559-734-7451 800-367-5480 FAX 559-734-7460
INSTALLATION INSTRUCTIONS
4880 Auto Level Compressor Kit
Thank you for purchasing a quality Hellwig Product.
PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING
YOUR INSTALLATION
IMPOR TANT NOTES
DO NOT INFLATE ANY AIR SPRING ASSEMBL Y UNLESS IT HAS BEEN
PROPERLY INSTALLED ON VEHICLE.
DO NOT INFLATE AIR SPRINGS OVER 100 PSI
A MINIMUM OF 5-10 PSI MUST BE MAINTAINED IN AIR SPRINGS
AFTER INSTALLA TION FOR WARRANTY TO BE VALID. F AILURE TO
KEEP MINIMUM PRESSURE IN AIR SPRINGS WILL VOID WARRANTY.
THIS UNIT IS DESIGNED TO INCREASE THE LEVEL LOAD CARRYING
CAPACITY OF YOUR VEHICLE. NEVER LOAD THE VEHICLE THIS
UNIT IS INSTALLED ON BEYOND THE MANUFACTURER’S MAXIMUM
GROSS VEHICLE WEIGHT RATING .
OVERINFLATION AND IMPROPER USE MAY RESUL T IN PERSONAL
INJURY AND/OR DAMAGE TO YOUR VEHICLE AND PROPERTY.
4880 ( R-4880) 03/09/07
559-734-7451 800-367-5480 FAX 559-734-7460
BEFORE STARTING YOUR PROJECT
WHEN LIFTING A VEHICLE WITH A JACK, BE SURE TO SET THE PARKING BRAKE AND USE SAFETY STANDS.
ENSURE THAT THE INSTALLATION OF COMPONENTS WILL NOT CRUSH OR DAMAGE FUEL AND BRAKE
LINES OR ELECTRICAL HARNESSES.
BEFORE DRILLING ANY HOLES, ENSURE THAT ALL ELECTRICAL WIRES, FUEL LINES, BRAKE LINES, BRAKE
HOSES AND ANY OTHER COMPONENTS ARE MOVED OR PROTECTED TO AVOID DAMAGE FROM DRILLING
ANY HOLES .
DO NOT ATTEMPT ANY MODIFICATIONS TO THE VEHICLE OTHER THAN THOSE OUTLINED IN THIS
INSTRUCTION SHEET. IF ANY INTERFERENCE WITH THE GAS TANK, FUEL LINES, BRAKE LINES, EXHAUST
PIPE, ETC. EXISTS, STOP YOUR INSTALLATION AND CALL HELLWIG PRODUCTS FOR TECHNICAL HELP.
IF WHEELS ARE REMOVED FOR INSTALLATION OF KIT, CHECK MANUFACTURERS SPECIFICATIONS FOR
PROPER LUG NUT TORQUE BEFORE REINSTALLING WHEELS.
WHEN CUTTING AIR BRAKE TUBING, A SQUARE CUT IS REQUIRED AND THE HOSE END MUST NOT BE
DEFORMED OR LEAKAGE MAY RESULT. IF DEFORMATION OF THE HOSE END OCCURS, THE HOSE END
MUST BE REWORKED SO THAT IT IS ROUND.
ENGAGEMENT OF THE SEALING O-RING WILL BE FELT WHEN THE AIR LINE HAS BEEN INSERTED
PROPERLY INTO THE FITTING. FITTINGS MAY BE DISCONNECTED IF REQUIRED BY PUSHING DOWN ON THE
OUTER RING WHILE PULLING FIRMLY ON THE AIR LINE.
ROUTE AIR LINES AWAY FROM EXHAUST PIPES OR ANY OTHER SOURCES OF HEAT AND ENSURE THAT THE
AIR LINES ARE PROTECTED FROM SHARP EDGES.
4880 ( R-4880) 03/09/07
559-734-7451 800-367-5480 FAX 559-734-7460
Air Filter
1. Prepare the compressor for mounting by HAND-TIGHTENING the air filter
into the port on the compressor. Select a convenient mounting location for the
compressor where it will be protected from moisture and debris but has enough
air flow to keep the compressor from overheating. Mount compressor using provided hardware. Select a mounting location for the tank as close to the compressor as possible. It is preferred to connect the braided stainless hose directly to the
tank. If necessary, adapters are provided with the compressor to connect nylon
hose from the tank to the compressor hose. Do not remove the braided hose or
check valve fro m the compressor.
2. Select a location for the leveling valve. Make sure that the
axle will not contact the valve or
plumbing during use. The leveling valve mounting bracket has
multiple holes for mounting the
valve and ca n be cut off if
needed to provide clearance. Attach mounting bracket to vehicle
bed support with supplied 5/16
bolts. See following diagrams
for valve installation.
4880 ( R-4880) 03/09/07
559-734-7451 800-367-5480 FAX 559-734-7460
Leveling Valve Installation Diagram
Attach leveling valve mounting bracket to bed rail by drilling 3/8” dia.
holes and fastening with 5/16” bolts supplied. Locate valve so that the
valve and plumbing will not contact axle during use.
To set ride height, center leveling valve by inserting 11/64”
drill bit in hole in handle and body.
Remove drill bit and rotate arm up and down to
check for clearance to vehicle components. Measure axle bump stop clearance and add 1-1/2”. This
dimension represents how much clearance above
top of linkage is required for valve to clear bottom
of bed. With arm of valve centered. Measure the
distance from the top of linkage to the bottom of
bed. This distance must be greater than the bump
stop dimension obtained.
Orient valve so that inlet/
exhaust ports are vertical.
Note: Base of inlet /
exhaust ports in valve
have a screen.
Attach axle brackets together
using stud pin. Orient stud pin
forward or rearward for best
orientation of linkage.
Adjust stud pins so that linkage is vertical when
viewed from side of vehicle. Adjust position of
valve and axle brackets so that linkage is positioned
as shown when viewed from rear of vehicle at desired ride height. Secure adjustable end of linkage
with supplied hose clamp to lock height setting.
Attach axle brackets to axle using rear
cover bolts. Brackets are slotted to
accommodate various axles and to allow best placement of stud pin.
4880 ( R-4880) 03/09/07
559-734-7451 800-367-5480 FAX 559-734-7460
Plumbing and Wiring Diag ram
4880 ( R-4880) 03/09/07
559-734-7451 800-367-5480 FAX 559-734-7460
Attach axle brackets to axle us-
Connect axle
brackets with stud
pin
ing rear cover bolts. Brackets
are slotted to accommodate various axles and to allow best
placement of stud pin.
3. Install axle brackets as shown in diagram and photo above. Care must be taken to install linkage so that it will not bind in use and that the leveling valve arm will not contact
any other components during use. Rotate valve and confirm that it will rotate freely and
without interference. Measure the axle to bump stop clearance and add 1-1/2” to this dimension. With the valve centered, measure from the top of the linkage to the bottom of
the bed. This dimension must be greater than the bump stop dimension obtained earlier.
Hellwig Products Co. will not warrant any components which are bent or damaged due to
contact with other vehicle components. Due to the universal nature of this kit, it is up to
the installer to confirm that the linkage, valve, and brackets will perform correctly and
without interference.
4. Follow plumbing and wiring diagram for connection of leveling valve, compressor, and
relay. Take care when routing air and electrical lines that they will not be crimped or
chafed during installation or use. Deviation from the electrical diagram and failure to use
an inline fuse holder (supplied) will void warranty. DO NOT install fuse in inline fuse
holder until all connections and circuits are verified to be completed correctly.
5. After all connections have been verified, install fuse in inline fuse holder, apply park
brake and start engine with shifter in park or neutral. Due to the amperage draw of the
compressor, failure to turn engine on during initial startup may drain the battery enough to
require a jump start.
6. Test system by adding air to air springs. Disconnect linkage from arm and rotate arm
up to fill air springs. Check all connections with soapy water for leaks. After the integrity of the system is verified, reconnect linkage to valve. A MINIMUM OF 5-10 PSI
MUST BE MAINTAINED IN AIR SPRINGS AFTER INSTALLATION FOR WARRANTY TO BE VALID. FAILURE TO KEEP MINIMUM PRESSURE IN AIR
SPRINGS WILL VOID WARRANTY.
4880 ( R-4880) 03/09/07
559-734-7451 800-367-5480 FAX 559-734-7460
Installation Reference Photos
INLET PORT
Note: Base of inlet /
exhaust ports in valve
have a screen.
4880 ( R-4880) 03/09/07
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