COMPACT ON-BOARD AIR KIT INSTALLATION GUIDE CKSA12 Part No.
No liability is assumed for damages resulting in the use of the information contained herein. ARB Air Locker Air Operated Locking Differentials, ARB Air Locker Air Activation System and Air Locker are trademarks of ARB Corporation Limited. Other product names used herein are for identification purposes only and may be trademarks of their respective owners.
1 Introduction 1.1 1.2 2 Pre-Installation Preparation Tool-Kit Recommendations 2 2 2 Installing the Compressor 2.1 2.2 2.3 2.4 2.5 3 Installing the solenoid(s) Installing the Pressure Switch Assembling / Installing the Air Filter Using an Air Filter Extension Tube (optional) Mounting the Compressor 3 Connecting the Air System 3.1 3.2 7 Running and Securing the Air Line Connection to the Air Locker Bulkhead Fitting 4 Mounting & Connecting the Electrical System 4.1 4.
1 Introduction IMPORTANT : To assure the highest level of planning and reliability goes into this installation, please read this guide in its entirety before attempting any modifications to the vehicle. 1.1 Pre-Installation Preparation Although your ARB Air Compressor comes complete with all the step by step instructions you will need to install your new air source, ARB recommends that you have your ARB Air Compressor installed by a trained professional.
2 Installing the Compressor 2.1 Installing the Solenoid(s) IMPORTANT : This step applies to the 12V solenoid that is packed with each ARB Air Locker differential. If the compressor is to be used for an alternate purpose then skip this step and plug or terminate the ports as required by the application. Remove one of the 1/8” BSPT plugs from its port in the compressor manifold using a 5mm hex key. Apply Teflon paste/tape to one end of the nipple (1/8” X 1/8” BSPT), insert into the port and tighten.
2 Installing the Compressor Measure the intended length of the extension tube. Maximum Length of Tube Minimum Inside Diameter of Tube 300mm [11.8”] = 8mm [0.32”] 800mm [31.5”] = 10mm [0.39”] 1770mm [69.7”] = 12mm [0.47”] 3430mm [135.0”] = 14mm [0.55”] 6130mm [241.3”] = 16mm [0.63”] Consult the chart above for the recommended minimum inside diameter of the tube.
2 Installing the Compressor Identify a position on the vehicle or inside the cabin where the compressor can be safely and conveniently mounted. NOTE : The ideal position of the compressor should give consideration to all of the following points: 1. Keep away from sources of heat (e.g., too close to exhaust system components or directly behind the radiator, etc.). 2. The position should be safe from damage or abrasion caused by sand or gravel from the road surface. 3.
2 Installing the Compressor Using the compressor backing plate as a template, or referring to Fig.2. for exact sizes, drill four mounting holes at a diameter of 6.5mm [0.26”]. NOTE : Try to drill holes accurately. Holes should never be drilled open to more than 8mm [0.31”] in size to compensate for misalignment. Figure 2. Hold compressor in place and assemble bolts through the rubber vibration isolators in the compressor mount and into the newly drilled holes. Figure 3.
3 Connecting the Air System 3.1 Running and Securing the Air Line IMPORTANT : The path taken by the air line from your compressor to your Air Locker is unique to your vehicle and the desired position of your compressor. Plan ahead carefully when running the air line and always follow these guidelines: NOTE : The flexible 5mm air line described here is supplied with your Air Locker kit and NOT with your ARB compressor kit.
3 Connecting the Air System 3.2 Connection to the Air Locker Bulkhead Fitting In the case of an IFS axle assembly or in the case that the axle assembly has been completely removed from the vehicle, the assembly will have to be remounted in order to position the bulkhead fitting in its correct location for air line access. Trim the air line to length using a sharp knife. Insert the support spring over the end of the air line - small end first. (Fig.4.) Insert the outer compression nut over the air line.
4 Mounting & Connecting the Electrical System 4.1 Mounting the Actuator Switch(es) ARB compressor and Air Locker actuator switch(es) can be easily panel mounted inside the vehicle in a 21mm x 36.5mm [0.83” x 1.44”] rectangular cutout. NOTE : Air Locker actuator switches are packed with each Air Locker differential. HINT : Only attach the cover plate to the face of the switch once the switch has been mounted and wired correctly as the cover plates are designed to be difficult to remove.
4 Mounting & Connecting the Electrical System 4.2 Wiring the Actuator System When wiring an ARB compressor switch, Air Locker pressure switch, Air Locker actuator switch(es) and Air Locker solenoid(s) to an ARB Air Compressor, all connections can easily be set up using only the supplied wiring loom (ARB #180408 - Fig.7.) Consulting the wiring diagram (Fig.7.) for wire colors, and the switch terminal illustration (Fig.6.), plug each of the female spade terminals onto their appropriate switch terminal.
4 Mounting & Connecting the Electrical System Figure 6. SWITCH TERMINALS Figure 7.
5 Testing & Troubleshooting 5.1 Leak Testing With the vehicle parked and the engine off, turn the compressor on and wait until the air system is fully charged. NOTE : With the Air Locker(s) disengaged, the compressor should not have to recharge over time. Intermittent recharging without Air Locker use usually indicates a leak at the solenoid or pressure switch fittings. Actuate the Air Locker(s). The compressor should not come on again for a period of at least 15min.
5 Testing & Troubleshooting 5.3 Electrical Fault Diagnosis The following describes an effective procedure for tracing an electrical fault in an ARB CKSA12 compressor which has been wired using a genuine ARB wiring loom. All steps must be performed in the order listed here for an accurate assessment.
5 Testing & Troubleshooting 5.4 Post-Installation Check List Now that the compressor installation has been completed, ARB recommends that you take the time to complete the following check list just to insure that you haven’t missed any of the vital steps. The air system has been leak tested. The air filter position will not be exposed to moisture, dust or dirt. All air lines and wiring have been securely cable tied to resist snagging.
6 Parts List 6.1 Exploded Assembly Diagram (See itemized parts list overleaf) Figure 8.
6 Parts List 6.2 Itemized Parts List (See exploded diagram figure 8.) AIR COMPRESSOR MODEL No. : ITEM # QTY 01 02 03 04 05 06 07 08 09 * * * * 4 1 4 1-2 1 2 1 1 1 1 1 1 1 * CKSA12 DESCRIPTION MOUNTING BOLT (M6 x 25mm) BACKING PLATE MOUNTING NUT (M6 locking) PNEUMATIC SOLENOID PRESSURE SWITCH PLUGS COMPRESSOR ASSEMBLY FILTER CARTRIDGE AIR FILTER HOUSING WIRING LOOM ACTUATOR SWITCH SWITCH COVER (COMPRESSOR ISOLATION) INSTALLATION GUIDE Not illustrated in exploded view.
