Dual 450C OBA - VIAIR Corporation
Contents
1. L Mounting Bolts 8pcs M Flat Washers 16pcs N Locking Washers 8pcs O Nuts 8pcs P Remote Mount Air Filter Assemblies 2pcs Q1 1 4 NPT F x 3 8 Barbed Fitting 2pcs Q2 1 4 NPT M x 3 8 Barbed Fitting 2pcs R 2 pack of Replacement Air Filters 2pcs S Leader Hose Bracket Clips 2pcs T1 3 8 O D Air lines 2pcs T2 1 4 O D Air lines 2pcs U 60 amp Tube Style Fuse 1pc V Screws 6pcs W Air Line Clips 6pcs Pressure Switch amp eo X af mo H Fa X Sealed Pressure Switch 110 PSI on 145 PSI off 1pc Y 40 amp Relays 2pcs Coil Hose with Couplers Z 30 ft Coil Hose with close ended Quick Connect Coupler USER MANUAL DUAL 450C ONBOARD AIR SYSTEM PARTS PACKAGES CONT D Accessories Air Tools Carry Bag BB CC DD FF A AA AD cu 60 oe k a sA Ly AA 1 8 BSP F to 1 4 NPT M Adaptors for air locker use 2pcs FF Inflation Gun with 0 200 PSI BB T Fitting 1 4 M x 1 4 F x 1 4 F NPT 1pc Pressure Gauge with 1 4 NPT CC 1 4 M NPT Plug for regulator port block off 1pc Quick Connect Stud 1pc DD 1 4 NPT M Compressor Fitting for 1 4 Air Line 1pc EE 0 220 PSI Air Pressure Regulator 1pc 2 5 GALLON AIR TANK amp PLUMBING The tank comes with six 1 4 NPT port openings to allow installation in many configurations on your vehicle To ensure safe and trouble2. USER MANUAL DUAL 450C ONBOARD AIR SYSTEM COMPRESSOR APPLICATION GUIDE To ensure that you get the highest level of satisfaction from your compressor performance refer to information below VIAIR COMPRESSOR REFERENCE CHART COMPRESSOR SERIES DUTY CYCLE MAX WORKING PRESSURE 100 PSI 72 F 090 SERIES 9 120 PSI 092 SERIES 9 120 PSI 095 SERIES 9 120 PSI 097 SERIES 10 130 PSI 098 SERIES 10 130 PSI 100 SERIES 15 130 PSI 250 IG SERIES 100 150 PSI 275 SERIES 25 150 PSI 280 SERIES 30 150 PSI 325 SERIES 33 150 PSI 330 IG SERIES 100 150 PSI 350 SERIES 100 150 PSI 380 SERIES 100 200 PSI 55 400 SERIES 33 150 PSI 420 SERIES 33 150 PSI 444 SERIES 100 200 PSI 50 450 SERIES 100 150 PSI 450 IG SERIES 100 150 PSI 460 SERIES 100 150 PSI 480 SERIES 100 200 PSI 50 Duty Cycle at 200 PSI and 72 F ABOUT COMPRESSOR DUTY CYCLE Duty cycle refers to the amount of time a compressor can beoperated in a given time period at 100 PSI and a standard ambient temperature of 72 F It is commonly expressed in percentage format Compressor on time on time off time Duty Cycle ONE HOUR DUTY CYCLE MINUTES ON 100 PSI 72 F MINUTES OFF 9 5 Min On 55 Min Off 10 6 Min On 54 Min Off 15 9 Min On 51 Min Off 20 12 Min On 48 Min Off 25 15 Min On 45 Min Off 30 18 Min On 42 Min Off 33 19 Min On 41 Min Off 50 30 Min On 30 Min Off 100 1 Hour Run Time NOTE All compr
3. Your Vital Air Source DUAL 450C ONBOARD AIR SYSTEM PART NO 20017 IMPORTANT It is essential that you and any other operator of this product read and understand the contents of this manual before installing and using this product SAVE THIS MANUAL FOR FUTURE REFERENCE USER MANUAL DUAL 450C ONBOARD AIR SYSTEM Thank you for purchasing this complete self contained onboard air system Contained in one package you ll find everything you ll need to install a high performance onboard air source for your vehicle Please follow these instructions to install your new system OBA Components 1 2 5 Gallon 6 port VIAIR Air Tank Max 150 PSI 2 450C Silver VIAIR compressors 2 15 ft Length of 1 4 Air Line for accessory and gauge installation PARTS PACKAGES Air Tank Installation A BCD E p F G mm A Mounting Bolts 4pcs B Flat Washers 8pcs C Locking Washers 4pcs D Nuts 4pcs E Rubber Tank Mount Bushings 6pcs F 1 4 NPT Drain Cock 1pc G 1 4 NPT 175 PSI Safety Valve 1 pc H 1 4 NPT Compression Fittings 3pcs l 1 4 NPT M Quick Connect Coupler 1pc J 6 Port Manifold amp Bracket 1pc K 1 4 NPT M Plugs 5pcs Compressor Installation L
4. THE BATTERY as possible so that length of positive lead wire required is at a minimum Choose mounting location that is as cool as possible and away from heat sources This compressor is moisture amp dust resistant but NOT WATERPROOF or DUSTPROOF Do not mount compressor in locations where the unit is likely to come in contact with water or excessive dirt For compressor with remote filter mounting select compressor s mounting location where air line can be routed from compressor air inlet to remote inlet air filter Make sure that the remote inlet air filter is located in a dry location away from water You will also want to select a compressor mounting location where the leader hose bracket can be mounted to secure the 2 ft leader hose If it is necessary to mount the air compressor further from the battery such as inside your vehicle or in the bed of your pickup use a minimum 8 AWG positive lead wire for remote installation Do not mount compressor near areas where flammable liquids are stored Use thread sealant for proper fitting installation Teflon tape is not recommended Properly sealed recommended torque is 12 to 15 ft Ibs 450C Compressor Wiring See Figure 3 on back of manual q 2 3 4 Disconnect ground cable from vehicle s battery Temporarily position the air compressor in the location where it will be mounted Route ground wire to the negative post of the battery or to an appropriate grounding
5. of your air tank PLEASE NOTE RUSTED TANKS CAN FAIL CAUSING EXPLOSIONS OR FATAL INJURIES Discard tank immediately if tank is rusted SAFETY VALVE When using a safety pressure relief valve point the safety pressure relief valve away from your body when releasing air Use the pull ring on the safety relief valve to vent pressure from the tank before servicing USER MANUAL DUAL 450C ONBOARD AIR SYSTEM DUAL 450C AIR COMPRESSOR INSTALLATION Your Onboard Air System comes complete with two 100 Duty Cycle compressors Please follow these installation instructions to enjoy the best use of your onboard air system CAUTION To reduce risk of electrical shock or electrocution Do not disassemble the compressor Do not attempt repairs or modifications Refer to qualified service agencies for all service and repairs Do not use this product in an area where it can fall or be pulled into water or liquids Do not reach for this product if it has fallen into liquid Use this compressor with 12 volt DC systems only This product should never be left unattended during use Guidelines for Selecting Mounting Location The selection of proper mounting location for your air compressor will help ensure a long and trouble free compressor service life Please pay close attention to the following Select a FLAT UPRIGHT amp SECURE LOCATION where the compressor can be mounted To maximize air compressor performance locate compressor as CLOSE TO
6. tighten 4 Clogged air filter element 3 Repair or replace compressor 4 Replace air filter element Compressor runs continuously 1 Bad pressure switch 1 Replace pressure switch causing safety valve if equipped 2 Defective safety valve 2 Replace safety valve to open Excessive moisture in discharge 1 Excessive water in air tank 1 Drain tank tilt tank to drain 2 High humidity Drain tank more frequently 2 Move compressor to area with less humidity or use air line filter Compressor will not run 1 No power or power switch 1 Make sure compressor in OFF position switch is ON 2 Blown fuse 2 Disconnect compressors 3 Motor overheats from power source replace 4 Faulty pressure switch fuse Refer to Specifications section for correct fuse amperage 3 Let compressors cool off for about 30 Minutes to allow thermal overload switch reset 4 Replace pressure switch Thermal 1 Lack of proper ventilation or 1 Move compressor to well overload protector cuts out ambient temperature too high ventilated area or area with repeatedly 2 Compressor valves failed lower ambient temperature 2 Repair or replace compressor Excessive 1 Loose mounting bolts 1 Tighten mounting bolts knocking or rattling 2 Worn bearing on eccentric or 2 Repair or replace motor shaft compressor 3 Cylinder or piston ring is worn 3 Repair or replace compressor CAUTION NEVER DISASSEMBLE COMPRESSOR WHILE COMPRESSOR IS PRESSURIZED
7. eduction from vibration is desired using the remote mount option for the inlet filter can reduce operation noise by up to 25 3 Always mount the compressor at a point higher than the inlet port of the tank This will keep moisture from being able to seep back to the compressor 4 When mounting the compressor use a paint pen on the rubber isolators and cover the side to go against the chassis or mounting location Then simply stamp the compressor against the chassis to make an imprint of exactly where to drill the mounting holes for the compressor PRESSURE SWITCH INSTALLATION Your VIAIR Onboard Air System comes complete with a heavy duty pressure switch that will turn on the compressor at 110 PSI and off at 145 PSI The pressure switch has a 1 4 NPT inlet and pre applied thread sealant Pressure Switch with Relay Installation Tips 1 Both terminals of the pressure switch are positive leads The use of a relay is always recommended 2 Never install your pressure switch in direct line from the inlet port coming from the compressor Tank pressure could be misread by the pressure switch Instead mount the pressure switch on the tank where it receives air pressure reading from deflected air in the tank 2 Never use a pressure switch that is rated beyond your compressor s rated Maximum Working Pressure 150 PSI 3 Replace the Pressure Switch P N 90227 if the pressure switch becomes faulty or fails in the future 4 See Fig 3 for
8. erature of the air compressor drops below safe levels After allowing air compressor to cool off for about 30 minutes you can safely resume use of the air compressor by turning on the system 3 To prevent discharge of your battery and to provide peak performance it is recommended that you keep the engine running while the air compressor is in use 4 ONLY OPERATE THE AIR COMPRESSOR IN WELL VENTILATED AREAS Dual 450C Compressor Maintenance amp Repairs 1 Periodically check all electrical and fitting connections Clean and tighten as needed 2 Periodically check all mounting screws Tighten as needed 3 Replace air filter element periodically Replacement frequency depends on operating frequency and operating environment For frequent use in dusty environment you should replace air filter element more often 4 Regularly clean dust and dirt from compressor 5 Your air compressor is equipped with permanently lubricated maintenance free motor Never lubricate compressor 6 Repairs should be performed by Manufacturer or Manufacturer s Authorized Service Agencies only CAUTION Never touch the air compressor or fittings connected to the air compressor with bare hands during or immediately after use Leader hose and fittings will become very HOT during and after use Dual 450C Compressor Installation Tips 1 Always use the remote intake filter option when possible This will extend the service life of your compressor 2 If noise r
9. essors regardless of rated duty cycle require sufficient rest time in between cycles to allow for partial or complete heat dissipation Heat dissipation rates may vary depending on ambient temperatures and operating conditions ABOUT RATED WORKING PRESSURE To ensure trouble free service life of your compressor always operate compressor within rated working pressure of the compressor Never use a pressure switch with a higher cut off pressure than compressor s rated working pressure USER MANUAL AMERICAN WIRE GAUGE GUIDE 12 VOLT DUAL 450C ONBOARD AIR SYSTEM Length of wire from battery to Amp Draw compressor in feet 5 10 iS 20 5 16 16 16 14 10 16 14 12 10 15 16 12 10 10 20 14 10 10 8 25 14 10 8 6 30 12 10 8 6 40 12 8 6 6 50 10 6 6 4 60 10 6 4 4 Wiring Diagram Figure 3 12V 40A Relay To Keyed Power Source Pressure 12V 40A Switen Relay USER MANUAL Fuse Battery DUAL 450C ONBOARD AIR SYSTEM LIMITED WARRANTY VIAIR Corporation warrants this product when properly installed and under normal conditions of use to be free from defects in workmanship and materials for a period of one year from its original date of purchase To receive warranty service or repair please contact VIAIR Corporation Returns should be made w
10. free use of your air tank we strongly recommend that you install the supplied drain cock and a safety pressure relief valve See Figure 1 Plumbing Diagram Figure 1 Q Safet Valve Sd Pressure Switch Leader Hose From Compressor 1 Aa 2 5 Gallon Tank ray Tsy Leader Hose From Compressor 2 Drain iB Cock 5 Open Ports Quick Connect Coupler 80 O O O BE coi Hose Compression Fitting Tank Fittings Install the supplied fittings for the air tank in areas where they are most appropriate for your installation using thread sealant or Teflon tape Not all installations will be plumbed exactly as shown in schematic Make sure that the safety valve is installed in the top most position on the tank and that the drain cock is installed in the lowest position on the tank if the tank is to be installed in any other position than upright on the tank s mounting legs Be sure that all fittings are accessible later in the installation process since you will have to plumb air lines to each fitting as needed to utilize the air tank USER MANUAL DUAL 450C ONBOARD AIR SYSTEM 2 5 GALLON AIR TANK amp PLUMBING CONT D Mounting the Tank We have included 6 pieces of rubber bushings in your tank mounting hardware You have the option of using two layers of rubber bushings on one of your tank legs to slightly
11. ithin one year of the date of purchase after a Return Goods Authorization RGA number has been assigned by VIAIR Corporation To obtain RGA fax a copy of your receipt to 949 585 0188 For complete warranty details please visit www viaircorp com warranty PLEASE NOTE THIS WARRANTY COVERS PRODUCT DEFECTS ONLY IT DOES NOT COVER INCIDENTAL OR CONSEQUENTIAL DAMAGES AS RESULT OF MISUSE OR ABUSE Your Vital Air Source 15 EDELMAN IRVINE CA 92618 TEL 949 585 0011 FAX 949 585 0188 www viaircorp com USER MANUAL
12. n the package depending on your application 3 Adjusting pressure 0 150 PSI The pressure regulator knob locks when pushed towards the unit To adjust pressure simply pull knob away from the regulator body and adjust as needed Always lock the adjustment knob in place before using pressure adjusted air supply to keep pressure regulated at a fixed pressure See Figure 2 Pressure Regulator Diagram Figure 2 AIR IN jf REGULATED FROM TANK AIR OUT HHH JHU PULL KNOB DOWN amp TURN TO ADJUST PRESSURE PRESS UPWARDS TO LOCK USER MANUAL DUAL 450C ONBOARD AIR SYSTEM TIRE INFLATION GUN OPERATING INSTRUCTIONS Your Onboard Air System also comes with a Tire Inflation Gun for airing up tires and adding compressed air to any inflatable items with a valve stem 1 Using the Tire Inflation Gun Use a 1 4 Quick Connect Coupler connect the Tire Inflation Gun to an air hose and connect to a tire valve stem or similar inflation collar by securing the folding lever on the Inflation Gun air chuck 2 Filling Tires and other Inflatable Items Squeeze the Inflation Trigger on the Inflation Gun by pressing it towards the handle of the gun This will allow stored air from the air tank to flow through the gun and through the chuck into your tire or other inflatable items 3 Checking Tire Pressure To check tire pressure release Inflation Trigger on Inflation Gun and allow the needle of the 0 200 PSI gauge to settle Ti
13. point and cut ground wire to length as needed Mount the air compressors with the eight sets of 13 64 5 mm bolts nuts washers and locking washers provided Use of thread locker is recommended NOTE For Remote Inlet Air Filter Installation refer to Remote Inlet Air Filter Installation Instructions included in the Remote Inlet Air Filter Pack This air compressor comes with a heavy duty heat resistant stainless steel braided leader hose with 1 4 NPT fittings This leader hose is designed to prolong the life of your air line Do not remove this leader hose from air compressor IMPORTANT Please note the leader hose that came with your compressor has a built in inline check valve pre installed Do not remove inline check valve from leader hose Select a proper location to mount leader hoses with hose brackets provided Avoid locations where leader hose may become tangled with wires and other hoses To mount hose bracket drill holes with 3 16 drill bit and push self anchoring hose bracket pin into hole Route leader hose through hose bracket and secure hose by pressing bracket clamp into locked position 10 To remove hose from the hose bracket simply press down on the hose clamp release tab to 11 release bracket clamp Follow wiring diagram on the back of manual Fig 3 12 Make sure that your compressor setup is properly fused Dual 450C compressors pull approximately 44 maximum amps of power 13 Always locate fuse a
14. re pressure will be able to be read only when the inflation trigger is released WARNING Never operate the Inflation Gun at any pressure exceeding 150 PSI Use caution when attaching or removing air chuck from valve stems Always ensure that tire valve stems are tight before inflating tires Be careful to never inflate any tire or other inflatable items past its rated pressure to avoid explosion possible injury or death Please Note Not intended for use with regular portable compressors or units meant to be operated with an open ended air chuck The Tire Inflation Gun is equipped with a close ended chuck and will hold pressure back which could cause the hose to burst 0 200 PSI Gauge Lever Air Chuck fe T e Inflation Trigger Bleeder Valve VIAIR TIRE INFLATION GUN Quick Connect Stud USER MANUAL DUAL 450C ONBOARD AIR SYSTEM TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION Tank pressure drops when 1 Loose drain cock 1 Tighten drain cock compressor s shut off 2 Check valve leaking 2 Replace check valve or 3 Loose connections compressor s 3 Check all connections with soap and water solution and tighten Compressor runs continuously 1 Excessive air usage 1 Decrease air usage and air flow lower than normal 2 Loose connections 2 Check all connections with 3 Worn piston ring or inlet soap and water solution and valve
15. relay and pressure switch installation tips USER MANUAL DUAL 450C ONBOARD AIR SYSTEM INLINE PRESSURE REGULATOR INSTALLATION Your Onboard Air System comes complete with an adjustable inline air pressure regulator that may be used to regulate the pressure in your air tank down to any pressure below 150 PSI This is especially useful for installations that will supply air to a locking differential or may be used to operate air tools Never attempt to use the regulator to adjust any tank pressure over 150 PSI since the component is only rated to a maximum of 150 PSI 1 Mounting the Inline Pressure Regulator Select a mounting location with a rigid mounting surface such as the bottom edge of a chassis Use the inline pressure regulator mounting bracket as a template to mark the two mounting points to be drilled Carefully drill the two holes as marked and mount the Pressure Regulator at this time 2 Air Line Connections to Inline Pressure Regulator Use a 1 4 NPT compression fitting on the IN side of the regulator receiving air from the air tank On the OUT side of the regulator you may install a 1 4 NPT quick connect coupler or use another 1 4 NPT compression fitting to route the air line to the source of the item that pressure is being regulated to If you are plumbing to air locking differentials we have included two 1 8 BSP Female to 1 4 NPT Male Adapters for this use You may require a T fitting included i
16. s close as possible to power source 14 Before connecting to power source check to make sure that all connections are made properly 15 Connect and test compressor system by running the compressor for a short time to build up pressure in your air tank 16 Once air pressure reaches preset cut out pressure of your pressure switch the compressor will shut off Inspect all air line connections for leaks with soap and water solution If a leak is detected the air line may not be cut squarely or pushed all the way in Tighten connections if needed USER MANUAL DUAL 450C ONBOARD AIR SYSTEM DUAL 450C OPERATING INSTRUCTIONS IMPORTANT The compressors have a maximum working pressure of 150 PSI Always operate the compressor at or below the MAXIMUM PRESSURE RATING of the compressor Operation exceeding maximum pressure ratings and or duty cycle will result in damage to air compressor 1 Your air compressor is equipped with an AUTOMATIC THERMAL OVERLOAD PROTECTOR This feature will protect the air compressor from overheating and causing permanent damage to your air compressor The thermal overload protector will automatically cut off power to your air compressor should the internal operating temperature of the air compressor rise above safe levels during excessive use 2 Should your air compressor automatically shut off during use turn power to the system off The automatic thermal overload protector will automatically reset when internal temp
17. tilt tank toward the drain cock port to improve drainage properties Use the provided longer bolts and corresponding washers lock washers and nuts to mount the tank to a suitable chassis or other place on your vehicle IMPORTANT Tank is rated for 150 PSI maximum working pressure Tank is NOT to be used as a breathing device Use only attachments or tools rated for 150 PSI working pressure or less CAUTION DO NOT PRESSURIZE YOUR TANK UNTIL YOU HAVE INSTALLED ALL NECESSARY PORT FITTINGS AND ACCESSORIES Apply sealant to threads of fittings prior to assembly and tighten each part with a wrench Do not over tighten if your port fittings are made from brass since brass threads can be stripped Bleed pressure from tank before servicing or adding attachments WARNING FAILURE TO DRAIN TANK AND REMOVE CONDENSATION WILL CAUSE TANK TO RUST PREMATURELY To remove accumulated condensation inside the tank bleed pressure from tank until pressure is approximately 5 20 PSI using drain cock Drain tank by opening the drain cock drain valve and close after draining tank If drain cock valve is plugged release all air pressure from tank remove drain valve and clean then reinstall IMPORTANT Please observe air tank s Date of Manufacture stamped on tank leg Replace air tank 2 to 5 years from date air tank was first used or use the date of manufacture as reference Adhering to air tank draining guidelines will prolong the life
Download Pdf Manuals
Related Search