VIAIR 20052 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
ONBOARD AIR HOOKUP KIT
PART NO. 20052 (30 amp - 110PSI on, 150PSI off)
PART NO. 20053 (30 amp - 85PSI on, 105 PSI off)
PART NO. 20055 (30 amp - 90 PSI on, 120 PSI off)

PARTS LIST:
A. Illuminated Dash Panel Gauge with On/Off Switch (1pc)
B. 20Ft. Air Line Tubing (1pc)
C. Pressure Switch with Built-in Relay (1pc)
D. 20 Ft. Positive Extension Lead Wire
with 30A / 40A Inline Fuse (1pc)
E. 1/4” NPT (M) Quick Connect Coupler (1pc)
F. 1/4” NPT (F) Quick Connect Stud (1pc)
G. 1/4” NPT Female Tee (1pc)
H. 1/4” NPT Male Tee Compression Fitting (1pc)
I. Reducer (1/4” M to 1/8” F NPT) (1pc)
J. 1/4” Compression Fitting (1pc)
K1. Insulated Female Push-On Terminal (2pcs)
K2. Insulated Female Disconnect Terminal (1pc)
L. Insulated Male Push-On Terminal (2pcs)
M. Ring Terminal Connectors (3pcs)
N. Quick Splice Connectors (2pcs)
O. Cable Ties (6pcs)
P. Cable Tie Brackets (3pcs)
Q. Air Line Clips (3pcs)
R. Continuous Grommet Strip (1pc)
S1. Gauge Mounting Screws (2pcs)
S2. Gauge Mounting Nuts (2pcs)
S3. Gauge Mounting Washers (2pcs)
ONBOARD AIR HOOKUP KIT
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Please read this instruction manual carefully prior to operating this product.
Pay attention to the CAUTION and WARNING statements in this manual. Failure to
comply with these instructions could result in personal injury or property damage. Retain
these instructions for future reference.
USER MANUAL
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INSTALLATION INSTRUCTIONS:
CHECK FOR CORRECT ONBOARD AIR HOOKUP KIT: Onboard Air Hookup Kits have been
designed for use with our 200, 300, and 400 series compressors. Please make sure that you have
the correct kit for use with your specic model compressor.
For Onboard Air Hookup to compressors or systems other than VIAIR components, refer to following
chart:
IMPORTANT:
The Illuminated Dash Panel Gauge has been fully function tested and calibrated for accuracy.
The air inlet on this gauge has a factory installed compression tting. DO NOT attempt to
tighten or loosen the body of this compression tting. Any adjustments will likely cause the
gauge to malfunction and void warranty. (See. Fig. 1)
NOTE: The Dash Panel Gauge included in this kit is rated for 150 PSI. Do not pressurize gauge over
150 PSI. Over-pressurization will cause the gauge to malfunction and will void your product warranty.
Compressor
Max. Amp Draw/Pressure Switch Cut-out Pressure
30 amp / 110PSI ON, 150 PSI OFF Part No. 20052
Part No. 20053
Part No. 20055
30 amp / 85 PSI ON, 105 PSI OFF
30 amp / 90PSI ON, 120 PSI OFF
VIAIR
Onboard Air Hookup Kit

STEP BY STEP INSTALLATION:
1. Select a mounting location with a rigid mounting surface such as the bottom edge of the
dashboard, on either side of the steering wheel column. Use the gauge mounting panel as a
template; mark off 2 mounting points to be drilled. Drill two 13/64” diameter holes as marked.
Do not mount Dash Panel Gauge at this time.
2. Remove only the collar of the compression tting from the back of the Dash Panel Gauge. Do
 notloosenortightenthebodyofthecompressiontting,whichispermanentlyafxedto
the air inlet of the gauge. Insert air line tubing through this collar, then, push air line tubing onto
the barb of the compression tting until the air line completely covers the barb. Tighten collar
onto the body of the compression tting. (See Fig. 1)
NOTE: When cutting air line tubing, always cut as squarely as possible. Use a hose
cutter or razor blade. To ease insertion of air line tubing into ttings, lightly lubricate tip of air
line, or soak air line tubing in warm water for about 5 minutes to soften the air line. When routing
air line tubing, always remember to avoid sharp edges, heat sources and tight bends (Air line
must be routed at least 12” away from exhaust systems & components.)
3. Route the air line tubing on the Dash Panel Gauge to the air source. (See Figures 3 & 4) Do
not cut air line at this time. In some cases a hole may be required to be drilled in the rewall to
enable the air line to pass through the rewall to the air source. Make sure that the air line tubing
is protected from any sharp edges of the drilled hole. A continuous grommet strip is included in
your kit. Seat grommet strip around the edge of the hole, measure and cut strip to appropriate
length. Work the strip around the hole opening until slot in the grommet strip seats rmly all the
way around the edge of the hole. It will be necessary to seal any grommets or holes that have
been cut or drilled so as to seal off elements from entering the cab area of vehicle. Use cable
ties, air line clips, and or cable tie brackets to secure the air line to the vehicle.
IMPORTANT:
Drilling through rewall --- Always make sure what is on the other side of the
rewall before drilling. Make sure not to damage your vehicle’s electronic systems
or components when drilling.
4. There are two tee ttings used in this kit, a female tee and a male tee. Install the quick connect
coupler onto one leg of the female tee tting as shown. (See Fig. 3) On the opposite leg, attach
the male tee as shown to complete Tee Fittings Assembly. (See Fig. 3) Note: Apply sealant to
 threadspriortoconnectingallttings.
5. Select a rigid surface where the cable tie bracket can be mounted. Use provided cable
tie(s) to secure the tee ttings assembly to the cable tie bracket. Use two cable ties if
necessary to secure the tee ttings assembly. Keep in mind that the location of the tee
ttings assembly (female tee/male tee/quick connect coupler), should be close enough
to the air compressor so that the 1.5 ft. leader hose of the compressor can reach the quick
connect coupler.
USER MANUAL
ONBOARD AIR HOOKUP KIT

ONBOARD AIR HOOKUP KIT
6. Route air line to the male tee, measure and cut to appropriate length. Connect air line to one
leg of the male tee as shown. (See Figs. 3 & 4) To connect air line to tee, remove collar of the
male tee tting, push airline onto the tee tting until the air line completely covers the barb, and
then tighten collar.
7. Attach the pressure switch with built-in relay to the remaining leg of the female tee by using
the included reducer (1/4” M to 1/8” F) (See: Parts List Letter I). Wire the pressure switch
with built in relay according to the instructions located on the pressure switch (See Fig. 3)
8. Place Dash Panel Gauge under dash over the two holes that were drilled. Using the
provided screws, nuts and washers, mount the Dash Panel Gauge to the dash. (See Fig. 4)
9. Route 20 ft. extension lead wire from pressure switch to the dash panel gauge through the same
hole drilled in the rewall for routing the air line. Measure and cut lead wire to appropriate
length. Do not discard the remaining length of the wire, which has the Inline Fuse.
10. Attach one of the two female disconnect terminal to the wire that was routed from
the pressure switch. There are two male spade connectors on the back of the On/Off switch.
Connect the female terminal connector to one of the male spade connector on the On/Off
switch. (See Fig. 4) Next, attach appropriate size ring terminal provided in the kit to the end of
the wire with the Inline Fuse. (The ring terminal will now be about 12” from the Inline Fuse.) This
wire is referred to as the power wire. Temporarily position the ring terminal at the power source
and route power wire to the dash panel gauge, measure and cut to appropriate length. (If
additional wire is necessary, use appropriate gauge wire.) (See Fig. 4)
Attach the remaining female disconnect terminal to end of power wire, and connect to male
spade connector on the ON/OFF switch. (NOTE: Do not connect gauge to power source at
this time).
NOTE: When routing wire, use cable ties included in the kit to secure wire to the vehicle.
11. There are two wires, one red, and one black connected to the light bulb of the gauge. Connect
the red wire to a suitable fused dash panel circuit. Use the quick splice connector included in
the kit for wire connections. See Fig. 2 for how to use the quick splice connector. The black
wire is to be connected to a suitable ground source. Use the ring terminal or the quick splice
connector for ground wire connection. (Note: Consult vehicle manufacturer’s electrical diagram.)
To use the quick splice connector, simply insert wire into one hole of the splice connector, and
slip the connecting wire into the other hole. Once the wires are properly placed, close the top of
the quick splice connector using pliers if necessary. The connector will pierce the wire insulation
to complete wire connection. (Note: If additional wire is required, use 22AWG to 18AWG wire for
quick splice connector.) (See Fig. 2)
12. Connect the remaining length of air line to the remaining leg of the male tee. Route air line from
male tee to air tank, measure and then cut to appropriate length. Use the 1/4” compression
tting provided to connect air line to air tank. (See Fig. 3)
USER MANUAL

13. Connect to air compressor is simple and easy with the Quick Connect Coupler by applying the
1/4” (NPT) Female Quick Connect Stud at the end of the compressor’s leader hose.
FYI: This quick connect setting is designed to have the option to air up tires directly
from air compressor by connecting an air hose with Quick Connect Coupler to the applied Quick
Connect Stud on compressor’s leader hose. (See Fig. 3)
NOTE: Compressor, ttings, & air hose connected to the compressor will become very
hot during and immediately after use. Do not touch with bare hands. Use gloves if necessary.
14. Before connecting the power wire to power source, check to make sure the On/Off switch
on dash panel gauge is in the OFF position. Connect the ring terminal of the power wire to
power source. (See Fig. 4) (This is the wire described in Step 11, which is connected to the ON/
OFF switch of the dash panel gauge.)
15. Your Onboard Air Hookup Kit installation is now complete. Run the compressor to build up
pressure in the air tank. Once air pressure reaches the preset cut out pressure, 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.
Fix connections as needed.
OPERATING INSTRUCTIONS:
1. Your Onboard Air Hookup Kit is designed for use in conjunction with an air tank. Make sure that
your air tank is rated for at least 150 PSI maximum working pressure, and that your air tank
setup is equipped with drain cock and pressure relief safety valve.
2. Your Dash Panel Gauge comes with ON/OFF power switch. This convenient feature allows you
to shut off power to air compressor when air compressor operation is not required. When
constant supply of compressed air is required, simply turn the ON/OFF switch to the ON
position, and when pressure in your air tank reaches pre-set cut-out pressure, the pressure
switch will shut off your air compressor automatically. When pressure in your air tank drops
below cut-in pressure, the pressure switch will automatically start air compressor.
3. Your Dash Panel Gauge is rated for maximum 150 PSI, do not use gauge on systems with
pressure ratings higher than 150 PSI.
ONBOARD AIR HOOKUP KIT
USER MANUAL

Air Fittings Leak 1. Loose tting connections
2. Air line tubing not published
all the way or cut squarely
1. Check connections with soap
& water solution. Reapply
sealant to tting, reassemble.
Do not over-tighten.
(Make sure system pressure is
released before making repairs).
2. Remove air line, cut off one
inch, and reinstall.
Gauge leaks 1. Gauge connection loose
2. Air line not pushed all the way
in or cut squarely.
1. Remove air line from back of
gauge, cut off one inch, and reinstall.
2. Tighten compression tting collar.
Compressor hooked up to
system will not run.
1. No power or ON/OFF switch is
in the OFF position.
2. Compressor hooked up to
system will not run.
1. Make sure power wire is
properly connected, and the ON/
OFF switch on Dash Panel
Gauge is in the ON position.
2. Check for the proper fuse
amperage. Replace fuse if needed.
Compressor hooked up to
system runs continuously.
1. Defective pressure switch.
2. If your air tank set up has a
safety valve, check for
defective safety valve.
1. Replace pressure switch.
2. Replace safety valve.
TROUBLESHOOTING GUIDE:
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

Fig. 1
Fig. 2
ONBOARD AIR HOOKUP KIT
USER MANUAL
Dash Panel Gauge
Compression
Fitting Body
Compression
Fitting Collar
Air Line
Quick Splice
Connector
(Open)
Wire From
Lightbulb
Connecting Wire
Quick Splice
Connector
(Closed)

ONBOARD AIR HOOKUP KIT
USER MANUAL
Fig. 3
Fig. 4
To Ground
Relay
Air
Line
Air
Line
Air Tank
Compressor
Drain Cock
Compression
Fitting
Pressure
Switch
Extension
Lead Wire
w/ built in relay
Compressor
(+) Lead
white wire - to compressor
black wire
Thick
red wire
Thin
red wire
To Fused
12-Volt
Car Battery
To Ground
B
J
FE
GH
I
B
C
Air
Line
Grommet
Extension Lead Wire
Female Terminal
Connectors
To Fused
Dash Panel Circuit
Quick Splice
Connector
To Ground
Inline Fuse
To Power
Source
On/Off
Switch
Fire Wall
*Refer to the parts list to match the letters in the diagram to the correct corresponding parts.

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 [phone]. 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: [phone] • FAX: [phone]
www.viaircorp.com