Lincoln Electric Owners Manual – Kubota
Contents
1. High oil temperature See frequent over temperature shut down Frozen solenoid valve Temperatures below 10 C 14 F can cause sticking run the engine to warm up the engine compartment Frequent over temperature shut down Low oil level Check oil level with equipment on level ground Restricted oil lines Check for kinked or pinched lines Plugged oil filter Replace oil filter Cooler not functioning or plugged Replace or clean oil cooler Engine cooling system failure high engine temperature Correct problem High ambient temperatures Reduce duty cycle Oil temperature switch failure Replace if defective Excessive oil in the air discharge Coalescing separator failure Replace element Clogged scavenge line screen Clean or replace High oil level Check oil level with equipment on level ground Operating angle in excess of 35 degrees from horizontal Reduce operating angle Air operated equipment is faulty or not correctly connected to supply valve Test air operated equipment for proper operation and connect to supply valve Objectionable noise level Excessive gear wear Replace gearbox assembly VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 27 4 0 Illustrated Parts Lists 4 1 Manifold and Filters 9300070 Assembly Ma2. 9300068 Assembly Cooler Item Qty Part Description 1 1 3600127 Cooler 16 ORB Ports Modified 2 1 1200565 Bracket Fan 3 6 1500595 Rivet Aluminum Standard Blind 1 4 4 1 3550749 Pusher Fan Modified 5 4 1510519 Bolt HHCS NC G8 FL LK PL 1 4X5 8 6 4 1550029 Nut Nylock NC 1 4 7 2 4900145 Fitting 16 ORB Male X 8 JIC Male 8 1 5000169 Plug Hex Head 1 4 NPT Brass 9 2 5300022 Plug Plastic Pull NPT 1 2 10 3 3550748 Wiring Harness S700066 11 3 1540538 Bolt SHCS M6 X 1 0 X 14 G8 8 12 2 5830116 O ring Viton ORB 16 13 1 3500942 Thermal Switch 88C 14 1 3500943 Thermal Switch 105C 15 1 3500941 Thermal Switch 66C 16 1 3500697 Connector Spade Female Insulated 22 16 17 1 4900047 Elbow Steel JIC 1 2 1 2 18 5 3500698 Connector Spade Male Insulated 22 16 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 30 4 4 Compressor and Brackets P170024 Assembly Compressor S700066 Item Qty Part Description 1 1 9300071 Inlet Valve 8700066 2 1 5830004 O ring Viton 3 1 8 ID x 1 8 3 1 P170023 Compressor 8700066 4 1 1520573 Bolt HHCS M8 1 25 X 20 G10 9 PL 5 1 1570058 Washer Split Lock 5 16 6 1 1200559 Bracket Compressor Brace VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201
3. 31 4 5 Electrical Components Wiring Harness Solenoid and Connectors Item Qty Part Description 1 2 5000020 Connector straight 1 8NPT 1 4Poly 2 1 4800591 Solenoid Valve with fittings 3 1 3550811 Harness with Connectors 32 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 4 6 Hoses Tubing and Harness VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 33 1 1 1752034 Hose assembly oil air separator tank to oil cooler 2 1 1752049 Hose assembly oil cooler to manifold 3 18 1710759 Tube 1 4 outside diameter scavenge line white manifold to compressor 4 16 1710714 Tube 1 4 outside diameter compressor ON OFF signal red solenoid valve to inlet valve 5 1 1770079 Hose assembly discharge manifold to supply valve 6 1 3550685 Electrical harness 7 17 1710760 Tube 1 4 outside diameter signal black compressor to solenoid valve 8 1 1772030 Hose assembly supply compressor to oil air separator tank 9 1 1770057 Hose assembly oil air separator tank to manifold 10 1 1751018 Hose assembly oil return manifold to compressor 11 16 1710622 Tube 1 4 outside diameter system pressure black manifold to inlet control valve 34 VMAC V
4. 25 3 0 System Diagnosis Problem diagnosis for the compressor system should follow sound recognized practice Quick accurate diagnosis of problems is possible by accurately identifying the problem by operating the system yourself following safety practices determining possible causes for the problem by understanding how the system operates isolating the potential causes by accurate testing using the correct recognized procedures performing proper repairs using the correct procedures outlined in this manual and the recommended replacements parts performing proper post repair testing to ensure that the repairs were effective When performing problem diagnostics do not use test practices that are potentially harmful to the people involved or the equipment Electrical testing should be performed according to the processes described in the troubleshooting charts and in conjunction with Lincoln s Manuals 26 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Frequent relief valve operation Pressure control line plugged or frozen Remove and clear the line System still at high pressure Wait for system blow down or bleed off all system pressure Defective relief valve Replace the valve Compressor does not run Solenoid valve open Check solenoid valve operation and replace if necessary
5. the warranty 2 2 Start up Procedure Read all the service procedures and safety warnings before operating the compressor VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 12 The unit must be level or must not exceed 35 as higher angles will affect lubrication and oil and air separation Never start the engine before the compressor system has fully depressurized Starting or restarting the engine with pressure in the system causes extremely high loads on the internal components and may cause premature failure that may void any warranty claims 2 2 1 Make sure the air operated equipment is securely connected to the supply valve and turned OFF If air operated equipment is faulty not securely connected or not connected then excessive oil may be noticed in discharge air 2 2 2 Place the engine main RUN STOP switch in the STOP position 2 2 3 Place the compressor ON OFF switch in the OFF position 2 2 4 Turn the air supply valve OFF 2 2 5 Perform the Before Start Up checks in procedure 2 1 2 2 6 Start the engine according to the starting instructions in the Lincoln Welder s Owners Manual Full air flow can only be achieved while the engine is operating at high idle 2 2 7 Turn the compressor ON OFF switch to the ON position 2 2 8 Slowly open the supply valve The compressor will supply compressed air as demand requires 2 3 Shutdown Procedure
6. 2 3 1 Turn OFF the air equipment connected to the supply valve 2 3 2 Close the supply valve 2 3 3 Turn the compressor ON OFF switch to the OFF position VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 13 2 3 4 Shutdown the engine according to the instructions in the Lincoln Welder s Owners Manual 2 4 Check oil level in oil air separator tank The air compressor system holds 5 litres of oil which includes enough to fill the oil filter The filter holds 0 3 litres of oil The compressor holds about 0 5 litres of oil The lower front panel and hose lengths have been designed to allow the tank to be accessed easily for servicing If the front panel tank is removed for oil change ensure the tank is oriented correctly to enable correct oil levels to be read 2 4 1 Unscrew the oil level dipstick and remove it Take care not to damage the O ring on the dipstick 2 4 2 Wipe the oil level dipstick with a clean cloth or paper towel 2 4 3 Insert the oil level dipstick and screw it all the way down then unscrew and remove it 2 4 4 Check the level mark the oil has reached on the oil level dipstick VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 14 2 4 5 Use a funnel inserted into the dipstick hole and pour in VMAC certified and approved synthetic oil 2 4 6 Inspect the O ring on the dipstick for abr
7. CONTENTS 1 0 INFOMATION oo eee cece eiea E aa iaa i E 5 11 Foreword nenea en E EE E 5 1 2 Important Safety Notice cccccceeeeseeeeeeeeeeeteeeseeeteneeeeees 5 1 3 Safety Messages eeseeeseeese essensen nesr nern nesr netnnsnnsennsenn 6 PAKS VSUOM seara e a a a 9 1 5 Auxiliary Air Tank ccrten eneen aaea aaiae 10 2 0 Routine Maintenance ssssssssesserressrnesernnesrnnnennnnneernnneseennne 11 2 1 Maintenance Schedule ccceccceeeeeeeeneeeeeeeeseaeeeenaeeeenees 11 2 2 Start up Procedure ccecceececeeeeeeeeeeeseeseeeeeseaeeesnaeeeneees 12 2 3 Shutdown Procedure ccccceesceceeeceeeeeeeeneeseeeeesseeesneeeeneees 13 2 4 Check oil level in oil air separator tank 14 2 5 Check pressure supply valve ccceeeeeseeeeeeeeeeeeeesteeeeenees 16 2 6 Check compressor for damage ccesceeeeeeeeeteeeseeeeeeees 17 2 7 Check air lines and hoses for daMage cceceeseeeeees 17 2 8 Change Compressor Oil ccceccceceeeeeeeeeeeeeeeseeeeeneeeeneees 18 2 9 Change compressor Oil filter cceeeseeeeeeeeseeeeeteeeeeeees 19 2 10 Change compressor air filter 0 cc ccsceeeeeeeseeeeeeeeeeeeeees 21 2 11 Change coalescing filter ccccceseeeeseeeeeeeeeeeeeeeeeeeeeeees 23 2 12 BlOCtriCalls nsii vee eian a EREE E TAEA 24 2 13 Temperature Control Circuit 0 ccccesceeeeeeeeeeeeeeteeeeeeees 25 3 0 System Diagnosis cccccceceeeeececeeeeeeeeeeeeeseee
8. Loctite is registered trademarks of Loctite Corporation Notice Manuals and products are subject to change without notice Copyright 2009 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 Local 250 740 3200 Fax 1 250 740 3201 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 Serial Number Breakdown Description P170023 X X X 000X Part Number _ Revision Year Month Manufacturing Number A H J N P R T W Y ONLY AS PER ASME STANDARD Y14 35M YEAR MONTH A JANUARY B FEBRUARY C MARCH D APRIL 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 Local 250 740 3200 Fax 1 250 740 3201 1 0 Information 1 1 Foreword This manual provides maintenance repair and troubleshooting instruction for the S700066 air compressor system Proper and regular servicing provide continuing high performance and long life at low cost For more information contact VMAC I I KEEP THIS MANUAL WITH THE WELDING AIR COMPRESSOR UNIT FOR USER REFERENCE I I i WHEN THE ENGINE IS RUNNING EVEN WITH THE j COMPRESSOR OFF THE COMPRESSOR WILL l PRODUCE UP TO 50 PSI 414 kPa OF COMPRESSED i AIR NEVER WORK ON THE C
9. Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 24 Fax 1 250 740 3201 Compressor ON Compressor lt Protection Risist Indicator esistor Switch AW sive ao Temperature Sensor 290 NC c e lt lt ul 3 Solenoid Valve 2 13 Temperature Control Circuit Low idle operation When oil temperature is below 66 C and engine is running at low idle all thermal switches are open and the cooling fan is de energized As the oil warms past 66 C thermal switch 1 closes As the oil warms past 88 C thermal switch 2 closes and the cooling fan remains de energized As a fail safe feature if oil temperature rises to 105 C thermal switch 3 closes and the cooling fan is energized High idle operation When oil temperature is below 66 C and engine running at high idle all thermal switches are open and cooling fan is de energized As the oil warms past 66 C thermal switch 1 closes As the oil warms past 88 C thermal switch 2 closes and energizes the fan As oil cools below 66 C thermal switch 1 opens and de energizes the fan THERMAL SWITCH 88 C T2 F i al als fF THERMAL SWITCH 105 C T3 mi y THERMAL SWITCH 66 C T1 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201
10. OMPRESSOR SYSTEM WITH THE ENGINE RUNNING ALWAYS ALLOW i l PRESSURE TO DRAIN FOR A MINIMUM OF 5 MINUTES i OPEN THE SUPPLY VALVE AND TRIGGER ANY TOOLS ATTACHED TO DEPRESSURIZE THE SYSTEM BEFORE i SERVICING THE COMPRESSOR AND COMPONENTS 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 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 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 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
11. asions or nicks Replace the O ring if damaged Install the oil level dipstick and tighten it securely 2 4 7 Start the engine following the start up procedure number 2 2 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 15 2 4 8 Turn the compressor switch on the control panel to the ON position 2 4 9 Allow the system to pressurize 2 4 10 Turn the compressor switch on the control panel to the OFF position 2 4 11 Shutdown the engine and wait 5 minutes then open the pressure supply valve to depressurize the system 2 4 12 Check for oil leaks 2 4 13 Repeat steps 2 4 3 through 2 4 13 until the oil level dipstick shows the oil level in the oil air separator tank is in the operational range 2 5 Check pressure supply valve Follow all safety precautions 2 5 1 Check that the ball valve rotates freely 2 5 2 Visually inspect the ball valve for damage cracks or damaged threads Pressure Supply Valve VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 16 2 6 Check compressor for damage Follow all safety precautions 2 6 1 Before starting the engine open the service door and visually inspect the compressor for e cracks in the case e oil leaks at the seams e loose mounting bolts e all the hoses and fittings are secure 2 7 Check air lines and hoses for damage AN Follow all safety precaut
12. ating the compressor e constant vigilance is necessary around high energy equipment e be attentive for unexplained changes in operation parameters and record any changes e never bypass or disable the oil temperature switch e never expose the tank or compressor to extreme heat e ensure that the air entering the compressor is free of flammable vapors Personal Hazards Follow all safe work practices Wear the appropriate safety equipment Do not breathe the compressor air Vaporized oil is a respiratory hazard VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 ZN ZN 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 bloodstream 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 serio
13. before installing the cover Fire in the compressor can cause an explosion and fire VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 21 Oe Filter Retainer 4 Air Filter Cover J Air Filter 2 10 5 Remove the masking tape or cloth from the compressor air intake The new VMAC filter is round and must be flattened a little into an oval make sure that the filter fits over the machined step on the intake housing 2 10 6 Place the filter cover over the air filter and secure it with the cover nut VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 22 2 11 Change coalescing filter Follow all safety precautions Manifold Oil Filter A je N n Coalescing A Filter S S 5Y iore Do not use a screwdriver punched into the side of the filter as this practice can damage the scavenging tube and screen Manifold ABS Check Surface Scavenging Tube Threaded Nipple Check the filter to make sure that the threaded nipple did not i unscrew with the filter If it is in the filter remove it carefully to avoid thread damage coat the threads that go into manifold block with a small amount of Loctite blue and install it into the manifold block 2 11 1 Check the gasket sealing surface of the manifold block for contamination old gasket material or damage VMAC Vehicle Moun
14. contamination iore 5 litres of VMAC certified approved synthetic oil is required to fill the system 2 8 5 Unscrew and remove the oil level dipstick Take care not to damage the O ring on the dipstick Use a funnel inserted into the oil level dipstick hole and pour in the required amount of VMAC oil 2 8 6 Follow the oil level checking procedure in Section 2 4 2 9 Change compressor oil filter Follow all safety precautions Manifold _ Oil Filter je n Coalescing 4 Filter S ee S i 2 9 1 Clean debris and dust from the area around the manifold block and the filter to prevent contamination 2 9 2 Remove the filter by turning it counterclockwise using a suitable filter wrench VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 19 unscrew with the filter If it is in the filter remove it carefully to avoid thread damage coat the threads that go into manifold block with a small amount of Loctite blue and install it into the manifold block A Check the filter to make sure that the threaded nipple did not Check Surface Threaded Nipple 2 9 3 Check the gasket sealing surface of the manifold block for contamination old gasket material or damage Make sure the new filter is a VMAC filter part number 9200039 This oil filter is a high pressure oil filter not an automotive oil filter which will rupture under hig
15. eeseaeeeeaeeteneeees 26 4 0 Illustrated Parts Lists 2 0 0 eecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeees 28 4 1 Manifold and Filters ccc eeeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeees 28 4 2 Oil Air Separator Tank ceccceeeeeceseeeceeneeeeeeeeseeeteseeeeneees 29 4 3 Oil COO aarxdiv tte hh in ee 30 4 4 Compressor and Brackets cccceeeeeseeceeeeeseeeeesseeeeseees 31 4 5 Electrical Components c cceeeceeeeeeeeeeeceeeeeteaeeetneeeeeeees 32 4 6 Hoses Tubing and HarneSs eccccecceceeeeeeeeeeeteeeeeeeees 33 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 Owner s Manual Document 1930156 S700066 Lincoln Welder Compressor Changes and Revisions Version Revision Details Revised by date Approved by date Implemented 000 Original manual issue SL May 29 2008 A ECN 08 306 SL Feb 11 2009 MH 11 Feb 2009 12 Feb 2009 B Service interval updates SL May 21 2009 MH 27 May 2009 28 May 2009 C ECN 09 074 SL July 21 2009 MH 21 Jul 2009 21 Jul 2009 D ECN 11 065 Service update MH Jun 09 2011 SM 12 Oct 2011 19 Oct 2011 E ECN 12 030 UPDATES SAR 14 Feb 2012 SC 30 Mar 2012 30 Mar 2012 F ECN 12 072 update pg 32 MH 15May 2012 SM 16 May 2012 16 May 2012 Trademarks S700066 and VMAC are registered trademarks of VMAC Division of Mangonel Corporation Lincoln is trademarks of The Lincoln Electric Company
16. ehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201
17. h pressure 2 9 4 Apply a thin coating of compressor oil to the filter sealing gasket 2 9 5 Spin the filter onto the threaded nipple until the gasket contacts the sealing surface of the manifold block 2 9 6 Tighten the filter an additional 3 4 to 1 turn to seat the sealing gasket i Never over tighten the filter as this may damage the seal or filter 2 9 7 Follow the oil level checking procedure in Section 2 4 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 20 2 10 Change compressor air filter Follow all safety precautions 2 10 1 Clean loose dust and debris from the area around the compressor and the filter cover to prevent contaminants from entering the system 2 10 2 Remove the air filter cover retainer and the cover 2 10 3 Immediately cover the compressor air intake with masking tape or a clean cloth to prevent contamination Do not use compressed air or perform any other tasks around the compressor until the filter and cover are replaced Never clean the filter element with compressed air as this will allow some contaminates into the compressor system Always replace the air filter element 2 10 4 Remove the filter element from the filter cover Clean the inside of the cover with a clean dry cloth Do not use flammable solvents to clean the inside of the cover If a solvent has been used rinse the cover thoroughly with water and dry it
18. ions 2 7 1 Trace all the airlines and hoses looking for chaffing against each other or metal edges If chaffing is seen use plastic convoluted loom to protect the area on the hose or airline 2 7 2 Check that all the lines and hoses are secure If loose hoses are seen secure the hoses using tie straps 2 7 3 Examine the hoses and air lines for cuts or cracks 2 7 4 lf any of the airlines or hoses show damage they should be replaced by an authorized VMAC Service Centre before operating the equipment VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 2 8 Change compressor oil Follow all safety precautions 2 8 1 Clean debris and dust from the area around the drain valve of the oil air separator tank to prevent contamination Drain valve 2 8 2 Insert a hose over the oil air separator tank s drain valve outlet and open the valve to drain the oil into a container large enough to hold at least 1 1 2 US Gallons 6 litres After the oil has drained close the valve VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 18 Dispose of the oil in accordance with the Environmental Protection Laws in your location 2 8 3 Remove and replace the oil filter at this time following procedure number 2 9 2 8 4 Clean debris and dust from the area around the oil level dipstick of the oil air separator tank to prevent
19. nd 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 System Components P pe Manifold Block Coalescing Separator Filter Oil Cooler Air Filter Compressor Inlet Control Valve Solenoid Valve Thermostat Cm Ia Fh GS Oil Fill Dipstick amp Drain Valve Pressure Relief Valve Oil Air Separator Tank VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 1 5 Auxiliary Air Tank If an auxiliary air tank is to be used with this system the following setup MUST be followed Failure to observe this procedure will result in damage to the system 1 The auxiliary air tank must be connected to the supply valve 2 The air line MUST have a one way check valve installed to prevent blow back from the auxiliary air tank into the compressor system 3 The air line also MUST be connected as high as possible on the auxiliary air tank 4 The auxiliary air tank MUST have a pressure protection valve calibrated for abo
20. nifold Item Qty Part Description 1 1 9300069 Manifold Machining 2 2 4900002 Elbow Steel JIC O ring 1 2 3 4 16 3 1 9200039 Oil Filter VR 3 250 Short 4 1 4900035 Nipple Steel Str Thrd 3 4 16 5 1 5000020 Elbow Brass NPT Poly 1 8 1 4 6 1 9300007 Adapter 7 1 9300025 Assembly Scavenge Tube 8 1 3600079 Oil Separator Spin On 9 1 4900151 Connector Steel 45 3 4 12 ORB Male 10 1 1200552 Bracket Manifold 11 3 1510003 Bolt HHCS NC G8 PL 5 16 X 1 12 3 1570058 Washer Split Lock 5 16 13 1 9300089 Fitting Modified 14 2 5830132 O Ring Viton 8 ORB 15 2 5830133 O Ring Viton 12 28 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 4 2 Oil Air Separator Tank 9300077 Assembly Tank Aluminum Item Qty Part Description 1 1 4900033 Connector Steel NPT JIC 3 4 3 4 2 1 5000089 Connector Brass NPT SAE 3 8 1 2 3 1 4900079 Elbow Steel 90 Deg 3 4 NPT 3 4 JIC 4 2 5300009 Cap Plastic 1 1 16 5 1 5300011 CAP Plastic 3 4 16 6 1 9300090 Assembly Dipstick Compressor Oil 7 1 3550691 Assembly Thermostat 290F 8 1 3200360 Valve Modified 3600085 9 1 3600054 Valve Safety 200 PSI 10 1 9300076 Weldment Tank Aluminum VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 29 4 3 Oil Cooler
21. 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 to 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 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 pe
22. rform 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 reliable operation of the equipment Always use genuine VMAC replacement parts do not use a substitute VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 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 You must observe the following when oper
23. rformance and long service life The hours indicated are those displayed on the hour meter Service should be performed at the lesser of the two intervals whichever occurs first VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 11 Check the Illustrated Parts List for replacement part numbers or call VMAC Every time before start up 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 aftercooler drain collection bottle if equipped Extreme Environmental Service Intervals Change the following items as per intervals specified e Stock small Air Filter 50 hrs e Heavy duty air filter optional 250 hrs e Compressor Oil 250 hrs e Oil Filter 250 hrs e Coalescent Filter 250 hrs Note Inspect air filter for contamination every 5 days whether compressor has been used or not Every 500 hours as displayed on the hour meter or 6 months which ever comes first more frequently if used in dusty or extreme working conditions e change compressor oil e change compressor oil filter e change compressor air filter Every 1000 hours as displayed on the hour meter or 1 year which ever comes first e change coalescing filter VMAC certified and approved synthetic oil must be used Failure to use this special oil will result in damage to the compressor and will void
24. ted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 23 Make sure the new filter is a VMAC filter part 3600079 This is a high pressure filter Use of other filters not rated to the required pressure may cause the filter to rupture 2 11 2 Apply a thin coating of compressor oil to the coalescing filter sealing gasket and coat the end of the threaded nipple as there is also a O ring inside the coalescing filter 2 11 3 Spin the filter onto the threaded nipple until the gasket contacts the sealing surface of the manifold block 2 11 4 Tighten the filter an additional 3 4 to 1 turn to seat the sealing gasket i Never over tighten the filter as this may damage the seal or filter 2 11 5 Check the oil level following the oil level checking procedure in Section 2 4 2 12 Electrical The air compressor electrical system receives power from the main engine RUN STOP switch on the control panel when the switch is in the RUN position The compressor switch is turned to ON to start the compressor producing high pressure air If the compressors oil temperature goes above 290 F 143 C the thermostat will turn OFF the compressor and illuminate the Compressor Protection indicator Compressor OFF lt Compressor Protection Indicator Resistor Ae Switch eal ook On Tar Temperature Sensor 290 NC bd a 6 CD Solenoid Valve VMAC Vehicle
25. us injury or death Oil air mixture could be 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 with the components or the oil can cause serious burns Components and hoses under pressure could separate 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 Pressure regulator and or lubricator A The compressor can produce air pressures up to approximately 150 PSI 896 kPa It is the responsibility of the user to know the pressure and air flow requirements of the tools powered by the air compressor system An appropriate air pressure regulator and lubricator can be externally installed to the outside of the pressure supply valve Failure to regulate the air pressure could cause damage to the tool VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 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 a
26. ut 200 PSI 1379 kPa Pressure Protection valve One way check F Auxiliary Tank Supply valve Install the line as high as possible NOT in the bottom of the auxiliary tank VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 10 Fax 1 250 740 3201 2 0 Routine Maintenance Maintenance is a planned program which provides an orderly series of service and inspection procedures together with cleaning A well planned maintenance program lowers maintenance costs reduces down time and can prevent possible accidents due to failed components Shut down the Welder Compressor for 5 minutes After 5 AN minutes open the pressure supply valve to ensure the system is depressurized Pressure Supply Valve Torque Specifications STANDARD GRADE 8 NATIONAL COARSE THREAD Size 1 4 5 16 3 8 7 146 1 2 9 16 5 8 ya Foot pounds ft lb 9 18 35 55 80 110 170 280 Newton meter Nem 12 24 47 74 108 149 230 379 STANDARD GRADE 8 NATIONAL FINE THREAD Size 3 8 7 16 1 2 5 8 A Foot pounds ft lb 40 60 90 180 320 Newton meter Nem 54 81 122 244 434 METRIC CLASS 10 9 Size M8 M10 M12 M14 M16 Foot pounds ft lb 19 41 69 104 174 Newton meter Nem 25 55 93 141 236 2 1 Maintenance Schedule The following maintenance schedule should be adhered to to assure good pe
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