Hellwig Air 6102 - Manual (Page 2)

8. Place the carriage bolts into the lower axle brackets so that the threads hang down next to the axles. Mount the
axle clamp brackets under the vehicles axle to align with the carriage bolts. Be sure to move any brake lines or
fuel hoses or other items on the axle to avoid damage during installation. Attach the axle brackets with the car-
riage bolts with the locknuts provided. Either set of holes in the lower axle bracket can be used. Choose for best
fit as per your vehicle. Leave loose at this time to allow for adjustment later.
9. Move the frame bracket on the frame and the axle bracket on the axle to align the air springs as straight up
and down as possible. Once the air springs are properly aligned make sure all lines , hoses and wires are out of
the way so that they will not be crushed during installation. Rotate the heat shield to protect the air spring from
the vehicles exhaust. Torque all frame mounting hardware to specified rate. Double check the alignment after
tightening. Torque the top air spring lock nuts to max. 25 ft lbs.
10. Tighten the axle clamp locknuts completely , be careful as to not bend the brackets. The corners of the lower axle
brackets will grip the top of the axle. This will prevent the bracket from rotating on the axle. With the clamp
bracket properly installed at the bottom of the axle it will not rotate.
11. Cut the 1/4” air line into two ( 2 ) equal lengths. Make sure that the air line has a straight clean cut to avoid
air leaks after installation. Connect one end of the air line to the brass air fitting on top of the air spring. See
the air hose fitting diagram for the style of fittings that are supplied in your particular kit. If an air compressor is
being installed on your vehicle follow the mounting instructions for proper hose routing.
12. Route the air line to the desired fill location. Using the supplied plastic tie straps , tie the air line to either existing
wires , lines or hoses. Be careful , and keep the air lines away from the exhaust system to avoid damage. Use the
black hose insulator if needed for extra protection. Keep air line and mounting hardware minimum 1-1/2” from
making contacting with any of the exhaust components. Find a location , either on the vehicles frame or bumper
to install the air fill valve. Using a 5/16” drill bit , drill a hole at desired fill location. Your kit is supplied with
( 2 ) schrader air fill valves , one per air spring. NOTE : see page #5 for the style of air fill valve that is supplied
in your installation kit.
13. With the air springs properly mounted and secured to the vehicle , inflate the air springs to approximately 30 lbs
PSI. Using a squirt bottle with a mixture of 30% liquid dish soap and 70% water check the entire system for air
leaks. If an air leak is detected remove the air pressure from the entire system before repairing the leak. Usually
tightening the fittings will repair the leak. Re-inflate and retest the system until no leaks are detected.
14. Keep a minimum of 5-10 lbs PSI in your systems at all times to avoid any damage. For best ride use only
enough air pressure as required to level the vehicle. If a firmer ride is desired , more pressure can be used.
The air springs can be inflated to any level between 10-100 PSI.
15. Check air pressure in the system regularly to ensure system performance and to maintain the warranty. Just like
tires the air pressure in the system will vary due to temperature changes. For your air springs to function properly
they must be checked on a regular basis.
NOTE : NEVER LOAD THE VEHICLE THAT THIS KIT IS BEING INSTALLED ON BEYOND THE
MANUFACTURERS MAXIMUM GROSS VEHICLE WEIGHT RATING
ATTENTION INSTALLER: BE SURE THAT THE CUSTOMER RECEIVES THIS INSTRUCTION
SHEET, ALL IMORTANT NOTE CARDS AND THE WARRANTY FORM
559-734-7451 800-367-5480 FAX 559-734-7460
6102 ( R-6102 ) 09-17-07