VIAIR 00098 Compressor Kit User Manual

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(P/N:00091,00097,and00098)or24-volt(P/N:02497)

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.

- 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&splashresistant,butNOTWATERPROOF.Donotmount 

compressorinlocationswheretheunitislikelytocomeincontactwithwater.

5.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12AWGpositiveleadwirefor

 remoteinstallation.(Seewiregaugereferencechart)

6.Donotmountcompressornearareaswhereammableliquidsarestored.

USER MANUAL

97C - 98C 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.

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13/64”(5mm)bolts,nuts,washers,andlocking

 washersprovided.Useofthreadsealantrecommended.

5. IMPORTANT:Pleasenote,yourcompressormayhaveacheckvalve.DONOTremove

checkvalvefromtheunit.

6. Connectcompressor’spositiveleadwiretooneoftheleadsofyourpressureswitch.

7. 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.

 Roundupwhenchoosingafuse.

8. Alwayslocatefuseascloseaspossibletopowersource.

9. Beforeconnectingtopowersource,re-checktomakesurethatallconnections

 areproperlyconnected.

10.Connectandtestcompressorsystembyrunningthecompressorforashorttimetobuildup

 pressureinyourairtank.

11.Onceairpressurereachespresetcutoutpressureofyourpressureswitch,thecompressor

 willshuto.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.

 Tightenconnectionsifneeded.

(Fig. 1) 97C - 98C Air Compressor Kit Installation Parts List:

P/N’s 00091, 00097, 02497, & 00098

A.RingTerminal(1pc)

B.MountingBolts(4pcs)(P/N 00091 & P/N 00098 only)

C.FlatWashers(8pcs)(P/N 00091 & P/N 00098 only)

D.LockingWashers(4pcs)(P/N 00091 & P/N 00098 only)

E.Nuts(4pcs)(P/N 00091 & P/N 00098 only)

F.VibrationIsolator(4pcs)(P/N 00091 & P/N 00098 only)

USER MANUAL

B C D E

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.Topreventdischargeofyourvehicle’sbattery,andenhanceperformance,ALWAYSkeepthe

 vehicle’senginerunningwhileusingthecompressor.

MAINTENANCE & REPAIRS

1.Periodicallycheckallelectricalandttingconnections.Cleanandtightenasneeded.

2.Periodicallycheckallmountingscrews.Tightenasneeded.

3.Regularlycleandustanddirtfromcompressorcoolingnsandmotorhousing.

4.Youraircompressorisequippedwithpermanentlylubricated,maintenance-freemotor.

 Nevertrytolubricatecompressor.

5.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compressorwillbecomeveryhotduringandafteruse.Ifnecessary,

wearheatresistantgloves.

PLEASE NOTE:

Usethreadsealantforproperinstallation.Threadtapeisnotrecommended.

Properlysealed,recommendedtorquefor1/8”NPTttingsis10to11ft.lbs.

USER MANUAL

97C - 98C Air Compressor Kit

SPECIFICATIONS

•PartNo.00097/97C12VAirCompressor

MotorVoltage:   12Volts

Max.CurrentConsumption:  12Amps

RecommendedFuse:  20Amps

MotorType:   PermanentMagnetic

Max.WorkingPressure:  130PSI

Max.DutyCycle(@72°F&100PSI): 10%

Max.AmbientTemperature:  158°F

Min.AmbientTemperature:  -40°F

•PartNo.02497/97C24VAirCompressor

MotorVoltage:   24Volts

Max.CurrentConsumption:  7Amps

RecommendedFuse:  15Amps

MotorType:   PermanentMagnetic

Max.WorkingPressure:  130PSI

Max.DutyCycle(@72°F&100PSI): 10%

Max.AmbientTemperature:  158°F

Min.AmbientTemperature:  -40°F

•PartNo.00098/98CAirCompressor

MotorVoltage:   12Volts

Max.CurrentConsumption:  12Amps

RecommendedFuse:  20Amps

MotorType:   PermanentMagnetic

Max.WorkingPressure:  130PSI

Max.DutyCycle(@72°F&100PSI): 10%

Max.AmbientTemperature:  158°F

Min.AmbientTemperature:  -40°F

•PartNo.00091/98CAirCompressorStealthBlack

MotorVoltage:   12Volts

Max.CurrentConsumption:  12Amps

RecommendedFuse:  20Amps

MotorType:   PermanentMagnetic

Max.WorkingPressure:  130PSI

Max.DutyCycle(@72°F&100PSI): 10%

Max.AmbientTemperature:  158°F

Min.AmbientTemperature:  -40°F

USER MANUAL

97C - 98C Air Compressor Kit

USER MANUAL

97C - 98C 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:

Tankpressuredropswhen

compressor(s)shuto

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

waterseparator

Compressorwillnotrun 1.Nopower,orpowerswitch

inOFFposition

2.Blownfuse

3.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.Replacepressureswitch

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

97C - 98C Air Compressor Kit

PROBLEM: POSSIBLECAUSE(S) CORRECTIVEACTION

SINGLE “C” MODEL

COMPRESSOR WIRING DIAGRAM

15 Edelman

Irvine, CA 92618

949-585-0011

www.viaircorp.com

Battery

To Keyed

Power Source

12V 40A

Relay

Fuse

Pressure

Switch

Rev.1

97C - 98C 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: 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.

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.

R2-102620

VIAIR 00098 Compressor Kit

Product's Documents

User Manual

Specifications

VIAIR 98 Questions and Answers