VIAIR 400H-A User manual

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-A – HARDMOUNT AUTOMATIC AIR COMPRESSOR KIT
PART NO. 40041
450H-A – HARDMOUNT AUTOMATIC AIR COMPRESSOR KIT
PART NO. 45041
450H-A
400H-A

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an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o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
dierentareasofyourvehicle.PleasereadandfollowtheseInstallationInstructionscarefullytoavoid
injuryordamagetothecompressororto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. 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)
7.Donotmountcompressornearareaswhereammableliquidsarestored.
USER MANUAL
400H-A - 450H-A Hardmount Automatic 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withthefoursetsofbolts,nuts,washers,andlockingwashers
 provided.(SeeFig.2forMountingInstructions).Useofthreadsealantisrecommended.
5. 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.
6. Re-checktomakesurethatallconnectionsaremadesecurely.
(Fig. 1) 400H-A/450H-A Hardmount Automatic Air Compressor Kit Installation Parts List:
K
A. MountingBolts(4pcs)
B. FlatWashers(8pcs)
C. LockingWasher(4pcs)
D. Nuts(4pcs)
E. 1/4”Fx3/8”TubeFitting(1pcs)
F. 3/8”AirLine(1pc)
G.AirLineClips(3pcs)
H. Screws(3pcs)
I. RemoteInletAirFilterwithFilterElement(1pc)
J. Positive(Red)RingTerminal(1pc)
K. Negative(Black)RingTerminals(2Sizes)
400H-A - 450H-A Hardmount Automatic Air Compressor Kit
USER MANUAL
ACDE
G
H
I
F
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
J
B
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yourcompressorshutosuddenlyafterextendeduse,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oforabout30minutes,
before resuming use of the air compressor.
5.Foryourconvenience,andtoprotecttheaircompressorfromover-pressureoperationthat

OPERATING INSTRUCTIONS (continued)
 cancausepermanentdamagetotheunit-thiscompressorisequippedwithbuilt-inpressure
 switchwithafactorysetcut-onpressureof130PSI(±5%)andafactorysetcut-opressureof
 155PSI(±5%).Duringinationoftirepressuresbetween130PSIto155PSI,ifyoustopination,
the compressor may not restart. This is completely normal, since inline pressure is greater than
 cut-onpressureofthepressureswitchandlessthancut-opressureofthepressureswitch.
 Torestartcompressor,deatetirepressuretobelow130PSI,reconnecttirechucktotirevalve
 stemandresumetireination
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1/4”quickconnectstud.Anextensioncoilhoseandatire
inationgunarealsoincludedwithyourcompressor.Eachendoftheextensioncoilhoseis
equippedwitha1/4”quickconnectcoupler.Thetireinationguncomeswitha1/4”quick
connectstud,pressuregauge,rubberhose,bleedervalveandtirechuck.Attachoneendof
theextensioncoilhosetothestudonyourcompressorandtheotherendtothestudonthe
tiregunkit.Thetiregunkitcanbeusedforbothairingupandairingdown.Pleasefamiliarize
yourselfwiththefollowingfunctionsofthisversatileairtool.
1.Attachoneendoftheextensioncoilhosetothecompressorandtheotherendtothetiregunkit.
2.Pushthetirechuck,withtheleverintheuprightposition,downoverthetirevalvestemandthen
 pushtheleverdowntothehorizontalpositiontolockinplace.
3.Turncompressorswitchonandholddownthetriggeronthetiregunkittobeginination.
TIRE DEFLATION
1.Pushthetirechuck(withtheleverintheuprightposition)downoverthetirevalvestemandthen
pushtheleverdowntothehorizontalpositiontolockinplace.
2.Pressthebleedervalvebuttononthetiregunkittodecreasetirepressure.
3.Whendesiredpressureisreached,releasethebleedervalvebuttontohaltdeation
IMPORTANT: AlwaysmakesurethePortableCompressor’spowercordisuncoiledandfully
extendedwhenusingyouraircompressortoavoidoverheatingthepowercord.
INLINE PRESSURE GAUGE
1.Thepressuregaugeontheinationgunprovidesconvenienttirepressuremonitoringwhenairing
 upordown(notairowofthecompressor).Thiseliminatesswitchingbackandforthbetweena
 tirechuckandatirepressuregauge.
2.Pleasenotethatduringinationanddeation,duetoairvelocity,pressuregaugecannotprovide
 accuratepressurereadings.Releaseleveronthetireinationgunduringinationtochecktire
air pressure.
NOTE:Toreleaseexcesspressure,turnocompressoranddisconnecthosefromcompressor.With
thetireinationgunstillconnectedtotheotherendofthecoilhose,pulltriggeronthetireination
guntoreleaseexcesspressure.
SAFETY PRECAUTIONS:
1.Alwaysinatetirestomanufacturer’srecommendedtirepressures.Exerciseextremecaution
whendrivingwithaired-downtires.Reinatetiresbeforehigh-speedroadwaytravel.
2.Neverexceed20M.P.H.whendrivingwithpartiallyinatedtires.
3.Nevermakesharpturnswhiledrivingwithreducedtirepressure.
4.Re-inatetiresbeforehighspeedtravelingontoroadways.
USER MANUAL
400H-A - 450H-A Hardmount Automatic Air Compressor Kit

INLINE PRESSURE GAUGE (continued)
5.Useheat-resistant,minimum200PSI-ratedworkingpressureextensionhose.Donotuse
 aftermarkethoseswithlessthan200PSI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.
MAINTENANCE & REPAIRS
1.Periodicallycheckallelectricalandttings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.Ifnecessary,wearheatresistantglovestohandlettings,
air line, and coil hose.
SPECIFICATIONS
•PartNo.40041/400H-AAutomaticAirCompressor
MotorVoltage:   12Volts
Max.CurrentConsumption:  30Amps
MotorType:   PermanentMagnetic
Max.WorkingPressure:  150PSI
Max.DutyCycle(@72°F&100PSI): 33%
(Min.On/O@72°F&100PSI) 20On/40O
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.45041/450H-AAutomaticAirCompressor
MotorVoltage:   12Volts
Max.CurrentConsumption:  23Amps
MotorType:   PermanentMagnetic
Max.WorkingPressure:  150PSI
Max.DutyCycle(@72°F&100PSI): 100%
(Min.On/O@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-A - 450H-A Hardmount Automatic Air Compressor Kit

USER MANUAL
400H-A - 450H-A Hardmount Automatic 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 MAX.WORKING DUTYCYCLE
 PRESSURE (100PSI@72°F)
090SERIES 120PSI 9% 
092SERIES 120PSI 9%
095SERIES 120PSI 9%
097SERIES 130PSI 10%
098SERIES 130PSI 10%
100SERIES 130PSI 15%
250IGSERIES 150PSI 100%
275SERIES 150PSI 25%
280SERIES 150PSI 30%
325SERIES 150PSI 33%
330IGSERIES 150PSI 100%
350SERIES 150PSI 100%
380SERIES 200PSI 100% 
  55%@200PSI
400SERIES 150PSI 33%
420SERIES 150PSI 33%
425SERIES 175PSI 33%@175PSI 
  50%
444SERIES 200PSI 100% 
  50%@200PSI
450SERIES 150PSI 100%
450IGSERIES 150PSI 100%
460SERIES 150PSI 100%
480SERIES 200PSI 100% 
  50%@200PSI
485SERIES 200PSI 100% 
  100%@200PSI
ABOUT COMPRESSOR DUTY CYCLE:
Dutycyclereferstotheamountoftimeacompressorcanbeoperated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+otime)=DutyCycle%.
ONE-HOUR DUTY CYCLE MINUTES ON /
(100PSI@72°F) MINUTES OFF
 9% 5Min.On/55Min.O
 10% 6Min.On/54Min.O
 15% 9Min.On/51Min.O
 20% 12Min.On/48Min.O
 25% 15Min.On/45Min.O
 30% 18Min.On/42Min.O
 33% 20Min.On/40Min.O
 50% 30Min.On/30Min.O
100%1HourRunTime
NOTE:Allcompressors,regardlessofrateddutycycle,requiresucient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-opressurethan
compressor’sratedworkingpressure.

TROUBLESHOOTING GUIDE:
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
1. Faulty pressure switch 1.Replacepressureswitch
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o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-A - 450H-A Hardmount Automatic Air Compressor Kit
PROBLEM: POSSIBLECAUSE(S) CORRECTIVEACTION

400H-A - 450H-A Hardmount Automatic Air Compressor Kit
15EDELMAN•IRVINE,CA92618
TEL:(949)585-0011•FAX:(949)585-0188
www.viaircorp.com
Wiring Diagram:
(Fuse Not Included)
USER MANUAL
AMERICAN WIRE GAUGE GUIDE 12-VOLT:
Amp Draw
Lengthofwirefrombatteryto
compressor(infeet)
5 10 15 20
5 16 16 16 14
10 16 14 12 10
15 16 12 10 10
20 14 10 10 8
25 14 10 86
30 12 10 86
40 12 8 6 6
50 10 6 6 4
60 10 6 4 4
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.
ThisManualisproprietarytoVIAIRCorporationandnoownershiprightsareherebytransferred.NopartoftheManualshallbe
used,reproduced,translated,converted,adapted,storedinaretrievalsystem,communicatedortransmittedbyanymeans,forany
commercialpurpose,includingwithoutlimitation,sale,resale,license,rentalorlease,withoutthepriorexpresswrittenconsentofVIAIR.
VIAIRdoesnotmakeanyrepresentations,warrantiesorguarantees,expressorimplied,astotheaccuracyorcompletenessofthe
Manual.UsersmustbeawarethatupdatesandamendmentswillbemadefromtimetotimetotheManual.Itistheuser’sresponsibility
todeterminewhethertherehavebeenanysuchupdatesoramendments.NeitherVIAIRnoranyofitsdirectors,ocers,employees
oragentsshallbeliableincontract,tortorinanyothermannerwhatsoevertoanypersonforanyloss,damage,injury,liability,costor
expenseofanynature,includingwithoutlimitationincidental,special,directorconsequentialdamagesarisingoutoforinconnection
withtheuseoftheManual.
R1-062220