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Kit 25004

Automatic Leveling On-Board Compressor System

MN-594 (161107) ECR 7119

INSTALLATION GUIDE
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.

SureSet

TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Notation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installing the SureSet System . . . . . . . . . . . . . . . . . . . . 5


Recommended Compressor Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installing the Compressor and Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installing the Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Attaching the Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Attaching the Digital Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Setting the Digital Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Things You Need to Know . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Checking the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . 10 Warranty and Returns Policy . . . . . . . . . . . . . . . . . . . . . 11 Replacement Information . . . . . . . . . . . . . . . . . . . . . . . . 12 Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

MN-594

SureSet

Introduction
The purpose of this publication is to assist with the installation, maintenance and troubleshooting of the SureSet 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 (800) 248-0892 for the latest version of this manual .

SySTem InfoRmaTIon
The SureSet Leveling System is designed to allow the consumer to maintain the air pressure in two separate air bags with one simple push-button controller. The kit consists of a digital controller/display, a solenoid based manifold, pressure transducers, a compressor, a wiring harness including all necessary connectors and mounting hardware . A left/right channel selector is used to select which air bag will be controlled . Air can be added or exhausted through the pressure adjust control buttons . Upon pressing the control buttons, the appropriate solenoid valve will be energized to either add or exhaust air to the air bag . During the event, the air pressure will be displayed in the cab of the vehicle . Once the pressure is set, the controller will remember and maintain the selected pressure .

ImPoRTanT SafeTy noTICe


The installation of this kit does not alter the Gross Vehicle Weight Rating (GVWR) or payload of the vehicle. Check your vehicles owners 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 inflation pressure data is shown on the vehicles Safety Compliance Certification 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 definitions explain the use of these notations as they appear throughout this guide.

DANGER WARNING CAUTION NOTE

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.

MN-594

SureSet

MN-594

+ Battery terminal Existing inflation valve


Side view

20 Amp fuse holder

Eye terminal
Adapter # 1 Adapter # 2*

Inset A

Adapter

Fuse

K M

Air springs are shown for reference only. They are not included in the kit.

*Uses 3/16 (smaller) female push on connector

P or Q
L R

O or S 3 Amp fuse

Installation Diagram

40 30 30 60 40 40 50 40

40 30 30 60 40 40 50 40

Fuse Panel
Left Sensor Ground

Existing fuse

F
Right Sensor

Existing inflation valve M B E G F A

Side view

Back view

30

85

86

87

Ground

Compressor mounting hardware is included with the compressor.

ECU/display connector J

ECU/display

fig. 1

SureSet

Hardware List
Item A B C D E F G H I J Part # 16092 26830 26455 21839 21807 17175 18512 20220 10466 24040 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Qty Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 150 PSI manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1/8 X 1/4 90 Connector . . . . . . . . . . . . 2 1/4 X 1/4 Connector . . . . . . . . . . . . . . . . . . . 1 1/4-20 X 3/4 Hex cap screw . . . . . . . . 2 1/4 Lock washer . . . . . . . . . . . . . . . . . . . . . . . . . . 2 dia. Black hose....................20 ft 8 Zip tie......................................10 ECU display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Item K L M N O P Q R S Part # 17318 18545 21838 20035 24524 24542 24543 24561 24594 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Qty Machine screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Lock washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Grommet....................................3.5 3/16 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1/4 ATC/ATO tap in fuse . . . . . . . . . . . . . . 2 AGC tap in fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Mini-fuse adapter . . . . . . . . . . . . . . . . . . . . . . . . . 2 16 Ga. terminal . . . . . . . . . . . . . . . . . . . . . . . 2

STOP! Missing or damaged parts? Call Air Lift customer


service at (800) 248-0892 for a replacement part.

MN-594

SureSet

Installing the SureSet System


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 filter or if mounting the compressor outside the vehicle, make sure to orient the compressor intake filter 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).

InSTaLLInG The ComPReSSoR anD manIfoLD


1. Attach the filter to the fitting on the end of the compressor. 2. Ensure that the air fittings are properly attached to the remaining three ports on the manifold (fig. 1 and fig. 2).
R L

The transducers should be mounted facing upward to avoid condensation and to prevent the collection of debris. Note the left and right transducers are opposite.

Ground

fig. 2

3. Select a rigid mounting location on your vehicles frame or cross member that shields the compressor from the elements and heat sources (fig. 2). 4. Attach the compressor and manifold to the frame rail or cross member using fig. 2 as a guide .

NOTE

The manifold should be mounted so that the transducers are facing upwards to prevent condensation and debris from collecting in them. 5 . Temporarily connect the wiring harness to the compressor and manifold to help locate these items . This will help insure that the harness/manifold/compressor will be installed properly. (fig. 1).

MN-594

SureSet
NOTE
The compressor and manifold must be mounted within reach of the wires when the wiring harness is plugged in.

1
Compressor Centerpunch and drill four diameter holes, using the compressor feet as a template .

2
Attach using four supplied screws .

3
Fasten using four supplied nuts .

manifold

Centerpunch and drill two Attach using two 3/16 diameter holes using supplied lock the manifold as a template . washers and bolts . MOUNT THE COMPRESSOR AND MANIFOLD AT LEAST 6 FROM ANY HEAT SOURCES. DO NOT MOUNT THE COMPRESSOR OR THE MANIFOLD IN THE ENGINE COMPARTMENT.

InSTaLLInG The eLeCTRICaL ComPonenTS


CAUTION
DO NOT PLUG THE ECU/DISPLAY CONNECTOR INTO THE DISPLAY UNIT UNTIL ALL WIRES ARE CORRECTLY HOOKED UP. THIS WILL HELP TO PREVENT ELECTRICAL FAILURE OF THE DISPLAY UNIT. 1. Run the harness from the dash to the manifold/compressor location.

NOTE

Place a grommet or silicone sealant around any holes that the harness passes through to protect it from abrasive surfaces. 2. Connect the transducer wires to the corresponding transducers on the manifold using

fig. 3
Transducer wires

Solenoid wires Compressor wire the supplied nuts (fig. 1 and fig. 3). 3. Attach the ground terminal to the manifold using the supplied screw and lock washer (fig. 3 and 1). 4. Connect single terminal connectors to connect the red compressor wire to the relay wire (fig. 3 and fig. 4). 5. Connect the double terminal connector from the solenoids on the manifold to the double terminal connector harness wires (fig. 3 and fig. 4).
6
MN-594

SureSet
Keyed power Back view To battery

fig. 4

6. Route to the vehicle fuse box (fig. 5). Use test light to determine which open terminal (accessory, etc.) works only when the key is in the ON or accessory position (or, refer to the ownerss manual for an available accessory fuse). The terminal should have an amperage rating equal to or greater than the 3 amp in-line fuse. Connection to the fuse terminal will depend on what type of fuse your vehicle uses . If your vehicle uses the 1/4 spade fuse, use adapter #1. If your vehicle uses the 3/16 spade fuse, use adapter #2 (see inset A on page 3). If adapter #2 is used, it will be necessary to cut off the 1/4 female connector attached to the power wire and crimp the smaller 3/16 female connector supplied with this kit. Fuse Existing fuse Terminal Back view 3 Amp fuse Keyed power wire

fig. 5

7. Route the 12 gauge wire from the terminal 30 on the back of the relay out to the vehicles battery. Attach the 20 AMP fuse holder to the wire using the butt connector. Attach the ring terminal to the 20 AMP fuse holder and install the ring terminal to the positive terminal on the battery. (fig. 6). 8. Find flexible grommet (N) in the sealed parts package. After the hole is drilled and before you route the harness through the firewall, simply insert the grommet and walk the material around the inside edge of the drilled hole (fig. 7). You may need to trim it to get an exact fit. To battery 20 Amp fuse holder Flexible grommet Edge of drilled hole

Back view
30 85 87 86

fig. 6

fig. 7

MN-594

SureSet
9. Attach a ground terminal to the small white wire coming out of the back of the ECU/Display Connector (Fig. 8). Ground

aTTaChInG The aIR LIneS


1. Insert two 1/8 x 1/4 air fittings into the two open ports at the top of the manifold (fig. 9). 2. Insert the 1/4 x 1/4 air fitting into the open port on the side of the manifold (fig. 9). 3. Using a standard tube cutter, a razor blade, or a very sharp knife, squarely cut a piece of air line to go between each of the air springs and the supplied tees . 4. Cut another length of air line to go between the other side of the tee and one of the two ports at the top of the manifold (fig. 9). 5. Insert a length of air line with the existing inflation valves to the other port of the tee.

fig. 8
+

ECU/display

ECU/display connector

Air springs are shown for reference only. They are not included in the kit.

Existing inflation valve


L R

Existing inflation valve

Leader hose Manifold Compressor

fig. 9

MN-594

SureSet
6. Cut a length of air line to go between the compressor and the manifold. Remove the nut from the fitting on the end of the compressor leader hose and slide it over the air line. Attach the air line to the compression fitting and tighten nut, locking the air line to the compressor. Insert the other end of the air line to the push-to-connect fitting on the end of the manifold (fig. 9).

NOTE

A denite click will be heard/felt when the air line is properly seated. The air line should go in approximately 9/16.

aTTaChInG The DIGITaL ConTRoLLeR


CAUTION
DO NOT PLUG THE ECU/DISPLAY CONNECTOR INTO THE DISPLAY UNIT UNTIL ALL WIRES ARE CORRECTLY HOOKED UP. THIS WILL HELP TO PREVENT ELECTRICAL FAILURE OF THE DISPLAY UNIT. 1. Choose a mounting location inside the cab of the vehicle for mounting the digital controller .

NOTE

This can be under the dash panel or on the dash board. 2. Attach the bracket to the chosen mounting location using the provided screws (fig. 10). 3. Attach the brackets to the digital controller using the provided screws (fig. 10). 4. Connect the ECU/display connector to the installed digital controller (fig. 11). 5. Tighten the ECU/display connector hardware. Optional digital controller bracket mounting methods

Back view of digital controller fig. 10

Ground

fig. 11
+

ECU/display

ECU/display connector

MN-594

SureSet SeTTInG The DIGITaL ConTRoLLeR


NOTE
When the system is started, the pressure will automatically set at the minimum pressure of 5 p.s.i. The system will not allow you to set your pressure below this point. 1. Press the plus or minus button on the controller to add or exhaust air from the air bags (fig. 12). Only one side of the system can be controlled at a time. 2. Once the pressure is changed, a check mark will appear on the screen. After 10 seconds has elapsed, the check mark will disappear and the pressure will then be set in memory fig. 12).

NOTE

The system will automatically maintain the set p.s.i. in the air bags until the air pressure setting has been changed.

L U5

R 5U

ThInGS you neeD To knoW


1. You can only air up one bag or side at a time. This is due to the fact that only three solenoids are utilized in the system so that the manifold can be smaller and more economical . 2. Once you have selected a pressure setting, you must wait for the check mark on the SureSet display screen to disappear before the setting will be permanently stored into the memory . Failure to wait or turning the vehicle off will cause the previous setting to remain stored . 3 . The SureSet system will maintain your pressure setting within a range of plus or minus 3 psi. This is necessary so that the SureSet system will not continue to make adjustments while the vehicle is being driven .

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 the 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.

Troubleshooting Guide
Problem
System doesnt work/no display . Compressor doesnt run.

Cause
Blown fuse or poor electrical connection . Blown fuse, bad ground or poor electrical connection . Blown fuse or poor electrical connection . Leak in the system or compressor relay is bad . Bad ground or bad sensor.

Solenoid doesnt work. Compressor runs all the time . Display shows sensor fault.
10

+
fig. 12

Solution
Replace fuse/repair connection . Replace the fuse, check ground or check compressor connection . Replace the fuse or check the solenoid connector . Locate the leak and replace the relay . Check ground or replace manifold .
MN-594

SureSet

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 verification. 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 (800) 248-0892 in the U.S. and Canada (elsewhere, (517) 322-2144) 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 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.) 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 and Performance

MN-594

11

SureSet

Replacement Information
If you need replacement parts, contact the local dealer or call Air Lift customer service at (800) 248-0892. Most parts are immediately available and can be shipped the same day. Contact Air Lift Company customer service at (800) 248-0892 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 (800) 248-0892, Monday through Friday, 8 a.m. to 7 p.m. Eastern Time. For calls from outside the USA or Canada, our local number is (517) 322-2144. 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 sales@airliftcompany .com or on the web at www .airliftcompany .com .

12

MN-594

Need Help?
Contact our customer service department by calling (800) 248-0892, Monday through Friday, 8 a.m. to 7 p.m. Eastern Time. For calls from outside the USA or Canada, our local number is (517) 322-2144. Register your warranty online at www .airliftcompany .com/warranty

Thank you for purchasing Air Lift products the professional installers choice!
Air Lift Company 2727 Snow Road Lansing, MI 48917 or PO Box 80167 Lansing, MI 48908-0167 Toll Free (800) 248-0892 Local (517) 322-2144 Fax (517) 322-0240 www.airliftcompany.com
Printed in the USA