ULTRA DUTY ONBOARD AIR SYSTEM PART NO. 20001 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.
ULTRA DUTY ONBOARD AIR SYSTEM Thank you for purchasing the world’s first 200 PSI onboard air system. Contained in one package, you’ll find everything you’ll need to install a high performance, 200 PSI onboard air source for your vehicle. Please follow the instructions on the following pages to install your new system. OBA Components: 1 - 2.5 Gallon, 200 PSI-rated 6 port VIAIR Air Tank 1 - 480C model VIAIR compressor 1 - 36-ft.
ULTRA DUTY ONBOARD AIR SYSTEM P/N 20001OF PARTS PACKAGE #1) 2.5 GALLON 200 PSI AIR TANK & PLUMBING (USE CONTENTS OBA PLUMBING DIAGRAM Typical System Configuration, May Vary Depending on Installation Your 2.5 Gallon air tank comes with six 1/4” NPT port openings to allow installation in many configurations on your vehicle. To insure safe and trouble-free use of your air tank, we strongly recommend that you install the supplied drain cock and a safety pressure relief valve.
ULTRA DUTY ONBOARD AIR SYSTEM 2.5 GALLON 200 PSI AIR TANK & PLUMBING (CONT’D) WARNING: FAILURE TO DRAIN TANK AND REMOVE CONDENSATION WILL CAUSE TANK TO RUST PREMATURELY. - To remove accumulated condensation inside the tank, bleed pressure from tank until pressure is approximately 5-20 PSI using drain cock - Drain tank by opening the drain cock drain valve and close after draining tank. - If drain cock valve is plugged, release all air pressure from tank, remove drain valve and clean, then reinstall.
ULTRA DUTY ONBOARD AIR SYSTEM 480C AIR COMPRESSOR INSTALLATION (USE CONTENTS OF PARTS PACKAGE #2) Your 200 PSI Onboard Air System comes complete with a 480C, 200 PSI maximum working pressure compressor. Please follow the installation instructions that follow to enjoy the best use of your onboard air system. CAUTION - To reduce risk of electrical shock or electrocution: - Do not disassemble the compressor. Do not attempt repairs or modifications.
ULTRA DUTY ONBOARD AIR SYSTEM 480C OPERATING INSTRUCTIONS IMPORTANT: The 480C has a maximum working pressure of 200 PSI and is capable of 50% duty cycle at 200 PSI. Always operate the compressor at or below the MAXIMUM PRESSURE RATING of the compressor. Operation exceeding maximum pressure ratings and or duty cycle will result in damage to air compressor. 1. Your air compressor is equipped with an AUTOMATIC THERMAL OVERLOAD PROTECTOR.
ULTRA DUTY ONBOARD AIR SYSTEM DASH PANEL GAUGE INSTALLATION (USE CONTENTS OF PARTS PACKAGE #4) Your VIAIR Constant Duty Onboard Air System comes complete with a Dash Panel Gauge to monitor the pressure of your 2.5 gallon 200 PSI rated VIAIR air tank. Additionally, the Dash Panel Gauge has an ON/OFF switch preinstalled that will allow you to turn the system off by cutting power to the pressure switch with relay that you have already installed.
ULTRA DUTY ONBOARD AIR SYSTEM DASH PANEL GAUGE INSTALLATION (CONT’D) 7. Connect to Power Source: Before connecting the power wire to a power source, check to make sure that the ON/OFF switch on the dash panel gauge is in the OFF position. Connect the ring terminal of the power wire to power source. (This is the wire described in Step 4, which is connected to the ON/OFF switch of the dash panel gauge.) 8. Testing Your Onboard Air System: Your Onboard Air System installation is now complete.
ULTRA DUTY ONBOARD AIR SYSTEM TROUBLESHOOTING GUIDE: PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION 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(s) 3. Check all connections with soap and water solution and tighten Compressor runs continuously and air flow lower than normal 1. Excessive air usage 2. Loose connections 3. Worn piston ring or inlet valve. 4.
ULTRA DUTY ONBOARD AIR SYSTEM 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 100 SERIES 15% 215 SERIES 17% 225 SERIES 20% 265 SERIES 22% 275 SERIES 25% 300 SERIES 30% 400 SERIES 33% 450 SERIES 100% 500 SERIES 33% 550 SERIES 100% WORKING PRESSURE 130 PSI 150 PSI 150 PSI 150 PSI 150 PSI 150 PSI 150 PSI 150
ULTRA DUTY ONBOARD AIR SYSTEM WIRE GAUGE GUIDE 12-VOLT: Amp Draw 10 15 20 25 30 40 50 60 Length of wire from battery to compressor 10 15 20 25 30 14 12 10 10 10 12 10 10 8 8 10 10 8 6 6 10 8 6 6 6 10 8 6 6 4 8 6 6 4 4 6 6 4 4 2 6 4 4 2 2 P/N 10003, 10005, 10007, 20001 COMPRESSOR WIRING DIAGRAM (with combination pressure switch / relay) Wiring Diagram: (Figure 2) To Lamp Circuit Dash Panel To Keyed Power Source White Black Small Red Large Red Fuse - + Battery 15 Edelman Irvine, CA 92618 LIMITED W
