ARB CKMA12, Installation Manual

Page 1: ...INSTALLATION GUIDE Part No 2102MA12 Revision Date 15 07 09 Copyright 2007 by ARB Corporation Limited HIGH OUTPUT ON BOARD AIR KIT CKMA12 24 ...

Page 2: ...nly 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 2004 108 EC EMC directive ARB 4x4 ACCESSORIES Corporate Head Office 42 44 Garden St Tel 61 3 9761 6622 Kilsyth Victoria Fax 61 3 9761 6807 AUSTRALIA 3137 Australian enquiries sales arb com au North and S...

Page 3: ... Air Filter 7 2 7 Using an Air Filter Extension Tube optional 7 3 Connecting the Air System 9 3 1 Running and Securing the Air Line to the Axle 9 3 2 Connection to the Air Locker Bulkhead Fitting 10 4 Mounting Connecting the Electrical System 11 4 1 Mounting the Actuator Switch es 11 4 2 Wiring the Actuator System 12 4 3 Connecting the Power Wires 15 5 Testing Troubleshooting 17 5 1 Leak Testing 1...

Page 4: ...ools parts and materials to complete this installation see section 1 2 Tool Kit Recommendations and minimize vehicle down time Please refer to your ARB Air Locker Operating Service Manual for information on operating servicing driving technique or trouble shooting your ARB Air Locker s HINT Place a mark inside each of the F symbols as you complete each step It is very important NOT to miss any of ...

Page 5: ...take extension tube is to be used then consideration should be given to the intake position so that the distance length of tube between the compressor mounting location and the actual air intake point can be kept to a minimum 10 The position must allow the compressor motor mounting bracket to firmly secure the compressor using all 4 bolts 11 The position must allow access to the opposite side of t...

Page 6: ... once installed and wired It is highly recommended to spend some time experimenting with different configurations prior to drilling the four mounting holes F Loosen the two motor mount screws 4mm HEX KEY so that the compressor can be freely rotated in its mount while establishing a good mount position Figure 1 F Loosen the manifold bolt 10mm SOCKET so that the solenoid s and pressure switch not sh...

Page 7: ...e 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 F Drill the four mounting holes at a diameter of 6 5mm 1 4 inch NOTE Try to drill mounting holes accurately Use the backing plate as a drilling template if desired Holes should never be drilled open ...

Page 8: ...ng the Solenoid s 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 simply skip this step and plug or terminate the ports as required by the application F Remove one of the 1 8 BSPT plugs from its port in the compressor manifold using a 5mm hex key This plug may be discarded F Apply Teflon paste ...

Page 9: ...ed by disassembling the cover removing the filter disk and using an 8mm 5 16 hex key on the center of the port F The cover logo may be rotated by hand as desired 2 7 Using an Air Filter Extension Tube optional The air filter of the CKMA was designed so that it could be relocated to a more suitable location if required using an extension tube IMPORTANT The length and inside diameter of the extensio...

Page 10: ...NG NOTE Do not run the tube through areas where it will be exposed to elevated temperatures while the compressor is running as this will pre heat the air intake and reduce compressor performance F Assemble an extension tube with a NPT male fitting at one end and a NPT female end at the other F Install the tube inline with the air filter NOTE If the extension tube is being used due to the possibili...

Page 11: ...r line has to be removed F Make sure the air line does not contact sharp edges or abrasive surfaces that may damage the tubing over time F Do not run the air line around tight bends which may kink the tubing and restrict or block the air flow F Keep the air line well away from the vehicle s exhaust components Air lines will melt if subjected to extreme heat F Do not run more air line than necessar...

Page 12: ...he air line F Push the airline onto the barb on the center compression nut ensuring that it is pushed all the way to the end Figure 5 HINT If the air line is too difficult to get over the nipple then place the end of the air line into a cup of boiled water to soften the tubing and the try again F Screw on the outer compression nut and tighten while supporting the center compression nut with a 3 8 ...

Page 13: ...uring vehicle use F Switch es should be within easy reach of the driver Ideally any Air Locker switch should be able to be operated without physical effort or distraction to the driver compressor switch location is not critical F Switch es should be mounted within the line of sight of the driver so that switch position ON or OFF can be visually determined by the rocker position and the illuminatio...

Page 14: ...4 Mounting Connecting the Electrical System 12 4 2 Wiring the Actuator System Figure 7 ARB AIR COMPRESSOR WIRING LOOM CKMA12 CKMA24 ...

Page 15: ...tches are supplied with each Air Locker differential kit not with this compressor kit F Using a multimeter or an automotive test light locate an accessory outlet or cigarette lighter port in the vehicle NOTE The desired outlet should supply positive 12 volts DC be fused at a minimum of 8 amps and be live only when the vehicle ignition key is in either the ACC position or in the ON position F Using...

Page 16: ...sed to protect the loom F Assemble the 4 spade connectors into the supplied plastic connector housing so that each wire color matches up with the same color on the matching connector housing of the short loom section when the 2 halves of the connector are plugged together F Route the remainder of the loom to the compressor mounting position F Plug the 2 female spade terminals onto any of the 2 com...

Page 17: ...e that is of the same gage or bigger than the wire being lengthened NOTE The inline fuse should be located as close to the battery connection as possible Never eliminate the fuse when shortening the RED wire and only ever lengthen the RED wire on the opposite side of the fuse from the battery F Crimp one yellow eye terminal supplied onto the heavy gage RED wire F Crimp the remaining yellow eye ter...

Page 18: ... the battery then splice in an extension using ONLY wire that is of the same gage or bigger than the wire being lengthened F Trim the RED wire and the lighter gage solid black wire with no stripe BLK for connection to battery 2 NOTE The inline fuse should be located as close to the battery connection as possible Never eliminate the fuse when shortening the red wire and only ever lengthen the red w...

Page 19: ...ly thread sealant tape 5 2 Testing the Air Locker Actuation To test that the air system electrical system and the Air Locker differential is functioning correctly F Support the vehicle such that the wheels are free to rotate e g on axle stands a chassis hoist etc F Leave the parking brake off the transmission in neutral and the Air Locker switch OFF F Turn the ignition to the ON position leaving t...

Page 20: ...st 11 5 volts 1 YES Proceed to STEP 2 NO Insufficient battery voltage Recharge or replace the battery Disconnect the compressor motor from the wiring loom at the connector plug Run a new wire directly from the negative terminal of the battery 1 to the BLK WHT wire of the compressor motor Momentarily connect a wire from the positive terminal of the battery 2 to the RED wire of the compressor motor ...

Page 21: ...een the negative terminal of the battery 2 and the RED wire connected to the pressure switch attached to the compressor tank Was approximately 12V detected 8 YES Proceed to STEP 9 NO Wiring fault between the isolating switch and the pressure switch Replace wiring Using a multimeter check for approximately 12V between the negative terminal of the battery 2 and the DK BLU wire connected to the press...

Page 22: ...nnector plug Using a multimeter check for MOTOR VOLTAGE between the negative terminal of the battery 1 and the RED WHT wire on the loom side of the plug Was MOTOR VOLTAGE detected 13 YES Proceed to STEP 14 NO Wiring fault between the relay and the compressor motor connector Replace wiring Using a multimeter check the continuity resistance between the BLK WHT wire on the loom side of the plug not o...

Page 23: ...ch yet well away from danger of accidental engagement F Switch es function properly and illuminate to indicate activation For warranty and service purposes please fill in the following fields and supply a copy to the customer if applicable ARB PRODUCT MODEL NUMBER SERIAL No POINT OF SALE NAME LOCATION DATE OF PURCHASE INSTALLATION PERFORMED BY DATE OF INSTALLATION VEHICLE MAKE VEHICLE MODEL VEHICL...

Page 24: ...5 Testing Troubleshooting 22 ...

Page 25: ...6 Parts List 23 CKMA12 CKMA24 Air Compressor Exploded Parts Diagram ...

Page 26: ...1 MOUNT ASSEMBLY 320101 The CKMA12 and CKMA24 compressors 23 a 1 MOTOR ASSEMBLY 12V 320104 2 CKM motors are serviceable Contact ARB 23 b 1 MOTOR ASSEMBLY 24V 320106 2 24 4 HEX BOLT M6 x 25mm 200405 3 AIR FILTER BASE 31 COVER 33 available 4 CARRIAGE BOLT M6 x 25mm 6151082 only in AIR FILTER ASSY 320501 which also 25 4 FLAT WASHER M6 200709 includes the element 26 1 BACKING PLATE 290603 27 4 NYLON L...