Pacbrake L6127 User manual

PACBRAKE ONBOARD AIR SYSTEM
PERSONALIZED ONBOARD AIR SYSTEMS FOR ALL VEHICLES APPLICATIONS

INSTALLATION MANUAL - PACBRAKE ONBOARD AIR SYSTEMS, L6127
PG. 1
Thank you and congratulations on the purchase of a Pacbrake onboard air system. Please read the installation
manual prior to starting to ensure you can complete the installation once started.
BEFORE STARTING please ensure the kit includes all the items shown in the photo.
HP10163 - Includes a ½Gallon Air Tank
HP10164 - Includes a 2½Gallon Air Tank
IMPORTANT: These kits include push-to-connect airline ttings. They require the end of the airline to be cut cleanly
and square to ensure the internal seal will not leak air. The airline must only be cut with a sharp knife or hose cutter.
Using scissors or wire cutters will distort the airline causing the connection to leak air past the o-ring seal.

INSTALLATION MANUAL - PACBRAKE ONBOARD AIR SYSTEMS, L6127
INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 2
INSTALLATION MANUAL - PACBRAKE ONBOARD AIR SYSTEMS, L5856
PG 2
3
4
5
3 Locate the inline air dryer provided. The dryer should be
mounted vertically between the compressor and the air
tank. The needle valve must be accessible to the operator
for periodic draining. A clamp and fastener is provided to
remote mount the air dryer if desired. Use thread sealant on
all ttings to ensure no air leaks exist.
ELECTRICAL CONNECTIONS
4 Provided in the kit is a pre-wired relay receptacle to make
this part of the installation easy. Find a convenient location
to mount the relay receptacle within 12" of the positive
battery terminal. Using the self tapping screw provided,
secure the relay receptacle and install the relay.
5 Locate the black wire of the relay harness, route it to the
air tank location. Using the ttings provided, install the pres
sure switch into one of the ports in the air tank (DO NOT
INSTALL IN THE BOTTOM PORT) Using the ttings
provided, install the pressure switch in a location for it to
sense air tank pressure. Connect the black wire of the relay
harness to one of the two wires of the pressure switch using
the heat shrink butt connector. Using the loose piece of
black wire and another heat shrink butt connector, connect
to the remaining wire of the pressure switch, heat the
connectors to provide a water tight seal. Then connect the
end with an eye terminal to a good chassis ground.
6 Locate the white wire of the relay harness. Connect it to
an ignition power source through the 5 amp inline fuse
provided. This wire can be connected through an ON/OFF
switch to over-ride the compressor activation should the
customer prefer this option.
If a HP10062 or HP10022 kit is being installed,
a compressor ON/OFF switch is included in these kits
White
5 Amp
Fuse
12v +
Ignition
Switched
14 to 16
gage wire
3M®T-tap connector
6
INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 2
INSTALLATION MANUAL - PACBRAKE ONBOARD AIR SYSTEMS, L5856
PG 2
3
4
5
3 Locate the inline air dryer provided. The dryer should be
mounted vertically between the compressor and the air
tank. The needle valve must be accessible to the operator
for periodic draining. A clamp and fastener is provided to
remote mount the air dryer if desired. Use thread sealant on
all ttings to ensure no air leaks exist.
ELECTRICAL CONNECTIONS
4 Provided in the kit is a pre-wired relay receptacle to make
this part of the installation easy. Find a convenient location
to mount the relay receptacle within 12" of the positive
battery terminal. Using the self tapping screw provided,
secure the relay receptacle and install the relay.
5 Locate the black wire of the relay harness, route it to the
air tank location. Using the ttings provided, install the pres
sure switch into one of the ports in the air tank (DO NOT
INSTALL IN THE BOTTOM PORT) Using the ttings
provided, install the pressure switch in a location for it to
sense air tank pressure. Connect the black wire of the relay
harness to one of the two wires of the pressure switch using
the heat shrink butt connector. Using the loose piece of
black wire and another heat shrink butt connector, connect
to the remaining wire of the pressure switch, heat the
connectors to provide a water tight seal. Then connect the
end with an eye terminal to a good chassis ground.
6 Locate the white wire of the relay harness. Connect it to
an ignition power source through the 5 amp inline fuse
provided. This wire can be connected through an ON/OFF
switch to over-ride the compressor activation should the
customer prefer this option.
If a HP10062 or HP10022 kit is being installed,
a compressor ON/OFF switch is included in these kits
White
5 Amp
Fuse
12v +
Ignition
Switched
14 to 16
gage wire
3M®T-tap connector
6
INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 1
INSTALLATION MANUAL - PACBRAKE ONBOARD AIR SYSTEMS, L5856
PG 1
AIR COMPRESSOR AND AIR TANK MOUNTING
1 Choose a location to install the air compressor, it should be
in a clean, dry location. The compressor makes an audible
noise when pumping, consider this when choosing a location.
Using the compressor as a template, drill the 4 mounting
holes. Using the fasteners provided, secure the compressor.
Some installers fabricate a mounting bracket like the one
shown in the photo.
2 Choose a location to mount the air tank. If possible keep
the tank within 21" of the air compressor. This will allow
the stainless steel braided hose supplied to be plumbed to
the air tank.The braided line has a one way check valve to
prevent air from leaking out through the compressor head.
Two ttings and extra nylon hose are provided to extend the
stainless braided hose if necessary.
Thank you and congratulations on the purchase of a Pacbrake onboard air system. Please read the installation
manual prior to starting to ensure you can complete the installation once started.
These are specially designed kits for those customers who want options when building their own onboard
air system. Pacbrake offers 7 different kits in which you can mix and match to develop your own system.
BEFORE STARTING please ensure the kits includes all the items shown in the photo below.
1
2
HP10066 - COMPRESSOR KIT
30% DUTY CYCLE
HP10067 - COMPRESSOR KIT
100% DUTY CYCLE
HP10022 -
AIR SPRING ACTIVATION KIT
HP10062 -
AIR SPRING ACTIVATION KIT
HP10053 -
½ GALLON AIR TANK KIT
HP10050 -
2½ GALLON AIR TANK KIT
HP10051 -
5 GALLON AIR TANK KIT
SIMULTANEOUS INDEPENDENT
NOTE: HP10051 CAN NOT
BE USED WITH HP10066
COMPRESSOR KIT
PG. 2
STEP 2
STEP 1
STEP 3
STEP 4
AIR COMPRESSOR AND AIR TANK MOUNTING
1 Thread sealant or Teon tape must be applied to all the tting threads
installed throughout the installation to prevent air leaks. Install the push-
to-connect ttings into the check valve, then install the assembly into the
compressor head, as shown in the photo.
The compressor makes an audible pumping noise when activated. Consider
this when choosing a mounting location. The location should also be in a
clean, dry area to maintain long compressor life. Using the compressor as a
template, mark and drill three 3/16" diameter holes. Secure the compressor
using the fasteners provided.
2Choose a location to mount the air tank. Using the supplied hardware mount
the tank with the drain port facing down.
ELECTRICAL CONNECTIONS
3Provided in the kit is a pre-wired relay receptacle to make this part of the
installation easy. Find a convenient location to mount the relay receptacle
within 12” of the positive battery terminal. Using the self tapping screw pro-
vided, secure the relay receptacle and install the relay.
CAUTION: Never extend the wire of the harness beyond the length supplied.
4 Locate the black wire of the relay harness, route it to the air tank location.
Using the ttings provided, install the pressure switch into one of the ports
in the air tank. DO NOT INSTALL IN THE BOTTOM PORT. Using the ttings
provided, install the pressure switch in a location for it to sense air tank
pressure. Connect the black wire of the relay harness to one of the two
wires of the pressure switch using the heat shrink butt connector. Using the
loose piece of black wire and another heat shrink butt connector, connect
to the remaining wire of the pressure switch. Heat the connectors to provide
a water tight seal. Then, connect the end with an eye terminal to a good
chassis ground.

INSTALLATION MANUAL - PACBRAKE ONBOARD AIR SYSTEMS, L6127
INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 3
INSTALLATION MANUAL - AIR SPRING CONTROL KITS, L5904
PG 3
COMPRESSOR AIR INTAKE FILTER
4 Locate the air intake lter housing, barbed tting and 6’ length
of blue nylon hose provided in kit. Choose a location to mount
the lter housing within 6” of the compressor, the housing re-
quires a 1/2” hole for mounting, the location must also provide
clean dry air. Secure the barbed tting to the lter housing,
connect the nylon hose to the barbed tting, install the housing
into the mounting hole. Route the nylon hose to the inlet tting at
the compressor, secure the hose with tie-straps provided.
ELECTRICAL CONNECTIONS
5 Provided in the kit is a pre-wired relay receptacle to make this
part of the installation easy. Find a convenient location close to
the positive battery terminal to mount the relay receptacle. Using
the self tapping screw provided, secure the relay receptacle and
install the relay provided.
6 Locate either one of the two red 12 gage wires of the relay
harness. Cut to length and connect the 30 amp fused link.
Connect the 30 amp fused link to the positive terminal of the
battery. Locate the second red 12 gage wire and route to the
compressor. Cut to length and crimp on the supplied blue butt
connector, then connect to the red compressor wire. Locate the
black wire of the compressor and connect to a good chassis
ground or the negative battery terminal. Heat the
connector’s to provide a water tight seal.
7 Locate the 16 gage red with white strip and the white wire of the
relay harness. Route these two wires into the cab through the
rewall boot. Connect the red with white strip wire to the 5 amp
inline fuse provided, then to a 12 volt ignition power source using
the “T” tap connector provided. Test the ignition power source
with a volt meter prior to attaching the “T” tap. Some ignition
circuits are less than 12 volts which may not be enough to acti-
vate the relay coil. This wire can be connected through an ON/
OFF switch to override the compressor activation, should the
customer prefer this option. (Switch not provided in the kit,
available separately)
Heat the butt connector’s to provide a water tight seal.
4
5
6
7
INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 3
INSTALLATION MANUAL - PACBRAKE ONBOARD AIR SYSTEMS, L5856
PG 3
7
8
7 Locate the red 12 gauge wire of the relay harness, route
this wire to the compressor mounting location. Connect to
the red wire at the compressor. Connect the black wire of
the compressor to a good chassis ground. Using the
convoluted loom provided cover the exposed wires and
secure with tie-straps provided.
8 Install the air compressors air intake lter, using the nylon
hose marked air intake connect one end to the barbed tting
below the compressor head. Install the lter housing in the
other end of the nylon hose. Install the lter housing in a dry
clean area below the level of the air intake port to ensure
maximum compressor life.
CONNECTING AIR ACCESSORIES TO THE AIR TANK
9 Do not source air from the bottom port of the air tank. Install
the drain valve provided in the bottom port of the air tank,
periodic draining of the tank will be necessary.
NOTE: The pressure switch included in this kit has a
maximum pressure of 130 PSI and a minimum pressure
of 110 PSI, please ensure your accessories are capable of
this pressure, a regulator maybe necessary for some
accessories. Pacbrake can supply lower pressure switches
upon request. Also, Pacbrake offers dual needle gauge kits
to monitor system pressure. This gauge kit can also be used
to monitor air spring pressure.
10 Locate the quick disconnect tting provided. Consult with the
vehicle operator for their preference on the mounting
location with easy access. This location should be away
from dirt and moisture which could contaminate the tting.
Using the mounting bracket, self tapping screws, nylon air
line and ttings provided, connect it to the air tank. Use
thread sealant on all ttings installed.
9
10
PG. 3
STEP 5
5Locate the white wire of the relay harness. Connect it to an ignition power
source through the 5 amp inline fuse provided. This wire can be connected
through an ON/OFF switch to override the compressor activation should the
customer prefer this option.
6 Locate the red 12 gauge wire of the relay harness, route this wire to the
compressor mounting location. Connect to the red wire at the compressor.
Connect the black wire of the compressor to a good chassis ground. Using
the convoluted loom provided cover the exposed wires and secure with tie-
straps provided.
7 Install the air compressors air intake lter using the blue nylon hose provided.
Connect one end to the barbed tting below the compressor head. Install the
lter housing in the other end of the nylon hose. Install the lter housing in a
dry clean area below the level of the air intake port to ensure maximum com-
pressor life.
CONNECTING AIR ACCESSORIES TO THE AIR TANK
8Do not source air from the bottom port of the air tank. Install the pressure
relief valve provided in the bottom port of the air tank. Periodic draining of
the tank will be necessary.
NOTE: The pressure switch included in this kit has a maximum pressure
of 130 PSI and a minimum pressure of 110 PSI. Please ensure your
accessories are capable of this pressure - a regulator may be necessary
for some accessories. Pacbrake can supply lower pressure switches upon
request. Also, Pacbrake offers dual needle gauge kits to monitor system
pressure. This gauge kit can also be used to monitor air spring pressure.
STEP 7
STEP 8
INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 2
INSTALLATION MANUAL - PACBRAKE ONBOARD AIR SYSTEMS, L5856
PG 2
3
4
5
3 Locate the inline air dryer provided. The dryer should be
mounted vertically between the compressor and the air
tank. The needle valve must be accessible to the operator
for periodic draining. A clamp and fastener is provided to
remote mount the air dryer if desired. Use thread sealant on
all ttings to ensure no air leaks exist.
ELECTRICAL CONNECTIONS
4 Provided in the kit is a pre-wired relay receptacle to make
this part of the installation easy. Find a convenient location
to mount the relay receptacle within 12" of the positive
battery terminal. Using the self tapping screw provided,
secure the relay receptacle and install the relay.
5 Locate the black wire of the relay harness, route it to the
air tank location. Using the ttings provided, install the pres
sure switch into one of the ports in the air tank (DO NOT
INSTALL IN THE BOTTOM PORT) Using the ttings
provided, install the pressure switch in a location for it to
sense air tank pressure. Connect the black wire of the relay
harness to one of the two wires of the pressure switch using
the heat shrink butt connector. Using the loose piece of
black wire and another heat shrink butt connector, connect
to the remaining wire of the pressure switch, heat the
connectors to provide a water tight seal. Then connect the
end with an eye terminal to a good chassis ground.
6 Locate the white wire of the relay harness. Connect it to
an ignition power source through the 5 amp inline fuse
provided. This wire can be connected through an ON/OFF
switch to over-ride the compressor activation should the
customer prefer this option.
If a HP10062 or HP10022 kit is being installed,
a compressor ON/OFF switch is included in these kits
White
5 Amp
Fuse
12v +
Ignition
Switched
14 to 16
gage wire
3M®T-tap connector
6

INSTALLATION MANUAL - PACBRAKE ONBOARD AIR SYSTEMS, L6127
INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 3
INSTALLATION MANUAL - PACBRAKE ONBOARD AIR SYSTEMS, L5856
PG 3
7
8
7 Locate the red 12 gauge wire of the relay harness, route
this wire to the compressor mounting location. Connect to
the red wire at the compressor. Connect the black wire of
the compressor to a good chassis ground. Using the
convoluted loom provided cover the exposed wires and
secure with tie-straps provided.
8 Install the air compressors air intake lter, using the nylon
hose marked air intake connect one end to the barbed tting
below the compressor head. Install the lter housing in the
other end of the nylon hose. Install the lter housing in a dry
clean area below the level of the air intake port to ensure
maximum compressor life.
CONNECTING AIR ACCESSORIES TO THE AIR TANK
9 Do not source air from the bottom port of the air tank. Install
the drain valve provided in the bottom port of the air tank,
periodic draining of the tank will be necessary.
NOTE: The pressure switch included in this kit has a
maximum pressure of 130 PSI and a minimum pressure
of 110 PSI, please ensure your accessories are capable of
this pressure, a regulator maybe necessary for some
accessories. Pacbrake can supply lower pressure switches
upon request. Also, Pacbrake offers dual needle gauge kits
to monitor system pressure. This gauge kit can also be used
to monitor air spring pressure.
10 Locate the quick disconnect tting provided. Consult with the
vehicle operator for their preference on the mounting
location with easy access. This location should be away
from dirt and moisture which could contaminate the tting.
Using the mounting bracket, self tapping screws, nylon air
line and ttings provided, connect it to the air tank. Use
thread sealant on all ttings installed.
9
10
PG. 4
STEP 9
9 Locate the quick disconnect tting provided. Consult with the vehicle operator
for their preference on the mounting location with easy access. This location
should be away from dirt and moisture which could contaminate the tting.
Using the mounting bracket, self tapping screws, nylon air line and ttings
provided, connect it to the air tank, Use thread sealant on all ttings installed.
BASIC AIRLINE & WIRING DIAGRAM
NYLON HOSE
¼" NYLON AIR INTAKE HOSE
MALE
AIR FITTING
AIR FILTER
ONE WAY
CHECK VALVE
AIR TANK
“T” TAP
TO IGNITION
POWER SOURCE
30 AMP
FUSE
DRAIN VALVE
Black
Black
White
Red
Red
30
87 85
86
BATTERY
RELAY
PRESSURE
SWITCH
TO ACCESSORY
5 AMP
FUSE
QUICK
DISCONNECT
FITTING
Printed in Canada L6127.REV2.01.24.17