MN-87 POLYAIR INSTALLATION (03006)

INSTRUCTIONS KIT 60756

Quantity PART # Description

2 ea. 41088 Cylinder 2 ea. 09333 Protector 2 ea. 09444 Styrofoam Protector 1 Kit 22007 Hose Kit Contains: 4 ea. 10466 Nylon Strap 2 ea. 18405 Flat Washers 2 ea. 18411 5/16 Star Washer 15 ft 20937 Air Hose 2 ea. 21230 Valve Cap 4 ea. 21233 Hex l\Jut 2 ea. 21234 Rubber Washer 1 ea. 21236 Barbed Tee 2 ea. 21478 Valve W/Core 6 ea. 10638 Hose Clamp

1. Lower axle or raise body of vehicle until suspension is fully extended.

2. Air cylinders are shipped in the "as molded" shape. For ease of installation, remove plastic cap from barbed stem on end of cylinder. Push on air cylinder to evacuate as much air as possible. It may be rolled up toward valve stem. Replace cap to maintain flat shape.

3. Install styrofoam protector into top spring seat as shown in Figures 1 and 2.

r-----------, ,-------------, 4. Roll or hot dog the deflated cylinder as shown in Figure 3.

5. Push the cylinder up within the coil by hand or with a blunt instrument such as a spoon-type tire iron (Figure 4).

6. When the cylinder is completely within the coil, remove the cap and allow the cylinder to assume it's "as molded" shape.

7. Push cylinder to the top of the coil and insert the black spacer on top of lower spring seat as shown in Figure 5.Figure 1 Figure 2

Figure 3 Figure 4 Figure 5

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Use this procedure for all hose connections: A. Slide a hose clamp onto the tubing. B. Push the tubing over the barbed stem. C. Compress the ears on the hose clamp

with pliers and slide it forward to fully cover the barbed section.

Figure 6

Figure 7

:'..lFigure 8

TEE HOSE ROUTING

A. Locate desired "tee" location on the frame rail or cross member.

B. Determine and cut adequate length of tubing to reach from tee to left and right side on air cylinders.

CAUTION: LEAVE SUFFICIENT HOSE SLACK TO PREVENT ANY STRAIN ON FITTINGS DURING AXLE MOTIONS.

C. Slide a hose clamp onto the tubing.

D. Push the tubing over one side of the "tee" until all the barbs are covered. Repeat procedure for other leg of tee (Figure 6).

E. With pliers slide the hose clamp forward until it fully covers the barbed section. Repeat for the other leg of tee (Figure 6).

F. Route tubing along cross member and either lower control arm or upper spring seat to left and right air cylinder (Figure 7).

G. Insert tubing through spring seat, spacer and slide on a hose clamp.

H. Push the tubing onto the stem, covering all the barbs (Figure 8).

I. With pliers slide the hose clamp upward until it fully covers the barbed section.

J. Push the remaining tubing over the last fitting on tee and route along frame to desired inflation valve location. Attach with plastic straps or wire.

TO PREVENT TUBING FROM MELTING, KEEP IT AT LEAST SIX INCHES FROM EXHAUST SYSTEM.

K. Select a location for inflation valve in the gas cap well, trunk, rear bumper, fender flange or behind the license plate, insuring that the valve will be protected and accessible with air hose (Figures 7, 9).

L. Drill a 5/16" hole for inflation valve and mount as in illustration (Rubber washer is for outside weather seal - Figure 9).

Rubber Washer

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Figure 9

M. Slide a hose clamp over hose. Push tubing onto fitting covering all barbs. With pliers slide the hose clamp forward until it fully covers the barbed section (Figure 10).

N. Raise axle or lower body until air cylinders lightly touch upper spring seat and lower spacers.

O. Check TAILPIPE clearance and insure that it is at least 6 inches from air cylinder. If necessary, loosen clamps and rotate or

move to obtain additional clearance.

Figure 10

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MAINTENANCE/OPERATION MINIMUM AIR PRESSURE MAXIMUM AIR PRESSURE

4 PSI 25 PSI

MAINTENANCE TIPS: 1. Check pressure monthly! 2. Always maintain at least 4 psi air pressure to prevent chafing or coil pinch. 3. If you develop an air leak in the system, use a soapy solution to check all hose connections and the valve core

before removing cylinder. OPERATING TIPS: 1. Inflate you air springs to 25 psi before adding the payload. This will allow the air cylinder to properly mesh with the

coil spring. After vehicle is loaded, adjust your air pressure (down) to level the vehicle and for ride comfort. 2. When you are carrying a payload it will be helpful to increase the tire inflation pressure in proportion to any overload

condition. We recommend a 2 psi increase above normal (not to exceed tire manufacturer's maximum) for each 100 Ibs. total overload on the axle.

Increase you Air Spring's versatility with our easy-to-install Load Controller System

Use with POLYAIR SPRINGS or LOADLIFTER 2500 system. Compressor mounts easily in engine compartment. Dash-mounted 0 - 100 psi gauge with fill and deflate controls. Includes complete installation kit: air hose, fittings, hardware, electrical wire, and in-line fuse. Ask for Part Number 25589 (Suggested Retail $69.95)

Thank you for purchasing Air Lift Products

AIR LIFT COMPANY P.O. BOX 80167

Lansing, MI 48908-0167

POLYAIR® SPRING

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FOR TECHNICAL ASSISTANCE CA 8 CAUTION: DO NOT EXCEED THE VEHICLE MANUFACTURER'S GROSS VEHICLRATING.

Prinled in the USA

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