Vanair Viper Series Operator's Manual & Parts List

ROTARY SCREW AIR COMPRESSOR

OPERATOR’S MANUAL & PARTS LIST

NOTE

This publication contains the
latest information available at

the time of preparation. Every

effort has been made to ensure

accuracy. However, Vanair

Manufacturing, Inc. takes no

responsibility for errors or

consequential damages

caused by reliance on the

information contained herein.

Vanair Manufacturing, Inc.
reserves the right to make

design change modifications

or improvements without prior

notification.

NOTE

Use only Vanai r Vanguard™

Premium Synthetic Oil and

Genuine Vana ir P ar ts. Inspect

and replace damaged

components before operation.

Substituting non-Vanguard™

Oil or non-genuine Vanair filter

components WILL VOID THE
COMPRESSOR WARRANTY!

Vanair Manufacturing, Inc.

10896 West 300 North

Michigan City, IN 46360

Phone: [phone]
[phone]

Service Fax: [phone]

Parts Fax: [phone]

Sales Fax: [phone]

www.vanair.com

Read this manual before

installing, operating or

servicing this equipment.

Failure to comply with the

operation and maintenance

instructions in this manual

WILL VOID THE EQUIPMENT

WARRANTY.

NOTE

Making unauthorized

modifications to the system

components WILL VOID THE

WARRANTY!

Always inform Vanair

Manufacturing, Inc., befo re

beginning any changes to the

Viper Diesel system.

KEEP THE MANUAL

WITH THE VEHICLE

©2014 Vanair Manufacturing, Inc.

All rights reserved.

P/N: 090058-OP_r0

Effective Date:

August-2014

WARRANTY: VIPER SERIES AIR COMPRESSORS

The rotary screw compressor unit is warranted for life when adhering to the prescribed maintenance schedule.
The hydraulic motor on the hydraulic Viper is warranted for two (2) years. This warranty does not cover damage
caused by accident, misuse or negligence. If a compressor unit is disassembled the warranty is void. Any
disassembly of major components must be approved by Vanair to avoid voiding of warranty. All other parts
including the compressor unit shaft seal are warranted for twelve (12) months subject to the same conditions
mentioned previously. Any and all such claims for warranty consideration must be coordinated prior to work being
performed through the Warranty-Service Department at the address below. Do not return parts without prior
authorization.

Warranty is limited to the supply of replacement part s failing within the warranty period. Credit for labor required to
refit replacement parts is NOT included. All warranted pa rts ar e to be shipped PREPAID to V ANAIR. Replacement
parts will be shipped back to the customer by VANAIR via ground shipment. Cost to expedite delivery of
replacement parts will be incurred by customer.

Warranty will commence upon receipt of the Warranty Registration Card. If the Warranty Registration Card is not
received within six (6) months, the warranty commencement date shall be thirty (30) days from the date of
shipment from VANAIR. Records of warranty adherence are the responsibility of end user.

This statement of warranty is expressly in lieu of and disclaims all other express warranties, implied warranties of
merchantability and fitness for a particular purpose and all other implied warranties which extend beyond the
description on the face hereof. In no event shall Vanair be responsible for special, indirect, incidental,
consequential or punitive damages of any kind, including without limitation, lost profits or other monetary loss,
whether or not any such matters or causes are within Vanair's control or due to negligence or other fault of Vanair,
its agents, affiliates, employees or representatives.

This warranty shall be void and VANAIR shall have no resp onsibili ty to repair, replace or repay the purchase price
of defective or damaged parts resulting from the use of or repair of replacement parts or fluids not of VANAIR'S
manufacture or from buyer's failure to store, install, maintain and operate the compressor according to the
recommendations contained in the Manual.

All claims under the Warranty shall be made by con tacting VANAIR Warranty-Service Department.

Please note that engines are warranted separately by the engine manufacturer. Consult engine manual.

Register Your Warranty Online at www.vanair.com under the Support Tab!

Or Call: [phone] • Fax: [phone]

Mail to: 10896 W 300 North • Michigan City, IN 46360

Effective February 11, 2013

DIESEL VIPER TABLE OF CONTENTS

TABLE OF

CONTENTS

WARRANTY ............................................... BEHIND COVER

TABLE OF CONTENTS...................................................... I

WARRANTY CLAIMS PROCEDURE ................................V

CLAIMS PROCESS FOR WARRANTED PARTS..................................................................................... V

PROCEDURE........................................................................................................................................... V

SECTION 1: SAFETY .....................................................1

1.1 GENERAL INFORMATION......................................................................................................1

1.2

1.3

1.4

DANGERS, WARNINGS, CAUTIONS AND NOTES...............................................................1

SUMMARY OF DANGERS, WARNINGS CAUTIONS AND NOTES.......................................1

1.3.1

1.3.2

1.3.3

1.3.4

DANGERS .......................................................................................................................................................1

WARNINGS......................................................................................................................................................1

CAUTIONS.......................................................................................................................................................2

SAFETY DECALS............................................................................................................................................3

DISPOSING OF MACHINE FLUIDS .......................................................................................3

SECTION 2: SPECIFICATIONS..........................................5

TABLE 2A: SPECIFICATIONS FOR VIPER DIESEL ROTARY SCREW COMPRESSOR........................5

SECTION 3: INSTALLATION..............................................7

3.1 MACHINE PACKAGE RECEIPT/INSPECTION............................................................................7

3.2 INSTALLATION INSTRUCTIONS.... ... ... .... .......................................... ... ......................................7

3.3 INSTRUMENT PANEL RELOCATION .........................................................................................8

FIGURE 3-1: DIMENSION DIAGRAM - PART 1 OF 2..............................................................................8

FIGURE 3-1: DIMENSION DIAGRAM - PART 2 OF 2..............................................................................9

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090058-OP_r0 (AUGUST-2014) PAGE - I

TABLE OF CONTENTS DIESEL VIPER

SECTION 4: OPERATION................................................ 11

FIGURE 4-1: MAIN MACHINE COMPONENT LOCATIONS................................................................. 10

4.1 GENERAL INFORMATION..........................................................................................................11

4.2 INSTRUMENTATION..................................................................................................................11

4.2.1 DIGITAL DISPLAY SCREEN ................................................................................................................................11

4.2.2 SCROLL SELECTOR ROCKER SWITCH...........................................................................................................11

4.2.3 ON AND STOP SELECTION KEY SWITCH........................................................................................................11

4.3 INITIAL START-UP PROCEDURE..............................................................................................11

4.4 SHUTDOWN PROCEDURE ...................................................................................................... 12

4.5 SUBSEQUENT START-UP PROCEDURE ................................................................................ 12

4.6 CONTROLLER GUIDE............................................................................................................... 12

4.6.1 HOME SCREEN..................................................................................................................................................13

4.6.2 SPLASH SCREEN ..............................................................................................................................................13

4.6.3 ADJUSTING USER SETTINGS.......................................................................................................................... 13

4.6.3.1 PARAMETERS.............................................................................................................13

4.6.3.2 AUTO SHUTDOWN............................. ... ... .... ... ... ....................................... ... ... ... .... .. 13

4.6.3.3 AUTO CRANK............... .... ... ... ... ....................................... ... ... .... ... ............................. 13

4.6.3.4 SLEEP STATE TIMER ................................................................................................13

4.6.4 SETTING PRESSURE.........................................................................................................................................13

4.6.5 SAFETY...............................................................................................................................................................13

4.6.6 SERVICE INTERVALS ........................................................................................................................................14

4.7 OPERATING CONDITIONS....................................................................................................... 14

4.8 EXTREME CONDITIONS...........................................................................................................14

SECTION 5: MAINTENANCE...........................................15

5.1 GENERAL INFORMATION ........................................................................................................ 15

5.2 ROUTINE MAINTENANCE SCHEDULE............................. ... .... ... .......................................... ... 15

5.3A MAINTENANCE SCHEDULE TABLE - COMPRESSOR INTERVALS....................................... 17

5.3B MAINTENANCE SCHEDULE TABLE - ENGINE INTERVALS................................................... 18

5.4 REPLACEMENT PARTS . .... ... ... ... .... ..........................................................................................21

5.5 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES............ .... ... ... ... .... ... ... ... ... .... ... 21

5.5.1 ADJUSTING THE ENGINE SPEED.....................................................................................................................21

5.6 SERVICING THE SYSTEM FUSES AND CIRCUIT BREAKER ................................................ 21

5.7 STORAGE AND INTERMITTENT USE .. ... .......................................... ... .... ... ... ... .... ... ................ 21

5.7.1 INTERMITTENT USE................................................................................................................................................22

5.7.2 LONG TERM STORAGE ..........................................................................................................................................22

PAGE - II 090058-OP_r0 (AUGUST-2014)

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DIESEL VIPER TABLE OF CONTENTS

SECTION 6: TROUBLESHOOTING .................................23

6.1 GENERAL INFORMATION.........................................................................................................23

6.2 TROUBLESHOOTING GUIDE....................................................................................................24

6.3 EXTREME CONDITION OPERATION........................................................................................28

6.3.1 HIGH MOISTURE CONDITION: EMULSIFICATION OF OIL IN

ROTARY SCREW COMPRESSOR SYSTEMS....................................................................................................28

TABLE 6.3A HIGH MOISTURE CONDITION OPERATION....................................................... 29

6.3.2 COLD WEATHER OPERATION...........................................................................................................................29

TABLE 6.3B COLD WEATHER OPERATION............................................................................30

6.3.3 HIGH TEMPERATURE OPERATION...................................................................................................................30

TABLE 6.3C HIGH TEMPERATURE OPERATION.................................................................... 31

6.3.4 HIGH DUST CONTENT OPERATION..................................................................................................................31

TABLE 6.3D HIGH DUST CONTENT OPERATION................................................................... 31

6.3.5 HIGH ALTITUDE OPERATION.............................................................................................................................32

SECTION 7: ILLUSTRATED PARTS LIST.......................33

7.1 PARTS ORDERING PROCEDURE............................................................................................33

TABLE 7A: RECOMMENDED SPARE PARTS LIST.................... .... ......................................... .... ... ... ... .34

TABLE 7B: MACHINE OPTIONS LIST ....................................................................................................34

TABLE 7C: MAINTENANCE TRACKING LOG.................... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... .................35

7.2 COMPRESSOR REPLACEMENT PARTS ................................................................................36

7.3 AIREND AND ATT ......................................................................................................................38

7.4 ENGINE AND DRIVE PARTS (1 OF 2).......................................................................................40

7.4 ENGINE AND DRIVE PARTS (2 OF 2).......................................................................................42

7.5 COOLING SYSTEM (PART 1 OF 2)...........................................................................................44

7.5 COOLING SYSTEM (PART 2 OF 2)...........................................................................................46

7.6 CANOPY AND FRAME PARTS....... ... ... .... ... ... ... .... ... ... ..............................................................48

7.7 COMPRESSOR THERMAL CONTROL .....................................................................................50

7.8 INSTRUMENT PANEL................................................................................................................50

7.9 ELECTRICAL SYSTEM..............................................................................................................52

7.10 FUEL TANK ASSEMBLY............................................................................................................54

7.11A DECALS (LOCATION)........................... .... ...................................... .... ... ... ... .... ... .......................56

7.11B DECALS (IDENTIFICATION)........... ... ... .... ...................................... .... ... ... ... .... ... .......................57

7.11C DECALS (PART NUMBERS).............. ... .... ... ... ... .... ... ... ... .... ... .......................................... ... ... ....58

7.12 WIRING DIAGRAM.....................................................................................................................59

7.13 SCHEMATIC FLOW DIAGRAM..................................................................................................60

7.14 HOSE INSTALLATION GUIDE....................................................................................................61

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090058-OP_r0 (AUGUST-2014) PAGE - III

TABLE OF CONTENTS DIESEL VIPER

BLANK PAGE

PAGE - IV 090058-OP_r0 (AUGUST-2014)

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL WARRANTY PROCEDURE

WARRANTY CLAIMS

PROCEDURE

CLAIMS PROCESS FOR

WARRANTED VANAIR PARTS

This process must be used by owners of

®

Vanair
warranted item needs repair or replacement
under the terms of the purchase warranty.
Do not return items to Vanair without prior
authorization from the Vanair Warranty
Administrator.

PROCEDURE:

When a customer needs assistance in
troubleshooting a system and/or returning
parts, follow the steps below.

1. Locate the machine’s serial number:

The machine package serial number plate is
located inside the machine com partment on
the floor near to the engine air filter mounting
location (see Figure W-1).

The engine and the compressor also have
individual serial numbers respectively (see
Figure W-1). For engine warranty issues,
consult the Engine Operator’s Manual for
the engine’s limited warranty details. For
particular compressor unit issues, the
compressor serial number may be needed.
In any case, engine and/or compressor
issues can be confirmed using the machin e
serial number as found in Figure W-1.

2. Have a list of the symptoms/condition/
malfunctions along with any applicable
temperature and pressure readings, and
also the number of operational hours
available:

Note that the above information will also
need to be included on the Return Material

equipment in situations where a

Authorization Form (per Step #6); this form
is necessary for warranty processing if the
warranty claim is deemed valid by the
service case review.

3. Contact the Vanair
by phone [phone]) to speak with
a Service Technician.

4. Vanair Service will troubleshoot the
problem based on the information
provided by the customer, and attempt to
return the unit to service as quickly as
possible.

5. If the unit cannot be returned to service,
and Vanair determines this matter is a
warranty issue, the Service Technician
will assign an RMA (Return Material
Authorization) number that will provide
for the return of the item to Vanair for
analysis and a final determination as to

the item’s warranty status.

®

Service Department

NOTE

The RMA number must be placed on the

outside of the package being returned.

6. Warranty Claims are solicited via a
Return Material Authorization (RMA)
Form. This form can be obtained via
download from the web site, or requested
directly from the Vanair Service
Department:

Once a current form has been obtained,
follow the instructions given on the form to fill
in the information needed. This form is used
for the purpose of soliciting a warranty case.
All of the field information except for the
bottom section block fields, which includes

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

090058-OP_r0 (AUGUST-2014) PAGE - V

WARRANTY PROCEDURE VIPER DIESEL

800-526-881 7

260940

MODEL NUMBER

SERIAL NU MBER

MAXIMUM PR ESSURE

COMPRESSOR INPUT R PM

www.v ana ir.c om

Machine Serial Number

Engine Serial Number

Compressor Unit

Serial Number

Disposition of Goods, Notifications and
Additional Notes, will be required.

Customers have 30 days after the RMA
number is issued to return the item. If the
part is not returned within this period, the

RMA is void and any claims will be denied.

Before sending a warranty part to a
customer, Vanair

card number to cover the cost of the part and
shipping. After the part is analyzed and
deemed to be covered under warranty,

Figure W-1: Machine Serial Number Location

NOTE

All labor claims or invoices must be

approved by the Vanair Warranty
Administrator prior to starting repair work
along with the cost of the repair . All p aper

work associated with the returned item

and warranty repair cost must reference

the RMA number issued against the part,

and be forwarded to Vanair within 30 days

of the completion of work.

®

will need a P.O. or credit

Vanair will issue credit to the customer. All
parts eligible for warranty must have the
RMA number on the invoice at the time of
purchase.

No items can be returned “freight collect”.
Freight costs will be addressed at the time
the claim is closed. The customer pays any
additional costs for warranty parts delivered
through expedited services (i.e., Next Day,
Second Day).

VANAIR WILL NEVER ACCEPT ANY
INVOICES FOR PARTS RETURNED: ANY
P ARTS RETURNED VIA INVOICE WILL BE
RETURNED FREIGHT COLLECT: NO
PARTS ARE TO BE RETURNED FREIGHT
COLLECT!

Vanair Mfg., Inc. strives to continuously
improve its customer service. Please forward
any questions, comments, or suggestions to
Vanair Service:

Phone: [phone], ext. 400 or toll free

Email: [e-mail]

844-VANSERV (826-7378)

PAGE - VI 090058-OP_r0 (AUGUST-2014)

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 1: SAFETY

SECTION 1:

SAFETY

1.1 GENERAL INFORMATION

IMPORTANT

Read this manual before operating or

servicing the Viper Diesel compressor

system. Failure to do could result in
damage equipment, bodily injury, or

death

The products provided by Vanair
Manufacturing, Inc., are designed and
manufactured for safe operation and
maintenance. But it is ultimately the
responsibility of the users and maintainers
for safe use of this equipment. Part of this
responsibility is to read and be familiar with
the contents of this manual before operation
or performing maintenance action s.

harm. When you see the international
warning symbol, pay extremely careful
attention, and follow the given instructions
or indications to avoid any possible hazard.

1.3 SUMMARY OF WARNINGS, CAUTIONS AND NOTES

These boxed inserts are placed throughout
this manual in the sections where they apply.
This subsection is a general summary of
their contents.

®

1.3.1 DANGERS

• Keep tools or other conductive objects away
from live electrical parts.

• Never touch electrical wires or components
while the machine is operating. They can be
sources of electrical shock.

1.3.2 WARNINGS

1.2 DANGERS, WARNINGS, CAUTIONS AND NOTES

These boxes are labeled clearly with the title
block listing either Danger, Warning,
Caution, or other non-safety issue. They
draw attention to specific issues that are
pertinent to the safe and correct operation of
the machine.

The symbols shown and defined in Section
1: Safety are used throughout this manual
and on the machine to call attention to, and
identify, possible hazards.

The international warning symbol (shown
below) is used on all decals, labels and signs
that concern information pertaining to bodily

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090058-OP_r0 (AUGUST-2014) PAGE - 1

• DO NOT EVER use this compressor as a
breathing air source. Vanair Manufacturing
Inc., disclaims any and all liabilities for
damage or loss due to fatalities, personal
injuries resulting from the use of a Vanair
compressor to supply breathing air.

• DO NOT perform any modifications to this
equipment without prior factory approval.

• DO NOT install this compressor in a
confined space that lacks proper
ventilation and airflow; breathing and
cooling air circulation must not be
compromised.

• DO NOT operate the compressor or any of
its systems if there is a known unsafe
condition. Disable the equipment by
disconnecting it from its power source.
Install a lock-out tag to identify the

SECTION1: SAFETY VIPER DIESEL

equipment as inoperable to other
personnel.

• DO NOT operate the compressor with
any by-pass or other safety systems
disconnected or rendered inoperative.

• DO NOT operate the equipment while
you are under the influence of alcohol or
drugs.

• DO NOT operate the equipment while
you are feeling ill.

• DO NOT attempt to service the
equipment while it is operating.

• Before performing maintenance or
replacing parts, relieve the entire system
pressure by opening a service valve
which will vent all pressure to the
atmosphere: remove all electrical power.

• DO NOT use the compressor for
purposes other than for which it is
intended. High pressure air can cause
serious and even fatal injuries.

• DO NOT operate the compressor
outside of its specified pressure and
speed ratings. (See Section 2:
Specifications or refer to the equipment
data plate.)

•DO NOT use flammable solvents or
cleaners for cleaning the compressor or
it parts.

• DO NOT operate the compressor in
areas where flammable, toxic, or
corrosive fumes, or other damaging
substance can be ingested by the
compressor intakes.

• Keep arms, hands, hair and other body
parts, and clothing away from fans, drive
shafts, and other moving parts.

• DO NOT wear jewelry, unbuttoned cuffs,
ties, or loose-fitting clothing when you are
working near moving/rotating parts.

• ALWAYS confine long hair when working
near moving/rotating parts.

• NEVER operate the equipment while
wearing a headset to listen to music or the
radio.

• Wear personal protective equipment
such as gloves, work shoes, and eye
and hearing protection as required for
the task at hand.

• DO NOT operate the compressor with
any guards removed or damaged, or
other safety devices inoperative.

• DO NOT operate the compressor in
enclosed or confined spaces where
ventilation is restricted or closed-off.

• Ensure that hoses connected to se rvice
valves are fitted with correctly sized and
rated flow limiting devices which comply
with applicable codes. Pressurized
broken or disconnected hoses c an whip
causing injuries or damage.

• Over speed is hazardous! NEVER
tamper with the governor components or
settings to increase the maximum
speed. Severe personal injury and
equipment damage can result if
operated at speeds above the maximum.

• DO NOT use tools, hoses, or equipment
that have maximum ratings below that of
this compressor .

• Keep metal tools, and other conductive
objects away from live electrical
components.

• Before performing maintenance or repair
operations on the compressor, ensure
that all power has been removed and
been locked out to prevent accidental
application.

• DO NOT assume that because the
compressor is in a STOPPED condition
that power has been removed.

• Use this compressor only to compress
atmospheric air. Use of this equipment
as a booster pump and/or to compress
any other gaseous or aerosol substance
constitutes improper use. It can also
cause damage or injuries. Such misuse
will also void the warranty.

• Install, operate, and maintain this
equipment in full compliance with all
applicable OSHA, other Federal, state,
local codes, standards, and regulations.

• When lifting objects, be aware of proper
lifting techniques to avoid injury.

• ALWAYS read and follow safety related
precautions found on containers of
hazardous substances.

• DO NOT play with compressed air. It can
cause serious injury.

1.3.3 CAUTIONS

• Check all safety devices for proper
operation on a routine basis.

• Ensure that no tools, rags, or other
objects are left on compressor drive
systems or near intakes.

PAGE - 2 090058-OP_r0 (AUGUST-2014)

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 1: SAFETY

• Keep the equipment clean when
performing maintenance or service
actions. Cover openings to prevent
contamination.

• DO NOT operate the compressor if
cooling air is not available (fan/cooler not
operating) or if lubricant levels are below
their specified minimum levels.

• Ensure all plugs, hoses, connectors,
covers, and other parts removed for
maintenance actions are replaced
before applying power to the
compressor.

• Avoid touching hot surfaces and
components.

• Ensure that electrical wiring, terminals;
hoses and fittings are kept in serviceable
condition through routine inspections
and maintenance. Replace any
damaged or worn components.

• DO NOT install safety devices and/or
replacement parts other than authorized

®

Vanair

• Keep personnel out of line with, and
away from discharge opening of valves,
hoses and tools.

• Immediately clean up any lubricant or
spills.

replacement parts.

hazard to operators or service personne l. All
pertinent decals listed in Section 7.11A,
Decal Locations are located near a
component, which is subject to respect in
terms of safety precautions. Always heed the

information noted on the safety decals.

WARNING

DO NOT REMOVE OR COVER ANY

SAFETY DECAL. Replace any safety

decal that becomes damaged or illegible.

1.4 DISPOSING OF MACHINE FLUIDS

Always dispose of machine fluids under the
guidance of all applicable local, regional and/
or federal law.

®

Vanair
For additional information, consult the
container label of the fluid in question.

encourages recycling when allowed.

1.3.4 SAFETY DECALS

Safety decals are placed onto, or located
near, system components that can present a

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090058-OP_r0 (AUGUST-2014) PAGE - 3

SECTION 1: SAFETY VIPER DIESEL

BLANK PAGE

PAGE - 4 090058-OP_r0 (AUGUST-2014)

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VIPER DIESEL SECTION 2: SPECIFICATIONS

SECTION 2:

SPECIFICATIONS

TABLE 2A: SPECIFICATIONS FOR VIPER DIESEL ROTARY SCREW COMPRESSOR

GENERAL SYSTEM

INFORMATION

ENGINE

Engine Speed
Engine Oil Capacity Four (4) Quarts 15W40 (Refer to Engi ne Operator’s Manual fo r Extreme

Fuel Consumption 1.25 GPH at Full Engine Speed / Load Nine (9) Hour Runtime (one

Fuel Tank Capacity Nine (9) Gallons
Fuel Type

Operating Temperature Limits

COMPRESSOR Single Stage, Oil Injected Rotary Screw

Model 80 CFM / 100 PSIG

Inlet Control Electric

Diesel 25HP
Idle Speed: 2200 RPM

Conditions)

gallon/hour @ 60% Duty Cycle)

Diesel Fuel
+10 °F (-7°C) to 120 °F (49 °C)

70 CFM / 125 PSIG
60 CFM / 150 PSIG
High Altitude: 70 CFM / 100 PSIG

I

II

SPECIFICATION

// Full Speed: 3600 RPM

III

Air Filter Pleated Paper, Dry Typ e

Table continued on next page

I

For specification and requirements regarding the Kubota® 25 HP Diesel Engine, refer to the Engine Operator’s
Manual. IMPORTANT: Do not adj ust the engine speed without first consulting the Vanair

(refer to Section 5.5.1).

II

Vanair recommends: Diesel Fuel Speci fica tion Type and Sulfur Content % (ppm) used must be compliant with all

applicable emission regulations for the area in which the engine is operated.

Engine manufacturer recommends a fuel sulfur content of less than 0.10% (1000 ppm). For fuels with a high sulfur
content 0.50% (5000 ppm) to 1.0% (10000 ppm) a more frequent engine oil and oil filter change schedule is needed
(approximately half). DO NOT USE fuels with a sulfur content greater than 1.0% (10000 ppm). For additional
information on fuel for this engine, consult Section 6.3 (Extreme Condition Operation), and the Engine Operator’s
Manual.

III

With cold weather option kit temperature range expands to: -40 °F (-40 °C). Refer to Section 7, Table 7B for options

list.

NOTE: Specifications are subject to change without notice.

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090058-OP_r0 (AUGUST-2014) PAGE - 5

®

Service Department

SECTION 2: SPECIFICATIONS VIPER DIESEL

TABLE 2A: SPECIFICATIONS FOR VIPER DIESEL ROTARY SCREW COMPRESSOR (cont.)

GENERAL SYSTEM

SPECIFICATION

INFORMATION

COMPRESSOR (specifications continued from previous page)

Oil Filter Spin-on Style
Oil Capacity / Type Air End - 3 Quarts // Machine - 4 Quarts (1 gallon) (Vanguard™

Premium Synthetic Oil)

Safety Relief Valve Setting 200 PSIG

Operating Pressure Range 75-100 (Maximum) PSI; Pressure setting is set at factory to 100 PSI, but

may be adjusted downward accordingly.

Electrical System 12 VDC
Cooling System Air to Oil Heat Exchanger
Instrumentation Display Run Hours, Fuel Level, Compressor Temperature, Pressure, RPM

I

For specification and requirements regarding the Kubota® 25 HP Diesel Engine, refer to the Engine Operator ’s
Manual. IMPORTANT: Do not adjust the engine speed without first consulting the Vanair

(refer to Section 5.5.1).

II

Vanair recommends: Diesel Fuel Specification Type and Sulfur Content % (ppm) used must be compliant with all

applicable emission regulations for the area in which the engine is operated.

Engine manufacturer recommends a fuel sulfur content of less than 0.10% (1000 ppm). For fuels with a high sulfur
content 0.50% (5000 ppm) to 1.0% (10000 ppm) a more frequent engine oil and oil filter change schedule is needed
(approximately half). DO NOT USE fuels with a sulfur content greater than 1.0% (10000 ppm). For additional
information on fuel for this engine, consult Section 6.3 (Extreme Condition Operation), and the Engine Operator’s
Manual.

®

Service Department

III

With cold weather option kit temperature range expands to: -40 °F (-40 °C). Refer to Section 7, Table 7B for options

list.

NOTE: Specifications are subject to change without notice.

PAGE - 6 090058-OP_r0 (AUGUST-2014)

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VIPER DIESEL SECTION 3: INSTALLATION

SECTION 3:

INSTALLATION

3.1 MACHINE PACKAGE RECEIPT/INSPECTION

Upon receipt of the machine package,
inspect the exterior of the shipping crate for
signs of shipping/transit damage. Any
damage should be reported immediately to
the shipping company. Open the lid and
inspect the component parts and supports to
ensure that there has been no internal
movements of assemblies or components
which may have caused damage. To install
the Viper Diesel Compressor System, refer

to the following sections.

NOTE

Contact Vanair® at

[phone] / [phone]

Service Fax: [phone]

www.vanair.com

to report missing items, incorrect part

numbers, or other discrepancies.

3.2 INSTALLATION INSTRUCTIONS

DANGER

DO NOT install in enclosed spaces.

WARNING

ELECTRICAL HAZARD! Be sure the

battery is disconnected before starting

the installation.

NOTE

In order to prevent accidental damage to

vehicle components (fuel tanks, lines,

brake lines, wiring harnesses), note their

location before drilling any holes.

Refer to Figure 3-1 (parts 1 and 2), and the
following procedure:

1. Position the machine so that there is no
restriction of cooling air through the
enclosure (minimum of 12 inches from
front access side; minimum of six
inches from rear side. Cooling air
enters the enclosure through the front
and rear panels, passes through the
cooler, and exits through vents in the
end shroud.

2. Ensure that adequate height and
clearance exists to allow for the hood to
open (minimum of 49.9 inches from
mounting surface), and a clear passage
for service allowance to the
maintenance access panel located at
the back.

3. Mounting surface or support should be
adequate for the weight of the machine
and should be level for normal operation.
Mounting holes for four (4) 1/2” hold
down bolts are provided. Refer to

Section 7, Illustrations and Parts Lists

for additional installation and system
schematic drawings.

4. Service connections are conveniently
grouped at the end of the unit in the
base frame.

5. Electrical connections (system
designed for 12VDC negative ground).

Ensure all supply hoses and electrical wiring
are correctly specified, adequately supported
and do not touch or rest on any sharp edges.
Wiring should be protected with split loom to
prevent corrosion and consequently, loose
due to down time.

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090058-OP_r0 (AUGUST-2014) PAGE - 7

SECTION 3: INSTALLATION VIPER DIESEL

NOTE

The dimensions listed in this diagram are

the minimum required clearance

distances needed for properly cooling the

machine. Additional clearance room may

be desired for easier access for control

and/or maintenance functions.

050848_r1_1of2

DISCLAIMER

If machine package is to be mounted

within a confined space such as beneath a

canopy, the unit must have a minimum of

eight (8) inch clearances on the front and

back sides for ventilation.

3.3 INSTRUMENT PANEL RELOCATION

The Viper Diesel compressor allows for the
instrument panel to be remote mounted if it
better-suits the vehicle’s mounting allowance
space or the compressor’s functions. The
optional extension harness must be used for
remote panel installation (see Table 7B).

Please note that if relocating the panel, you
should re-apply any zip ties that were cut to
re-establish the cable wire to the new
location. Tying the wire at intervals may be
needed to secure the panel cable away from
moving objects or sharp edges during
operation.

PAGE - 8 090058-OP_r0 (AUGUST-2014)

Figure 3-1: Dimension Diagram - Part 1 of 2

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VIPER DIESEL SECTION 3: INSTALLATION

050848_r1_2of2

NOTE

The dimensions listed in this

diagram are the minimum

required clearance distances

needed for properly cooling the

machine. Additional clearance

room may be desired for easier

access for control and/or

maintenance functions.

VANAIR MANUFACTURING, INC.

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Figure 3-1: Dimension Diagram - Part 2 of 2

090058-OP_r0 (AUGUST-2014) PAGE - 9

SECTION 4: OPERATION VIPER DIESEL

B

C

F
E

D

G

H

A

T

S

Q

P

Y

Z

X

K

L

M

N

J

V

W

U

AA

R

KEY DESCRIPTION KEY DESCRIPTION KEY DESCRIPTION

A BATTERY K LIFTING BAIL U ENGINE OIL DRAIN OUTLET/TUBE
B DIESEL FUEL PORT CAP L ENGINE OIL FILL PORT CAP V ENGINE AIR FILTER (HOUSING)
C COMPRESSOR UNIT M COOLER ASSEMBLY - ENGINE

D COMPRESSOR AIR INLET N COOLER ASSEMBLY / COM-

E PRESSURE RELIEF VALVE P ENGINE OIL FILTER Y COMPRESSOR OIL LEVEL SIGHT

W INLET VALVE SOLENOID

RADIATOR

X COMPRESSOR OIL DRAIN OUTLET/

PRESSOR OIL COOLER

TUBE

GLASS

F COMPRESSOR OIL FILTER Q RADIATOR FILL PORT Z COMPRESSOR OIL FILL PORT
G COMPRESSOR AIR FILTER

R COOLING FAN ASSEMBLY AA ENGINE OIL LEVEL/ DIPSTICK

(HOUSING)

H COMPRESSOR AIR/OIL

S COOLANT RECOVERY TANK

SEPARATOR

J ENGINE EXHAUST MUFFLER T RADIATOR DRAIN VALVE

I

There is an oil dipstick indicator locat ed on either side of the engine.

INDICATOR

I

Figure 4-1: Main Machine Component Locations

PAGE - 10 090058-OP_r0 (AUGUST-2014)

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VIPER DIESEL SECTION 4: OPERATION

SECTION 4:

OPERATION

4.1 GENERAL INFORMATION

Refer to Figure 4-1. The Vanair® Viper
Diesel compressor has a comprehensive
array of controls and indicators for optimum
machine performance. Understanding the
correct operation of the system will help to
distinguish between a properly functioning
system and a system that may be indicating
the beginning of a malfunction. The
information in the Operation Section will help
the operator to recognize and interpret the
readings to assure that the system is

performing optimally.

NOTE

Before starting the Vanair Viper Diesel

compressor, read this section

thoroughly and familiarize yourself with

the controls and indicators - their

purpose, location and use.

NOTE

If start-up and shut-do wn procedures are

not followed, damage to the system and

its components may occur.

4.2 INSTRUMENTATION

Refer to Figure 4-2. The standard
instrument panel for the Viper Diesel
compressor features a digital display sc reen
with scrolling and operational rocker
switches.

4.2.1 DIGITAL DISPLAY SCREEN

The air pressure readout monitors service air
pressure and incorporates an over-pressure
shutdown function.

4.2.2 SCROLL SELECTOR ROCKER SWITCH

The scroll selector rocker switch allows the
operator to navigate through the settings and
displays related to the machine’s functions
during operation.

4.2.3 ON AND STOP SELECTION KEY

SWITCH

The ON AND STOP selection key switch is
used to turn the machine on and off.

4.3 INITIAL START-UP

PROCEDURE

The following procedure should be used to
make the initial start-up of the compressor.

1. Position the compressor on a level
surface so that proper amounts of
liquid can be added, if required.

2. Check engine and compressor oil levels
and add oil, if necessary.

3. Fill fuel tank.

4. Connect air hose/piping to discharge.

5. Press and hold Start button for one (1)
second to turn on display.

6. Press and hold Start button a second
time for one (1) second to start Engine
cranking sequence.

7. Allow the machine to sufficiently warm-up
before operating.

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090058-OP_r0 (AUGUST-2014) PAGE - 11

SECTION 4: OPERATION VIPER DIESEL

A B C

KEY DESCRIPTION

A INS TRU MENT PANEL MODULAR DIS-

PLAY SCREEN: Di splay con ta ins fou r lines,
20 characters/line.

B SCROLL SELECTOR ROCKER SWITCH
C ON/START AND STOP SELECTION

ROCKER SWITCH

8. After the initial run, shut down machine
allow it to depressurize and top off
compressor oil sump, as required.
Inspect for any leaks, and tighten any
loose fittings.

4.4 SHUTDOWN PROCEDURE

1. Allow engine to run at idle for
approximately sixty (60) seconds.

2. Press the STOP button; NOTE: Allow the
compressor to blow down prior to re-

starting.

IMPORTANT

In case of emergency where immediate

shutdown is required, this procedure is

not necessary.

Press the STOP button immediately.

4.5 SUBSEQUENT START-UP PROCEDURE

On subsequent starts, follow the procedure

PAGE - 12 090058-OP_r0 (AUGUST-2014)

explained below:

Figure 4-2: Controller Panel

1. Check engine and compressor oils
and add oil, if necessary.

2. Fill the fuel tank.

3. Press and hold Start button for one (1)
second to turn on display.

4. Press and hold Start button a second
time for one (1) second to start Engine
cranking sequence.

5. Allow the machine to warm up
sufficiently before operating.

WARNING

Engage stop button prior to opening

panel or servicing machine. Engine can

start at any time in Auto mode.

4.6 CONTROLLER GUIDE

Refer to Figure 4-2 for controller panel
display features. The electronic controller
supplied in the Diesel Viper package has
been designed to work in conjunction with
the linear actuator that operates the speed
control. When used properly, they will reduce
fuel consumption, remind the user when
periodic service is due, extend the useful life

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VIPER DIESEL SECTION 4: OPERATION

of the package, and help diagnose any
problems that may arise during the life of the
compressor system.

4.6.1 HOME SCREEN

The home screen displays the basic
information required during each state the
package can exist in. Before startup, it
displays fuel level and a message that helps
instruct the user how to start the engine.
While the engine is in its cranking sequence,
it displays a message describing what it is
doing (glow plugs, warm-up period, etc.).
During regular operation, it displays engine
RPM, compressor pressure and
temperature, fuel level, and hours of
operation. After shutdown, it displays the
blowdown timer required to elapse before
engine can be restarted.

4.6.2 SPLASH SCREEN

When the display first turns on, it displays the
manufacturer information, software version,
current hours, and serial number of the
machine. To access this screen after the
display goes to the home screen, press the
Up or Down button while at the home screen
and it can be accessed like the adjustable
parameters.

2. Press ON/START to select a parameter
to adjust.

3. Use the Up and Down buttons to cycle
between available settings.

4. Press ON/START to confirm the
parameter setting. This will return view
access to the home screen.

4.6.3.2 AUTO SHUTDOWN

When enabled, auto shutdown will turn off
the compressor package until air demand is
needed again.

4.6.3.3 AUTO CRANK

When enabled (ON/OFF , default to ON), auto
crank will apply the appropriate length of
glow plugs, crank the engine until it starts,
and allow for a brief warm-up period before
making air. When off, manual crank by
depressing ON/OFF switch.

4.6.3.4 SLEEP STATE TIMER

The sleep state timer is the length of time
that the package can be “asleep” before it
will turn off completely to reduce battery draw
and reduce the possibility of accidental
restart when no one is around.

4.6.4 SETTING PRESSURE

4.6.3 ADJUSTING USER SETTINGS

The Diesel Viper controller has several
settings that can be adjusted to suit each
user's specific requirements. The following
parameters can be adjusted as follows:

4.6.3.1 PARAMETERS

Parameter Name

Auto Shutdown (min.) 0-30 (1) 5
Auto Crank On/Off On
Sleep State Timer (min.) 0-15 (5) 10

1. After the display is turned on, from the
home screen press the Up or Down
buttons on the control panel to toggle
between each parameter.

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Setting Limits

(Increment)

Default

090058-OP_r0 (AUGUST-2014) PAGE - 13

Refer to Section 2, Specifications for
pressure range. When the machine is
running, the Up and Down buttons adjust the
pressure set point.

4.6.5 SAFETY

The controller is designed with the user's
safety in mind. There are several safety
conditions that must be met to run the
compressor package. The pressure
transducer and temperature thermistor on
the compressor must be plugged in and
functional for the package to run. The
alternator connector must be plugged in for
the package to run. The hood must remain
closed until after the engine has started. If
any unsafe condition is present before the
package is started or during it s opera tion, the
controller will alert the user with a message

SECTION 4: OPERATION VIPER DIESEL

on the display. Once the problem is
corrected, the message can be cleared by
holding the Up button.

4.6.6 SERVICE INTERVALS

The controller will remind the user of periodic
service intervals. Once the package has
been serviced, the message can be cleared
by holding the Up button.

4.7 OPERATING CONDITIONS

1. Operate only in well-ventilated areas.
Exhaust fumes can be lethal.

2. Ensure there are no obstructions on
cooling air intakes at both ends of the
machine.

3. Do not leave anything resting on top of
the machine. Hot engine exhaust and
cooling air will generate high heat.

4. Be sure to leave sufficient room around
the machine for cooling air. See Figure
3-1.

5. Operate machine with top cover closed to
avoid engine exhaust fumes and heat
from being deflected.

6. Refer to specifications for operating
parameters, speeds, etc.

4.8 EXTREME CONDITIONS

When operating in extreme cold or hot
conditions, in the presence of high humidity,
or at a high altitude, extra attention should be
given to any indication that could lead to a
serious problem. Preventative safeguards
exist that can minimize the possibility of
malfunctions that are prone to occur under
certain ambient conditions. Refer to Section

6.3, Extreme Condition Operation, for

additional information on variable ambient
operating conditions, and adjustment
adaptations that can be made accordingly.

PAGE - 14 090058-OP_r0 (AUGUST-2014)

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VIPER DIESEL SECTION 5: MAINTENANCE

KEY DESCRIPTION

A COMPRESSOR FILL CAP
B FILL CAP BLEED VENT GROOVE: Open/crack

cap slightly to allow bleed vent to relieve air
pressure before removing cap.

C OIL FILL LEVEL: Full indication is the center of

the sight glass.

Figure 5-1: Compressor Pressure Relief Check

A

B

C

WARNING

DO NOT remove caps, plugs and/or other

components when compressor is running or

pressurized. Stop compressor and de-

pressurize system prior to maintenance of

system. Relieve the entire system pressure

by opening the air tank drain/vent valve, if

equipped, which will vent all pressure to the

atmosphere.

Wear personal protective equipment such as

gloves, work boots, and eye and hearing

protection as required for the task at hand.

Refer to Figure 5-1. Open fill cap SLOWLY

(contents under pressure ) to mak e s ure all

pressure has been relieved.

MAINTENANCE

5.1 GENERAL INFORMATION

A strict maintenance program is the key to
long life for the Viper Series Compressor
System package. Below is a program that,
when adhered to, should keep the package
in top operating condition. Refer to Table

5.3A, Table 5.3B, and Section 5.5, Parts
Replacement and Adjustment Procedures

for detailed descriptions of specific
compressor system components. Refer to
Table 7A in Section 7 for part order

information.

WARNING

To avoid accidental system start-ups

during periods of maintenance,

disconnect the positive (+) cable to the

battery terminal, and place the wire
aside, or tape the contact end so that it
cannot accidentally contact the battery

post.

SECTION 5:

Operating the machine package in a

severe environment requires more

frequent service interval s.

5.2 ROUTINE MAINTENANCE SCHEDULE

Vanair® Manufacturing, Inc. considers the
maintenance schedule given in Section 5.3,

Maintenance Schedule Table (5.3A for
compressor; 5.3B for engine), to be part of

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the warranty agreement with the customer.
This maintenance regimen must be followed
in order to protect the warranty of the
machine package.

NOTE

090058-OP_r0 (AUGUST-2014) PAGE - 15

SECTION 5: MAINTENANCE VIPER DIESEL

NOTE

Follow the prescribed periodic

maintenance (PM) schedule as

recommended. Perform the required PM

schedule at recommended intervals.

Failure to follow this prescribed periodic

maintenance at the recommended

intervals will impair the package safety,

performance characteristics, shorten the

package’s life, and will negatively affect

the warranty coverage

of the package.

Vanair® Manufacturing, Inc. especially
requires that a consistent service regimen be
established for engine oil changes, and
engine and compressor air filter servicing.
The following schedule is designed so that
many of the other maintenance tasks are
completed when the engine and compressor

air filters are serviced, and the engine oil is
changed.

WARNING

Follow all applicable safety

recommendations as outlined in Section

1: Safety of this manual.

Please take a moment to acquaint yourself
with the service schedule presented in

Section 5.3 (5.3A for compressor; 5.3B for
engine) to assist the customer in

establishing a maintenance routine log.
For assistance in obtaining routine

maintenance or replacement parts, consult
Section 7.1, Parts Ordering Procedure,
and Table 7A: Recommended Spare Parts

List.

PAGE - 16 090058-OP_r0 (AUGUST-2014)

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VIPER DIESEL SECTION 5: MAINTENANCE

NOTE

ACTION TO TAKE

If working in dusty or dirty conditions, reduce the

recommended time intervals between servicing by

half for engine and compressor oil change, and

engine and compressor filter servicing.

SCHEDULE

Hours

MAINTENANCE

DAILY

Hours

PERIOD

BREAK-IN

(2) years

Hours or Two

Every 1000

(1) year

Hours or One

Every 500

Every 100

First 50

Refer to Figure 5-1 to determine proper oil level, which is

equal to the center of the sight glass. Add as necessary.

• •

Ensure that all connections and fittings, including tubing and

electrical connections, are snugly fastened without being

twisted or compromised by extreme bending or contact with

sharp corners or surfaces. Zip-tie any loose length of fitting if

it appears to have a tendency to shift or cause wear while

machine is in operation.

Visually review the entire machine being mindful of any

evidence of abnormal wear, including pooled oil, frayed or

rubbed connection piping, loose fasteners or hardware, l eaks,

etc.

Order oil and oil filter element replacement kits. Refer to

Table 7A: Recommended Spare Parts for reorder number.

Order air filter replacement element.Refer to Table 7A:

Recommended Spare Parts for reorder number.

Use low pressure wash down on exterior.

Order separator/coalescer replacement element. Refer to

Table 7A: Recommended Spare Parts for reorder number.

•

•

•

•

• •

• •

WARNING

Before performing maintenance:

5.3A MAINTENANCE SCHEDULE TABLE - COMPRESSOR INTERVALS

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Shut down machine, relieve all system pres-

ing maintenance.

Section of this manual.

Always clearly tag the start-up instrumenta-

sure and lock out all power , as per the Safety

tion against accidental system start-up s dur-

Check oil level

KEY TASK DESCRIPTION

090058-OP_r0 (AUGUST-2014) PAGE - 17

Check line fittings and electrical

connections

1

2

System inspection

Change compressor oil and filter

3

Change air filter element

(check every 100 hours)

Clean cooler

(check every 100 hours)

Change separator element

4

5

6

7

SECTION 5: MAINTENANCE VIPER DIESEL

NOTE

and engine and compressor filter servicing.

by half for engine and compressor oil change,

recommended time intervals between servicing

If working in dusty or dirty conditions, reduce the

years

Every two (2)

Every 500 Hours

Consult the Engine Operator’s Manual for engine oil

specification. Consult Table 7A: Recommended Spare

Parts List for replacement kit or part order number.

Ensure that all fuel hose connections and fittings are

free of any telltale signs of leaking and well connected.

Zip-tie any loose length of hose fitting if it appears to

have a tendency to shift or contact an abrasive surface

while machine is in operation.

Consult the Engine Operator’s Manual for procedure on

changing the engine air filter element. Should the

element need to be replaced, refer to Table 7A:

Recommended Spare Parts List for replacement kit or

part order number. Consult the Engine Operator’s

Manual for procedure on cleaning the engine fuel filter.

Tighten if necessary. Consult the Engine Operator’s

Manual for fan belt information.

Consult the Engine Operator’s Manual for procedure on

changing the engine oil filter, and manufacturer’s

recommended oil usage.

Ensure that the intake hose is properly fastened and

free from any compromises such as tears or holes.

or One (1) Year

Every 50 Hours

MAINTENANCE SCHEDULE

PERIOD

BREAK-IN

Daily

First 50 Hours

Every 400 Hours

Every 200 Hours

Every 100 Hours

•

••

• •

•• •

•

•

WARNING

5.3B MAINTENANCE SCHEDULE TABLE - ENGINE INTERVALS

negative (-) battery cable.

Shut down machine, relieve all

Before performing maintenance:

system pressure and lock out all power,

For lock-out/tag-out disconnect the

as per the Safety Section of this manual.

KEY TASK DESCRIPTION ACTION TO TAKE

Change engine oil.

1

PAGE - 18 090058-OP_r0 (AUGUST-2014)

Check fuel lines and clamps

2

Check engine air filter element

(replace if necessary), and fuel filter

3

bowl (clean if necessary).

Check alternator belt tightness

Change oil filter

4

5

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Check air intake hose

6

VIPER DIESEL SECTION 5: MAINTENANCE

Continued on next page

NOTE

and engine and compressor filter servicing.

by half for engine and compressor oil change,

recommended time intervals between servicing

If working in dusty or dirty conditions, reduce the

years

Every two (2)

Ensure that the radiator hoses and clamp bands are

intact, in good working order and fastened correctly. If

hoses are showing signs of wear (cracking, stretching,

etc.), replace hoses (refer to Section 7.14, Hose

Installation Guide for assistance when replacing

damaged hoses).

Consult the Engine Operator’s Manual for procedure on

replacing the engine fuel filter element. Refer to Table

7A: Recommended Spare Parts List for replacement

kit or part order number.

Consult the Engine Operator’s Manual for procedure on

cleaning the radiator water jacket.

Consult the Engine Operator’s Manual for procedure on

replacing the engine fan belt. Refer to Table 7A:

Recommended Spare Parts List for replacement kit or

part order number.

Consult the Engine Operator’s Manual for procedure on

changing the engine air filter. Refer to Table 7A:

Recommended Spare Parts List for replacement kit or

part order number.

or One (1) Year

Every 50 Hours

MAINTENANCE SCHEDULE

PERIOD

BREAK-IN

Daily

First 50 Hours

Every 500 Hours

Every 400 Hours

Every 200 Hours

Every 100 Hours

I

•

•

•

•

WARNING

Shut down machine, relieve all

Before performing maintenance:

5.3B MAINTENANCE SCHEDULE TABLE - ENGINE INTERVALS

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system pressure and lock out all power,

negative (-) battery cable.

For lock-out/tag-out disconnect the

as per the Safety Section of this manual.

KEY TASK DESCRIPTION ACTION TO TAKE

Check radiator hoses and clamp

bands

7

Replace fuel filter element

8

Flush cooling system

Replace fan belt

9

10

Replace air filter element

11

Every 200 hours or six (6) months.

I

090058-OP_r0 (AUGUST-2014) PAGE - 19

SECTION 5: MAINTENANCE VIPER DIESEL

Continued on next page

NOTE

and engine and compressor filter servicing.

by half for engine and compressor oil change,

recommended time intervals between servicing

If working in dusty or dirty conditions, reduce the

years

Every two (2)

Every 500 Hours

Replace the radiator hoses and clamp bands. Refer to

Section 7.14, Hose Installation Guide for assistance

when replacing worn or damaged hoses. Refer t o Table

7A: Recommended Spare Parts List for replacement

kit or part order number.

Due to shipping regulations pertaining to lead acid bat-

teries, Vanair recommends procuring a replacement bat-

tery from a localized source. Two possible replacement

•

•

Replace the fuel hose and clamp bands. Refer to

Section 7.14, Hose Installation Guide for assistance

when replacing worn or damaged tubing. Refer to Table

7A: Recommended Spare Parts List for replacement

kit or part order number.

Consult the Engine Operator’s Manual for procedure on

changing the radiator coolant. Follow Engine Operator’s

models include: BatteriesPlus® no. SLi96R, and NAPA

battery no. BAT 7590.

II

Manual recommendations for coolant type to use.

•

or One (1) Year

Every 50 Hours

MAINTENANCE SCHEDULE

PERIOD

BREAK-IN

Daily

First 50 Hours

Every 400 Hours

Every 200 Hours

Every 100 Hours

•

Service Department.

®

WARNING

negative (-) battery cable.

Shut down machine, relieve all

5.3B MAINTENANCE SCHEDULE TABLE - ENGINE INTERVALS

Before performing maintenance:

system pressure and lock out all power,

as per the Safety Section of this manual.

For lock-out/tag-out disconnect the

KEY TASK DESCRIPTION ACTION TO TAKE

PAGE - 20 090058-OP_r0 (AUGUST-2014)

Replace radiator hoses and clamp

bands

12

Replace battery

13

Inspect fuel lines and clamps

14

Change radiator coolant

15

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Consult the Vanair

II

VIPER DIESEL SECTION 5: MAINTENANCE

KEY DESCRIPTION

A 50 AMP CIRCUIT BREAKER - AUTO RESET
B ENGINE STARTER (Location reference)
C ENGINE OIL FILTER (Location reference)

Figure 5-2: 50A Circuit Breaker Location

AC B

5.4 REPLACEMENT PARTS

Replacement parts should be purchased

®

through your local Vanair
where the Viper Diesel Air Compressor
System was purchased. If, for any reason,
parts are not available in this manner, they

can be purchased through Vanair directly.

NOTE

For assistance when ordering new

replacement parts, consult Section 7.1,

Parts Ordering Procedure, and Table 7A:

Recommended Spare Parts List.

NOTE

If additional spare parts are being stored

for future use, make certain that they are

stored in proper cont ainers that a llow for

protection against contamination, and

kept in a clean area of moderate

temperature reading. For information on

storing the machine package for periods

of non-use, consult Section 5.7.2, Long

Term Storage.

representative or

NOTE

Do not tamper with the RPM setting to

increase the maximum engine speed.

Overspeed is hazardous and will void the

engine warranty.

5.6 SERVICING THE SYSTEM FUSES AND CIRCUIT BREAKER

Consult Section 7.9, Electrical System,
(FUSE LAYOUT diagram insert) to
determine the location of the specific fuses.
Refer to Figure 5-2 for reference location of

the 50A circuit breaker.

NOTE

Refer to the Engine Operator’s Manual for

detailed maintenance and replacement

procedures for the engine.

5.7 STORAGE AND

INTERMITTENT USE

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10896 West 300 North

Michigan City, IN 46360
Telephone: [phone]
[phone]

Service Fax: [phone]

Parts Fax: [phone]

Sales Fax: [phone]

www.vanair.com

5.5 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES

5.5.1 ADJUSTING THE ENGINE SPEED

The Viper Diesel was designed in such a
way that the governor speeds should not
need to be adjusted. Should the unit operate

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outside of specified speeds, consult the

090058-OP_r0 (AUGUST-2014) PAGE - 21

SECTION 5: MAINTENANCE VIPER DIESEL

5.7.1 INTERMITTENT USE

If the unit is not used very regularly always
treat the fuel with a fuel stabilizer.

Check all belts and hoses for signs of
deterioration such as visible surface cracks,
stiffness or discoloration.

5.7.2 LONG TERM STORAGE

Disconnect the battery cable that is
connected to the negative (-) side of the
battery.

Cover the unit with a tarp or plastic to
prevent the accumulation of dust, but le ave
the bottom open for air circulation.

Fill the fuel tank with fuel and fuel stabilizer
to prevent moisture build-up in the tank.

PAGE - 22 090058-OP_r0 (AUGUST-2014)

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 6: TROUBLESHOOTING

Figure 6-1: Machine Serial Plate Location

NOTE

When contacting the Vanair Service

Department, please have machine serial

number on hand to quickly expedite

service. See below for machine serial plate

location.

NOTE

Machine serial number also displays on

instrument panel at start-up, on the hours

screen.

TROUBLESHOOTING

6.1 GENERAL INFORMATION

The information contained in this section has
been compiled from years’ worth of inform a­tion gathered from the field. It contains symp­toms and usual causes for the most common
types of problems that may occur. All avail­able data concerning the trouble should be
systematically analyzed before undertaking
any repairs or component replacement.

A visual inspection is worth performing for
almost all problems and may avoid unneces­sary additional damage to the machine. The
procedures which can be performed in the
least amount of time and with the least
amount of removal or disassembly of parts

should be performed first.

SECTION 6:

WARNING

Before starting, performing maintenance,

or replacing parts, relieve the entire

system pressure by opening a service

valve, which will vent all pressure to the

atmosphere.

Although Vanair
tions that may occur during the operation life
of the machine package, the Troubleshooting
Guide may not cover all possible situations.
Be aware that additional troubleshooting
information may be found in other sources,
such as the Engine Operator’s Manual.
Should the situation remain unresolved after
exhausting available sources, contact the
Vanair Service Department at:

Phone: [phone] (toll free)
Phone: [phone]
Fax: [phone]

®

strives to anticipate situa-

VANAIR MANUFACTURING, INC.

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090058-OP_r0 (AUGUST-2014) PAGE - 23

SECTION 6: TROUBLESHOOTING VIPER DIESEL

6.2 TROUBLESHOOTING GUIDE

Fault/Malfunction Possible Cause Corrective Action

Machine does not start

Fault:
Freq Sensor Error, Machine Will
Not Run

Engine will not crank Faulty battery connection. Check for proper battery connections and

Engine will not start Low fuel and/or oil supply Check fuel gauge. Replenish as necessary.

Controller is not receiving input from
alternator connector

ENGINE

Battery out of power Recharge or replace battery.
Control module fuse blown Check fuse; refer to Section 7.9.
Machine hood shutdown safety switch

prevents start-up of engine
Faulty starter or starter solenoid Replace.
Faulty 50A circuit breaker Replace.

Check connection/continuity.
During extremely cold weather, use of

heater pads is required to get engine to spin
fast enough to generate a usable signal. If
no heater pads are installed, change crank
sequence to Manual Crank (refer to Section

4.6.3.1, Parameters).

battery charge.

Close hood panel or check if roof switch is
faulty.

Consult the Engine Operator’s Manual for
additional information on engine

maintenance.
Pinched fuel line Replace or reroute if necessary.
Plugged fuel filter(s) Replace if necessary. Refer to the Engine

Low battery voltage Recharge or replace if necessary.

Plugged engine air filter Replace engine air filter. Refer to Engine

Defective oil pressure switch Check continuity, and replace if necessary.
Defective engine temperature switch Check continuity, and replace if necessary.
Poor ground connection Check and clean/renew connection.

Improper Control Operation:
Engine does not speed up

Speed control actuator stuck Lubricate; replace speed control actuator if

Engine speed control lever stuck Free lever and lubricate if necessary.

PAGE - 24 090058-OP_r0 (AUGUST-2014)

Operator’s Manual for additional information

on engine maintenance.

Loose connections; tighten connections.

Dirty connections; clean connections.

Operator’s Manual.

necessary.

Continued on next page

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VIPER DIESEL SECTION 6: TROUBLESHOOTING

6.2 TROUBLESHOOTING GUIDE

Fault/Malfunction Possible Cause Corrective Action

ENGINE (CONTINUED)

Improper Control Operation:
Engine does not speed up
(continued)

Improper Control Operation:
Engine does not slow down

Engine stops during operation

Fault:
Engine High Temp Shutdown

Engine stops during operation

Fault:
Low Engine Oil Pressure

Fuel filter partly plugged Replace fuel filter. Refer the Engine

Operator’s Manual.
Auxiliary fuel pump may be needed for

remote fuel tank.

Speed control actuator stuck Lubricate; replace speed control actuator if

necessary.

Engine speed control lever stuck Free lever and lubricate if necessary. Refer

to Engine Operator’s Manual.
Faulty pressure tranducers Check and replace, if necessary.
Located too close to obstruction Move further from obstruction.
Engine radiator plugged Clear debris/dirt from engine radiator.
Fault with engine cooling system Consult Engine Operator’s Manual.
Ambient temperature too high Consult Section 6.3.3, High Temperature

Operation.
Faulty temperature switch Replace.
Low oil level Check engine oil level; replenish as

necessary. Consult the Engine Operator’s

Manual for additional information on engine

maintenance.
Engine shutdown switch activated Confirm that access door is properly in

place. Replace faulty engine shutdown

switch.
Faulty oil pressure switch Replace.
Engine oil filter plugged Replace engine oil filter. Refer to the Engine

Operator’s Manual.

Gradual loss of engine power Contaminated fuel Drain and replace fuel supply.

Engine air filter contaminated Check air filter. Replace if necessary (refer

to the Engine Operator’s Manual).
Fuel filter(s) contaminated Check fuel filters. Refer to the Engine

Operator’s Manual for additional information

on engine maintenance.
Low fuel level Add fuel.
Overload Reduce load; check load use, and reduce

Continued on next page

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

090058-OP_r0 (AUGUST-2014) PAGE - 25

SECTION 6: TROUBLESHOOTING VIPER DIESEL

6.2 TROUBLESHOOTING GUIDE

Fault/Malfunction Possible Cause Corrective Action

ENGINE (CONTINUED)

Gradual loss of engine power
(continued)

For additional information concerning an engine problem, consult the Engine Operator’s Manual.

Compressor overheats

Fault:

Compressor High Temp
Shutdown

Compressor will not build up
pressure

Engine not warmed up Allow engine to warm up.

COMPRESSOR

Low compressor oil level Check oil level and refill to proper level if

necessary (ensure machine is parked on a

level surface).
Obstructed cooler fins Clear/clean if required.
Insufficient air flow over cooler Check for obstructions (frame, body, etc.) to

cooling air flow.
Defective temperature thermistor Check sensor; replace if necessary.
Compressor oil filter plugged Replace compressor oil filter.
Defective compressor thermal valve Replace valve.
Low compressor oil level Check oil level and refill to proper level if

necessary (ensure machine is parked on a

level surface).
Unload solenoid valve defective Replace solenoid valve.
Air demand too high Check for leaks and take corrective action.

Check air tools for wear, damage, or

malfunctions. Replace or repair.
Compressor capacity too low to

accommodate demand
Compressor air filter plugged Check air filter. Replace if necessary.
Engine does not speed up: input RPM

too slow
Engine speed control lever stuck Free lever and lubricate if necessary.

Service valve is open Close service valve.
Pressure transducer is malfunctioning Replace as necessary.

Inlet valve fails to open
Inlet valve frozen shut
Leak in air control line Check for leaks and take corrective action.

PAGE - 26 090058-OP_r0 (AUGUST-2014)

Substitute larger capacity compressor

system.

Check engine speed control actuator.

Consult the Engine Operator’s Manual.

Check for proper operation with an auxiliary

air source. Replace if necessary.

Repair/replace inlet valve.

Repair/replace inlet valve.

Continued on next page

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 6: TROUBLESHOOTING

6.2 TROUBLESHOOTING GUIDE

Fault/Malfunction Possible Cause Corrective Action

COMPRESSOR (CONTINUED)

Compressor system over­pressures

Fault:
Compressor High Press

Shutdown or safety relief valve

No service air output (See also

Compressor will not build up
pressure)

Unload solenoid valve defective Replace solenoid valve.
Restricted or plugged bleed orifice Clean if soiled; if ice is present, clear and

remove.

Damaged/kinked control line Check line for damage (wear, kinks, etc.).

Re-route, re-tie or replace if necessary.

Control line connections are not prop­erly seated/poor connection quality

Inlet valve poppet not seating correctly. Valve will need to be dis-assembled to

Inlet valve piston is stuck in open posi­tion.

Compressor shaft seal is leaking Replace shaft seal with available kit.
Pressure transducer is malfunctioning Check transducer for proper operation;

Defective safety valve Replace safety valve.
Plugged coalescer Replace coalescer element.
If equipped, OSHA valve/velocity fuse,

not functioning properly
Minimum pressure/check valve is

malfunctioning

Check lines for proper seating/ensure line
ends have been cut cleanly and are square
(DO NOT use wire cutters: use a loom cut­ting tool or a clean, sharp razor blade).

check; consult with Service Department.
Check for proper operation with an auxiliary

air source—replace or rebuild inlet valve.

replace if necessary and check controls.

Reset or replace OSHA valve.

Rebuild or replace check valve.

Low service air output (See also

Compressor will not build up
pressure)

Compressor stalls Idle speed is set too low Adjust idle speed; consult factory.
Excess amount of oil in air

discharge

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Clogged compressor air filter Check air filter. Replace if necessary.
Solenoid valve sending continuous

signal to inlet valve
Incorrect compressor speed Adjust engine speed. Refer to Section

Minimum pressure/check valve is
malfunctioning

Machine not on level surface Move machine to level surface.

Rebuild or replace solenoid valve if
defective.

5.5.1, Adjusting the Engine Speed.

Rebuild or replace check valve.

Continued on next page

090058-OP_r0 (AUGUST-2014) PAGE - 27

SECTION 6: TROUBLESHOOTING VIPER DIESEL

6.2 TROUBLESHOOTING GUIDE

Fault/Malfunction Possible Cause Corrective Action

COMPRESSOR (CONTINUED)

Excess amount of oil in air
discharge (continued)

Excessive moisture in the
compressed air

System oil appears to be cloudy or
milky

Compressor oil level too high The correct oil level is is to the center of the

Scavenger system not operating Inspect scavenger line for obstructions or

Coalescer element plugged or
damaged

Moisture accumulating in air tank Drain water from air tank (if applicable to

Excessive moisture in system oil;
defective thermal valve

6.3 EXTREME CONDITION OPERATION

When operating in extreme cold or hot
conditions, in the presence of high humidity,
or at a high altitude, extra attention should be
given to any indication that could lead to a
serious problem. Engine power and
compressor air output will be reduced at high
altitude or hot ambient temperatures.

Machine review and maintenance check
schedules should be more frequent than the
normal suggestions given in the

Maintenance Schedule Tables (Table

5.3A, and Table 5.3B in Section 5).

sightglass.

leaks. Replace if necessary.
Replace the coalescer element.

installation).
Check/replace thermal valve. Consult

factory for assistance.

6.3.1 HIGH MOISTURE CONDITION: EMULSIFICATION OF OIL IN ROTARY SCREW COMPRESSOR SYSTEMS

Consult the information in Table 6.3A for
preventative and/or repair measures. If
machine is operating in a high moisture
environment, water contamination may
persists after following the regular
preventative maintenance schedule and
standard operating procedures.

Become acquainted with the situation­adjusted operation approaches given in this
section before operating the power system
package in any type of extreme ambient
condition. For additional operation
information consult the Engine Operator’s
Manual, or visit the engine manufacturer’s
web site given in that manual.

PAGE - 28 090058-OP_r0 (AUGUST-2014)

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 6: TROUBLESHOOTING

TABLE 6.3A HIGH MOISTURE CONDITION OPERATION

Symptom Cause Prevention / Corrective Action

Emulsification of oil in compres­sor system:

• Compressor oil is milky white
in color

• Compressor oil is broken
down and lacks lubricity.

• Compressor oil may develop
solid chunks or clumps

Operating the compressor system
for short periods of time:

• Short cycling prevents the tem­perature of the oil from attaining a
high enough temperature capa­ble of vaporizing the moisture
droplets.

Operating the compressor system
unloaded without air flow from the
service line for long periods of
time:

• This can keep the oil temperature
from getting hot enough to vapor­ize the moisture droplets, pre­venting the moisture from being
able to escape the system. Addi­tionally, there is no path for the
moisture to escape the system.

The thermal valve is faulty and
activating the cooling fan too
soon:

• This prevents the oil from attain­ing a high enough temperature
capable of vaporizing the mois­ture droplets.

The air filter is saturated with
water:

• This forces moisture to be
ingested by the compressor.

Any of the above causes will be
exacerbated in especially humid
environments.

RECOMMENDED CHANGES:

If the problem is not corrected by standard
operating practices and regular preventative
maintenance, consider the following:

• Raise the average temperature of the com­pressor oil.

• Change the operating procedure to allow
for the compressor oil temperature to
reach 180 °F before discharging any air. If
the compressor isn't discharging any air,
it's not ingesting any potentially humid air.
It will build pressure upon initial startup, but
then it will run closed and allow it to heat
up.

REPAIR/MAINTENANCE:

Refer to Section 5 of the Operator's Manual
for inspection, cleaning, and repair instruc­tions.

1. Once the com presso r oil becom es emul ­sified, it must be replaced along with the
oil filter. Depending on the severity ,
other parts might also need to be
replaced.

2. Check that the separator element is in
good, working condition.

3. Check that the scavenge line is working
properly.

If the system is badly contaminated, Vanair
recommends a lube flush that will help clean
out any remaining contamination throughout
the system. Consult Vanair Service Depart­ment for lube flush instructions.

Check the moisture drain frequently on the air
tank reservoir, to alleviate moisture build-up.

®

6.3.2 COLD WEATHER OPERATION

Consult the information in Table 6.3B for
preventative and/or repair measures. The
Diesel Viper’s 25HP engine runs on diesel
fuel, which can be more difficult to start in
cold weather. Once the engine is started, the
air density becomes larger and the intake

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090058-OP_r0 (AUGUST-2014) PAGE - 29

efficiency also becomes higher. More output
can be expected in cold areas. When the
temperature is very low, extra care must be
taken regarding fuel and oil changes in their
viscosity, freezing of water contained in the
piping, or of water adhering on the filter.
Diesel fuel may gel at very cold
temperatures.

SECTION 6: TROUBLESHOOTING VIPER DIESEL

TABLE 6.3B COLD WEATHER OPERATION

Symptom Cause Prevention / Corrective Action

Water freezes in the fuel line
Lubrication oil viscosity

increases
Diesel fuel turns to a gel-like

consistency at temperatures
around 0°F (-18°C)

WATER

Water in the fuel can freeze at tem­peratures below 32°F (0°C), block­ing fuel lines.

At an extremely cold temperature,
the viscosity of lubrication oil may
increase and the torque of starter
may exceed its permissible value,
hindering proper starting.

GELLING

The diesel forms wax crystals wh en
the temperatures drop below 15°F
(-9°C).

As it gets colder, these wax crystals
turn to gel. This thicker substance
cannot pass the fuel filter, so the
engine may run intermittently, or
may not start at all.

• Park the vehicle or equipment indoors
when not in use.

• Use a block heater or glow plugs.

• Maintain the battery; this will make it easier
to start a diesel engine in cold weather.

• In below zero temperatures a fuel line
deicer product may need to be used.

• Check the fuel filter regularly to insure that
it contains no water.

• Vanguard™ Premium Synthetic Oil is suit­able for use from -40°F to 110°F
(-40°C to 43°C).

• For additional engine precautions, consult
the Engine Operator’s Manual.

• Vanair® recommends installation of the
cold weather heater option kit. Consult
Vanair for details.

• Keep the fuel tank full to prevent conden­sation from forming inside the tank and
lessen the chances of water getting in the
fuel line.

• The standard recommendation of 15W-40
engine oil is suitable for temperatures
down to -4°F (-20°C). If temperatures are
consistently below 30°F (-1°C), it is recom­mended that 5W-30 oil be used. If temper­atures are below -25°F (-32°C), a high­performance, fully synthetic oil, such as
AMSOIL 5W-30 should be used which is
suitable to temperatures of -55°F (-48°C).

6.3.3 HIGH TEMPERATURE OPERATION

the Engine Operator’s Manual for fuel,
lubrication oil and cooling requirements und er

Consult the information in Table 6.3C for
preventative and/or repair measures. Reduce
load duty cycle to less than 60% when
operating in ambient temperatures above
104°F (40°C).

Extra care should be taken to keep the
engine and air compressor clean and to not

extreme temperatures.
When operating the machine in high

temperature areas, precautions should be
taken to prevent overheating. At the
minimum, all coolers, including air passage
ways around the coolers, should be free of
debris and dirt. The fan, driven by the engine,

restrict the air flow around the unit. Consult

PAGE - 30 090058-OP_r0 (AUGUST-2014)

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 6: TROUBLESHOOTING

is designed to run continuously to assure a
constant flow of cooling air.

performance, which can directly effect some
machine function capacity outputs.

The operator should be aware that high
temperatures can influence engine

TABLE 6.3C HIGH TEMPERATURE OPERATION

Symptom Cause Prevention / Corrective Action

Overheating/high
compartment temperatures

Diminished engine
performance

High ambient temperatures, con­fined spaces, soundproof cases
and other reasons. Among these
the most important factor is the
temperature of the intake and
cooling air.

• Extra care should be taken to keep the engine and
air compressor clean and to not restrict the air flow
around the unit.

• Consult the Engine Operator’s Manual for fuel,
lubrication oil and cooling requirements under
extreme temperatures.

• At the minimum, all coolers, including air passage
ways around the coolers, should be free of debris
and dirt. The fan, driven by the engine, is designed
to run continuously to assure a constant flow of
cooling air.

The operator should be aware that high temperatures
can influence engine performance, which can directly
effect some machine function capacity outputs.

6.3.4 HIGH DUST CONTENT OPERATION

the machine is to be used in continuously

dusty environments, special care must be
Consult the information in Table 6.3D for
preventative and/or repair measures. When

taken with the engine’s air cleaner and

radiator.

TABLE 6.3D HIGH DUST CONTENT OPERATION

Symptom Cause Prevention / Corrective Action

Overheating
System contamination
Stalling

Machine components exposed to
frequent or constant dust interac­tion, can result in diminished sys­tem performance, or machine
cessation.

• The intake air must be cleaned with the air
cleaner—inspect the air filter frequently for dust
build-up and replace as needed.

• Ensure that the radiator and oil cooler fins are
kept clean to prevent overheating.

• If the machine is not being used for an extended
period of time, an additional precaution, such as
covering the machine with a tarp, will help to keep
the inside of the machine free of dust particle
accumulation.

• For extreme cases of high dust content environ­ments, machine fluids may need to be replaced at
more frequent intervals. Adjust maintenance
schedule accordingly.

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090058-OP_r0 (AUGUST-2014) PAGE - 31

SECTION 6: TROUBLESHOOTING VIPER DIESEL

6.3.5 HIGH ALTITUDE OPERATION

Engine horsepower will decrease by 3.5% for
every 1,000 feet over 6,000 feet increase in
altitude. At high altitude overall unit
performance will deteriorate, and care will
need to be taken not to overload the engine.

PAGE - 32 090058-OP_r0 (AUGUST-2014)

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 7: ILLUSTRATED PARTS LIST

NOTE

Machine serial number also displays on

instrument panel at start-up, on the hours

screen.

SECTION 7:

ILLUSTRATED PARTS LIST

7.1 PARTS ORDERING PROCEDURE

Part orders should be placed through the distributor from
whom the unit was purchased. If for any reason parts
cannot be obtained in this manner, contact the factory
directly at the address or phone numbers below.

When ordering parts always indicate the Serial Number
of the machine package. This can be obtained form the
Bill of Lading for the machine package, or from the
compressor unit serial number plate. See Figure 7-1 for
location of machine package serial plate. Consult Table
7A: Recommended Spare Parts List on the next page
for a listing of replacement parts.

VANAIR MANUFACTURING, INC.

10896 West 300 North

Michigan City, IN 46360
Telephone: [phone]
[phone]

Service Fax: [phone]

Parts Fax: [phone]

Sales Fax: [phone]

www.vanair.com

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

Figure 7-1: Machine Package Serial Number Plate Location

090058-OP_r0 (AUGUST-2014) PAGE - 33

SECTION 7: ILLUSTRATED PARTS LIST VIPER DIESEL

TABLE 7A: RECOMMENDED SPARE PARTS LIST

KEY NO. PART NUMBER DESCRIPTION QTY

ROUTINE/SCHEDULED MAINTENANCE ITEMS

1 264626-1GAL

Vanguard Premium Oil (One [1] Gallon)

I

1
2 273080 Element, Compressor Coalescing Air/Oil Separator Spin-on Style 1
3 266801 Element, Compressor Oil Filter 1
4 273673 Element, Compressor Air Filter 1
5 270764 Element, Engine Air Filter Replacement 1
6 RC77662 Filter, Engine Fuel 1
7 269136 Filter, Engine Oil 1

KIT (FULL) MAINTENANCE ITEMS

8 KIT1154 Kit, Maintenance for Engine Filters 1
9 KIT1212 Kit, Maintenance for Compressor - Initial 50 Hours 1

10 KIT1213 Kit, Maintenance for Compressor - Annual / 500 hours 1

NON-ROUTINE MAINTENANCE ITEMS

11 EN270451-007

Belt, Engine Replacement

II

1

12 267306 Breaker, Circuit Replacement 1
13 260246 Relay, NO/NC Weatherproof with Resistor 1
14 263532 Fuse, A to 5A Tan 1
15 264316 Fuse, A to 25A Clear 1
16 264695 Fuse, Block 4-Way ATC 1
17 267880 Fuse, ATC 20A Yellow 1
18

III

Battery, Replacement 1

19 Consult Factory Kit, Shaft Seal 1

I

Use only Vanair® Vanguard™ Premium Synthetic Oil and Genuine Vanair Parts. Inspect and replace damaged components
before operation. Substituting non-Vanguard™ Oil or non-genuine Vanair filter components WILL VOID THE COMPRESSOR
WARRANTY!

II

This belt replaces the engine alternator belt only. For full engine belt coverage, consult factory.

III

Due to shipping regulations pertaining to lead acid bat teries, Vanair recommends procuring a replacement battery from a

localized source. Two possible replacement models include: BatteriesPlus® no. SLi96R, and NAPA battery no. BAT 7590.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

TABLE 7B: MACHINE OPTIONS LIST

KEY NO. PART NUMBER DESCRIPTION QTY

1 032894 Aftercooler 12VDC 1
2 032895 Cold Weather 12VDC Pad 1
3 032905 Cold Weather 120VAC Pad 1
4 032939 Heater, Engine Block 120VAC 1
5 032896-030, 032896-060, 032896-120 Remote Control Module 1
6 032901 Bolt-on Fork Pockets 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

IMPORTANT

If additional spare parts are being stored for future use,

ensure that they are stored in proper containers that allow

for protection against contamination, and kept in a cl e an

area of moderate temperatur e reading. Fo r informat ion on

storing the machine package for periods of non-use,

Use only approved Vanair® Vanguard™ Premium Synthetic

Oil and Genuine Vanair Parts. Inspect and replace damaged

components before operation. Substituting non-Vanguard

Oil or non-genuine Vanair filter components will VOID THE

IMPORTANT

COMPRESSOR WARRANTY!

consult Section 5.7.2, Long Term Storage.

PAGE - 34 090058-OP_r0 (AUGUST-2014)

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[phone] • www.vanair.com

VIPER DIESEL SECTION 7: ILLUSTRATED PARTS LIST

TABLE 7C: MAINTENANCE TRACKING LOG

DATE DESCRIPTION OF MAINTENANCE PART(S) REPLACED

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090058-OP_r0 (AUGUST-2014) PAGE - 35

SECTION 7: ILLUSTRATED PARTS LIST VIPER DIESEL

3

2

8

4

5

9

5

4

6

7

14

18

13

17

17

16

17

15

10

11

12

15

1

2

17

15

13

17

7.2 COMPRESSOR REPLACEMENT PARTS

6010148ID_r3

PAGE - 36 090058-OP_r0 (AUGUST-2014)

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 7: ILLUSTRATED PARTS LIST

7.2 COMPRESSOR REPLACEMENT PARTS

ITEM DESCRIPTION PART NUMBER QTY

1 DECAL, VANGUARD OIL FILL CAP 1” 263533-2 1
2 CLAMP, HOSE SUPPORT 1.50 ID 263812 1
3 CAP, JIC 5/8 264322-004 1
4 WASHER, SNUBBING RUBBER MOUNT 264829 4
5 MOUNT, RUBBER ARMOR PLATED 200# GREEN 272442 2
6 HOUSING, D902 AL W/STARTER COVER VM180 273483 1
7 HUB, COUPLING, 1.125 DIA. BORE 273559 1
8 HOSE, COMPRESSOR DRAIN (PART OF KIT 273968) 273968-001 1

9 SUPPORT, AIREND VA DIESEL VIPER 273970 1
10 AIREND & ATT, DIESEL VIPER 6180000 1
11 AIREND & ATT, VSE075GDSS240 6180001 1
12 AIREND & ATT, VSE075GDSS215 6180005 1
13 NUT, HEX LOCKING 3/8-16 825506-198 3
14 CAPSCREW, HEX GR8 5/16-18 x 1-1/4 829405-125 4
15 CAPSCREW, HEX GR8 3/8-16 x 1-3/4 829406-175 3
16 CAPSCREW, HEX GR8 1/2-13 x 3 829408-300 2
17 WASHER, FLAT 3/8 838206-071 6
18 WASHER, LOCK 5/16 838505-078 4

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

COMMONLY REPLACED PARTS

ITEM DESCRIPTION PART NUMBER QTY

A ELEMENT, COALESCING

(SEPARATOR)

B ELEMENT, OIL FILTER 266801 1
C ELEMENT, AIR FILTER 273673 1
D VANGUARD OIL 264626-1GAL 1

273080

1

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

090058-OP_r0 (AUGUST-2014) PAGE - 37

SECTION 7: ILLUSTRATED PARTS LIST VIPER DIESEL

6180000ID_r4

9

7

8

1

2

5

3

5

6

4

29

11

13

14

16

30

31

32

17

12

27

18

19

33

28

15

26

23

20

22

25

24

36

21

34

35

37

10

7.3 AIREND AND ATT

PAGE - 38 090058-OP_r0 (AUGUST-2014)

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 7: ILLUSTRATED PARTS LIST

7.3 AIREND AND ATT

ITEM DESCRIPTION

1 CAP, OIL FILL W/VENT 1-5/16” 048063 1 20 VALVE, MIN PRESS INTERNAL

2 SIGHTGLASS, O-RING TMBD

1-5/16”

3 CONNECTOR, O-RING 1/4 SAE

x 1/4 JIC

4 CONNECTOR, #10 MSAE x #10

MJIC

5 ELBOW, 90 DEG #10 MJIC x

MSAE

6 ELBOW, 1/4T x 1/8P PUSH-ON 261309 1 25 ADAPTER, AIR/OIL

7 ELBOW, 90 DEG PUSH-ON

1/4T x 1/4P

8 TUBING, PLASTIC 1/4 WHITE 261322 1 27 HOSE, ASSY 0.25 x 18 JIC SWV

9 ADAPTER, FEMALE PIPE x

BSPP 1/4

10 VALVE, RELIEF 200 PSI 1/4

NPT MALE

11

CLAMP, HOSE #28

12 FILTER, OIL 6” TANK 266801 1 31 AIREND ASSY,

THERMISTOR, TEMP. 1/2 NPT 266844 1 32 AIREND ASSY,

13
14 PLUG, PIPE HEX SOCKET 1/8”

NPT

RANSDUCER, PRESSURE 267363 1 34 O-RING, VITON .941 OD x .070 826502-019 1

15 T
16 PLUG, PIPE 1/2 NPT HOLLOW

HEX

17 PLUG, SAE O-RING HOLLOW

HEX #16

18 CONNECTOR, OIL FILTER

VANIR ENCAPS

19 ORIFICE, STRAINER 0.030 #6

MSAE x #4 MJIC

PART

NUMBER

260097-610 1 21 REGULATOR, INTAKE 85/150

260387-103 1 22 O-RING, VITON 1/16 DIA x

260387-109 1 23 MANIFOLD, AIR/OIL VMI80 272920 1

260403-106 2 24 SEPARATOR, AIR/OIL SPIN ON

261310 1 26 CAPSCREW, HX SOC 5/16-18 x

263748-004 1 28 ELBOW, 45 DEG MSAE #14 x

264232 1 29 FILTER, AIR 90 CFM 2” 273672 1

265560

267258 1

267942 1

268081-010

270037

271054

QTY

ITEM DESCRIPTION

PARTS VMI80

ADHD

1.176 ID

106CFM

SEPARATOR M42 x M39

3

STR x JIC SWV90

MJIC #14 w 1/8 FNPT

1

1 36 WASHER, FLAT 5/16 838205-071 4

1 37 WASHER, LOCK 5/16 838505-078 4

1

30 AIREND ASSY,

VSE075GDSS193

VSE075GDSS240

VSE075GDSS215

33 O-RING, VITON .691 OD x .070

CAPSCREW, FERRY HD 5/16-

35

18 x 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

PART

NUMBER

271079

271701

272689 1

273080 1

273081 1

273239 3

273247 1

273583 1

6170000 1

6170001

6170004

826502-015

828405-100 4

QTY

1

1

1

1

1

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

090058-OP_r0 (AUGUST-2014) PAGE - 39

SECTION 7: ILLUSTRATED PARTS LIST VIPER DIESEL

60

60

60

56

NOTES:

4. CAN USE 9V BATTERY TO EXTEND/
RETRACTACTUATOR.

7. SEE CLOSE UP VIEW FORACTUATOR
MOUNTING TO THROTTLE LINKAGE.

3

5

3

23

44

45 52 54 43 52 16 12 52 41

24 47 20 40

32 46

52

5553

26

42

22

4

9

6

4

8

50

36
48

47

39

51

49

25

1

29

33

30

27

28

34

38

13

33

4837

7.4 ENGINE AND DRIVE PARTS (PART 1 OF 2)

PAGE - 40 090058-OP_r0 (AUGUST-2014)

6100108ID_r1_1of2

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 7: ILLUSTRATED PARTS LIST

7.4 ENGINE AND DRIVE PARTS (PART 1 OF 2)

ITEM DESCRIPTION PART

1 WASHER, NYLON FLAT 1/4 262704 3 33 NUT, HEX LOCKING 1/4-20 825504-145 2

2 CLAMP, EXHAUST 1-1/2 262906-150 2 34 NUT, HEX LOCKING #10-32 825702-083 2
3 WASHER, SNUBBING RUBBER

MOUNT

4 CLAMP, HOSE #28 265560 2 36 CAPSCREW, HEX GR5 1/4-20 x 1 829104-100 2
5 STRAP, GROUND 8” W/ 3/8

HOLES

6 FILTER, AIR 6” 90 DEG 269660 1 38 CAPSCREW, HEX GR5 1/4-20 x 1-1/2 829104-150 1

GASKET, MUFFLER REPLC

7

KUBOTA D902

8 HOSE, FLEX 1-3/4” I.D. 270698 1.5

9 BRACKET, THROTTLE ADJ 272019 1 41 CAPSCREW, S.H. M8x1.25 x 20mm 829308-020 1
10 GUARD, FAN 272074 1 42 CAPSCREW, S.H. M8x1.25 x 30mm 829308-030 5
11 ELBOW, EXHAUST 272127 1 43 CAPSCREW, S.H. M8x1.25 x 40mm 829308-040 2
12 SPACER, COMPRESSOR 272158 1 44 CAPSCREW, S.H. M8x1.25 x 45mm 829308-045 1
13 ACUTATOR, LINEAR 2”

STROKE, 30#, 12V
14 FAN, 15.50” DIA PUSHER 272165 1 46 CAPSCREW, HEX GR8 1/2-13 x 3 829408-300 2
15 SPACER, FAN 272166 1 47 SCREW, SER WASH 5/16-18 x 1 829705-100 8
16 BRACKET, MUFFLER 272168 1 48 WASHER, FLAT 1/4 838204-071 4
17 EXHAUST, ENGINE OUT 272174 1 49 WASHER, FLAT 5/16 838205-071 4
18 ELBOW, EXHAUST OUT BACK 272211 1 50 WASHER, LOCK 1/4 838504-062 2
19 BRACKET, ENGINE STARTER

SIDE
20 BRACKET, ENGINE THROTTLE

SIDE
21 SUPPORT, ENGINE FRONT 272230 1 53 WASHER, LOCK METRIC M10 838810-220 12
22 FLANGE, COUPLING D902 272265 1 54 WASHER, FLAT METRIC M8 838909-180 2
23 MOUNT, RUBBER ARMOR

PLATED 200 GREEN
24 SUPPORT, ENGINE REAR 272516 1 56 HOSE, FUEL LINE 5/16” 842315-031 2.0

25 SUPPORT, TOWER 272553 1 57 EXHAUST, KUBOTA (INCL. W/

26 CAPSCREW, HEX 10 MM 1.25 x

25 MM
27 BRACKET, THROTTLE

EXTENSION
28 SPRING, EXTENSION

THROTTLE
29 BRACKET, ACTUATOR ROD 273307 1 61 DRAIN, ENGINE OIL FI273012 1
30 CAPSCREW, S.H. 10-32 x 1/2

ZINC

31 HOSE, ENGINE DRAIN 274253 1 63 HEADER WRAP, HIGH TEMP 2” WIDE PR81122 32

32 NUT, HEX 5/16-18 825205-273 6 64 OIL, DIESEL 15W-40 SE271475 4.0

NUMBER

264829 4 35 CAPSCREW, HEX 8mm 1.25 x 40 828008-040 3

267498 1 37 CAPSCREW, HEX GR5 1/4-20 x 1-1/4 829104-125 1

269961 1 39 CAPSCREW, HEX GR5 5/16-18 x 1 829105-100 4

272160 1 45 CAPSCREW, S.H. M8x1.25 x 50mm 829308-050 2

272228 1 51 WASHER, LOCK 5/16 838505-078 8

272229 1 52 WASHER, LOCK METRIC M8 838808-200 9

272442 2 55 WASHER, FLAT METRIC M10 838910-220 12

272864 12 58 ENGINE DIESEL, 25 HP, HZ SHAFT EN270451 1

273300 1 59 U-BOLT, 3/8-16 x 3-1/2 WD x 5-1/16 FA270399 2

273302 1 60 CLAMP, HOSE, T-BOLT STYLE, 13mm SSFA38355 4

273310 2 62 TIES, THERMAL STAINLESS HA42205 4

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

QTY ITEM DESCRIPTION PART

NUMBER

40 CAPSCREW, HEX GR5 5/16-18 x 1-1/4 829105-125 6

FT

EN270396 1

ENGINE)

QTY

FT.

FT.

QT

COMMON REPLACEMENT PARTS

ITEM DESCRIPTION PART NUMBER
A ELEMENT, AIR FILTER 270764
B ELEMENT, FUEL FILTER RC77662
C ELEMENT, OIL FILTER 269136

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

090058-OP_r0 (AUGUST-2014) PAGE - 41

SECTION 7: ILLUSTRATED PARTS LIST VIPER DIESEL

3

3

7

2

35

52

14

10 15

31

21

47

23

46

40

32

26

53

55

61

11

58

32

51

40

57

59

17

18

19

NOTES:

4. CAN USE 9V BATTERY TO EXTEND/
RETRACT ACTUATOR

7. SEE CLOSE UP VIEW FOR ACTUATOR
MOUNTING TO THROTTLE LINKAGE.

12. CONCAVE SIDE OF FAN BLADE FACES
AWAY FROM ENGINE.

17. TORQUE: 221 IN-LBS.

7.4 ENGINE AND DRIVE PARTS (PART 2 OF 2)

PAGE - 42 090058-OP_r0 (AUGUST-2014)

6100108ID_r1_2of2

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 7: ILLUSTRATED PARTS LIST

7.4 ENGINE AND DRIVE PARTS (PART 2 OF 2)

ITEM DESCRIPTION PART

1 WASHER, NYLON FLAT 1/4 262704 3 33 NUT, HEX LOCKING 1/4-20 825504-145 2

2 CLAMP, EXHAUST 1-1/2 262906-150 2 34 NUT, HEX LOCKING #10-32 825702-083 2
3 WASHER, SNUBBING RUBBER

MOUNT
4 CLAMP, HOSE #28 265560 2 36 CAPSCREW, HEX GR5 1/4-20 x 1 829104-100 2
5 STRAP, GROUND 8” W/ 3/8

HOLES
6 FILTER, AIR 6” 90 DEG 269660 1 38 CAPSCREW, HEX GR5 1/4-20 x 1-1/2 829104-150 1

GASKET, MUFFLER REPLC
7

KUBOTA D902
8 HOSE, FLEX 1-3/4” I.D. 270698 1.5

9 BRACKET, THROTTLE ADJ 272019 1 41 CAPSCREW, S.H. M8x1.25 x 20mm 829308-020 1

10 GUARD, FAN 272074 1 42 CAPSCREW, S.H. M8x1.25 x 30mm 829308-030 5
11 ELBOW, EXHAUST 272127 1 43 CAPSCREW, S.H. M8x1.25 x 40mm 829308-040 2
12 SPACER, COMPRESSOR 272158 1 44 CAPSCREW, S.H. M8x1.25 x 45mm 829308-045 1
13 ACUTATOR, LINEAR 2”

STROKE, 30#, 12V

14 FAN, 15.50” DIA PUSHER 272165 1 46 CAPSCREW, HEX GR8 1/2-13 x 3 829408-300 2
15 SPACER, FAN 272166 1 47 SCREW, SER WASH 5/16-18 x 1 829705-100 8
16 BRACKET, MUFFLER 272168 1 48 WASHER, FLAT 1/4 838204-071 4
17 EXHAUST, ENGINE OUT 272174 1 49 WASHER, FLAT 5/16 838205-071 4
18 ELBOW, EXHAUST OUT BACK 272211 1 50 WASHER, LOCK 1/4 838504-062 2
19 BRACKET, ENGINE STARTER

SIDE

20 BRACKET, ENGINE THROTTLE

SIDE

21 SUPPORT, ENGINE FRONT 272230 1 53 WASHER, LOCK METRIC M10 838810-220 12
22 FLANGE, COUPLING D902 272265 1 54 WASHER, FLAT METRIC M8 838909-180 2
23 MOUNT, RUBBER ARMOR

PLATED 200 GREEN

24 SUPPORT, ENGINE REAR 272516 1 56 HOSE, FUEL LINE 5/16” 842315-031 2.0

25 SUPPORT, TOWER 272553 1 57 EXHAUST, KUBOTA (INCL. W/

26 CAPSCREW, HEX 10 MM 1.25 x

25 MM

27 BRACKET, THROTTLE

EXTENSION

28 SPRING, EXTENSION

THROTTLE

29 BRACKET, ACTUATOR ROD 273307 1 61 DRAIN, ENGINE OIL FI273012 1
30 CAPSCREW, S.H. 10-32 x 1/2

ZINC

31 HOSE, ENGINE DRAIN 274253 1 63 HEADER WRAP, HIGH TEMP 2” WIDE PR81122 32

32 NUT, HEX 5/16-18 825205-273 6 64 OIL, DIESEL 15W-40 SE271475 4.0

NUMBER

264829 4 35 CAPSCREW, HEX 8mm 1.25 x 40 828008-040 3

267498 1 37 CAPSCREW, HEX GR5 1/4-20 x 1-1/4 829104-125 1

269961 1 39 CAPSCREW, HEX GR5 5/16-18 x 1 829105-100 4

272160 1 45 CAPSCREW, S.H. M8x1.25 x 50mm 829308-050 2

272228 1 51 WASHER, LOCK 5/16 838505-078 8

272229 1 52 WASHER, LOCK METRIC M8 838808-200 9

272442 2 55 WASHER, FLAT METRIC M10 838910-220 12

272864 12 58 ENGINE DIESEL, 25 HP, HZ SHAFT EN270451 1

273300 1 59 U-BOLT, 3/8-16 x 3-1/2 WD x 5-1/16 FA270399 2

273302 1 60 CLAMP, HOSE, T-BOLT STYLE, 13mm SSFA38355 4

273310 2 62 TIES, THERMAL STAINLESS HA42205 4

QTY ITEM DESCRIPTION PART

40 CAPSCREW, HEX GR5 5/16-18 x 1-1/4 829105-125 6

FT

ENGINE)

NUMBER

EN270396 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

QTY

FT.

FT.

QT

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

COMMON REPLACEMENT PARTS

ITEM DESCRIPTION PART NUMBER

A ELEMENT, AIR FILTER 270764
B ELEMENT, FUEL FILTER RC77662
C ELEMENT, OIL FILTER 269136

090058-OP_r0 (AUGUST-2014) PAGE - 43

SECTION 7: ILLUSTRATED PARTS LIST VIPER DIESEL

2

5

5

4

3

8

1

9

7

22

21

13

12

18

19

18
16

20

17

18

22

18

18

15

NOTES:

3. WIRE GUARD IS INSTALLED ON ENGINE
ASSEMBLYAND MOUNTS TO COOLER

SHROUD WHEN BOTH COMPONENTS

ARE SET IN PLACE.

4. HOSE SUPPLIED WITH COOLANT

RECOVERY TANK.

7.5 COOLING SYSTEM (PART 1 OF 2)

PAGE - 44 090058-OP_r0 (AUGUST-2014)

6020127ID_r0_1of2

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 7: ILLUSTRATED PARTS LIST

7.5 COOLING SYSTEM (PART 1 OF 2)

ITEM DESCRIPTION PART NUMBER QTY

1 CONNECTOR, #12 MSAE x #10 MJIC 260387-110 1

2 ELBOW, 90 DEG #10 MJIC x #12 MSAE 260403-131 1
3 NUT, HEX #6-32 KEPS 261595-632 2
4 CLAMP, HOSE SUPPORT .50 261837 1
5 CLAMP, EXHAUST 1-1/2 262906-150 2
6 SEAL, RUBBER “D” TRIM-LOK 1” x 1” 264138 1.375 ft
7 COOLER, ENGINE/COMPRESSOR 270843 1
8 SHROUD, COOLER 272169 1

9 BRACKET, COOLER SUPPORT BACK SIDE 272171 1
10 BRACKET, COOLANT TANK MTG BOTTOM 272172 1
11 BRACKET, COOLANT TANK MTG CLIP 272173 1
12 BRACKET, COOLER / EXHAUST SUPPORT 272797 1
13 ** HOSE, RADIATOR TOP 272816ID 1
14 ** HOSE, RADIATOR BOTTOM 272817ID 1
15 BRACKET BELT GUARD 272996 1
16 BRACKET, HOOD SWITCH 273289 1
17 NUT, HEX FLANGE 5/16-18 825305-283 4
18 SCREW, SER WASH 5/16-18 x 0.75 829704-075 17
19 SCREW, MACHINE #6-32 x 1 831600-100 2
20 SWITCH, HOOD SAFETY NO/NC 15A-125V. AC CO81774 1
21 CLAMP, HOSE, #20, 1.75DIA. FA47720 4
22 GASKET, SEAL AND TRIM PR35734 5.063 ft

** Made from EN271127.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

090058-OP_r0 (AUGUST-2014) PAGE - 45

SECTION 7: ILLUSTRATED PARTS LIST VIPER DIESEL

21

10

18

18

18

12

11

1814

21

NOTES:

3. WIRE GUARD IS INSTALLED ON ENGINE
ASSEMBLYAND MOUNTS TO COOLER

SHROUD WHEN BOTH COMPONENTS

ARE SET IN PLACE.

4. HOSE SUPPLIED WITH COOLANT

RECOVERY TANK.

7.5 COOLING SYSTEM (PART 2 OF 2)

PAGE - 46 090058-OP_r0 (AUGUST-2014)

6020127ID_r0_2of2

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 7: ILLUSTRATED PARTS LIST

7.5 COOLING SYSTEM (PART 2 OF 2)

ITEM DESCRIPTION PART NUMBER QTY

1 CONNECTOR, #12 MSAE x #10 MJIC 260387-110 1

2 ELBOW, 90 DEG #10 MJIC x #12 MSAE 260403-131 1
3 NUT, HEX #6-32 KEPS 261595-632 2
4 CLAMP, HOSE SUPPORT .50 261837 1
5 CLAMP, EXHAUST 1-1/2 262906-150 2
6 SEAL, RUBBER “D” TRIM-LOK 1” x 1” 264138 1.375 ft
7 COOLER, ENGINE/COMPRESSOR 270843 1
8 SHROUD, COOLER 272169 1

9 BRACKET, COOLER SUPPORT BACK SIDE 272171 1
10 BRACKET, COOLANT TANK MTG BOTTOM 272172 1
11 BRACKET, COOLANT TANK MTG CLIP 272173 1
12 BRACKET, COOLER / EXHAUST SUPPORT 272797 1
13 ** HOSE, RADIATOR TOP 272816ID 1
14 ** HOSE, RADIATOR BOTTOM 272817ID 1
15 BRACKET BELT GUARD 272996 1
16 BRACKET, HOOD SWITCH 273289 1
17 NUT, HEX FLANGE 5/16-18 825305-283 4
18 SCREW, SER WASH 5/16-18 x 0.75 829704-075 17
19 SCREW, MACHINE #6-32 x 1 831600-100 2
20 SWITCH, HOOD SAFETY NO/NC 15A-125V. AC CO81774 1
21 CLAMP, HOSE, #20, 1.75DIA. FA47720 4
22 GASKET, SEAL AND TRIM PR35734 5.063 ft

** Made from EN271127.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

090058-OP_r0 (AUGUST-2014) PAGE - 47

SECTION 7: ILLUSTRATED PARTS LIST VIPER DIESEL

4

3

3

4

4

3

34

3

4

7

9

2

8

7

30

32
13

19

27

31

26

23

15

32

14

10

22

32

32

22

23

18

32

28

29

11

5

212524

3

12

28

29

32

16

20

32

1

17

7.6 CANOPY AND FRAME PARTS

PAGE - 48 090058-OP_r0 (AUGUST-2014)

6030086ID_r4

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 7: ILLUSTRATED PARTS LIST

7.6 CANOPY AND FRAME PARTS

ITEM DESCRIPTION PART NUMBER QTY

1 BULKHEAD, 90 DEG. 3/4 250006-058 1

2 TRIM-LOK, 1/8 GROOVE 261228 1 FT
3 WASHER, NYLON 5/16-18 262943 22
4 SCREW, TRUSS HD 5/16-18 x 3/4 SS 262945 18
5 CLAMP, HOSE SUPPORT 1.50 ID 263812 1
6 SEAL, RUBBER “D” TRIM-LOK 1” x 1” 264138 3.375 FT
7 LATCH, SENTRY PANEL 267124 4
8 HOOD, CANOPY 272250 1

9 PANEL, OPEN SIDE 272253 1
10 DOOR, FRONT ACCESS 272257 1
11 INSULATION, ACOUSTICAL FOAM, HOOD 272713-001 1
12 INSULATION, ACOUSTICAL FOAM, BAFFLE 272713-002 1
13 INSULATION, HEAT SHIELD 272713-006 1
14 PANEL, REMOVABLE BATTERY ACCESS DIESEL VIPER VANAIR 273468 1
15 PLATFORM, VIPER DIESEL VANAIR 273469 1
16 BAFFLE, SHROUD 273709 1
17 HOSE, AIR OUT LOWER 273968-008 1
18 PANEL, REAR SIDE 274299 1
19 PLATE, OIL FILTER ACCESS 274302 1
20 NUT, HEX LOCKING 1/4-20 825504-145 4
21 CAPSCREW, HEX GR5 1/4-20 x 1 829104-100 1
22 SCREW, SER WASHER 5/15-18 x 0.75 829705-075 6
23 WASHER, LOCK INTERNAL 1” 837414-100 2
24 WASHER, FLAT 1/4 838204-071 1
25 WASHER, LOCK 1/4 838504-062 1
26 BULKHEAD, 3/4 FN PT x #12 MJIC 862012-075 1
27 NUT, LOCK M6 x 1.0 PITCH FA55272 8
28 STUD, BALL, .39 DIA. x .55LG. FA58724 4
29 GAS SPRING, 6 STROKE, 20# HA72205 2
30 HINGE, 2” x 2”, BLACK HA88014 2
31 PLUG, PLASTIC, 1-3/8 DIA., RIBBED BLACK PR273179 1
32 GASKET, SEAL AND TRIM PR35734 24.022 FT

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

090058-OP_r0 (AUGUST-2014) PAGE - 49

SECTION 7: ILLUSTRATED PARTS LIST VIPER DIESEL

6

9

6

9

5

8

1

2

7

7

4

3

OPTIONAL
LOCATION

7.7 COMPRESSOR THERMAL CONTROL

6120191ID_r1

7.8 INSTRUMENT PANEL

6040049ID_r1

PAGE - 50 090058-OP_r0 (AUGUST-2014)

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 7: ILLUSTRATED PARTS LIST

7.7 COMPRESSOR THERMAL CONTROL

ITEM DESCRIPTION PART NUMBER QTY

1 CONNECTOR, #12 MSAE x #10 MSAE 260387-110 1

2 ELBOW, 90 DEG #10 MJIC x #12 MSAE 260403-131 1
3 TEE, JIC/JIC/SAE 5/8 x 3/4 263749-009 1

4

5 BRACKET, SUPPORT THERMAL VALVE 273548 1
6 NUT, HEX LOCKING 1/4-20 825504-145 2
7 CAPSCREW, HEX GR5 1/4-20 x 3 829104-300 2
8 SCREW, SER WASH 5/16-18 x 0.75 829705-075 2
9 WASHER, FLAT 1/4 823204-071 2

VALVE, THERMAL 180 DEGREE ALUM BODY 3/4 SAE
FPE

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

273480 1

7.8 INSTRUMENT PANEL

ITEM DESCRIPTION PART NUMBER QTY

1 WASHER, NYLON 5/16-18 262943 8

2 SCREW, TRUSS HD 5/16-18 x 3/4 SS 262945 8

3 MODULE, CONTROL AUTO SPD CTRL 272527 1

4 PLATE, COVER INST. OPENING 272535 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

090058-OP_r0 (AUGUST-2014) PAGE - 51

SECTION 7: ILLUSTRATED PARTS LIST VIPER DIESEL

A

7.9 ELECTRICAL SYSTEM

PAGE - 52 090058-OP_r0 (AUGUST-2014)

6060080ID_r9

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 7: ILLUSTRATED PARTS LIST

7.9 ELECTRICAL SYSTEM

ITEM DESCRIPTION PART NUMBER QTY

1 RELAY, NO/NC WEATHERPROOF w/RESISTOR 260246 1
2 FUSE, ATO 5 AMP TAN 263532 1
3 FUSE, ATO 25 AMP CLEAR 264316 1
4 FUSE, BLOCK 4-WAY ATC 264695 1
5 INSULATOR, BATTERY TERM RED 466 267208 1
6 FUSE, ATC 20 AMP YELLOW 267880 2
7 WEDGELOCK, W4S 268907 1
8 PLUG, SEALING 269055 4

9 CONNECTOR, DTP06-4S 269415 1
10 BRACKET, BATTERY HOLD DOWN 272213 1
11 WD, DIESEL VIPER 272618 1
12 HARNESS, DIESEL VIPER 272621 1
13 CABLE, BATT E RY NEGAT IVE 272735 1
14 CABLE, BATT E RY POSITIVE 272736 1
15 * BAT TERY, 12V LEAD-ACID AUTOMOTIVE 600 CCA 273937 1
16 TERMINAL, BATTERY POST 273940 2
17 SCREW, SER WASH 5/16-18 x 1.5 829705-150 2
18 SCREW, MACHINE #10-32 x 3/4 831702-075 3
19 WASHER, FLAT #10 838202-045 3
20 WASHER, LOCK #10 838502-047 3
21 GASKET, SEAL AND TRIM PR35734 2.740 ft

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

* NOTE

See page 34 (Key No. 18) for battery

recommendations.

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

090058-OP_r0 (AUGUST-2014) PAGE - 53

SECTION 7: ILLUSTRATED PARTS LIST VIPER DIESEL

3

4

5

7

6

9

1

2

8

6

17

12

17

14

13

22

18
19

10

21

11

16

20

18

15

18

22

18

7.10 FUEL TANK ASSEMBLY

6140011ID_r6

PAGE - 54 090058-OP_r0 (AUGUST-2014)

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 7: ILLUSTRATED PARTS LIST

7.10 FUEL TANK ASSEMBLY

ITEM DESCRIPTION PART NUMBER QTY

1 WASHER, NYLON FLAT 1/4 262704 1
2 SCREW, TRUSS HD 1/4-20UNC x 3/4 LG S.S. 262953 4
3 TERMINAL, DEUTSCH 0462-201-16141 263582 2
4 PLUG, DEUTSCH DT06-2S 268902 1
5 WEDGELOCK, DEUTSCH W2S 268903 1
6 CLAMP, HOSE, #24, 1”-2” DIA. 270493 2
7 TANK, FUEL 9 GALLON 272236 1
8 NECK, FUEL FILL DIESEL TETHERED, NO VENT 272855 1

9 SUPPORT, FUEL NECK 272865 1
10 NUT, NEX FLANGE 5/16-18 825305-283 4
11 SCREW, SER WASH 1/4-20 x 0.75 829704-075 3
12 HOSE, FUEL LINE 5/16” x 18” LG. 842315-031 1.5 FT
13 TUBE, FUEL PICK UP A1270398 1
14 SENDER UNIT, FUEL LEVEL, 5.50 LG CO22750 1
15 VALVE, CHECK INLINE 3/16 TUBING CO273306 1
16 SCREW, PHILLIPS PAN HEAD #10-32 x 1/2” LG. SS FA33542 1
17 CLAMP, HOSE, T-BOLT STYLE, 13mm SS FA38355 2
18 CLAMP, HOSE, T-BOLT STYLE, 10M FA91153 4
19 PUSH-ON, MALE ADAPTER, 1/4 MALE x 3/16 PUSH FI92363 1
20 CAP, DIESEL VENTED TETHERED HA271677 1
21 HOSE, 1-1/2 DIA. FUEL x 12-1/2” LONG TU269928 1.04 FT
22 HOSE, 3/16 DIA. HT, FUEL x 30 LG. TU28641 2.5 FT

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

090058-OP_r0 (AUGUST-2014) PAGE - 55

SECTION 7: ILLUSTRATED PARTS LIST VIPER DIESEL

3
1

9

8

7

4

7

7

5

6

2

8

7

17

12

13

14

22

16

12

18

15

10

11

19

19

20

21

15

7.11A DECALS (LOCATION)

WARNING

DO NOT REMOVE OR COVER ANY

PAGE - 56 090058-OP_r0 (AUGUST-2014)

SAFETY DECAL. Replace any safety

decal that becomes damaged or illegible.

6110029ID_r1

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 7: ILLUSTRATED PARTS LIST

ENGINE OIL

DRAIN

1

DIESEL

ONLY

2

COMPRESSOR

FLUID DRAIN

3

800-526-8817

PSIG

260940

MODEL NUMBER

SERIAL NUMBER

MAXIMUM PRESSURE

COMPRESSOR INPUT RPM

www.vanai r.com

4

5

6

7

8

9

10

11

18

21

19 & 20

12

13

14

15

16

17

7.11B DECALS (IDENTIFICATION)

WARNING

DO NOT REMOVE OR COVER ANY

SAFETY DECAL. Replace any safety

decal that becomes damaged or illegible.

6110029ID_r1

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

090058-OP_r0 (AUGUST-2014) PAGE - 57

SECTION 7: ILLUSTRATED PARTS LIST VIPER DIESEL

7.11C DECALS (PART NUMBERS)

ITEM DESCRIPTION PART NUMBER QTY

1
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16
17
18
19
20
21
22

DECAL, ENGINE OIL DRAIN 1
DECAL, DIESEL FUEL ONLY 1
DECAL, COMPRESSOR OIL DRAIN 1
PLATE, SERIAL VANAIR 260940 1
DECAL, CONNECT AIR HOSE 261885 1
DECAL, DO NOT USE AIR 261886 1
DECAL, HOT PARTS 264372 3
DECAL, ROTATING PARTS 264374 2
DECAL, SULFURIC ACID 264375 1
DECAL, CARBON MONOXIDE 264376 2
DECAL, EXPLOSIVE FUEL 264377 1
DECAL, WARNING PLUGS 264378 2
DECAL, WARNING FAN GUARD 264383 1
DECAL, WARNING ELECTRIC TAMPER 271510 1
DECAL, CAUTION AUTO-START 272041 3
DECAL, READ MANUAL 272424 2
DECAL, ROTARY SCREW OIL 272501 1
DECAL, WIRING DIAGRAM 272672 1
DECAL, VIPER DIESEL LARGE 272850-001 2
DECAL, VIPER DIESEL SMALL 272850-002 1
DECAL, QUICK START GUIDE 273312 2
DECAL, MAINTENANCE VANAIR DIESEL VIPER 274130 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

PAGE - 58 090058-OP_r0 (AUGUST-2014)

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 7: ILLUSTRATED PARTS LIST

7.12 WIRING DIAGRAM

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

272618_r8

090058-OP_r0 (AUGUST-2014) PAGE - 59

SECTION 7: ILLUSTRATED PARTS LIST VIPER DIESEL

7.13 SCHEMATIC FLOW DIAGRAM

PAGE - 60 090058-OP_r0 (AUGUST-2014)

273387_r2

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

VIPER DIESEL SECTION 7: ILLUSTRATED PARTS LIST

7.14 HOSE INSTALLATION GUIDE

1. Hose is weakened when installed in twisted
position. Pressure in twisted hose tends to
loosen fitting connections. Design so that
machine motion produces bending rather than
twisting.

2. Ample bend radius should be provided to
avoid collapsing of line and restriction of flow.

3. Exceeding minimum bend radius will greatly
reduce hose assembly life.

5. When hose assembly is installed in a flexing
application, remember that metal hose fittings
are not part of the flexible portion. Allow
ample free length for flexing.

4. Use elbows or other adapters as necessary to
eliminate excess hose length and to insure
neater installation for easier maintenance.

6. When properly routing, u se clamps to secure
the hose in its proper position.

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

090058-OP_r0 (AUGUST-2014) PAGE - 61

SECTION 8: ILLUSTRATED PARTS LIST VIPER DIESEL

BLANK PAGE

PAGE - 62 090058-OP_r0 (AUGUST-2014)

VANAIR MANUFACTURING, INC.

[phone] • www.vanair.com

Vanair Manufacturing, Inc.

10896 West 300 North

Michigan City, IN 46360

Phone: [phone]

[phone]

Service Fax: [phone]

Parts Fax: [phone]

Sales Fax: [phone]

www.vanair.com

Printed in the U.S.A.
Specifications Subject to Change

Without Prior Notice

050847 050850
050848 051294
050849

AUGUST-2014