ONBOARD AIR HOOKUP KIT
Contents
1. 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 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 fitting provided to connect air line to air tank See Fig 3 USER MANUAL 13 14 15 ONBOARD AIR HOOKUP KIT 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 fittings amp 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 Before connecting the power wire to power source check to make2. Gauge is rated for maximum 150 PSI do not use gauge on systems with pressure ratings higher than 150 PSI USER MANUAL PROBLEM TROUBLESHOOTING GUIDE POSSIBLE CAUSE S CORRECTIVE ACTION Air Fittings Leak Loose fitting connections 2 Air line tubing not published all the way or cut squarely 1 Check connections with soap amp water solution Reapply sealant to fitting reassemble Do not over tighten Make sure system pressure is released before making repairs Remove air line cut off one inch and reinstall Gauge leaks 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 Tighten compression fitting collar Compressor hooked up to system will not run No power or ON OFF switch is in the OFF position Make sure power wire is properly connected and the ON 2 Compressor hooked up to OFF switch on Dash Panel system will not run Gauge is in the ON position 2 Check for the proper fuse amperage Replace fuse if needed Compressor hooked up to 1 Defective pressure switch 1 Replace pressure switch system runs continuously 2 If your air tank set up has a 2 Replace safety valve safety valve check for defective safety valve ONBOARD AIR HOOKUP KIT Fig 1 Dash Panel Gauge N si Compression Compress
3. 3pcs Air Line Clips 3pcs Continuous Grommet Strip 1pc S1 Gauge Mounting Screws 2pcs S2 Gauge Mounting Nuts 2pcs S3 Gauge Mounting Washers 2pcs DON vpvozzrgaeriIonm USER MANUAL E F G SON n T I J K1 K2 gw GG I M N O CEI CO RD J P Q R Z i bo S1 S2 S3 Comm 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 specific model compressor For Onboard Air Hookup to compressors or systems other than VIAIR components refer to following chart Compressor VIAIR Max Amp Draw Pressure Switch Cut out Pressure Onboard Air Hookup Kit 30 amp 110PSI ON 150 PSI OFF gt Part No 20052 30 amp 85 PSI ON 105 PSI OFF gt Part No 20053 30 amp 90PSI ON 120 PSI OFF gt Part No 20055 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 fitting DO NOT attempt to tighten or loosen the body of this compression fitting Any adjustments will likely cause the gauge to malfunction and void war
4. Your Vital Air Source 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 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 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 PARTS LIST Illuminated Dash Panel Gauge with On Off Switch 1pc 20Ft Air Line Tubing 1pc Pressure Switch with Built in Relay 1pc 20 Ft Positive Extension Lead Wire with 30A 40A Inline Fuse 1pc 1 4 NPT M Quick Connect Coupler 1pc 1 4 NPT F Quick Connect Stud 1pc 1 4 NPT Female Tee 1pc 1 4 NPT Male Tee Compression Fitting 1pc Reducer 1 4 M to 1 8 F NPT 1pc 1 4 Compression Fitting 1pc Insulated Female Push On Terminal 2pcs Insulated Female Disconnect Terminal 1pc Insulated Male Push On Terminal 2pcs Ring Terminal Connectors 3pcs Quick Splice Connectors 2pcs Cable Ties 6pcs Cable Tie Brackets
5. ails 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 Your Vital Air Source 15 EDELMAN IRVINE CA 92618 TEL 949 585 0011 FAX 949 585 0188 www viaircorp com
6. ion Fitting Body Fitting Collar do Quick Splice Quick Splice Connector Connector Open Closed Wire From Lightbulb Connecting Wire USER MANUAL ONBOARD AIR HOOKUP KIT Fig 3 Compression Fitting Pressure Switch w built in relay white wire to compressor Compressor Lead Thi ick Compressor red wire Relay black wire Thin red wire gt To Ground To Fused 12 Volt y Car Battery Extension To Ground Lead Wire Refer to the parts list to match the letters in the diagram to the correct corresponding parts Fig 4 Grommet Extension Lead Wire Female Termina 2 Connectors Inline Fuse To Fused To Power ey ley 3 Dash Panel Circuit Source a E R j Quick Splice f Connector On Off Switch To Ground USER MANUAL 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 det
7. length of the wire which has the Inline Fuse 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 12 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
8. ranty 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 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 Remove only the collar of the compression fitting from the back of the Dash Panel Gauge Do not loosen or tighten the body of the compression fitting which is permanently affixed 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 fitting until the air line completely covers the barb Tighten collar onto the body of the compression fitting 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 fittings 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 sy
9. stems amp components Route the air line tubing on the Dash Panel Gauge to the air source See Figures 3 amp 4 Do not cut air line at this time In some cases a hole may be required to be drilled in the firewall to enable the air line to pass through the firewall 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 firmly 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 firewall Always make sure what is on the other side of the firewall before drilling Make sure not to damage your vehicle s electronic systems or components when drilling There are two tee fittings used in this kit a female tee and a male tee Install the quick connect coupler onto one leg of the female tee fitting 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 fittings Select a rigid surface where the cable
10. 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 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 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 Your Dash Panel
11. tie bracket can be mounted Use provided cable tie s to secure the tee fittings assembly to the cable tie bracket Use two cable ties if necessary to secure the tee fittings assembly Keep in mind that the location of the tee fittings 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 10 ONBOARD AIR HOOKUP KIT 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 amp 4 To connect air line to tee remove collar of the male tee fitting push airline onto the tee fitting until the air line completely covers the barb and then tighten collar 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 Wire the pressure switch with built in relay according to the instructions located on the pressure switch See Fig 3 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 Route 20 ft extension lead wire from pressure switch to the dash panel gauge through the same hole drilled in the firewall for routing the air line Measure and cut lead wire to appropriate length Do not discard the remaining
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