Installation Manual for R170003 Compressor – Lincoln Air
Contents
1. l The information contained in this manual is based on sound engineering principles research extensive field experience and technical information Information is constantly changing with the addition of new models assemblies and service techniques If a discrepancy is noted in this service manual contact VMAC prior to initiating or proceeding with service Current information may clarify the matter Any person with knowledge of such discrepancies who performs service and repair assumes all risks VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 Only proven service procedures are recommended Anyone who departs from the specific instructions provided in this manual must first assure that their safety and that of others is not being compromised and that there will be no adverse effects on performance or the operational safety of the equipment Neither VMAC nor Lincoln will be held responsible for any liability injuries loss or damage to individuals or to equipment as a result of the failure of any person to properly adhere to the procedures set out in this manual or standard safety practices Safety should be your first consideration in performing service operations If you have any questions concerning the procedures in this manual or require any more information on details that are not included in this manual please contact VMAC before beginning repairs 1 3 Safety Messages This symbol is used t2. oil temperature switch never expose the tank or compressor to extreme heat ensure that the air entering the compressor is free of flammable vapors Personal Hazards Follow all safe work practices Wear the appropriate safety equipment ZN ZN Do not breathe the compressor air Vaporized oil is a respiratory hazard Always use the appropriate personal protective equipment particularly eye and hearing protection when operating air powered equipment The compressor system is under sufficient pressure that a leak could force the oil air mixture through the skin directly into your blood stream This will cause death Never adjust or attempt to make any repairs to the compressor system while engine is running Components and hoses under pressure could separate suddenly and fly out and cause serious injury or death Never perform maintenance procedures on the system until the Welder Compressor has been shut down for 5 minutes After 5 minutes open the pressure supply valve to ensure the system is depressurized Failure to depressurize the system could cause parts to separate explosively Flying parts could cause serious injury or death Oil air mixture could be VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 sprayed out with sufficient force to penetrate the skin which could cause serious injury or death The compressor and the compressor system gets very hot during operation contact
3. with the components or the oil can cause serious burns Components and hoses under pressure could separate A N suddenly and fly out and cause serious injury or death The auxiliary air tank must be drained before servicing any components in the compressor system 1 4 System The compressor system is protected from over pressurization by a mechanical inlet control in the compressor that regulates air flow in response to the demand There is also a 200 PSI 1 379 kPa pressure relief valve in the oil air separation tank to protect the system from over pressurization If the oil temperature exceeds 290 F 143 C the system is switched off draining the high pressure air and reducing the load on the engine VMAC certified and approved high performance synthetic oil is used to lubricate the compressor and is the only approved lubricant Any other oil will void the warranty The oil air separator tank removes most of the oil from the compressed air and the coalescing separating filter removes the remaining oil The oil is passed through a replaceable filter to remove contaminants The compressor intake is equipped with a replaceable paper filter element VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 Illustrated Parts Lists New Model Cummins System Old Model Cummins System VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 Figure 1 New Model Cum
4. 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 Installation Manual for P170002 R170003 Compressor Lincoln Air Vantage 500 Welder Cummins MoO MAO a a a O a aN Preparato Nissinen a a E EEEE Compressor Removal csecesceeesseeeseeesseeeseeeeseeeeseeeees Flushing Procedure ssssssnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnn Compressor Installation ccccssssseeecsssesseeeeeeeesseeeeeeeees Completing the Installation ccccccssessseeesesessseeeeeeees Preparing to Operate iscccesccicivecteeniceteceesiieeectcdiieeesteeeiteces Starting the System siiani Component Failure Procedure cccccsesseeeeeeeeeeeeeeeeeeees Servicing Intervals and Information cccessssseeeeeeeees VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 Install or Repair Manual Document 1900906 Compressor G4481 for Lincoln Air Vantage 500 Welder Changes and Revisions Revision Details Revised by date Approved by date Implemented Original manual issue SL 08 Dec 2009 MH 10 Dec 2009 SL 11 Dec 2009 B ECN 09 123 SL 28 Jan 2010 MH 02 Feb 2010 SL 02 Feb 2010 ECN 11 144 MH 06 Dec 2011 MH 06 Dec 2011 20 Dec 2011 D ECN 14 026 MH 23APR2014 MP 12 Jun 2014 12 Jun 2014 Trademarks VMAC is a registered trademark of VMAC Division of Mangonel Corporation Lincoln is trademarks of The Lincoln Electric Company Loctite is registered trademarks of Loctite Corporation No
5. C Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 19 Figure 5 8 Bracket fasteners 5 10 Align the 3 bracket holes and thread in 2 fasteners loosely as shown in figure 5 8 Install engine oil dipstick previously removed and align with hole which does not have fastener installed Install remaining fastener with flat washer and lock washer and tighten only until dipstick remains in place Figure 5 9 Securing the engine oil dipstick VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 20 5 11 Tighten engine bracket fasteners rear compressor bracket fasteners and 3 bracket fasteners in that order Figure 5 10 Figure 5 10 Securing the compressor bracket 5 12 Connect 7 oil return hose from compressor to oil filter manifold at the compressor end 5 13 Connect the discharge hose to the steel fitting at the rear of the compressor 5 14 Remove the protective cover on the inlet valve port Reattach inlet valve to compressor in same orientation as was removed using 4 M8 Socket head cap screws Note Ensure two longer inlet bolts are at the top and the two shorter bolts are at the bottom 5 15 Reconnect the black red and white poly lines to the inlet control valve free from any contact with sharp corners that may cause Note Ensure that the black red and white poly lines are excessive abrasion VMAC Vehicle Mounted Air Compress
6. eavy Duty Air Filter complete unit A700138 Remote Heavy Duty Air Filter w Cyclone 70CFM Heavy Duty or extreme dust environment service intervals Change Stock small Air Filters 50 hours of compressor use Heavy Duty Air Filters 250 hours of compressor use Oil 250 hours of compressor use Oil Filters 250 hours of compressor use Coalescent Filter 250 hours of compressor use VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 25 Check Inspect Inspect air filter for contamination every 5 days whether compressor has been used or not Before each use e check the level of oil in the oil air separator tank e check pressure supply valve is in good working order e check compressor and hoses for damage or wear e check after cooler drain collection bottle if equipped Each 250 Hrs Check Flange stud Torque compressor to PTO studs VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 26
7. me variation due to gauge error 9 0 Component Failure Procedure The following procedure should be followed in the event of component failure such as compressor gearbox tank hose or cooler core In short any sort of component failure which could introduce foreign material into the oil system 9 1 9 2 9 3 24 Prior to the replacement of any failed components check all other system components for evidence of contamination and thoroughly clean as far as is practical This may involve blowing out lines compressor with compressed air etc When all reasonable precautions have been made to remove any foreign materials from the oil system install the replacement component and reconnect all lines Add 4L of VMAC compressor oil to the system The VMAC oil has been proven to be the best course of action to remove any debris from the system VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 9 4 Run the system for about 15min in a no load state i e without discharging any compressed air from service air lines 9 5 Do a 500hr servicing 10 0 Servicing Intervals and Information Regular service intervals are 500 hours Use service kit P N A700100 this includes VMAC Part Number 3600037 Air Filter 9200039 Oil Filter A700091 VR High Performance Oil 1 L A700094 VR High Performance Oil 4 L Heavy Duty or extreme dust environment VMIAG Park Number A700136 Remote H
8. mins System Diagram Toll Free 1 888 241 2289 Fax 1 250 740 3201 VMAC Vehicle Mounted Air Compressors 10 Parts List for New Model Cummins System Item QTY Part Description Number 1710619 Hose Assembly Oil Air Separator Tank to Cooler 1710620 Hose Assembly Oil Cooler to Manifold 1710759 Tube 1 4 Outside Diameter Scavenge Line White Manifold to Compressor 1 1 2 4 5 7 Tube 1 4 Outside Diameter Compressor On Off Red Solenoid Valve to Inlet Valve Assembly Discharge Valve Hose Assembly Supply Compressor to Oil Air Separator Tank 17 Tube 1 4 Outside diameter System Pressure Black Manifold to Inlet Control Valve 20 1 1710623 Tube 1 4 Outside Diameter System Pressure Black Manifold to Inlet Control Valve A 5 6 Kai 9 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 11 Old Model Cummins System Diagram Figure 2 Toll Free 1 888 241 2289 Fax 1 250 740 3201 VMAC Vehicle Mounted Air Compressors 12 Parts List for Old Model Cummins System Pari Number 1710619 Hose Assembly Oil Air Separator Tank to Cooler 1710620 Hose Assembly Oil Cooler to Manifold 3 1 1710621 Tube 1 4 Outside Diameter Scavenge Line White Manifold to Compressor 4800382 Assembly Bracket Manifold r 1710625 Tube 1 4 Outside Diameter Compressor On Off red Solenoid to Manifold e Pi70008 Assomby C
9. o call your attention to instructions concerning your personal safety Watch for this symbol it points out important safety precautions it means attention become alert Your personal safety is involved Read the message that follows and be alert to the possibility of personal injury or death Be alert your safety is involved While it is impossible to warn about every conceivable hazard let good common sense be your guide This symbol is used to call your attention to instructions on a specific procedure that if not followed may damage or reduce the useful life of the compressor This symbol is used to call your attention to additional instructions or special emphasis on a specific procedure VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 Safety Precautions Read this information before operating the compressor for the first time Follow the information and procedures in this manual for operation maintenance and repair Observe the following items to reduce the chance of personal injury or equipment damage Follow all safety precautions for mechanical work Moving drive belts or fan blades are an extreme hazard Stay clear of all moving parts when the system is operating Only qualified personnel should perform maintenance and repair on system components with the welder compressor shutdown Proper service and repair are important to the safety of the service technician and the safe
10. ompressor SSS 7 1 1710626 Hose Assembly 33 11 9800016 Assembly Inlet Control Valve e m esse Assembly Solenoid Valve o 1 1710618 Hose Assembly Discharge Manfoldo Supply Vawe 1 Tassos Electical Hames 4800371 Assembly Discharge Valve 1 1710624 Hose Assembly Supply Compressor to Oil Air Separator Tank 1710623 Tube 1 4 Outside Diameter Black Compressor to Solenoid Valve 9300031 Assembly Tank Aluminum EE 1710627 Hose Assembly Oil Air Separator Tank to Manifold 1 1200365 Bracket Compressor r 1200366 Bracket Compressor 1710623 Tube 1 4 Outside Diameter Black Manifold to Inlet Control Valve 20 1710619 Hose Assembly Oil Return Manifold to Compressor 21 11 9300056 Assembly Cooler 19 r r r 7 i 7 e 7 gt r VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 13 2 0 2 1 2 2 2 3 OE 3 1 3 2 3 3 3 4 3 5 3 6 3 7 14 Preparation Disconnect battery Drain compressor system oil Remove the unit side panels for good access Label all hoses and air lines and wiring before disconnection Compressor Removal To release the poly tube from the fittings push on the outer ring and pull the tube out Disconnect the black red and white poly lines from the inlet control valve Remove the inlet control valve from the compressor 4 M8 socket head bolts Cover the inlet to the compressor r
11. ors Toll Free 1 888 241 2289 Fax 1 250 740 3201 21 6 0 Completing the Installation 6 1 Reconnect all wiring and hoses be flushed Please follow the flushing procedure as outlined in section 4 0 T If old hoses or any old components are used they MUST 6 2 Tighten all fasteners to recommended toque figures 6 3 Fill the system with correct level of oil account that there will be residual oil remaining in various components If the system is overfilled oil carry over may result i When adding oil to the system it should be taken into Approximate Component amounts System Component Compressor Compressor to tank discharge hose Oil Filter Coalescing filter unit Tank Cooler Total This oil should be drained out as much as possible If necessary remove components to complete draining process 7 0 Preparing to Operate Before you start the system you must install a connector into the outlet of the system Depending on your application this could include a right angle adapter and quick connect or could be a flexible line that runs to a remote location We recommend that you purchase the factory test device part number A700052 with an orifice size of 3 16 inch or you can construct a device as shown in Figure 4 1 and install this onto the discharge outlet so that you can control and monitor system operation VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 vp 0 200 p
12. otors to prevent debris entering Remove the 3 4 air discharge hose from the compressor Disconnect the 1 2 oil return hose from the compressor to the oil filter manifold at the compressor end Remove the three fasteners from the rear compressor brackets then remove the engine bracket and oil dip stick Loosen the two front compressor securing nuts on the engine studs and slide the compressor back to allow nuts to be removed Remove the compressor by sliding it off the splines Clean any debris from the PTO port on the engine and inspect the female spline on the engine for damage and replace it if necessary VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 4 0 Flushing Procedure Component failure such as a gearbox compressor hose or cooler core can leave metal filings and other foreign materials in the system To flush the system follow this procedure 4 1 Before replacing any failed component check all other system components for evidence of contamination and clean as thoroughly as possible Use compressed air to blow out the lines and other components 4 2 Once the system has been cleaned as thoroughly as possible replace the failed component and reconnect all lines and fittings 4 3 Install a new oil filter and fill the system with VMAC compressor oil to the correct level 4 4 Start the engine and engage the air system Allow the system to pressurize and allow it to o
13. perate in no load mode for about 15 minutes without discharging any air 4 5 Shut down allow the system to cool and change the oil oil filter and coalescing element Refill with compressor oil to the correct level 4 6 After 50 hours replace the oil filter and top up the oil level VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 15 The replacement compressor issued has the same performance as the compressor removed However the replacement compressor features a lightweight aluminum housing for easy installation 5 0 Compressor Installation 5 1 Remove the two compressor mounting studs from engine and install two new studs provided and apply Loctite 242 blue to external thread Ensure slotted end is not installed into the engine Figure 5 1 Figure 5 1 Installing mounting studs 5 2 Install new o ring on compressor spline port housing Figure 5 2 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 16 Figure 5 2 Spline port housing O ring 5 3 Before installing the compressor apply a sufficient amount of spline grease to the spline shaft 5 4 Remove the compressor mounting bracket from the rear of the replacement compressor before installation Figure 5 3 Figure 5 3 Compressor mount bracket 9 5 To install the compressor move the compressor into position and align the compressor mounting holes at the front of the compre
14. reliable operation of the equipment Always use genuine VMAC replacement parts do not use a substitute The procedures described in this service manual are effective methods of service and repair Some procedures may require the use of tools specially designed for a specific purpose Anyone using a replacement part service procedure or tool must first determine that neither their safety nor the safe operation of the equipment will be compromised by the replacement part service procedure or tool selected This manual contains various warnings cautions and notices that must be observed to reduce the risk of personal injury during service or repair and the possibility that improper service or repair may damage the equipment or render it unsafe Be aware that it is impossible to warn of all the possible hazardous consequences that might result from failure to follow these instructions Fire and Explosion Hazards Fire in the compressor can cause an explosion and flame projection Should this occur there is potential for serious injury or death Vaporized oil propelled by high pressure air is an explosive mixture VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 You must observe the following when operating the compressor constant vigilance is necessary around high energy equipment be attentive for unexplained changes in operation parameters and record any changes never bypass or disable the
15. si pressure gauge Ball valve Short pipe nipple Pipe tee Reducer Allen screw C Make this fitting by drilling the center of the Allen screw to 3 16 Figure 7 1 Typical test device If you use a solid plug rather than a reducer you must drill out the inside of the plug Figure 7 2 as a straight small hole through the solid plug will not provide proper operational simulation MVVVVVVV Drill an orifice in Drill out the center of the plug the head of the plug AAAAAAAA Figure 7 2 Drilling the orifice Once you have installed the test device and have verified that the installation is complete you are ready to start the system VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 23 8 0 Starting the System Follow the start up procedure as per operator s manual Lincoln Airvantage 500 1 While the system operates at high idle do an inspection tour Check the following e lines and hose to make sure that the fittings are not leaking e oil cooler and engine cooling system to make sure that there are not leaks e lines and fittings at the tank for leaks e air filter filter for leaks e any unusual vibration or grinding noises Once you are satisfied that everything is operating normally and that the engine cooling system level is correct open the valve on the test attachment The gauge should read approximately 100psi with so
16. ssor with mounting studs Engage the spline and ease the compressor spline into the PTO spline on the engine Figure 5 4 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 17 Figure 5 4 Installing the compressor 5 6 Secure compressor to the engine using the two M10 nuts provided The lower M10 nut needs to be installed first by sliding the compressor back so the mounting stud is flush with the compressor mounting flange Now place the M10 nut into position and slide the compressor forward so the stud is now in contact with the M10 nut Figure 5 5 Thread the nut onto the stud and slide the compressor forward and tighten M10 nut onto lower stud Now thread upper M10 nut to the upper stud and tighten Figure 5 5 Securing lower mount stud VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 18 5 7 Take the engine mount bracket provided and mount it to the engine using the engine mount fasteners from the previous bracket used but do not tighten Refer to figure 5 6 Figure 5 6 Engine mount bracket 5 8 Mount the rear compressor bracket onto the compressor Figure 5 7 loosely and align so compressor bracket is flush with the engine bracket previously installed Figure 5 7 Installing compressor bracket 5 9 Apply Loctite 242 on threads Align and install two compressor bracket fasteners as shown in Figure 5 7 Do not tighten VMA
17. tice Manuals and products are subject to change without notice Copyright 2010 The contents of this manual may not be reproduced in any form without written permission of VMAC PRINTED IN CANADA VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 Serial Number Breakdown Description P120132 X X X 000X Part Revision Year Month Manufacturing A H J N P R T W Y ONLY AS PER ASME STANDARD Y14 35 YEAR MONTH X 2009 A JANUARY Y 2010 B FEBRUARY Z 2011 C MARCH AA 2012 D APRIL AB 2013 E MAY F JUNE G JULY H AUGUST SEPTEMBER J OCTOBER K NOVEMBER L DECEMBER VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 1 0 Information 1 1 Forward This manual provides replacement instructions for the G4481 air compressor Proper and regular servicing provide continuing high performance and long life at low cost For more information contact VMAC KEEP THIS MANUAL WITH THE WELDING AIR COMPRESSOR UNIT FOR USER REFERENCE l l l l A WHEN THE ENGINE IS RUNNING EVEN WITH THE i COMPRESSOR OFF THE COMPRESSOR WILL PRODUCE UP TO 50 PSI 414 kPa OF COMPRESSED AIR NEVER i WORK ON THE COMPRESSOR SYSTEM WITH THE l ENGINE RUNNING ALWAYS ALLOW PRESSURE TO l i DRAIN FOR A MINIMUM OF 5 MINUTES OPEN THE i SUPPLY VALVE AND TRIGGER ANY TOOLS i ATTACHED TO DEPRESSURIZE THE SYSTEM BEFORE SERVICING THE COMPRESSOR AND COMPONENTS l
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