Pacbrake HP10098 User manual

HP10098
BASIC INDEPENDENT AIR SPRING ACTIVATION KIT

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BASIC INDEPENDENT AIR SPRING ACTIVATION KIT - HP10098
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L5904
COMPONENT MOUNTING
1 Choose a location to mount the gauge and switch panel. It should
be in reach and in clear view to the driver. Using the bracket as a
template, mark and drill two 3/16 diameter holes to secure the
bracket. Do not install the bracket until the electrical and airlines
are connected.
2Thread sealant or Teon tape must be applied to all the tting
threads installed throughout the installation to prevent air leaks.
Installation of the compressor
Install the push to connect tting into the check valve, then install
the assembly into the compressor head, As shown in photo.
3The 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.
Thank you and congratulations on the purchase of a Pacbrake basic independent air spring activation kit. Please
read the entire installation manual prior to starting the installation to ensure you can complete the installation once
started. Plan the location and mounting of the control panel, compressor, airline routing and electrical connections
before starting.
BEFORE STARTING: Ensure the kit includes all the items shown in the photo.
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2
HP10098
IMPORTANT:
This kit includes 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.

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L5904
COMPRESSOR AIR INTAKE FILTER
4Locate 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
5Provided 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.
6Locate either one of the two red 12 gauge 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 gauge 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.
7Locate the 16 gauge 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

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ELECTRICAL CONNECTIONS AT THE REAR
OF THE GAUGE
8 The red wire needs to be connected to the dash board illumina-
tion circuit using the “T” tap provided.
NOTE: If the customer does not want the gauge light to dim with
the dash lights, the red wire can be connected through an inline
fuse to a 12 VDC circuit. The eyelet terminal with the single black
wire and two white wires needs to be attached to a good chassis
ground.
9In the cab, locate the white wire routed into the cab in step 7
(originating at the relay harness). This wire connects to the
white wires at the control panel with a blue heat shrinkable
butt connector. Crimp the wire to the connector, then heat the
connector to provide a water tight seal.
GAUGE PLUMBING
10 Locate the two 1/8 NPT female “push-to-connect” ttings
provided. These ttings are installed on the back of the dual
needle gauge. Use thread sealant or Teon tape. When
tightening these ttings, hold the jam nut on the back of the
gauge tting to provide support.
Using the black nylon airline provided cut off two 4” lengths. In-
sert one end of each length on to the barbed “T” tting provided
(g 10). Connect the ends of the black nylon hoses to the port on
the back of the switch marked “supply” (g 10-3).
10-1 Using the green nylon airline provided, cut one length at 3” and
the other to 3½". Connect the two airlines to the barbed “T” tting
provided, as shown in the photo (g 10-1). Connect the 3½" long
airline onto the R/H switch DELIVERY port. Insert the 3”
long airline into the left air gauge supply tting.
10-2 Using the red nylon airline provided, cut one length at 5“ and the
other to 1½". Connect the two airlines to the barbed “T” tting
provided, as shown in the photo (g 10-2). Connect the 5” long
airline onto the L/H switch DELIVERY port. Insert the 1½" long
airline into the left air gauge supply tting.
9
10
10-3
10-1
10-2
3”
3½”
5”
1½”
4” 4”

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PLUMBING CONNECTIONS
11 Using a sharp razor knife, cut the end of the black nylon tube off squarely, push this end rmly into the push-
to-connect tting on the compressor until it stops. Route the other end of the nylon hose through the rewall
boot into the cab then to the gauge and switch panel (as shown in the drawing below).
12 The remaining lengths of red and green nylon airline are to connect the control panel to the air springs.
The airline colour identifies which air spring they will be connected to. Red is for the left and Green is for
the right air spring. Starting at the control panel, route two lengths of nylon airline through the firewall boot
and along the frame rail to the correct air spring. Cut the ends of the airlines off squarely with a sharp knife,
then push firmly all the way into the fitting at the air spring. Secure the nylon airline with tie-straps provided.
13 At the rear of the control panel, locate the three
“T” fittings with different coloured airline. These
colours pertain to where they get connected.
Black is the supply line from the compressor to the
control panel. Green is the inflate/deflate line to the
right side air spring and red is the inflate/deflate line
to the left side air spring.
See diagram for airline routing.
14 Using the fasteners provided, secure the control panel
to the chosen mounting location. Secure the wiring
and airlines with the tie-straps provided.
VIEW FROM REAR
GAUGE
SWITCH SWITCH
TO R/H
SPRING
DELIVERY
SUPPLY
GREEN GREEN GREEN
GREEN
RED
RED RED
RED
RED
REDRED
BLACK
BLACK
BLACK BLACK BLACK
BLACK
TO L/H
SPRING
TO COMPRESSOR
DELIVERY
SUPPLY
Battery
Ignition Power
Source
To Dashboard
Illuminated Circuit
To Either 87 or 30
86 Red 14 Gauge
Red
Air
Filter
Red 14 Gauge
Air Compressor
To Either 30 or 87
85
87or 30
30or 87
5 AMP Fuse
30 AMP Fuse
RELAY
White White
Chassis Ground
Connector
Black Airline
Green Airline
R/H Air Spring
Red Airline
L/H Air Spring Air Supply Red
OPTIONAL
Compressor
ON/OFF Switch
Connector
Connector
Red / White
Tracer

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TESTING THE SYSTEM
Turn the ignition ON, move the left paddle switch to the UP position. The compressor should activate and the left
side needle of the gauge should show air pressure being delivered to the air spring raising the left side of the ve-
hicle. Then move the left paddle switch to the lower position. The needle of the gauge should show the air pressure
dropping and lowering the left side of the vehicle. Repeat on the right side switch. The right side air spring should
raise and lower with movement of the switch. Check the system for air leaks, ll both air springs to a predetermined
value, then periodically check the gauge for any air pressure loss. Repeat as necessary.
DO NOT EXCEED 100 PSI TO THE AIR SPRINGS AT ANY TIME
AIR LEAK CHECK
Inate both the air springs to 90 PSI. Use a dish soap and water mixture on all airline
connections to detect air leaks. Repair as necessary and retest. Inate the air springs
to a predetermined value and then the following day recheck the pressure. If one or
both of the air springs have lost pressure, a leak is present. The leak must be repaired
and then retest the vehicle until no leaks exist.
OPERATING YOUR VEHICLE WITH PACBRAKE AIR SUSPENSION
Air springs have minimum and maximum pressure requirements. Never operate your vehicle with less than 10 PSI in
the air spring and never inate the air springs over 100 PSI. Damage to the air springs will result.
Check the air pressure in the air springs daily for the rst couple of days to ensure a leak does not develop. The air
springs are designed to maintain the vehicles stock ride height with a load. Do not use the air springs as a means to
lift the vehicle with no load. A rough ride will result.
SERVICING YOUR VEHICLE WITH PACBRAKE AIR SUSPENSION
When lifting the vehicle with a oor jack or hoist on the frame, never allow the air spring to limit the travel of the axle.
Try to always jack the vehicle on the axle. Suspending the axle with the air spring limiting the axle travel will damage
the air spring and void the air spring warranty.
Patents pending. Pacbrake is a registered trademark of Pacbrake Company. Other trademarks used herein are property of their respective holders. Printed in Canada L5904_rev4.3.30.11