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45042

VIAIR 45042, 40042 User manual

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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
IMPORTANT SAFETY INSTRUCTIONS
CAUTION - To reduce risk of electrical shock or electrocution:
- Donotdisassemble.Donotattemptrepairsormodications.Refertoqualiedservice
agenciesforallserviceandrepairs.
- Donotusethisproductinorareawhereitcanfallorbepulledintowaterorotherliquid.
- 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.
WARNING - To prevent injury:
- Neverallowchildrentooperatethiscompressor.Closesupervisionisnecessarywhenthis
compressor is being used near children.
- Thiscompressorwillbecomeveryhotduringandimmediatelyafteruse.Donottouchanypartof
this compressor with bare hands, other than the ON/OFF switch, during and immediately after use.
- Donotusethisproductnearamesorexplosivematerialsorwhereaerosolproductsarebeingused.
- Donotoperatethisproductwhereoxygenisbeingadministered.
- Do not pump anything other than atmospheric air.
- Neverusethisproductwhilesleepyordrowsy.
- Donotuseanytoolsorattachmentswithoutrstdeterminingmaximumairpressureforthat
tool or attachment.
- Neverpointanyairnozzleorairsprayertowardanotherpersonoranypartofthebody.
- ThisaircompressorisequippedwithAutomaticResetThermalProtector,andcanautomatically
 restartafterthethermalprotectorresets.Alwayscutoffpowersourcewhenthermalprotector
 becomesactivated.
- Wear safety glasses or goggles when operating this product.
- Useonlyinwellventilatedareas.
INSTALLATION
Thisaircompressorisidealformountingunderthehoodoreveninsideyourvehicle.Thecompact
sizeofthiscompressorrequiresminimalspace,andoil-lessdesignpermitsmountinginmany
differentareasofyourvehicle.PleasereadandfollowtheseInstallationInstructionscarefullytoavoid
injuryordamagetothecompressororyourvehicle.
Eachofouraircompressorsandpartshavebeencarefullyproducedandpackaged.Beforeyou
begininstallation,pleasefamiliarizeyourselfwithInstallationPartsList(Fig.1)ofthismanual.
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 guidelines:
1. Select a FLAT,UPRIGHTANDSECURE location where the compressor can be mounted.
2.Tomaximizeaircompressorperformance,locatecompressorasCLOSETOTHEBATTERY
aspossiblesothatlengthofpositiveleadwirerequiredisataminimum.
3.ChoosemountinglocationthatisascoolaspossibleandAWAYFROMHEATSOURCES.
Thecoolertheambienttemperaturethelesschancethecompressorwilloverheat.
4. This compressor is moisture & splash resistant, but NOTWATERPROOF. Do not mount
compressorinlocationswheretheunitislikelytocomeincontactwithwater.
5. Select compressor mounting location where air line can be routed from compressor air inlet to
remoteinletairlter.MakesureRemoteInletAirFilterislocatedinadrylocation,awayfrom
water splashes.
6.Youwillalsowanttoselectacompressormountinglocationwheretheleaderhosebracket
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
yourvehicleorinthebedofyourpickup,useaminimum8AWGpositiveleadwirefor
remoteinstallation.(Seewiregaugereferencechart)
8.Donotmountcompressornearareaswhereammableliquidsarestored.
USER MANUAL
400H - 450H Air Compressor Kit
MOUNTING AND WIRING
1. Disconnectgroundcablefromvehicle’sbattery.
2. Temporarilypositiontheaircompressorinthelocationwhereitwillbemounted.Routethe
positivewiretothepositivepostofthebattery.Measureandcutpositivewiretotheappropriate
length and use appropriate inline fuse.
3. Routegroundwiretothenegativepostofthebatteryortoanappropriatechassisgrounding
point and cut ground wire to length as needed.
4. Mounttheaircompressorbyusingthepairofanti-vibrationmountingbracketsandfoursets
of13/64”(5mm)bolts,nuts,washers,andlockingwashersprovided.Use13/64”drillbittodrill
holesfortherstsetofbrackets.Mountthisrstbracketwithscrews,atwashers,locking
washersandnutsprovided.(RefertoFig.2forplacementofwashers.)
5. Placecompressorintomountedbracket.Placesecondsetofbracketundertheaircompressor,
makesurethatthecompressorsitssnugglyinbetweenthetwobrackets.Markoffholestobe
drilledusingthesecondsetofbracketsasguides.Drillholes,andplacecompressorsnugly
betweenbracketsandmountthesecondbracket.
6. RefertoRemoteAirFilterInstallationInstructionsincludedintheRemoteInletAirFilterPack
forinstallationofRemoteInletAirFilter.
7. Thisaircompressorcomesequippedwitha1.5ft.heavydutyheatresistantleaderhose.
Thisleaderhoseisdesignedtoprovideeasyaccessforairhoseattachmentandtoprolongthe
lifeofyourextensionhoseaswellasminimizingweartothecompressorairoutlet.Donot
removethisleaderhosefromtheaircompressor.
8. PLEASE NOTE:Theleaderhosethatcomeswithyourcompressormayhavea
built-ininlinecheckvalveinstalled.Donotremoveinlinecheckvalvefromleaderhose.
9. Selectaproperlocationtomountleaderhosewithhosebracketprovided.
Avoidlocationswhereleaderhosemaybecometangledwithwiresandotherhoses.
10.Tomounthosebracket,drillhole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.
11.Toremovehosefromthehosebracket,simplypressdownonthehoseclampreleasetabto
releasebracketclamp.(Fig.3)
12.Attachgroundwiretothenegativepostofthebatteryorchassisgroundingpoint.
Checktomakesurethattheaircompressor’sON/OFFswitchisintheOFFposition.
Attachpositivewiretopositiveterminalofthebattery.
13.Re-checktomakesurethatallconnectionsaremadesecurely.
(Fig. 1) 400H/450H Hardmount Air Compressor Kit Installation Parts List:
M
A. HoseBracket(1pc)
B. MountingBolts(4pcs)
C. FlatWashers(8pcs)
D. LockingWasher(4pcs)
E. Nuts(4pcs)
F. 1/4”Fx3/8”TubeFitting(1pcs)
G. 1/4”Mx3/8”TubeFitting(1pcs)
H. 3/8”AirLine(1pc)
I. AirLineClips(3pcs)
J. Screws(3pcs)
K. RemoteInletAirFilterwithFilterElement(1pc)
L. Positive(Red)RingTerminal(1pc)
M.Negative(Black)RingTerminals(2Sizes)
400H - 450H Air Compressor Kit
USER MANUAL
A
B D
F
G
I
J
K
H
B
C
C
D
E
F
(Fig. 2) Compressor
Mounting Hardware
B.MountingBolt
C.FlatWasher
D.LockingWasher
E. Nut
F. Vibration Isolator
(Fig. 3) Leader Hose Bracket
L.HoseClamp
M.ClampReleaseTab
N.Self-AnchoringPin
L
M
N
L
OPERATING INSTRUCTIONS
1. IMPORTANT:AlwaysoperatethecompressoratorbelowtheMAXIMUMPRESSURERATINGof
thecompressor.PleaserefertoApplication&SpecicationsSectionsofthismanualfordetails.
2.AlwaysobservetheMAXIMUMDUTYCYCLEoftheaircompressor.RefertoCompressor
ApplicationsandSpecicationsSectionsofthismanualfordetails.Operationexceeding
maximumpressureratingsand/ordutycyclewillresultindamagetotheaircompressor.
3.YouraircompressorisequippedwithanAUTOMATICTHERMALOVERLOADPROTECTOR.
Thisfeatureisdesignedtoprotecttheaircompressorfromoverheatingandcausingpermanent
damagetoyouraircompressor.Thethermaloverloadprotectorwillautomaticallycutpowerto
youraircompressorshouldtheinternaloperatingtemperatureoftheaircompressorriseabove
safelevelsduringexcessiveuse.
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.
Theautomaticthermaloverloadprotectorwillautomaticallyresetwheninternaltemperatureofthe
aircompressordropsbelowsafelevels.Allowaircompressortocooloffforabout30minutes,
before resuming use of the air compressor.
5.Keepthevehicleenginerunningwhileusingtheaircompressortopreventdischargeof
yourvehicle’sbattery.
6.ONLYOPERATETHEAIRCOMPRESSORINWELL-VENTILATEDAREAS.
7.Compressorperformanceisalsoenhancedwhenoperatingcompressorwithvehicle’s
engine running.
TIRE INFLATION
Thisaircompressorcomeswith1.5feetheavydutyheat-resistantleaderhosewith1/4”industrial
seriesquickconnectstud.Byattachinganairhosewith1/4”industrialseriesquickcouplertothe
leaderhose,youraircompressorisreadytoinatetires.Readandfollowtireinationinstructions
carefullytoavoidpersonalinjuryanddamagetoaircompressororvehicle.
1.Useheat-resistant,minimum200PSI-ratedworkingpressureextensionhose.Donotuse
aftermarkethoseswithlessthan200PSIworkingpressure.Someaftermarkethosesmaynotbe
suitable for use with this air compressor due to heat and pressure typically generated by this type
of air compressors.
2.Useofourconvenient25ft.extensioncoilhosewithin-linedeatorandBuilt-inPressureGauge
isrecommended(PartNo.00025,5-in-1InlineInator/Deator).
3.Useofaclose-endedtirechuckwillcauseexcessivepressurebuildupiftirechuckisnotattached
totirevalvestemwhileaircompressorisinoperation.AlwaysuseanOpen-Endedtirechuck
suchasthetirechuckequippedontheInator/DeatorCoilHose(P/N00025)fortireination.
4.Alwaysinatetirestomanufacturer’srecommendedtirepressures.Exerciseextremecaution
whendrivingwithaireddowntires.Re-inatetiresbeforehighspeedroadwaytravel.
MAINTENANCE & REPAIRS
1.Periodicallycheckallelectricalandttingconnections.Cleanandtightenorrepairasneeded.
2.Periodicallycheckallmountingbolts.Tightenasneeded.
3.Replaceairlterelementperiodically.Replacementfrequencydependsonoperatingfrequency
andoperatingenvironment.Forfrequentuseindustyenvironment,werecommendthatyou
replaceairlterelementatleastonceamonth.
4.Regularlycleandustanddirtfromcompressorcoolingnsandmotorhousing.
5.Youraircompressorisequippedwithapermanentlylubricated,maintenance-freemotor.
Nevertrytolubricatecompressor.
6.AllrepairsshouldbeperformedbyManufacturerorManufacturer’sAuthorized
ServiceAgenciesonly.
CAUTION:Nevertouchtheaircompressororttingsconnectedtotheaircompressor,withbare
handsduringorimmediatelyafterusage.Theleaderhoseandttingsconnectedtotheleader
hosewillbecomeveryHOTduringandafteruse.Ifnecessary,wearheatresistantglovestohandle
ttings,airline,andleaderhose.
USER MANUAL
400H - 450H Air Compressor Kit
SPECIFICATIONS
•PartNo.40042/400HAirCompressor
MotorVoltage: 12Volts
Max.CurrentConsumption:  26Amps
MotorType: PermanentMagnetic
Max.WorkingPressure: 150PSI
Max.DutyCycle(@72°F&100PSI): 33%
(Min.On/Off@72°F&100PSI) 15On/30Off
Max.RestartPressure:  150PSI
Max.AmbientTemperature: 158°F
Min.AmbientTemperature: -40°F
Fuse: 40 amps
Dimensions: 11.25”Lx4”Wx6.75H”
NetWeight: 8.95Lbs.
•PartNo.45042/450HAirCompressor
MotorVoltage: 12Volts
Max.CurrentConsumption:  19Amps
MotorType: PermanentMagnetic
Max.WorkingPressure: 150PSI
Max.DutyCycle(@72°F&100PSI): 100%
(Min.On/Off@72°F&100PSI) Continuous
Max.RestartPressure:  150PSI
Max.AmbientTemperature: 158°F
Min.AmbientTemperature: -40°F
Fuse: 30 amps
Dimensions: 12”Lx4”Wx6.75H”
NetWeight: 11.05Lbs.
USER MANUAL
400H - 450H Air Compressor Kit
USER MANUAL
400H - 450H Air Compressor Kit
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 WORKINGPRESSURE
100SERIES 15% 130PSI
215SERIES 17% 150PSI
225SERIES 20% 150PSI
265SERIES 22% 150PSI
275SERIES 25% 150PSI
300SERIES 30% 150PSI
400SERIES 33% 150PSI
450SERIES 100% 150PSI
500SERIES 33% 150PSI
550SERIES 100% 150PSI
ABOUT COMPRESSOR DUTY CYCLE:
CompressorDutyCyclereferstoamountoftimeacompressorcanbeoperatedinagiventime
period,at100PSI&atastandardambienttemperatureof72°F.
DutyCycleiscommonlyexpressedas:
CompressorOnTime/(CompressorOnTime+OffTime)
Asanexample,acompressorthatisratedfor20%dutycyclemeansthatcompressorcanbe
operatedat100PSI@72°Ffor8Minutesandrestedfor32Minutes.
8min.on/(8min.on+32min.off)=20%DutyCycle
DUTY CYCLE REFERENCE CHART
DUTYCYCLE@100PSI/72°F MINUTESON/OFF
15% 6Min.On/34Min.Off
17% 7Min.On/30Min.Off
20% 8Min.On/32Min.Off
22% 9Min.On/30Min.Off
25% 10Min.On/30Min.Off
30% 13Min.On/30Min.Off
33% 15Min.On/30Min.Off
100% ContinuousDuty
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.
TROUBLESHOOTING GUIDE:
Tankpressuredropswhen
compressor(s)shutoff
1.Loosedraincock
2.Checkvalveleaking
3.Looseconnections
1.Tightendraincock
2.Replacecheckvalveor
compressor
3.Checkallconnectionswith
soap and water solution
and tighten
Compressorruns
continuouslyandairow
lower than normal
1.Excessiveairusage
2.Looseconnections
3.Wornpistonringorinletvalve.
4.Cloggedairlterelement
1. Decrease air usage
2.Checkallconnectionswith
soap and water solution
and tighten.
3.Replacecompressor
4.Replaceairlterelement
Compressorruns
continuously causing
safetyvalve(ifequipped)
to open
1. Faulty pressure switch
2.Defectivesafetyvalve
1.Replacepressureswitch
2.Replacesafetyvalve
Excessivemoisturein
discharge
1.Excessivewaterinairtank
2. High humidity
1.Draintank,tilttanktodrain.
Draintankmorefrequently
2.Movecompressortoarea
with less humidity, or use
water separator
Compressorwillnotrun 1. No power, or power switch
in OFF position
2.Blownfuse
3.Motoroverheats
4. Faulty pressure switch
(ifhookeduptoa
pressureswitch).
1.Makesurecompressor
switch is ON
2. Disconnect compressor
from power source, replace
fuse.(RefertoSpecications
section for correct
fuseamperage)
3.Letcompressorscoolofffor
about 30 minutes to allow
thermaloverloadswitchtoreset.
4.Replacepressureswitch
Thermaloverload
protector cuts out
repeatedly
1.Lackofproperventilationor
ambient temperature is too high
2.Compressorvalvesfailed
1.Movecompressortowell
ventilatedarea,orareawith
lower ambient temperature
2.Replacecompressor
Excessiveknocking
or rattling
1.Loosemountingbolts
2. Worn bearing on eccentric or
motor shaft
3.Cylinderorpistonringisworn
1. Tighten bolts
2.Replacebearingor
piston assembly
3.Replacepistonorcompressor
CAUTION: NEVER DISASSEMBLE COMPRESSOR WHILE
COMPRESSOR IS PRESSURIZED.
USER MANUAL
400H - 450H Air Compressor Kit
PROBLEM: POSSIBLECAUSE(S) CORRECTIVEACTION
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within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.
WIRE GAUGE GUIDE 12-VOLT:
400H - 450H Air Compressor Kit
AmpDraw
Lengthofwirefrombatterytocompressor
10 15 20 25 30
10 14 12 10 10 10
15 12 10 10 8 8
20 10 10 8 6 6
25 10 8 6 6 6
30 10 8 6 6 4
40 8 6 6 4 4
50 6 6 4 4 2
60 6 4 4 2 2
15EDELMAN•IRVINE,CA92618
TEL:(949)585-0011•FAX:(949)585-0188
www.viaircorp.com
Wiring Diagram:
(Fuse Not Included)
“H” MODEL
COMPRESSOR WIRING DIAGRAM
15 Edelman
Irvine, CA 92618
949-585-0011
www.viaircorp.com
Rev.1
+
-
Battery
Fuse
USER MANUAL
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