VIAIR Ultra Duty OBA User Manual

ULTRA DUTY

ONBOARD AIR SYSTEM

PART NO. 20001

IMPORTANT:

It is essential that you and any other operator of this

product read and understand the contents of this manual

before installing and using this product.

SAVE THIS MANUAL FOR FUTURE REFERENCE

USER MANUAL

*Only Compressor

is CE Certied

ULTRA DUTY ONBOARD AIR SYSTEM

Thank you for purchasing the world’s rst 200 PSI onboard air system. Contained in one package, you’ll
nd everything you’ll need to install a high performance, 200 PSI onboard air source for your vehicle.

Please follow the instructions on the following pages to install your new system.

OBA Components:

1 - 2.5 Gallon, 200 PSI-rated 6 port VIAIR Air Tank
1 - 480C model VIAIR compressor
1 - 36-ft. Length of 1/4” Air Line (for accessory and gauge installation)
1 - 30-foot Coil Accessory Hose
1 - Ination Gun with 200 PSI gauge

(Please check to make sure that you have four labeled packages in your Onboard Air System kit.
Each package contains the parts needed for specic areas of onboard air installation, and may contain
smaller bags within each package labeled for specic use.)

PARTS PACKAGES

Package #1 – Air Tank Installation:

A

BLCMD

F

G H I J

E

A. Mounting Bolts (4pcs)
B. Flat Washers (8pcs)
C. Locking Washers (4pcs)
D. Nuts (4pcs)
E. Rubber Tank Mount Bushings (6pcs)
F. 1/4” NPT Drain Cock (1pc)

G. 1/4” NPT 250 PSI Safety Valve (1pc)

H. 1/4” NPT Compression Fittings (3pcs)
I. 1/4” NPT F Quick Connect Coupler (1pc)
J. 1/4” NPT M Quick Connect Stud (1pc)

Package #2 – Compressor Installation:

K

N O P Q

R S T U

V

W

X

Y

Z

K. Mounting Bolts (4pcs)
L. Flat Washers (8pcs)
M. Locking Washers (4pcs)
N. Nuts (4pcs)
O. Remote Mount Air Filter Assembly (1pc)
P. Remote Mount Air Filter Fittings for
Compressor and Air Filters (2pcs)
Q. 2-pack of Replacement Air Filters (1pc)
R. Leader Hose Bracket Clip (1pc)
S. Air Line for Remote Mounting Air Filter (1pc)
T. 4-inch Strip of continuous Grommet Material (1pc)
U. Reducer – compressor-to-tank connection.
(3/8” NPT F to 1/4” NPT M) (1pc)
V. Fuse Holder & 20 ft. 12 Gauge Wire (1pc)
W. 30-amp Tube Style Fuse (1pc)
X. 12-gauge Ring Terminal (1pc)
Y. 12-gauge Butt Connectors (2pcs)
Z. Self-tapping Screw (1pc)

USER MANUAL

Package #3 – Pressure Switch & Reducer:

AA BB

AA. Pressure Switch with Relay
(165 PSI on, 200 PSI off) (1pc)
BB. Reducer (1/8” NPT F to 1/4” NPT M) (1pc)

Package #4 – Gauge Panel Installation:

CC DD EE FF GG HH

0

2

5

2
5

1

1

0

1

0

3

2

3

5

5

0

0

II

JJ

KK

CC. Dash Panel Gauge with ON/OFF Switch (1pc)
DD. Mounting Bolts (2pcs)
EE. Flat Washers (4pcs)
FF. Locking Washers (2pcs)
GG. Nuts (2pcs)
HH. Push-on Female Terminals (2pcs)
II. 12-gauge Ring Terminal (1pc)
JJ. 12-gauge Butt Connectors (2pcs)
KK. Self-tapping Screw (1pc)

ULTRA DUTY ONBOARD AIR SYSTEM

P/N 20001

OBA PLUMBING DIAGRAM

Typical System Configuration, May Vary Depending on Installation

2.5

Gallon

Tank

Drain
Cock

Reducer

Pressure Switch

with Relay

Safety

Valve

Compression

Fitting

Compression

Fitting

Quick Connect

Couplers

Coil Hose

Dash Panel

Gauge

Leader Hose

From Compressor

2.5 GALLON 200 PSI AIR TANK & PLUMBING (USE CONTENTS OF PARTS PACKAGE #1)

Your 2.5 Gallon air tank comes with six 1/4” NPT port openings to allow installation in many congurations on
your vehicle. To insure safe and trouble-free use of your air tank, we strongly recommend that you install the
supplied drain cock and a safety pressure relief valve. (See Figure 1)

Plumbing Diagram:

(Figure 1)

Tank Fittings:

Install the supplied compression ttings and/or quick connect tting for the air tank in areas where they are
most appropriate for your installation using thread sealant or Teon tape. Make sure that the safety valve is

installed in the top most position on the tank, and that the drain cock is installed in the lowest position on the
tank if the tank is to be installed in any other position than upright on the tank’s mounting legs. Be sure that all

ttings are accessible later in the installation process since you will have to plumb air lines to each tting as

needed to utilize the air tank.

Mounting the Tank:

We have included 6 pieces of rubber bushings in your tank mounting hardware. You have the option of using
two layers of rubber bushings on one of your tank lags to slightly tilt tank toward the drain cock to improve
drainage. Use the provided longer bolts, and corresponding washers, and nuts to mount the tank to a suitable
chassis or body point on your vehicle.

IMPORTANT:

- Tank is rated for 200 PSI maximum working pressure.

- Tank is NOT to be used as a breathing device.

- Bleed pressure from tank before servicing or adding attachments.

- Use only attachments or tools rated for 200 PSI working pressure or less.

CAUTION! DO NOT PRESSURIZE YOUR TANK UNTIL YOU HAVE INSTALLED
ALL NECESSARY PORT FITTINGS AND ACCESSORIES.

- Apply sealant to threads of ttings prior to assembly and tighten each part with a wrench.

- Do not over tighten if your port ttings are made from brass, since brass threads can be stripped.

- Always release air from tank before servicing.

USER MANUAL

ULTRA DUTY ONBOARD AIR SYSTEM

2.5 GALLON 200 PSI AIR TANK & PLUMBING (CONT’D)

WARNING: FAILURE TO DRAIN TANK AND REMOVE CONDENSATION
WILL CAUSE TANK TO RUST PREMATURELY.

- To remove accumulated condensation inside the tank, bleed pressure from tank until pressure is

approximately 5-20 PSI using drain cock

- Drain tank by opening the drain cock drain valve and close after draining tank.

- If drain cock valve is plugged, release all air pressure from tank, remove drain valve and clean, then reinstall.

IMPORTANT: Please observe air tank’s Date of Manufacture (stamped on tank leg).
Replace air tank 2 to 5 years from date air tank was rst used, or use the date of manufacture as reference.

Adhering to air tank draining guidelines will prolong the life of your air tank.

PLEASE NOTE: RUSTED TANKS CAN FAIL CAUSING EXPLOSIONS OR FATAL INJURIES.
Discard tank immediately if tank is rusted.

SAFETY VALVE: When using a safety pressure relief valve, point the safety pressure relief valve away
from your body when releasing air. Use the pull ring on the safety relief valve to vent pressure from the
tank before servicing.

USER MANUAL