VIAIR 420C User manual

420C AIR COMPRESSOR KIT
PART NO. 42042
460C AIR COMPRESSOR KIT
PART NO. 46043
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
420C
460C

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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.
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, 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an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
Pleasereadandfollowthe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
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WATERPROOF. Do not mount
compressor in locations where the unit is likely to come in contact with water.
5.Forremoteltermounting,selectcompressor’s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 the elements.
6.Youwillalsowanttoselectcompressormountinglocationwheretheleaderhosebracketcanbe
mounted to secure the 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.
8.Donotmountcompressornearareaswhereammableliquidsarestored.
9.Usethreadsealantforproperttinginstallation.Teontapeisnotrecommended.
 Properlysealed,recommendedtorqueis12to15ft.lbs
USER MANUAL
420C - 460C 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.
3. Routegroundwiretothenegativepostofthebatteryortoanappropriategroundingpointand
cut ground wire to length as needed.
4. Mount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. NOTE:ForRemoteInletAirFilterInstallation,refertoRemoteInletAirFilterInstallation
 InstructionsincludedintheRemoteInletAirFilterPack.
6. VIAIRaircompressor(s)comeequippedwithheavydutyheatresistantleaderhose(s)
 with3/8”NPTttings.Thisleaderhoseisdesignedtoprolongthelifeofyourairline.
 Donotremovethisleaderhosefromaircompressor.
7. IMPORTANT:Pleasenote,theleaderhosethatcomeswithyourcompressorhasabuilt-ininline
 checkvalve.DoNotremoveinlinecheckvalvefromleaderhose.
8. Selectproperlocationtomountleaderhosewithhosebracketprovided.Avoidlocationswhere
leader hose may become tangled with wires and other hoses.
9. 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.
10.Toremovehosefromthehosebracket,simplypressdownonthehoseclampreleasetabto
 releasebracketclamp.(Fig.3)
11.Connectcompressor’spositiveleadwiretooneoftheleadsofyourpressureswitch.
12.Makesurethatyourcompressorsetupisproperlyfused.Forappropriatefusesize,referto
 ampdrawofcompressorinthespecicationssectionofthismanual.
13.Alwayslocatefuseascloseaspossibletopowersource.
14.Beforeconnectingtopowersource,re-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.Repairconnections
as needed.
(Fig. 1) 420C / 460C Compressor Installation Parts List:
A. HoseBracket(1pc)
B. MountingBolts(4pcs)
C.FlatWashers(8pcs)
D.LockingWashers(4pcs)
E.Nuts(4pcs)
F.3/8”NPTFx1/2”BarbedFitting(1pc)
G.3/8”NPTMx1/2”BarbedFitting(1pc)
H.RemoteMountFilterAirLine(1pc)
I. AirLineClips(3pcs)
J.Screws(3pcs)
K.RemoteInletAirFilterwithFilterElement(1pc)
USER MANUAL
420C - 460C COMPRESSOR KIT
C E
REDUCER
B
ADFG
I
J
K
H

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totheaircompressorOFF.Theautomaticthermaloverload
protector will automatically reset when internal temperature of the air compressor drops below
 safelevel.Afterallowingaircompressortocooloffforabout30minutes,youcansafelyresume
use of the air compressor.
5.Topreventdischargeofyourvehicle’sbattery,werecommendthatyoukeepthevehicle’sengine
running while using the air compressor.
6.ONLYOPERATETHEAIRCOMPRESSORINWELL-VENTILATEDAREAS.
7.Compressorperformanceisenhancedwhenoperatingcompressorwithvehicle’senginerunning.
MAINTENANCE & REPAIRS
1.Periodicallycheckallelectrical,ttings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,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the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use.Theleaderhoseandttingsconnectedto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
420C - 460C COMPRESSOR KIT
RELAY WIRING SCHEMATIC
Pressure Switch
86
Fused
12-Volt 30
To Ground
85
87 Compressor
(+) Lead
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
REDUCER
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SPECIFICATIONS
•PartNo42042/420CAirCompressor(CESpec.)
MotorVoltage: 12Volts
Max.CurrentConsumption: 28Amps
RecommendedFuse:40Amps
MotorType: PermanentMagnetic
Horsepower: 1/4
Max.WorkingPressure: 150PSI
Max.DutyCycle(@72ºF&100PSI): 33%
MinutesOn/Off(@72ºF&100PSI): 20On/40Off
Max.AmbientTemperature: 158ºF
Min.AmbientTemperature: -40ºF
Auto.ResetThermalProtection: Yes
Dimensions: 10”Lx4.3”Wx6.5”H
NetWeight: 9.0Lbs.
•PartNo.46043/460CAirCompressor(CESpec.)
MotorVoltage: 12Volts
Max.CurrentConsumption: 24Amps
RecommendedFuse: 30Amps
MotorType: PermanentMagnetic
Horsepower: 1/4
Max.WorkingPressure: 150PSI
Max.DutyCycle(@72ºF&100PSI): 100%
MinutesOn/Off(@72ºF&100PSI): Continuous
Max.AmbientTemperature: 158ºF
Min.AmbientTemperature: -40ºF
Auto.ResetThermalProtection: Yes
Dimensions: 11.5”Lx4.3”Wx6.5”H
NetWeight: 11.10Lbs.
USER MANUAL
420C - 460C COMPRESSOR KIT

COMPRESSOR APPLICATION GUIDE
Toensurethatyougetthehighestlevelofsatisfactionfromyourcompressor’s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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+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%    20Min.On/40Min.Off
50%    30Min.On/30Min.Off
100%    1HourRunTime
NOTE:Allcompressors,regardlessofrateddutycycle,requiresuf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-offpressure
thancompressor’sratedworkingpressure.
USER MANUAL
420C - 460C COMPRESSOR KIT

420C - 460C COMPRESSOR KIT
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
airlinelter
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compressor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
PROBLEM: POSSIBLECAUSE(S) CORRECTIVEACTION

USER MANUAL
420C - 460C COMPRESSOR KIT
Wiring Diagram:
(Fuse Not Included)
SINGLE “C” MODEL
COMPRESSOR WIRING DIAGRAM
15 Edelman
Irvine, CA 92618
949-585-0011
www.viaircorp.com
87
86
30
85
+-
Battery
To Keyed
Power Source
12V 40A
Relay
Fuse
Pressure
Switch
Rev.1
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.
15EDELMAN•IRVINE,CA92618
TEL:(949)585-0011•FAX:(949)585-0188
www.viaircorp.com
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