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TJM Pro Series - User Manual

TJM Pro Series
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Installation and User Manual
Product:
TJM Pro Series Twin Air Compressor
Vehicle:
Generic
Part No.
013COMPVPROT
For product warranty please refer to our website www.tjm.com.au
File: F-31070
23/02/2021
• Before commencing fitment read all instructions and ensure all listed components are supplied.
• It is a condition of the warranty that the product has been correctly installed by suitably qualified
personnel and is used in accordance with accompanying instructions where provided. For product
warranty please refer to our website www.tjm.com.au
• Estimated Fitting Time: 2hrs (Horizontal Configuration or Vertical Configuration in open area), 5hrs
(Vertical Configuration in confined area)
• Treat any holes drilled into the vehicle body with rust preventative paint.
• Holes drilled for cable routing should have a suitable sized rubber wiring grommet installed. This will
prevent damage to the cables.
• Always place the product on a soft workspace to prevent damage prior to installation.
• Do not mount compressor below the water-wading line of the vehicle. Refer to the vehicle manufacturer
for this specification.
• Compressor surfaces, especially the head section becomes very hot during operation. Mount away from
flammable materials and avoid locations where it may be accidently touched while operating.
• Rated for 12 V DC systems only.

Table of Contents

Questions and Answers

Summary

Compressor Specifications

Electrical Specifications

Details voltage, current draw, fuse rating, and IP rating for the compressor's electrical system.

Performance

Outlines key performance metrics like air flow, duty cycle, and pressure switch operation.

Compressor Assembly

Air Filter Installation

Vehicle Mounting

Mounting Location

Advises on selecting a suitable location for the compressor, considering clearances and environmental factors.

Wiring the Compressor System

Post-Installation Examination

Leak Testing

Outlines the procedure to check for air leaks in the installed system.

Operating Instructions

Pro Locker activation

Instructions on how to activate and use the Pro Locker feature.

Tyre inflation

Guides on using the compressor for inflating vehicle tires.

Safety information

Maintenance

Routine Maintenance

Troubleshooting Guide

Summary

Compressor Specifications

Electrical Specifications

Details voltage, current draw, fuse rating, and IP rating for the compressor's electrical system.

Performance

Outlines key performance metrics like air flow, duty cycle, and pressure switch operation.

Compressor Assembly

Air Filter Installation

Vehicle Mounting

Mounting Location

Advises on selecting a suitable location for the compressor, considering clearances and environmental factors.

Wiring the Compressor System

Post-Installation Examination

Leak Testing

Outlines the procedure to check for air leaks in the installed system.

Operating Instructions

Pro Locker activation

Instructions on how to activate and use the Pro Locker feature.

Tyre inflation

Guides on using the compressor for inflating vehicle tires.

Safety information

Maintenance

Routine Maintenance

Troubleshooting Guide

Overview

  1. Function Description
  2. Important Technical Specifications
  3. Usage Features
  4. Maintenance Features

The TJM Pro Series Twin Air Compressor (Part No. 013COMPVPROT) is a robust 12V DC air compressor designed for vehicle-mounted applications, primarily for off-road enthusiasts and those requiring on-demand compressed air. Its main function is to provide compressed air for various tasks, including activating TJM Pro Lockers and inflating vehicle tires.

Function Description:

The compressor operates by drawing in ambient air, filtering it, compressing it using two internal pumps, and then delivering it through a series of outlet ports. It is equipped with a pressure switch that automatically turns the compressor off at 120 PSI and on at 90 PSI to maintain optimal operating pressure. A safety relief valve is factory-set to open at 155 PSI, ensuring safe operation by preventing over-pressurization. The unit is designed for intermittent use, with a 100% duty cycle at 80 PSI for 60 minutes at 23°C, indicating its capability for sustained operation under typical conditions. The compressor's twin-motor design allows for a high airflow rate, making it efficient for tasks like tire inflation.

Important Technical Specifications:

  • Electrical Specifications:
    • Voltage: 12 V DC
    • Current Draw: 46 A (0 Bar / 0 PSI), 55 A (30 PSI)
    • Fuse Type and Rating: 2x ANS 40 A
    • IP Rating: 54 (Dust protected and protected against water splashes from all directions)
    • Motor Thermal Cut-off: 105°C (Protects the motor from overheating)
  • Performance:
    • Airflow (0 Bar / 0 PSI): 170 LPM (6.0 CFM)
    • Airflow (2 Bar / 29 PSI): 120 LPM (4.2 CFM)
    • Duty Cycle (80 PSI, 60 minutes @ 23°C): 100%
    • Pressure Switch Operation: Off @ 120 PSI / On @ 90 PSI
    • Safety Relief Valve Opening Pressure: 1070 kPa (155 PSI)
  • Hardware and Fittings:
    • Pro Locker Solenoid / Pressure Switch Ports: 4 x ⅛" BSPT ports (2 each side of air tank)
    • Tyre Inflation / Accessory Ports: 5 x ¼" BSPT ports (2 each side of air tank & 1 on Top Cover)
    • Safety Relief Valve: Factory-set 155 PSI, ½” NPT male thread
    • Compressor to Bracket Bolts (Included): 12 x M5 x 22 Socket Head Cap Screw (Base Bracket), 6 x M5 x 18 Socket Head Cap Screw (Top Cover)
    • Base Bracket to Mounting Surface Bolts (Included): 6 x M8 x 1.25 x 30 Socket Button Head Cap Screws, 6x M8 x 1.25 Hex Nyloc Nuts, 12x M8 x 18 x 20 Flat Washers
  • Recommended Fastener Torque Settings:
    • M5: 5 Nm +/- 10%
    • M6: 9 Nm +/- 10%
    • ⅛" BSPT: 5-6 Nm
    • ¼" BSPT: 6-8 Nm

Usage Features:

The TJM Pro Series Twin Air Compressor is designed for ease of integration into a vehicle.

  • Mounting Flexibility: It can be mounted horizontally (as supplied) or vertically using the provided Vertical Wall Braces (F-30798L & F-30798R). Drill templates (F-31390 and F-31397) are supplied to aid in selecting a suitable mounting location and ensuring correct clearances. Spacers are included to adjust installation heights, with a recommendation not to exceed a 3-spacer pack (15mm) for elevation.
  • Accessory Integration: The compressor features multiple BSPT ports (⅛" and ¼") for connecting various accessories, such as TJM Pro Locker solenoids, TJM Airline Kits, and other inflation accessories. It is recommended to install these fittings before mounting the compressor, especially in confined spaces. Sealant paste (e.g., Loctite 567) or sealant tape should be used on threaded fittings to prevent leaks.
  • Air Filter System: Each compressor includes a two-stage air filter that must be installed prior to operation. The filter housing screws into the inlet port and should be hand-tightened only. The filter elements (foam and felt) are replaceable, and regular checking is advised to ensure optimal performance and prevent damage from dirt or moisture.
  • Wiring System: The compressor comes with a Solenoid/Pressure Switch harness (F-30638) and a Switching Harness (F-14002) that plug directly into the unit. A separate power supply harness, which is not included, needs to be fabricated by suitably qualified personnel according to the provided wiring diagram (Figure 1 and 2). This harness requires 18 AWG, 8 B&S, and 6 B&S or larger automotive electrical cables, suitable ring terminals, sheathing, heat shrink, and grommets. The compressor activation switch and Pro Locker actuator switches are designed for dash mounting, requiring 21mm x 41mm cut-outs. The switches illuminate green when dash lights are on and red when the compressor is active, providing clear visual feedback.
  • Operation:
    • Pro Locker Activation: Simply switch on the compressor from the actuator switch. The compressor will pressurize to 120 PSI and then automatically turn off. Pro Locker actuation switches can then be used to engage/disengage lockers. The compressor will automatically restart if pressure drops below 90 PSI.
    • Tyre Inflation: Connect the inflation hose to a ¼" BSPT port with a quick-connect fitting. Switch on the compressor. Once the system is pressurized, connect the tire chuck to the tire valve. The compressor will automatically restart to supply air as needed. Always measure tire pressure with no airflow for accurate readings.
  • Safety Features: The compressor is equipped with a thermal cut-off switch to prevent overheating. The safety relief valve can be manually actuated by pulling on its ring to discharge air pressure, a recommended practice after use. Surfaces, especially the head section, become very hot during operation, so mounting away from flammable materials and out of reach is crucial. Gloves should be used when handling hot components. Compressed air should never be directed at people or pets.

Maintenance Features:

The TJM Pro Series Twin Air Compressor is designed for straightforward maintenance to ensure longevity and reliable performance.

  • Routine Maintenance:
    • Air Filter Inspection and Replacement: Periodically inspect and replace the two-stage air filter elements. Blocked or damaged filters significantly reduce compressor performance and can shorten its lifespan. The compressor should never be operated without a filter.
    • Leak Checks: Regularly check all fittings and airlines for leaks. A leak test procedure is provided, involving pressurizing the system, spraying soapy water on fittings, and observing for bubbles. Leaks should be addressed by re-tightening or reapplying sealant and reassembling.
    • Mount Bolt Inspection: Periodically inspect all mount bolts to ensure they remain tight, preventing vibration and potential damage.
    • Safety Relief Valve Check: Periodically check the safety relief valve to ensure it releases air when the manual override ring is pulled.
  • Troubleshooting Guide: A comprehensive troubleshooting guide is provided to assist in diagnosing common issues such as the compressor not running, frequent switching on/off, not switching off at 120 PSI, low airflow, or unusual noise/vibration. This guide covers possible causes like active thermal cut-off, wiring faults, blown fuses, relay issues, faulty pressure switches, air leakage, blocked air filters, worn isolators, and loose mounts, offering corresponding resolutions.
  • Serviceable Components: While major components are designed to be maintenance-free, several serviceable parts are available for replacement, including:
    • 013COMPVFILTER01 - Filter housing and element combined kit
    • 013COMPVFILTER02 - Filter housing kit (housing only)
    • 013COMPVFILTER03 - Filter element kit
    • 013COMPVACTSWITCH - Replacement activation switch kit
    • 013COMPVMOUNTKIT – Replacement rubber isolator and bolt kit
    • 013COMPVSRV155-18N – Safety relief valve 155 PSI, male ½" NPT
    • 013COMPVPS120-90 - Pressure switch OFF 120 PSI / ON 90 PSI It is recommended that all servicing of these components be performed by suitably qualified personnel. Accessing these components requires disconnecting the 5-Pin and 2-Pin compressor plugs and removing the top cover using a 4mm hex key.

TJM Pro Series Specifications

General IconGeneral
BrandTJM
ModelPro Series
CategoryAir Compressor
LanguageEnglish