HIGH OUTPUT ON-BOARD AIR KIT INSTALLATION GUIDE CKMA12 / 24 Part No. 2102MA12 Revision Date 15/07/09 Copyright © 2007 by ARB Corporation Limited Downloaded from www.Manualslib.
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. 12V Model CKMA12 is certified compliant to EN 55014.1 (AS/NZS CISPR 14.1) and meets or surpasses the following Australian and European directives.
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 2.6 2.7 3 Identifying the Best Mounting Position Configuring the Compressor for Best Fit Drilling & Mounting the Compressor Installing the Solenoid(s) Installing the Pressure Switch Assembling / Installing the Air Filter Using an Air Filter Extension Tube (optional) 3 Connecting the Air System 3.1 3.
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 Identifying the Best Mounting Position F Using the following points as guideline, 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. The location should allow for quick and easy access to the compressor for attaching an optional pump-up kit air hose for tire re-filling if desired. 2.
2 Installing the Compressor 2.2 Configuring the Compressor for the Best Fit ARB’s CKMA series compressors are highly configurable to suit the most difficult mounting locations. Once the compressor’s ideal location has been determined, the shape of the unit can be configured in several ways to best suit the mounting position, provide best access to the ports, and look the most attractive once installed and wired.
2 Installing the Compressor 2.3 Drilling & Mounting the Compressor F Establish the mounting hole locations for the compressor by using the compressor backing plate as a template, or referring to Fig.3. for exact sizes. Figure 3. NOTE : The mounting bracket holes are slotted in a circular pattern allowing the backing plate and bolts to be partially rotated relative to the compressor. This should make finding a place for the four bolt holes an easier task. Figure 4.
2 Installing the Compressor IMPORTANT : The installation kit includes 4 hex head bolts, 4 dome head carriage bolts and 4 flat washers. The hex head bolts and washers are to be used if the tightening is to be done from the compressor side of the mounting panel. Alternatively, if the nuts are to be tightened from the backing plate side of the mounting panel then the carriage bolts can be used as they will not spin in the mounting bracket slots.
2 Installing the Compressor 2.5 Installing the Pressure Switch F Remove the plastic dust plug from the larger ¼ NPT port in the compressor manifold and discard. F Generously apply Teflon paste/tape to the threads of the pressure switch and assemble it into the port and tighten with a wrench/spanner. NOTE : Pressure fittings do not require high torque to form a good air tight seal. Do not tighten any more than hand tight or damage to the manifold may occur.
2 Installing the Compressor NOTE : ARB does not recommend connecting the compressor intake to the air supply in a ‘snorkel’ or other part of the air ducting for engine aspiration. However, if an extension tube is used to relocate the compressor intake to the engine intake supply then it must be understood that the negative pressure (vacuum) created by the engine when it is running will adversely affect compressor performance.
3 Connecting the Air System 3.1 Running & Securing the Air Line to the Axle IMPORTANT : The path taken by the air line from the compressor to the Air Locker is unique to each vehicle and the desired position of the 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 each Air Locker kit and NOT with this ARB compressor kit.
3 Connecting the Air System 3.2 Connection to the Air Locker Bulkhead Fitting F 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. F F F F 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.5.
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 described here are supplied with each ARB Air Locker kit and NOT with the ARB compressor kit. If you require switches to complete the installation then contact your ARB Air Locker distributor.
4 Mounting & Connecting the Electrical System 4.2 Wiring the Actuator System ARB AIR COMPRESSOR WIRING LOOM (CKMA12 & CKMA24) Figure 7. 12 Downloaded from www.Manualslib.
4 Mounting & Connecting the Electrical 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 #180409 shown in Figure 7.) F Consulting the wiring diagram (Fig.7.) for wire colors, and the switch terminal illustration (Fig.8.), plug each of the female spade terminals onto their appropriate switch terminal.
4 Mounting & Connecting the Electrical System NOTE : If shortening the BLU-WHT wire, make sure not to remove the heat shrinked inline diode that protects sensitive electronics from current leakage. F Insulate the junction area well with electrical tape. F Route the 4 loose male spade terminals of the long section of loom through any panel work that separates the compressor mount position from the switches (e.g., the firewall separating the cabin from the engine compartment).
4 Mounting & Connecting the Electrical System 4.3 Connecting The Power Wires IMPORTANT : Although the wiring loom in this kit was designed to work with either a 12 volt or 24 volt system, the DC motor of the compressor has been designed ONLY for use on one specific voltage system. Make sure you have the CKMA12 compressor kit for 12V systems or the CKMA24 for 24V systems.
4 Mounting & Connecting the Electrical System 4.3.2 Power Connection To A 24V Vehicle / System NOTE : Vehicles equipped with aftermarket ‘dual battery kits’ are not classified as 24V systems. They require the 12 volt compressor kit, and connection to the primary battery only according to section 4.3.1. F Identify which battery in the system will be used as the 24V negative (-) terminal (i.e., Battery #1 in the wiring diagram Fig. 7.
5 Testing & Troubleshooting 5.1 Leak Testing F 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. F Actuate the Air Locker(s). F 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 a CKMA12 or CKMA24 compressor which has been wired using a genuine ARB wiring loom (refer to the diagram in Figure 7.). All steps must be performed in the order listed here for an accurate assessment.
5 Testing & Troubleshooting STEP # 5 Using a multimeter, check for MOTOR VOLTAGE between a chassis ground and the RED wire at the relay block (i.e., the wire leading directly from the fuse). Was MOTOR VOLTAGE detected? YES Proceed to STEP 6. NO Wiring fault between the fuse and the relay. Replace wiring and/or fuse socket.
5 Testing & Troubleshooting STEP # 12 Using a multimeter, check for MOTOR VOLTAGE between the negative (-) terminal of the battery [#1] and the RED-WHT wire connected to the relay block and while the relay is still connected. Pierce the RED-WHT wire with the multimeter probe to make connection if necessary. Was MOTOR VOLTAGE detected? YES Proceed to STEP 13. NO Relay fault. Replace with a new 12V - 40A relay of the same type.
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. F The air system has been leak tested. F The air filter position will not be exposed to moisture, dust or dirt. F All air lines and wiring have been securely cable tied to resist snagging.
5 Testing & Troubleshooting 22 Downloaded from www.Manualslib.
6 Parts List CKMA12 & CKMA24 Air Compressor – Exploded Parts Diagram 23 Downloaded from www.Manualslib.
6 Parts List CKMA12 & CKMA24 Air Compressor ITEM # QTY 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23(a) 23(b) 24 1 1 1 2 1 2 1 1 1 1 1 4 1 # # # 3 1 1 1 1 1 1 1 4 4 4 1 4 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 * 25 26 27 28 29 30 31 32 33 34 * * * * * * * * * * DESCRIPTION PART # NOTES O-RING (BS010V75) 160242 5 MANIFOLD CAP (1/4” NPT) 320214 PRESSURE SWITCH (1/4” NPT) CO35 O-RING (BS031N70) 160241 5 MANIFOLD TUBE 320215 HEX BOLT (M6 x 60mm) 200703 COMPRESSOR HEAD ASSEMBLY 3201
