400H – HARDMOUNT AIR COMPRESSOR KIT PART NO. 40042 450H …
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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 400H – HARDMOUNT AIR COMPRESSOR KIT PART NO. 40042 450H – HARDMOUNT AIR COMPRESSOR KIT PART NO. 45042 450H 400H
Transcript of 400H – HARDMOUNT AIR COMPRESSOR KIT PART NO. 40042 450H …
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
400H – HARDMOUNT AIR COMPRESSOR KITPART NO. 40042
450H – HARDMOUNT AIR COMPRESSOR KITPART NO. 45042
450H
400H
IMPORTANT SAFETY INSTRUCTIONS
CAUTION - To reduce risk of electrical shock or electrocution:-Donotdisassemble.Donotattemptrepairsormodifications.Refertoqualifiedservice agenciesforallserviceandrepairs.-Donotusethisproductinorareawhereitcanfallorbepulledintowaterorotherliquid.-Donotreachforthisproductifithasfallenintoliquid.-Usethiscompressorwith12-voltDCsystemsonly.-Thisproductshouldneverbeleftunattendedduringuse.
WARNING - To prevent injury:-Neverallowchildrentooperatethiscompressor.Closesupervisionisnecessarywhenthis compressor is being used near children.- Thiscompressorwillbecomeveryhotduringandimmediatelyafteruse.Donottouchanypartof this compressor with bare hands, other than the ON/OFF switch, during and immediately after use. -Donotusethisproductnearflamesorexplosivematerialsorwhereaerosolproductsarebeingused.-Donotoperatethisproductwhereoxygenisbeingadministered.- Do not pump anything other than atmospheric air.-Neverusethisproductwhilesleepyordrowsy.-Donotuseanytoolsorattachmentswithoutfirstdeterminingmaximumairpressureforthat tool or attachment.-Neverpointanyairnozzleorairsprayertowardanotherpersonoranypartofthebody.- ThisaircompressorisequippedwithAutomaticResetThermalProtector,andcanautomatically restartafterthethermalprotectorresets.Alwayscutoffpowersourcewhenthermalprotector becomesactivated.- Wear safety glasses or goggles when operating this product.-Useonlyinwellventilatedareas.
INSTALLATION
Thisaircompressorisidealformountingunderthehoodoreveninsideyourvehicle.Thecompactsizeofthiscompressorrequiresminimalspace,andoil-lessdesignpermitsmountinginmanydifferentareasofyourvehicle.PleasereadandfollowtheseInstallationInstructionscarefullytoavoidinjuryordamagetothecompressororyourvehicle.
Eachofouraircompressorsandpartshavebeencarefullyproducedandpackaged.Beforeyoubegininstallation,pleasefamiliarizeyourselfwithInstallationPartsList(Fig.1)ofthismanual.
Guidelines for Selecting Mounting Location:The selection of proper mounting location for your air compressor will help ensure a long and troublefreecompressorservicelife.Pleasepay close attention to the following guidelines:
1. Select a FLAT,UPRIGHTANDSECURE location where the compressor can be mounted.2.Tomaximizeaircompressorperformance,locatecompressorasCLOSETOTHEBATTERY aspossiblesothatlengthofpositiveleadwirerequiredisataminimum.3.ChoosemountinglocationthatisascoolaspossibleandAWAYFROMHEATSOURCES. Thecoolertheambienttemperaturethelesschancethecompressorwilloverheat.4. This compressor is moisture & splash resistant, but NOTWATERPROOF. Do not mount compressorinlocationswheretheunitislikelytocomeincontactwithwater.5. Select compressor mounting location where air line can be routed from compressor air inlet to remoteinletairfilter.MakesureRemoteInletAirFilterislocatedinadrylocation,awayfrom water splashes. 6.Youwillalsowanttoselectacompressormountinglocationwheretheleaderhosebracket can be mounted to secure the 1.5 ft. leader hose.7. If it is necessary to mount the air compressor further away from the battery, such as inside yourvehicleorinthebedofyourpickup,useaminimum8AWGpositiveleadwirefor remoteinstallation.(Seewiregaugereferencechart)8.Donotmountcompressornearareaswhereflammableliquidsarestored.
USER MANUAL
400H - 450H Air Compressor Kit
MOUNTING AND WIRING
1. Disconnectgroundcablefromvehicle’sbattery.2. Temporarilypositiontheaircompressorinthelocationwhereitwillbemounted.Routethe positivewiretothepositivepostofthebattery.Measureandcutpositivewiretotheappropriate length and use appropriate inline fuse.3. Routegroundwiretothenegativepostofthebatteryortoanappropriatechassisgrounding point and cut ground wire to length as needed. 4. Mounttheaircompressorbyusingthepairofanti-vibrationmountingbracketsandfoursets of13/64”(5mm)bolts,nuts,washers,andlockingwashersprovided.Use13/64”drillbittodrill holesforthefirstsetofbrackets.Mountthisfirstbracketwithscrews,flatwashers,locking washersandnutsprovided.(RefertoFig.2forplacementofwashers.)5. Placecompressorintomountedbracket.Placesecondsetofbracketundertheaircompressor, makesurethatthecompressorsitssnugglyinbetweenthetwobrackets.Markoffholestobe drilledusingthesecondsetofbracketsasguides.Drillholes,andplacecompressorsnugly betweenbracketsandmountthesecondbracket.6. RefertoRemoteAirFilterInstallationInstructionsincludedintheRemoteInletAirFilterPack forinstallationofRemoteInletAirFilter.7. Thisaircompressorcomesequippedwitha1.5ft.heavydutyheatresistantleaderhose. Thisleaderhoseisdesignedtoprovideeasyaccessforairhoseattachmentandtoprolongthe lifeofyourextensionhoseaswellasminimizingweartothecompressorairoutlet.Donot removethisleaderhosefromtheaircompressor.8. PLEASE NOTE:Theleaderhosethatcomeswithyourcompressormayhavea built-ininlinecheckvalveinstalled.Donotremoveinlinecheckvalvefromleaderhose.9. Selectaproperlocationtomountleaderhosewithhosebracketprovided. Avoidlocationswhereleaderhosemaybecometangledwithwiresandotherhoses.10.Tomounthosebracket,drillholewith3/16”drillbitandpushself–anchoringhosebracketpin intohole.Routeleaderhosethroughhosebracketandsecurehosebypressingbracketclamp intolockedposition.11.Toremovehosefromthehosebracket,simplypressdownonthehoseclampreleasetabto releasebracketclamp.(Fig.3)12.Attachgroundwiretothenegativepostofthebatteryorchassisgroundingpoint. Checktomakesurethattheaircompressor’sON/OFFswitchisintheOFFposition. Attachpositivewiretopositiveterminalofthebattery.13.Re-checktomakesurethatallconnectionsaremadesecurely.
(Fig. 1) 400H/450H Hardmount Air Compressor Kit Installation Parts List:
M
A. HoseBracket(1pc)B. MountingBolts(4pcs)C. FlatWashers(8pcs)D. LockingWasher(4pcs)E. Nuts(4pcs)F. 1/4”Fx3/8”TubeFitting(1pcs)G. 1/4”Mx3/8”TubeFitting(1pcs)
H. 3/8”AirLine(1pc)I. AirLineClips(3pcs)J. Screws(3pcs)K. RemoteInletAirFilterwithFilterElement(1pc)L. Positive(Red)RingTerminal(1pc)M.Negative(Black)RingTerminals(2Sizes)
400H - 450H Air Compressor Kit
USER MANUAL
A B D F G
I
J
K
H
BC
CDE
F
(Fig. 2) Compressor Mounting HardwareB.MountingBoltC.FlatWasherD.LockingWasherE. NutF. Vibration Isolator
(Fig. 3) Leader Hose BracketL.HoseClampM.ClampReleaseTabN.Self-AnchoringPin
L
M
N
L
OPERATING INSTRUCTIONS 1. IMPORTANT:AlwaysoperatethecompressoratorbelowtheMAXIMUMPRESSURERATINGof thecompressor.PleaserefertoApplication&SpecificationsSectionsofthismanualfordetails.2.AlwaysobservetheMAXIMUMDUTYCYCLEoftheaircompressor.RefertoCompressor ApplicationsandSpecificationsSectionsofthismanualfordetails.Operationexceeding maximumpressureratingsand/ordutycyclewillresultindamagetotheaircompressor.3.YouraircompressorisequippedwithanAUTOMATICTHERMALOVERLOADPROTECTOR. Thisfeatureisdesignedtoprotecttheaircompressorfromoverheatingandcausingpermanent damagetoyouraircompressor.Thethermaloverloadprotectorwillautomaticallycutpowerto youraircompressorshouldtheinternaloperatingtemperatureoftheaircompressorriseabove safelevelsduringexcessiveuse.4. Should at any time during use, your air compressor automatically shuts off; do not attempt to restart the air compressor. Turn power switch to the air compressor to the OFF position. Theautomaticthermaloverloadprotectorwillautomaticallyresetwheninternaltemperatureofthe aircompressordropsbelowsafelevels.Allowaircompressortocooloffforabout30minutes, before resuming use of the air compressor.5.Keepthevehicleenginerunningwhileusingtheaircompressortopreventdischargeof yourvehicle’sbattery.6.ONLYOPERATETHEAIRCOMPRESSORINWELL-VENTILATEDAREAS.7.Compressorperformanceisalsoenhancedwhenoperatingcompressorwithvehicle’s engine running.
TIRE INFLATION
Thisaircompressorcomeswith1.5feetheavydutyheat-resistantleaderhosewith1/4”industrialseriesquickconnectstud.Byattachinganairhosewith1/4”industrialseriesquickcouplertotheleaderhose,youraircompressorisreadytoinflatetires.Readandfollowtireinflationinstructionscarefullytoavoidpersonalinjuryanddamagetoaircompressororvehicle.
1.Useheat-resistant,minimum200PSI-ratedworkingpressureextensionhose.Donotuse aftermarkethoseswithlessthan200PSIworkingpressure.Someaftermarkethosesmaynotbe suitable for use with this air compressor due to heat and pressure typically generated by this type of air compressors.2.Useofourconvenient25ft.extensioncoilhosewithin-linedeflatorandBuilt-inPressureGauge isrecommended(PartNo.00025,5-in-1InlineInflator/Deflator).3.Useofaclose-endedtirechuckwillcauseexcessivepressurebuildupiftirechuckisnotattached totirevalvestemwhileaircompressorisinoperation.AlwaysuseanOpen-Endedtirechuck suchasthetirechuckequippedontheInflator/DeflatorCoilHose(P/N00025)fortireinflation.4.Alwaysinflatetirestomanufacturer’srecommendedtirepressures.Exerciseextremecaution whendrivingwithaireddowntires.Re-inflatetiresbeforehighspeedroadwaytravel.
MAINTENANCE & REPAIRS
1.Periodicallycheckallelectricalandfittingconnections.Cleanandtightenorrepairasneeded.2.Periodicallycheckallmountingbolts.Tightenasneeded.3.Replaceairfilterelementperiodically.Replacementfrequencydependsonoperatingfrequency andoperatingenvironment.Forfrequentuseindustyenvironment,werecommendthatyou replaceairfilterelementatleastonceamonth.4.Regularlycleandustanddirtfromcompressorcoolingfinsandmotorhousing.5.Youraircompressorisequippedwithapermanentlylubricated,maintenance-freemotor. Nevertrytolubricatecompressor.6.AllrepairsshouldbeperformedbyManufacturerorManufacturer’sAuthorized ServiceAgenciesonly.
CAUTION:Nevertouchtheaircompressororfittingsconnectedtotheaircompressor,withbarehandsduringorimmediatelyafterusage.TheleaderhoseandfittingsconnectedtotheleaderhosewillbecomeveryHOTduringandafteruse.Ifnecessary,wearheatresistantglovestohandlefittings,airline,andleaderhose.
USER MANUAL
400H - 450H Air Compressor Kit
SPECIFICATIONS
•PartNo.40042/400HAirCompressor
MotorVoltage: 12VoltsMax.CurrentConsumption: 26AmpsMotorType: PermanentMagneticMax.WorkingPressure: 150PSIMax.DutyCycle(@72°F&100PSI): 33%(Min.On/Off@72°F&100PSI) 15On/30OffMax.RestartPressure: 150PSIMax.AmbientTemperature: 158°FMin.AmbientTemperature: -40°FFuse: 40 ampsDimensions: 11.25”Lx4”Wx6.75H”NetWeight: 8.95Lbs.
•PartNo.45042/450HAirCompressor
MotorVoltage: 12VoltsMax.CurrentConsumption: 19AmpsMotorType: PermanentMagneticMax.WorkingPressure: 150PSIMax.DutyCycle(@72°F&100PSI): 100%(Min.On/Off@72°F&100PSI) ContinuousMax.RestartPressure: 150PSIMax.AmbientTemperature: 158°FMin.AmbientTemperature: -40°FFuse: 30 ampsDimensions: 12”Lx4”Wx6.75H”NetWeight: 11.05Lbs.
USER MANUAL
400H - 450H Air Compressor Kit
USER MANUAL
400H - 450H Air Compressor Kit
COMPRESSOR APPLICATION GUIDE
Toensurethatyougetthehighestlevelofsatisfactionfromyourcompressorperformance,refertoinformation below:
VIAIR COMPRESSOR REFERENCE CHARTCOMPRESSORSERIES DUTYCYCLE WORKINGPRESSURE100SERIES 15% 130PSI215SERIES 17% 150PSI225SERIES 20% 150PSI265SERIES 22% 150PSI275SERIES 25% 150PSI300SERIES 30% 150PSI400SERIES 33% 150PSI450SERIES 100% 150PSI500SERIES 33% 150PSI550SERIES 100% 150PSI
ABOUT COMPRESSOR DUTY CYCLE:CompressorDutyCyclereferstoamountoftimeacompressorcanbeoperatedinagiventimeperiod,at100PSI&atastandardambienttemperatureof72°F.
DutyCycleiscommonlyexpressedas:CompressorOnTime/(CompressorOnTime+OffTime)
Asanexample,acompressorthatisratedfor20%dutycyclemeansthatcompressorcanbeoperatedat100PSI@72°Ffor8Minutesandrestedfor32Minutes.8min.on/(8min.on+32min.off)=20%DutyCycle
DUTY CYCLE REFERENCE CHARTDUTYCYCLE@100PSI/72°F MINUTESON/OFF15% 6Min.On/34Min.Off17% 7Min.On/30Min.Off20% 8Min.On/32Min.Off22% 9Min.On/30Min.Off25% 10Min.On/30Min.Off30% 13Min.On/30Min.Off33% 15Min.On/30Min.Off100% ContinuousDuty
ABOUT RATED WORKING PRESSURE:Toensuretroublefreeservicelifeofyourcompressor,alwaysoperatecompressorwithinratedworkingpressureofthecompressor.Neveruseapressureswitchwithahighercut-offpressurethancompressor’sratedworkingpressure.
TROUBLESHOOTING GUIDE:
Tankpressuredropswhencompressor(s)shutoff
1.Loosedraincock2.Checkvalveleaking3.Looseconnections
1.Tightendraincock2.Replacecheckvalveor
compressor3.Checkallconnectionswith
soap and water solution and tighten
Compressorrunscontinuouslyandairflowlower than normal
1.Excessiveairusage2.Looseconnections3.Wornpistonringorinletvalve.4.Cloggedairfilterelement
1. Decrease air usage2.Checkallconnectionswith
soap and water solution and tighten.
3.Replacecompressor4.Replaceairfilterelement
Compressorrunscontinuously causing safetyvalve(ifequipped)to open
1. Faulty pressure switch2.Defectivesafetyvalve
1.Replacepressureswitch2.Replacesafetyvalve
Excessivemoistureindischarge
1.Excessivewaterinairtank2. High humidity
1.Draintank,tilttanktodrain.Draintankmorefrequently
2.Movecompressortoarea with less humidity, or use water separator
Compressorwillnotrun 1. No power, or power switch in OFF position
2.Blownfuse3.Motoroverheats4. Faulty pressure switch (ifhookeduptoa pressureswitch).
1.Makesurecompressor switch is ON
2. Disconnect compressor from power source, replace fuse.(RefertoSpecifications section for correct fuseamperage)
3.Letcompressorscoolofffor about 30 minutes to allow thermaloverloadswitchtoreset.
4.Replacepressureswitch
Thermaloverloadprotector cuts out repeatedly
1.Lackofproperventilationor ambient temperature is too high
2.Compressorvalvesfailed
1.Movecompressortowellventilatedarea,orareawith lower ambient temperature
2.Replacecompressor
Excessiveknockingor rattling
1.Loosemountingbolts2. Worn bearing on eccentric or
motor shaft3.Cylinderorpistonringisworn
1. Tighten bolts2.Replacebearingor piston assembly3.Replacepistonorcompressor
CAUTION: NEVER DISASSEMBLE COMPRESSOR WHILE COMPRESSOR IS PRESSURIZED.
USER MANUAL
400H - 450H Air Compressor Kit
PROBLEM: POSSIBLECAUSE(S) CORRECTIVEACTION
LIMITED WARRANTY:VIAIRCorporationwarrantsthisproduct,whenproperlyinstalledandundernormalconditionsofuse,tobefreefromdefectsinworkmanshipandmaterialsforaperiodofoneyearfromitsoriginaldateofpurchase.Toreceivewarrantyserviceorrepair,pleasecontactVIAIRCorporation.
Returnsshouldbemadewithinoneyearofthedateofpurchase,afteraReturnGoodsAuthorization(RGA)numberhasbeenassignedbyVIAIRCorporation.ToobtainRGA,faxacopyofyourreceiptto(949)585-0188.Forcompletewarrantydetails,pleasevisit:www.viaircorp.com/warranty
PLEASE NOTE:THISWARRANTYCOVERSPRODUCTDEFECTSONLY;ITDOESNOTCOVERINCIDENTALORCONSEQUENTIALDAMAGESASRESULTOFMISUSEORABUSE.
WIRE GAUGE GUIDE 12-VOLT:
400H - 450H Air Compressor Kit
AmpDrawLengthofwirefrombatterytocompressor
10 15 20 25 3010 14 12 10 10 1015 12 10 10 8 820 10 10 8 6 625 10 8 6 6 630 10 8 6 6 440 8 6 6 4 450 6 6 4 4 260 6 4 4 2 2
15EDELMAN•IRVINE,CA92618TEL:(949)585-0011•FAX:(949)585-0188
www.viaircorp.com
Wiring Diagram: (Fuse Not Included)
“H” MODELCOMPRESSOR WIRING DIAGRAM
15 EdelmanIrvine, CA 92618949-585-0011www.viaircorp.com Rev.1
+ -Battery
Fuse
USER MANUAL
