In some applications, electric...
In some applications, electric valves cause the bags to react too quickly. This is an adjustable valve used to regulate the rate of infla-tion/deflation.
Teflon tape is used on the...
Teflon tape is used on the tapered pipe fittings in the system. The first few threads are left bare to keep chunks of tape from contaminating the valves.
We opted to install control...
We opted to install control valves on all four supply lines of our system. Note the plug on the right side of the case, it’s for the harness that connects to the control panel.
Compressors are the heart of the system, but they can’t run continuously. A compressor is rated by the pressure it will produce, but even more important is the duty cycle, which is how long it can run in a given period of time. Most airbagit.com compressors have a 50-percent duty cycle, which means that the compressor can run for 10 minutes, then must be off for 10-minutes. During the “on” time the motor is pressurizing the tank, during the “off” time, the suspension uses the air stored under pressure in the tank. If the suspension is raised and lowered too frequently the compressor’s motor will run longer than it should, which leads to overheating, which will shorten its life considerably.
This is the water/oil separator....
This is the water/oil separator. It discharges condensation automatically through a pressure-sensitive drain in the bottom of the housing.
In most cases a storage tank will be part of an air suspension system and Joe cautions that this is one case where bigger is not necessarily better. The air capacity of the tank has to be matched to the volume produced by the compressor. Joe recommends one DC5000, or DC7500 compressor for each 3-gallons of tank capacity. He adds that larger air tanks are OK, as long as the system has the capability to fill them. Joe also points out that it takes longer for one compressor to fill a big tank and the lifespan of the compressor will be drastically shortened if it is overworked.
Its recommended that all tanks be equipped with a drain valve and the system must have a pressure switch to turn the compressor on and off. Joe cautions that when more than 135 psi is required to shut off the pressure switch the bags are too small in diameter.
Inside the separator are directional...
Inside the separator are directional vanes that help separate the oil and water from the air and a bronze filter element.
In our experience, it’s always best to control bags individually. In some cases the bags on one axle are hooked together, however, this can cause them to transfer air when cornering. As the truck leans, air is transferred from the bag under a heavier load to the other side, which makes the truck lean even more.
The simplest and most affordable air control system is a Schrader valve (just like those used to inflate and maintain the pressure in tires). These manual valves can be installed in a hidden location. Schrader valves are also handy to have to inflate a bag in an emergency if there is a problem with an airline.
Incoming air also needs to...
Incoming air also needs to be filtered. This filter screws into the compressor’s inlet.
These are miniature valves that connect directly to each airbag to control their inflation. For a two-bag system there will be two up buttons and two down buttons and usually one gauge with two needles. Four bag systems will have four sets of buttons and two dual-needle gauges. These controls typically use ¼-inch airlines.
These systems use switches to control electrically operated valves to inflate or deflate the bags and are much faster than the pneumatic style.
With electric controls, each bag will have a switch with three positions—up, down and neutral. Again, dual needle gauges are often used, however, controls with digital readouts are also available.
One of the best means to eliminate...
One of the best means to eliminate rust from contaminating the system is by stepping up to a stainless steel air tank.
The biggest enemy of air systems, particularly electric control valves, is contamination from moisture. When air is compressed, condensation forms in the system and that can cause steel air tanks to rust. That rust finds its way into the valves and prevents them from operating properly. The best protection from this is upgrading to a stainless steel tank.
In addition, air systems should be equipped with a water trap. The simplest is a manual drain on the tank. The problem is you have to remember to use it regularly. A better choice is an automatic drain. When installing a water trap it should be placed on the outlet of the tank before the valves.
Another source of contamination is often the installer. The careless use of sealant and Teflon tape can result in trash in the system that will get caught in the valves. Use sealant sparingly, and start Teflon tape one or two threads from the end of the fittings.
Our tank is equipped with...
Our tank is equipped with a safety valve that prevents pressure in the system from going over 140 psi.
We had to find a place to...
We had to find a place to mount the tank and compressor. Our pal, Tim Smith, bent up a mount from 10-gauge steel to hold them both.
Our tank and compressor mount...
Our tank and compressor mount fits between the frame and the bedside. It bolts to the supports on the underside of the bed; they were reinforced with 2x2x1⁄8-inch angle iron. To make installation easier, nuts were welded in place before the reinforcements were welded in place.