
Adapter #1
Adapter #2
Adapter #3 *
Adapter
Fuse
* Uses 3/16 (smaller) Female Push On Connector
g. 15
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12 MN-750
Frequently asked questions
Q. Will installing air springs increase the weight ratings of a vehicle?
No. Adding air springs will not change the weight ratings (GAWR, GCWR and/or GVWR)
of a vehicle. Exceeding the GVWR is dangerous and voids the Air Lift warranty.
Q. Is it necessary to keep air in the air springs at all time and how much pressure
will they need?
The minimum air pressureshould be maintained at all times. Theminimum air pressure
keeps the air spring in shape, ensuring that it will move throughout its travel without
rubbing or wearing on itself.
Q. Is it necessary to add a compressor system to the air springs?
No.Air pressure can beadjusted withany typeof compressoras long asit canproduce
sufcient pressure to service the springs. Even a bicycle tire pump can be used, but
it’s a lot of work.
Q. How long should air springs last?
If the air springs are properly installed and maintained they can last indenitely.
Q. Will raising the vehicle on a hoist for service work damage the air springs?
No.The vehiclecan belifted on ahoistfor short-termservice worksuch as tirerotation
oroilchanges. However, if thevehicle will beon the hoistfor a prolongedperiod of time,
support the axle with jack stands in order to take the tension off of the air springs.
Tuning the air pressure
Pressure determination comes down to three things — level vehicle, ride comfort, and
stability.
1. Level vehicle
If the vehicle’s headlights are shining into the trees or the vehicle is leaning to one side,
then it is not level (g. 16). Raise the air pressure to correct either of these problems
and level the vehicle.
2. Ride comfort
If the vehicle has a rough and harsh ride it may be due to either too much pressure or
not enough (g. 17). Try different pressures to determine the best ride comfort.
3. Stability
Stability translates into safety and should be the priority, meaning the driver may need
to sacrice a perfectly level and comfortable ride. Stability issues include roll control,
bounce, dive during braking and sponginess (g. 18). Tuning out these problems
usually requires an increase in pressure.
Bad headlight aim
g. 16
Sway and body roll g. 17
Rough ride g. 18
Product Use Information
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13
MN-750
Guidelines for adding air:
1. Start with the vehicle level or slightly above.
2. When in doubt, always add air.
3. For motorhomes, start with 50-100 p.s.i. in the rear because it can be safely assumed
that it is heavily loaded.
4. If the front of the vehicle dives while braking, increase the pressure in the front air
bags, if equipped.
5. If it is ever suspected that the air bags have bottomed out, increase the pressure (g.
19).
6. Adjust the pressure up and down to nd the best ride.
7. If the vehicle rocks and rolls, adjust the air pressure to reduce movement.
8. It may be necessary to maintain different pressures on each side of the vehicle. Loads
such as water, fuel, and appliances will cause the vehicle to be heavier on one side
(g. 20). As much as a 50 p.s.i. difference is not uncommon.
g. 19
Bottoming out Unlevel Level g. 20
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14 MN-750
Air Lift 1000....................Lifetime Limited
RideControl....................Lifetime Limited
LoadLifter 5000*.............Lifetime Limited
SlamAir...........................Lifetime Limited
AirCell.............................Lifetime Limited
Air Lift Performance**..........1 Year Limited
LoadController/Single......2 Year Limited
LoadController/Dual.........2 Year Limited
Load Controller (I) ............2 Year Limited
Load Controller (II) ...........2 Year Limited
SmartAir ............................2 Year Limited
Wireless AIR......................2 Year Limited
WirelessONE.....................2 Year Limited
Other Accessories............2 Year Limited
*formerly SuperDuty
**formerly LifeStyle & Performance and EasyStreet
Warranty and Returns Policy
Air Lift Company warrants its products, for the time periods listed below, to the original
retail purchaser against manufacturing defects when 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, improperly installed, used in racing or off-road applications, used for
commercial purposes, or which have not been maintained in accordance with installation
instructions furnished with all 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 verication.
Air Lift will repair or replace, at its option, defective products or components. A minimum
$10.00 shipping and handling charge will apply to all warranty claims. Before returning
any defective product, you must call Air Lift at [phone] in the U.S. and Canada
(elsewhere, [phone]) 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 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 tness, 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.)
Load Controller / Single

15
MN-750
Contact Information
If you have any questions, comments or need technical assistance contact our customer
service department by calling [phone], Monday through Friday. 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.
Replacement Information
If you need replacement parts, contact the local dealer or call Air Lift customer service at
[phone]. Most parts are immediately available and can be shipped the same day.
Contact Air Lift Company customer service at [phone] rst 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.
Load Controller / Single

16 MN-750
Notes
Load Controller / Single

17
MN-750
Notes
Load Controller / Single

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], Monday through Friday. For calls
from outside the USA or Canada, our local number
is [phone].
Register your warranty online at
www.airliftcompany.com/warranty