Vanair Viper Series Installation and operation manual

ROTARY SCREW AIR COMPRESSOR
OPERATOR’S MANUAL & PARTS LIST
P/N: 090058-OP_r0
Effective Date:
August-2014
NOTE
Use only Vanair Vanguard™
Premium Synthetic Oil and
Genuine Vanair Parts. Inspect
and replace damaged
components before operation.
Substituting non-Vanguard™
Oil or non-genuine Vanair filter
components WILL VOID THE
COMPRESSOR WARRANTY!
Vanair Manufacturing, Inc.
10896 West 300 North
Michigan City, IN 46360
Phone: [phone]
[phone]
Service Fax: [phone]
Parts Fax: [phone]
Sales Fax: [phone]
www.vanair.com
KEEP THE MANUAL
WITH THE VEHICLE
Read this manual before
installing, operating or
servicing this equipment.
Failure to comply with the
operation and maintenance
instructions in this manual
WILL VOID THE EQUIPMENT
WARRANTY.
NOTE
Making unauthorized
modifications to the system
components WILL VOID THE
WARRANTY!
Always inform Vanair
Manufacturing, Inc., before
beginning any changes to the
Viper Diesel system.
NOTE
This publication contains the
latest information available at
the time of preparation. Every
effort has been made to ensure
accuracy. However, Vanair
Manufacturing, Inc. takes no
responsibility for errors or
consequential damages
caused by reliance on the
information contained herein.
Vanair Manufacturing, Inc.
reserves the right to make
design change modifications
or improvements without prior
notification.
©2014 Vanair Manufacturing, Inc.
All rights reserved.

The rotary screw compressor unit is warranted for life when adhering to the prescribed maintenance schedule.
The hydraulic motor on the hydraulic Viper is warranted for two (2) years. This warranty does not cover damage
caused by accident, misuse or negligence. If a compressor unit is disassembled the warranty is void. Any
disassembly of major components must be approved by Vanair to avoid voiding of warranty. All other parts
including the compressor unit shaft seal are warranted for twelve (12) months subject to the same conditions
mentioned previously. Any and all such claims for warranty consideration must be coordinated prior to work being
performed through the Warranty-Service Department at the address below. Do not return parts without prior
authorization.
Warranty is limited to the supply of replacement parts failing within the warranty period. Credit for labor required to
refit replacement parts is NOT included. All warranted parts are to be shipped PREPAID to VANAIR. Replacement
parts will be shipped back to the customer by VANAIR via ground shipment. Cost to expedite delivery of
replacement parts will be incurred by customer.
Warranty will commence upon receipt of the Warranty Registration Card. If the Warranty Registration Card is not
received within six (6) months, the warranty commencement date shall be thirty (30) days from the date of
shipment from VANAIR. Records of warranty adherence are the responsibility of end user.
This statement of warranty is expressly in lieu of and disclaims all other express warranties, implied warranties of
merchantability and fitness for a particular purpose and all other implied warranties which extend beyond the
description on the face hereof. In no event shall Vanair be responsible for special, indirect, incidental,
consequential or punitive damages of any kind, including without limitation, lost profits or other monetary loss,
whether or not any such matters or causes are within Vanair's control or due to negligence or other fault of Vanair,
its agents, affiliates, employees or representatives.
This warranty shall be void and VANAIR shall have no responsibility to repair, replace or repay the purchase price
of defective or damaged parts resulting from the use of or repair of replacement parts or fluids not of VANAIR'S
manufacture or from buyer's failure to store, install, maintain and operate the compressor according to the
recommendations contained in the Manual.
All claims under the Warranty shall be made by contacting VANAIR Warranty-Service Department.
Please note that engines are warranted separately by the engine manufacturer. Consult engine manual.
Register Your Warranty Online at www.vanair.com under the Support Tab!
Or Call: [phone] • Fax: [phone]
Mail to: 10896 W 300 North • Michigan City, IN 46360
Effective February 11, 2013
WARRANTY: VIPER SERIES AIR COMPRESSORS

DIESEL VIPER TABLE OF CONTENTS
090058-OP_r0 (AUGUST-2014) PAGE - I
TABLE OF
CONTENTS
VANAIR MANUFACTURING, INC.
[phone] • www.vanair.com
WARRANTY ............................................... BEHIND COVER
TABLE OF CONTENTS...................................................... I
WARRANTY CLAIMS PROCEDURE ................................ V
CLAIMS PROCESS FOR WARRANTED PARTS..................................................................................... V
PROCEDURE........................................................................................................................................... V
SECTION 1: SAFETY .....................................................1
1.1 GENERAL INFORMATION......................................................................................................1
1.2 DANGERS, WARNINGS, CAUTIONS AND NOTES...............................................................1
1.3 SUMMARY OF DANGERS, WARNINGS CAUTIONS AND NOTES.......................................1
1.3.1 DANGERS.......................................................................................................................................................1
1.3.2 WARNINGS......................................................................................................................................................1
1.3.3 CAUTIONS.......................................................................................................................................................2
1.3.4 SAFETY DECALS............................................................................................................................................3
1.4 DISPOSING OF MACHINE FLUIDS .......................................................................................3
SECTION 2: SPECIFICATIONS..........................................5
TABLE 2A: SPECIFICATIONS FOR VIPER DIESEL ROTARY SCREW COMPRESSOR........................5
SECTION 3: INSTALLATION..............................................7
3.1 MACHINE PACKAGE RECEIPT/INSPECTION............................................................................7
3.2 INSTALLATION INSTRUCTIONS.................................................................................................7
3.3 INSTRUMENT PANEL RELOCATION .........................................................................................8
FIGURE 3-1: DIMENSION DIAGRAM - PART 1 OF 2..............................................................................8
FIGURE 3-1: DIMENSION DIAGRAM - PART 2 OF 2..............................................................................9

TABLE OF CONTENTS DIESEL VIPER
PAGE - II 090058-OP_r0 (AUGUST-2014) VANAIR MANUFACTURING, INC.
[phone] • www.vanair.com
SECTION 4: OPERATION................................................ 11
FIGURE 4-1: MAIN MACHINE COMPONENT LOCATIONS ................................................................. 10
4.1 GENERAL INFORMATION..........................................................................................................11
4.2 INSTRUMENTATION..................................................................................................................11
4.2.1 DIGITAL DISPLAY SCREEN ................................................................................................................................11
4.2.2 SCROLL SELECTOR ROCKER SWITCH...........................................................................................................11
4.2.3 ON AND STOP SELECTION KEY SWITCH........................................................................................................11
4.3 INITIAL START-UP PROCEDURE..............................................................................................11
4.4 SHUTDOWN PROCEDURE ...................................................................................................... 12
4.5 SUBSEQUENT START-UP PROCEDURE ................................................................................ 12
4.6 CONTROLLER GUIDE............................................................................................................... 12
4.6.1 HOME SCREEN..................................................................................................................................................13
4.6.2 SPLASH SCREEN ..............................................................................................................................................13
4.6.3 ADJUSTING USER SETTINGS..........................................................................................................................13
4.6.3.1 PARAMETERS.............................................................................................................13
4.6.3.2 AUTO SHUTDOWN................................................................................................... 13
4.6.3.3 AUTO CRANK.............................................................................................................13
4.6.3.4 SLEEP STATE TIMER ................................................................................................13
4.6.4 SETTING PRESSURE.........................................................................................................................................13
4.6.5 SAFETY...............................................................................................................................................................13
4.6.6 SERVICE INTERVALS........................................................................................................................................14
4.7 OPERATING CONDITIONS ....................................................................................................... 14
4.8 EXTREME CONDITIONS...........................................................................................................14
SECTION 5: MAINTENANCE...........................................15
5.1 GENERAL INFORMATION ........................................................................................................ 15
5.2 ROUTINE MAINTENANCE SCHEDULE.................................................................................... 15
5.3A MAINTENANCE SCHEDULE TABLE - COMPRESSOR INTERVALS....................................... 17
5.3B MAINTENANCE SCHEDULE TABLE - ENGINE INTERVALS................................................... 18
5.4 REPLACEMENT PARTS............................................................................................................21
5.5 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES................................................ 21
5.5.1 ADJUSTING THE ENGINE SPEED.....................................................................................................................21
5.6 SERVICING THE SYSTEM FUSES AND CIRCUIT BREAKER ................................................ 21
5.7 STORAGE AND INTERMITTENT USE...................................................................................... 21
5.7.1 INTERMITTENT USE................................................................................................................................................22
5.7.2 LONG TERM STORAGE ..........................................................................................................................................22

DIESEL VIPER TABLE OF CONTENTS
090058-OP_r0 (AUGUST-2014) PAGE - III
VANAIR MANUFACTURING, INC.
[phone] • www.vanair.com
SECTION 6: TROUBLESHOOTING .................................23
6.1 GENERAL INFORMATION.........................................................................................................23
6.2 TROUBLESHOOTING GUIDE....................................................................................................24
6.3 EXTREME CONDITION OPERATION........................................................................................28
6.3.1 HIGH MOISTURE CONDITION: EMULSIFICATION OF OIL IN
ROTARY SCREW COMPRESSOR SYSTEMS....................................................................................................28
TABLE 6.3A HIGH MOISTURE CONDITION OPERATION.......................................................29
6.3.2 COLD WEATHER OPERATION...........................................................................................................................29
TABLE 6.3B COLD WEATHER OPERATION............................................................................30
6.3.3 HIGH TEMPERATURE OPERATION...................................................................................................................30
TABLE 6.3C HIGH TEMPERATURE OPERATION....................................................................31
6.3.4 HIGH DUST CONTENT OPERATION..................................................................................................................31
TABLE 6.3D HIGH DUST CONTENT OPERATION...................................................................31
6.3.5 HIGH ALTITUDE OPERATION.............................................................................................................................32
SECTION 7: ILLUSTRATED PARTS LIST.......................33
7.1 PARTS ORDERING PROCEDURE............................................................................................33
TABLE 7A: RECOMMENDED SPARE PARTS LIST...............................................................................34
TABLE 7B: MACHINE OPTIONS LIST ....................................................................................................34
TABLE 7C: MAINTENANCE TRACKING LOG........................................................................................35
7.2 COMPRESSOR REPLACEMENT PARTS ................................................................................36
7.3 AIREND AND ATT......................................................................................................................38
7.4 ENGINE AND DRIVE PARTS (1 OF 2).......................................................................................40
7.4 ENGINE AND DRIVE PARTS (2 OF 2).......................................................................................42
7.5 COOLING SYSTEM (PART 1 OF 2)...........................................................................................44
7.5 COOLING SYSTEM (PART 2 OF 2)...........................................................................................46
7.6 CANOPY AND FRAME PARTS..................................................................................................48
7.7 COMPRESSOR THERMAL CONTROL .....................................................................................50
7.8 INSTRUMENT PANEL................................................................................................................50
7.9 ELECTRICAL SYSTEM..............................................................................................................52
7.10 FUEL TANK ASSEMBLY............................................................................................................54
7.11A DECALS (LOCATION)................................................................................................................56
7.11B DECALS (IDENTIFICATION)......................................................................................................57
7.11C DECALS (PART NUMBERS)......................................................................................................58
7.12 WIRING DIAGRAM.....................................................................................................................59
7.13 SCHEMATIC FLOW DIAGRAM..................................................................................................60
7.14 HOSE INSTALLATION GUIDE....................................................................................................61

TABLE OF CONTENTS DIESEL VIPER
PAGE - IV 090058-OP_r0 (AUGUST-2014)
BLANK PAGE
VANAIR MANUFACTURING, INC.
[phone] • www.vanair.com

VIPER DIESEL WARRANTY PROCEDURE
090058-OP_r0 (AUGUST-2014) PAGE - V
VANAIR MANUFACTURING, INC.
[phone] • www.vanair.com
CLAIMS PROCESS FOR
WARRANTED VANAIR PARTS
This process must be used by owners of
Vanair®equipment in situations where a
warranted item needs repair or replacement
under the terms of the purchase warranty.
Do not return items to Vanair without prior
authorization from the Vanair Warranty
Administrator.
PROCEDURE:
When a customer needs assistance in
troubleshooting a system and/or returning
parts, follow the steps below.
1. Locate the machine’s serial number:
The machine package serial number plate is
located inside the machine compartment on
the floor near to the engine air filter mounting
location (see Figure W-1).
The engine and the compressor also have
individual serial numbers respectively (see
Figure W-1). For engine warranty issues,
consult the Engine Operator’s Manual for
the engine’s limited warranty details. For
particular compressor unit issues, the
compressor serial number may be needed.
In any case, engine and/or compressor
issues can be confirmed using the machine
serial number as found in Figure W-1.
2. Have a list of the symptoms/condition/
malfunctions along with any applicable
temperature and pressure readings, and
also the number of operational hours
available:
Note that the above information will also
need to be included on the Return Material
Authorization Form (per Step #6); this form
is necessary for warranty processing if the
warranty claim is deemed valid by the
service case review.
3. Contact the Vanair®Service Department
by phone [phone]) to speak with
a Service Technician.
4. Vanair Service will troubleshoot the
problem based on the information
provided by the customer, and attempt to
return the unit to service as quickly as
possible.
5. If the unit cannot be returned to service,
and Vanair determines this matter is a
warranty issue, the Service Technician
will assign an RMA (Return Material
Authorization) number that will provide
for the return of the item to Vanair for
analysis and a final determination as to
the item’s warranty status.
6. Warranty Claims are solicited via a
Return Material Authorization (RMA)
Form. This form can be obtained via
download from the web site, or requested
directly from the Vanair Service
Department:
Once a current form has been obtained,
follow the instructions given on the form to fill
in the information needed. This form is used
for the purpose of soliciting a warranty case.
All of the field information except for the
bottom section block fields, which includes
NOTE
The RMA number must be placed on the
outside of the package being returned.
WARRANTY CLAIMS
PROCEDURE

WARRANTY PROCEDURE VIPER DIESEL
PAGE - VI 090058-OP_r0 (AUGUST-2014) VANAIR MANUFACTURING, INC.
[phone] • www.vanair.com
Figure W-1: Machine Serial Number Location
800-526 -8817
260940
MODEL NUMBER
SERIAL NUMBER
MAXIMUM PRESSURE
COMPRESSOR INPUT RPM
ww w.va na i r.co m
Machine Serial Number
Engine Serial Number
Compressor Unit
Serial Number
Disposition of Goods, Notifications and
Additional Notes, will be required.
Customers have 30 days after the RMA
number is issued to return the item. If the
part is not returned within this period, the
RMA is void and any claims will be denied.
Before sending a warranty part to a
customer, Vanair®will need a P.O. or credit
card number to cover the cost of the part and
shipping. After the part is analyzed and
deemed to be covered under warranty,
Vanair will issue credit to the customer. All
parts eligible for warranty must have the
RMA number on the invoice at the time of
purchase.
No items can be returned “freight collect”.
Freight costs will be addressed at the time
the claim is closed. The customer pays any
additional costs for warranty parts delivered
through expedited services (i.e., Next Day,
Second Day).
VANAIR WILL NEVER ACCEPT ANY
INVOICES FOR PARTS RETURNED: ANY
PARTS RETURNED VIA INVOICE WILL BE
RETURNED FREIGHT COLLECT: NO
PARTS ARE TO BE RETURNED FREIGHT
COLLECT!
Vanair Mfg., Inc. strives to continuously
improve its customer service. Please forward
any questions, comments, or suggestions to
Vanair Service:
Phone: [phone], ext. 400 or toll free
844-VANSERV (826-7378)
Email: [e-mail]
NOTE
All labor claims or invoices must be
approved by the Vanair Warranty
Administrator prior to starting repair work
along with the cost of the repair. All paper
work associated with the returned item
and warranty repair cost must reference
the RMA number issued against the part,
and be forwarded to Vanair within 30 days
of the completion of work.

VIPER DIESEL SECTION 1: SAFETY
090058-OP_r0 (AUGUST-2014) PAGE - 1
VANAIR MANUFACTURING, INC.
[phone] • www.vanair.com
1.1 GENERAL INFORMATION
The products provided by Vanair®
Manufacturing, Inc., are designed and
manufactured for safe operation and
maintenance. But it is ultimately the
responsibility of the users and maintainers
for safe use of this equipment. Part of this
responsibility is to read and be familiar with
the contents of this manual before operation
or performing maintenance actions.
1.2 DANGERS, WARNINGS,
CAUTIONS AND NOTES
These boxes are labeled clearly with the title
block listing either Danger, Warning,
Caution, or other non-safety issue. They
draw attention to specific issues that are
pertinent to the safe and correct operation of
the machine.
The symbols shown and defined in Section
1: Safety are used throughout this manual
and on the machine to call attention to, and
identify, possible hazards.
The international warning symbol (shown
below) is used on all decals, labels and signs
that concern information pertaining to bodily
harm. When you see the international
warning symbol, pay extremely careful
attention, and follow the given instructions
or indications to avoid any possible hazard.
1.3 SUMMARY OF WARNINGS,
CAUTIONS AND NOTES
These boxed inserts are placed throughout
this manual in the sections where they apply.
This subsection is a general summary of
their contents.
1.3.1 DANGERS
• Keep tools or other conductive objects away
from live electrical parts.
• Never touch electrical wires or components
while the machine is operating. They can be
sources of electrical shock.
1.3.2 WARNINGS
•DO NOT EVER use this compressor as a
breathing air source. Vanair Manufacturing
Inc., disclaims any and all liabilities for
damage or loss due to fatalities, personal
injuries resulting from the use of a Vanair
compressor to supply breathing air.
•DO NOT perform any modifications to this
equipment without prior factory approval.
•DO NOT install this compressor in a
confined space that lacks proper
ventilation and airflow; breathing and
cooling air circulation must not be
compromised.
•DO NOT operate the compressor or any of
its systems if there is a known unsafe
condition. Disable the equipment by
disconnecting it from its power source.
Install a lock-out tag to identify the
IMPORTANT
Read this manual before operating or
servicing the Viper Diesel compressor
system. Failure to do could result in
damage equipment, bodily injury, or
death
SECTION 1:
SAFETY

SECTION1: SAFETY VIPER DIESEL
PAGE - 2 090058-OP_r0 (AUGUST-2014) VANAIR MANUFACTURING, INC.
[phone] • www.vanair.com
equipment as inoperable to other
personnel.
•DO NOT operate the compressor with
any by-pass or other safety systems
disconnected or rendered inoperative.
•DO NOT operate the equipment while
you are under the influence of alcohol or
drugs.
•DO NOT operate the equipment while
you are feeling ill.
•DO NOT attempt to service the
equipment while it is operating.
• Before performing maintenance or
replacing parts, relieve the entire system
pressure by opening a service valve
which will vent all pressure to the
atmosphere: remove all electrical power.
•DO NOT use the compressor for
purposes other than for which it is
intended. High pressure air can cause
serious and even fatal injuries.
•DO NOT operate the compressor
outside of its specified pressure and
speed ratings. (See Section 2:
Specifications or refer to the equipment
data plate.)
•DONOTuse flammable solvents or
cleaners for cleaning the compressor or
it parts.
•DO NOT operate the compressor in
areas where flammable, toxic, or
corrosive fumes, or other damaging
substance can be ingested by the
compressor intakes.
• Keep arms, hands, hair and other body
parts, and clothing away from fans, drive
shafts, and other moving parts.
•DO NOT wear jewelry, unbuttoned cuffs,
ties, or loose-fitting clothing when you are
working near moving/rotating parts.
•ALWAYS confine long hair when working
near moving/rotating parts.
•NEVER operate the equipment while
wearing a headset to listen to music or the
radio.
• Wear personal protective equipment
such as gloves, work shoes, and eye
and hearing protection as required for
the task at hand.
•DO NOT operate the compressor with
any guards removed or damaged, or
other safety devices inoperative.
•DO NOT operate the compressor in
enclosed or confined spaces where
ventilation is restricted or closed-off.
• Ensure that hoses connected to service
valves are fitted with correctly sized and
rated flow limiting devices which comply
with applicable codes. Pressurized
broken or disconnected hoses can whip
causing injuries or damage.
• Over speed is hazardous! NEVER
tamper with the governor components or
settings to increase the maximum
speed. Severe personal injury and
equipment damage can result if
operated at speeds above the maximum.
•DO NOT use tools, hoses, or equipment
that have maximum ratings below that of
this compressor.
• Keep metal tools, and other conductive
objects away from live electrical
components.
• Before performing maintenance or repair
operations on the compressor, ensure
that all power has been removed and
been locked out to prevent accidental
application.
•DO NOT assume that because the
compressor is in a STOPPED condition
that power has been removed.
• Use this compressor only to compress
atmospheric air. Use of this equipment
as a booster pump and/or to compress
any other gaseous or aerosol substance
constitutes improper use. It can also
cause damage or injuries. Such misuse
will also void the warranty.
• Install, operate, and maintain this
equipment in full compliance with all
applicable OSHA, other Federal, state,
local codes, standards, and regulations.
• When lifting objects, be aware of proper
lifting techniques to avoid injury.
•ALWAYS read and follow safety related
precautions found on containers of
hazardous substances.
•DO NOT play with compressed air. It can
cause serious injury.
1.3.3 CAUTIONS
• Check all safety devices for proper
operation on a routine basis.
• Ensure that no tools, rags, or other
objects are left on compressor drive
systems or near intakes.