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VIAIR 40040 400C Air Compressor Kit

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Main documentSpecificationQuestions and answersRelateds Products
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User Manual

This is the main product document for model 40040. Additionally, the document applies to other VIAIR models: 32530, 32533, 32534, 32538, 35030, 35033, 45040

The file format is pdf, 8 pages, you can download this manual here .

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325C AIR COMPRESSOR KIT
PART NO. 32530 - 32533 - 32534 - 32538
350C AIR COMPRESSOR KIT
PART NO. 35030 - 35033
400C AIR COMPRESSOR KIT
PART NO. 40040
450C AIR COMPRESSOR KIT
PART NO. 45040
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
325C 350C
400C 450C
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IMPORTANT SAFETY INSTRUCTIONS
CAUTION - To reduce risk of electrical shock:
- 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or24-volt(P/N32538)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and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&dustresistant,butNOTDIRTORWATERPROOF. Do not mount
compressor in locations where the unit is likely to come in contact with the elements.
5.Forcompressorwith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thattheremoteinletair
lterislocatedinadrylocation,awayfromtheelements.
6.Youwillalsowanttoselectacompressormountinglocationwheretheleaderhosebracketcanbe
mounted to leader hose. (Not applicable to P/N 32534)
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positiveleadwireforremoteinstallation.Referto
the wire gauge guide on the back of this manual.
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
325C - 350C - 400C - 450C COMPRESSOR KIT
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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recommended.
5. NOTE:Forremoteinletairlterinstallation,refertoinstructionsincludedintheRemoteInletAir
FilterPack.
6. Thisaircompressormaybeequippedwithaheavydutyheatresistantleaderhose.Thisleader
hoseisdesignedtoprolongthelifeofyourairline.Donotremovethisleaderhosefromair
compressor. (Not applicable to P/N 32534)
7. IMPORTANT:Pleasenote,theleaderhosethatmaybeequippedwithyourcompressormay
alsohaveabuilt-ininlinecheckvalve.Donotremoveinlinecheckvalvefromleaderhoseif
soequipped.
8. Selecta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.
(Fig. 1) 325C / 350C / 400C / 450C Compressor Installation Parts List:
A.HoseBracket(1pc) - N/A 32534
B.MountingBolts(4pcs)
C.FlatWashers(8pcs)
D.LockingWashers(4pcs)
E.Nuts(4pcs)
F.1/4”NPTFx3/8”BarbedFitting(1pc)
G.1/4”NPTMx3/8”BarbedFitting(1pc)
H.3/8”AirLine
I.AirLineClips(3pcs)
J.Screws(3pcs)
K.RemoteInletAirFilterwithFilterElement(1pc)
(Fig. 2) Compressor
Mounting Hardware
B.MountingBolt
C.FlatWasher
D.LockingWasher
E.Nut
K. Vibration Isolator
USER MANUAL
325C - 350C - 400C - 450C COMPRESSOR KIT
REDUCER
B
A
C D E
F
G
I
J
K
(Fig. 3) Leader Hose Bracket (N/A 32534)
L.HoseClamp
M.ClampReleaseTab
N.Self-AnchoringPin
B
C
C
D
E
K
REDUCER
L
M
N
H
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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 it. Turn off power and allow unit to cool for about 30 minutes. This will allow the Thermal
OverloadProtectortoresetsoyoucansafelyresumeuseoftheaircompressor.
5.Topreventdischargeofyourvehicle’sbattery,andenhanceperformance,keepthevehicle’s
engine running while using the compressor.
6.Onlyoperatecompressorinwellventilatedareas.
7.Theuseofarelayisstronglyrecommendedforinstallationofthiscompressor,butnotincluded.
(40-amprelayvalueorhigherpercompressorrecommended).
MAINTENANCE & REPAIRS
1.Periodicallycheckallelectricaland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
325C - 350C - 400C - 450C COMPRESSOR KIT
RELAY WIRING SCHEMATIC
Pressure Switch
86
Fused
12-Volt
30
To Ground
85
87
Compressor
(+) Lead
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SPECIFICATIONS
•PartNo.32530/32533/32534/32538/325CAirCompressorKit/Silver&Chrome(CESpec.)
MotorVoltage: 12volts
24volts(32538)
Max.CurrentConsumption: 21amps-12v
13amps-24v
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.RestartPressure:  200PSI
Max.AmbientTemperature: 158°F
Min.AmbientTemperature: -40°F
Auto.ResetThermalProtection: Yes
Dimensions: 8”Lx4”Wx6.75H”
NetWeight: 7.50Lbs.
•PartNo.35030&35033/350CAirCompressorKit/Silver&Chrome(CESpec.)
MotorVoltage: 12Volts
Max.CurrentConsumption: 20Amps
MotorType: PermanentMagnetic
Horsepower: 1/4
Max.WorkingPressure: 150PSI
Max.DutyCycle(@72°F&100PSI): 100%
MinutesOn/Off(@72°F&100PSI): 1HourRunTime
Max.RestartPressure: 200PSI
Max.AmbientTemperature: 158°F
Min.AmbientTemperature: -40°F
Auto.ResetThermalProtection: Yes
Dimensions: 9”Lx4”Wx6.75H”
NetWeight: 8.55Lbs.
•PartNo.40040/400CAirCompressorKit/Silver(CESpec.)
MotorVoltage: 12Volts
Max.CurrentConsumption: 28Amps
MotorType: PermanentMagnetic
Horsepower: 1/4
Max.WorkingPressure: 150PSI
Max.DutyCycle(@72°F&100PSI): 33%
MinutesOn/Off(@72°F&100PSI): 20On/40Off
Max.RestartPressure: 200PSI
Max.AmbientTemperature: 158°F
Min.AmbientTemperature: -40°F
Auto.ResetThermalProtection: Yes
Dimensions: 9”Lx4”Wx6.75H”
NetWeight: 8.65Lbs.
•PartNo.45040/450CAirCompressorKit/Silver(CESpec.)
MotorVoltage: 12Volts
Max.CurrentConsumption: 23Amps
MotorType: PermanentMagnetic
Horsepower: 1/4
Max.WorkingPressure: 150PSI
Max.DutyCycle(@72°F&100PSI): 100%
MinutesOn/Off(@72°F&100PSI): 1HourRunTime
Max.RestartPressure: 200PSI
Max.AmbientTemperature: 158°F
Min.AmbientTemperature: -40°F
Auto.ResetThermalProtection: Yes
Dimensions: 10.6”Lx4”Wx6.87H”
NetWeight: 10.80Lbs.
USER MANUAL
325C - 350C - 400C - 450C COMPRESSOR KIT
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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
325C - 350C - 400C - 450C COMPRESSOR KIT
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325C - 350C - 400C - 450C 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
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USER MANUAL
325C - 350C - 400C - 450C 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
40A Relay
Fuse
Pressure
Switch
Rev.1
325C, 350C @ 30A
400C, 450C @ 40A
AMERICAN WIRE GAUGE GUIDE 12-VOLT: AMERICAN WIRE GAUGE GUIDE 24-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 8 6
30 12 10 8 6
40 12 8 6 6
50 10 6 6 4
60 10 6 4 4
AmpDraw
Lengthofwirefrombatteryto
compressor(infeet)
5 10 15 20
5 16 16 16 16
10 16 16 16 14
15 16 16 14 12
20 16 14 12 10
25 16 12 12 10
30 16 12 10 10
40 14 10 10 8
50 14 10 8 6
60 12 10 8 6
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

Specifications

Indexed Terms: Air Compressor, Air, Kit

VIAIR 40040 Questions and Answers

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