Lincoln Electric AirVantage 500 Welder Compressor
Contents
1. Item Part Qty Description 1 3800467 1 FASTENER PACK TANK INSTALLATION 1 1 1530282 4 BOLT SHCS NC G8 5 16 X 3 4 BUTTON 2 3800468 1 FASTENER PACK OIL COOLER MANIFOLD INST 2 1 1510025 6 BOLT HHCS NC G8 PL 3 8 X 1 2 2 1570009 6 WASHER SPLIT LOCK 3 8 3 3800784 1 FASTENER PACK FAN SPACER 3 1 1520588 1 BOLT HHCS PL G10 9 FL M8X1 25X 40MM 3 2 3400072 4 SPACER FAN 4 3800785 1 FASTENER PACK COALESCER MOUNT 4 1 1540146 2 BOLT SHCS M10 X 1 5 X 25 4 2 1540530 1 BOLT SHCS M8 X 1 25 X 55 G12 9 PLT 4 3 1570044 2 WASHER ALLOY PL SAE 3 8 4 4 1570067 1 WASHER SAE 3 8 5 3800787 1 FASTENER PACK FILTER OIL MOUNT 5 1 1520513 3 BOLT HHCS G10 9 M8 X 1 25 X 30 5 2 1560407 3 NUT NYLOCK M8 5 8 1570067 6 WASHER SAE 5 16 6 4 3800789 1 FASTENER PACK FILTER REMOTE MOUNT 6 1 1700387 3 HOSE COOLANT 2 GREEN STRIPE 6 2 1700523 11 MOULDING EDGE BLACK 9 32 6 3 2200027 2 CLAMP HOSE HS32 6 4 2200062 2 CLAMP HOSE HS24 6 5 9300103 1 CONNECTOR REMOTE FILTER 7 3800790 1 FASTENER PACK ASSEMBLY COMPRESSOR 7 1 1520513 3 BOLT 5 G10 9 M8 X 1 25 X 30 7 2 1570058 3 WASHER SPLIT LOCK 5 16 7 3 1570067 3 WASHER SAE 5 16 74 4900138 1 FITTING M JIC 8 X ORB 8 LONG 8 3800791 1 FASTENER PACK FITTING OIL COOLER 8 1 4900047 1 ELBOW STEEL JIC 90 DEG 1 2 1 2 9 3800792 1 FASTENER PACK BRACKET MAIN 9 1 1540171 2 BOLT SHCS M10 X 1 5 X 30 9 2 1540561 2 BOLT SHC2. 5 1 01 4 1 1 Foreword uae cete edes 4 1 2 Important Safety Notice pp 4 1 3 Safety 6 A SyS O tede n 9 1 5 Auxiliary Air Tank seen en 10 2 0 Routine Maintenance esee 11 2 1 Maintenance Schedule pp 12 2 2 Start up Procedure 13 2 3 Shutdown 14 2 4 Check oil level in oil air separator 14 2 5 Check pressure supply valve 16 2 6 Check compressor for damage 17 2 7 Check air lines and hoses for 17 2 8 Change compressor 19 2 9 Change compressor oil filter essees eeeeesenese reenen 20 2 10 Change compressor air 22 2 11 Change coalescing 23 2 12 Electrical einer ec ree ecce 25 3 0 System 26 4 0 Illustrated Parts Lists 28 4 1 Manifolds and Filters pp 28 4 2 Oil Air Separator Tank and 30 4 3 Compressor and drive components 31 4 4 Pressure Switch Assembly ppp 33 4 5 Solenoid 34 4 6 Electrical
3. I n gt za glg gle gt E gt gt 9 4 D m 3 alee alg ela gt LS c B le 88 IZ lo amp B 9 UA a Y I 5 5 E5 zE A 2 On I is HL 55 co VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 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 the manuals provided by Lincoln Electric 26 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 SYMPTOM POSSIBLE CAUSE
4. SECONDARY SEPARATOR PRESSURE SWITCH OIL FILTER NS E v PRIMARY NS SEPARATOR 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 Hose reels may be considered as air storage device and must be treated same as auxiliary tank 1 The auxiliary air tank must be connected to the supply valve 2 The air line MUST have a 60 psi minimum pressure check valve installed to prevent blow back from the auxiliary air tank into the compressor system 3 The air line 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 about 200 PSI 1379 kPa Pressure Protection valve E Auxiliary Tank Supply valve Install 60 psi Minimum Install the line as high as pressure check valve possible NOT in the on to supply valve bottom of the auxiliary tank VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 10 2 0 Routine Maintenance Impact damage and premature bearing failure may occur in the compressor bearings if the system is not operated on a regular basis due to vibration caused by truck operation Operate the system at least
5. CORRECTIVE ACTION Frequent relief valve operation Pressure control line plugged or frozen Remove and clear the line Defective relief valve Replace the valve Compressor does not run High system pressure Clutch will not engage with more than 2 psi system pressure High oil temperature See frequent over temperature shut down 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 sensor failure Replace if defective Inadequate ventilation See Lincoln Operator manual Excessive oil in the air 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 Incorrect start up shutdown procedures Observe start up shutdown procedures detailed
6. Components pp 35 4 7 HOSES and tubing 2 441 36 4 8 Fastener Pack 3800783 37 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 Owner s Manual Document 1930174 5700157 Lincoln Welder Compressor Changes and Revisions Version Revision Details Revised by date Approved by date Implemented A Released for production S Coker 09 21 2010 S Coker 09 21 2010 09 21 2010 B Updated for current production M H 02 22 11 S Coker 02 22 2011 02 22 2011 12 041 SAR 14 03 2012 03 Apr 2012 12 2012 D ECN 12 092 SAR 14 Jun 12 MH 22 Jun 2012 29 Jun 2012 Trademarks S700157 registered trademarks of VMAC Division of Mangonel Corporation Lincoln is atrademark of The Lincoln Electric Company Loctite is a registered trademark of Loctite Corporation Notice 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 Local 250 740 3200 Fax 1 250 740 3201 Serial Number Breakdown Description P120132 X X X 000X Part Revision Year Month Manufacturing A H J N P T W Y ONLY AS PER ASME STANDARD 14 35 YEAR MONTH X 2009 A
7. in this manual 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 4 0 Illustrated Parts Lists 4 1 Manifolds and Filters 9300107 Coalescing filter assembly Item Qty Part Description 1 1 9300105 Filter head machining 2 1 3600079 Oil separator spin on 3 1 9300102 Fitting modified 4 1 9300025 Assembly scavenge tube 5 1 5000162 Connect Brass NPT Poly 3 16 1 8 NPT 6 1 9300007 Adapter 7 1 4900158 Conn Steel 45 10 JIC 12 ORB 8 A R 5400396 Loctite 242 blue 9 A R 5400579 Loctite 567 Thread sealant high temp 28 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 9300097 Oilfilter assembly ltem Qty Part Description 1 1 3200392 Manifold 2 1 4900002 Elbow steel JIC O ring 1 2 3 4 16 3 2 5830132 O ring Viton 8 ORB 4 1 9200039 Oil Filter VR 3 250 Short 5 1 4900035 Nipple steel str thrd 34 16 6 1 4900046 Conn Stl 3 4 16 O ring to 1 2 Tube 7 5400396 Loctite 242 Blue VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 29 4 2 Oil Air Separator Tank and Cooler Item Qty Part
8. safety of the equipment The hoses used in VMAC compressor systems have a N specific inner liner that is compatible with our compressor oil Use of hoses other than those supplied or recommended by VMAC may cause compressor damage and may void your warranty Please contact VMAC for replacement hoses and further information 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 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 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 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 impossi
9. 3550764 Assy Valve Solenoid Norm Open 12V 2 1 1200618 Bracket Solenoid 3 2 1500604 Screw Phillips Head M4 X 10 4 1 4500104 Muffler Sintered Exhaust 1 8 5 1 5000121 Tee Street Extruded 1 8 6 2 5000162 Connect Brass NPT POLY 3 16 1 8 NPT 7 5400579 Loctite 567 Threadsealant High 8 5400396 Loctite 242 Blue VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 34 4 6 Electrical Components _ Item Qty Part Description 3550769 Harness 5700157 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 35 4 7 tubing Item Qty Part Description 1 1 1771023 Hose crimped x 23 2 1 1710775 Hose crimped 5 8 x 46 3 1 1710774 Hose crimped 5 8 x 65 4 1 1752016 Hose crimped 75 x 16 5 1 1752069 Hose crimped 75 x 69 6 1 1752020 Hose crimped 1 2 x 20 7 8 0 1700571 Tube Teflon 3 16 OD 8 12 1700571 Tube Teflon 3 16 OD 9 33 1700571 Tube Teflon 3 16 OD 10 33 1700570 Tube Teflon OD 36 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 4 8 Fastener Pack 3800783
10. Description 1 1 3600054 Valve pressure relief 1 379 kPa 200 PSI 2 1 5000089 Connector brass NPT SAE 3 8 1 2 3 1 5000141 Connector 90 3 4 NPT to 5 8 SAE 4 1 3550691 Temperature thermostat 5 1 9300090 Dipstick compressor oil 6 1 5830112 O ring Viton 7 1 3200360 Valve Modified 3600085 gasket supplied 8 1 9300055 Oil air separator tank assembly 9 1 9300056 Oil cooler 10 1 4900033 Connector 11 A R 5400345 Loctite 592 thread sealant slow cure VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 30 4 3 Compressor drive components P120132 Compressor Assembly ltem Qty Part Description 1 1 P120010 VR70 Compressor assembly 2 1 1540550 Bolt SHCS M8 X 1 25 X 50 G12 9 plt 3 1 1540530 Bolt SHCS 8 X 1 25 X 55 G12 9 plt 4 1 4900045 Plug steel hex SAE O ring port 5 1 9300104 Inlet valve 5700157 6 1 4300076 Pipe ftg plug skt head 1 8 T 1 5000165 Elbow 90 brass NPT Poly 1 8 3 16 8 A R 5400345 Loctite 592 thread sealant slow cure 9 1 5830004 O ring viton 3 1 8 ID X 1 8 10 1 4400594 Label Name Plate Generic 11 2 1500355 Screw Long U Drive 2 3 16 12 2 1540427 Bolt SHCS 8 X 1 25 X 60 13 1 1200617 Guard clutch 14 1 3200373 Fitting inlet scavenge 15 1 5830132 O ring VITON 48 ORB 16 1 5000121 Tee street extruded 1 8 17 1 5000012 Co
11. 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 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 5700157 air compressor system Proper and regular servicing provides continued high performance and long life at low cost For more information contact VMAC 1 1 5 MANUAL WITH WELDING AIR COMPRESSOR UNIT FOR USER REFERENCE 1 2 Important Safety 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
12. S M10 X 1 5 X 75 9 3 5830138 1 RING BUNA M3 X 84 10 3800841 1 FASTENER PACK POLY TUBES 10 1 1700570 15 TUBE TEFLON PTFE 1 4 OD 10 2 1700571 20 5 TUBE TEFLON PTFE 3 16 OD X 1 8 ID 10 3 1700571 19 LOOM SPLIT PLASTIC 1 4 HIGH TEMP 10 4 1700571 8 LOOM SPLIT PLASTIC 1 4 HIGH TEMP VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 37 10 5 1700581 13 LOOM SPLIT PLASTIC 1 4 HIGH TEMP 10 6 1700581 18 5 LOOM SPLIT PLASTIC 1 4 HIGH TEMP 10 7 1700581 17 LOOM SPLIT PLASTIC 1 4 HIGH TEMP 10 8 1700581 6 LOOM SPLIT PLASTIC 1 4 HIGH TEMP 10 9 2200019 12 TIE NYLON MD 6 11 3800841 1 FASTENER PACK ENGINE MOD PACK 5700157 11 1 4300085 3 PIPE FTG PLUG SKTHD MODIFIED 11 2 5000055 1 ELBOW BRASS STREET 1 8 amp OOO 36 3 OOO 38 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 pp Ss ome mm M im Sm mp mE Nm S oo m mS p yn gm y Smp IE T Vehicl oll Free Sing Ave 1 2289 due ege SEU IMS 00 Fax ax 1 250 740 3201
13. Welder s Owners Manual 2 4 Check oil level in oil air separator tank The air compressor system holds 5 litres of oil which or includes enough to fill the oil filter The filter holds 0 3 litres of oil The compressor holds about 0 5 litres of oil 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 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 14 2 4 4 Check the level mark the oil has reached on the oil level dipstick 2 4 5 Use a funnel inserted into the dipstick hole and pour certified or approved synthetic oil Call VMAC for information VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 15 2 4 6 Inspect the O ring on the dipstick for abrasions 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 2 4 8 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 41 Shutdown the engine and wait 5 minutes then open the pr
14. ble 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 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 reliable operation of the equipment Always use genuine VMAC replacement parts do not use any substitutes 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 comp
15. d nipple until the gasket contacts the sealing surface of the manifold block 2 11 6 Tighten the filter an additional 3 4 to 1 turn to seat the sealing gasket 1 over tighten the filter as this damage the seal filter 2 11 7 Check the oil level following 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 24 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 compressor s oil temperature goes above 290 F 143 C the thermal switch located in the primary air oil separator will disengage the compressor clutch and illuminate the Compressor Protection indicator This circuit is non latching and the compressor clutch will re engage when pressure and temperature allow The compressor system is also protected from engaging the clutch while at pressure The clutch will not engage when the compressor system pressure is above 2 psi LLI gt 25 EWA n 06 89 gt TBNA o 9o E N mo I gt S Russ 565 8 a e cl N LLI a9 2 5 658 9 gt I LLI
16. esser of the two intervals whichever occurs first 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 Check pressure supply valve is in good working order Check compressor and hoses for damage or wear Check after cooler drain collection bottle if equipped Check area around clutch for dirt oil Extreme Environmental Service Intervals Change the following items as per intervals specified e Heavy duty air filter 250 hrs e Compressor 250 hrs e Oil Filter 250 hrs e Coalescing Filter 250 hrs Every 500 hours as displayed on the hour meter or 1year 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 e Change coalescing filter this oil or other recommended alternatives may result in or VMAC certified synthetic oil should be used Failure to use damage to the compressor and will void the warranty VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 12 2 2 Start up Procedure Read all the service procedures and safety warnings before operating the compressor The unit must be level or must not exceed 35 as higher angles will affect lubrication and oil and air separation 2 2 1 Make sure the a
17. essure 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 N 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 Cracks in the bracket Oil leaks at the seams Loose mounting bolts Hoses and fittings are secure 2 7 Check air lines and hoses for damage Follow all safety precautions 2 7 1 Trace all the airlines and hoses looking for chaffing against each other or metal edges If chaffing is seen 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 f any of the airlines or hoses show damage they should be replaced by an authorized VMAC or Lincoln Electric Service Centre before operating the equipment VMAC Vehicle Mounted Air Comp
18. every 30 days for 15 minutes at no load to ensure bearing lubrication and rotation 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 N minutes open the pressure supply valve to ensure the system is fully depressurized Pressure Supply Valve Torque Specifications STANDARD GRADE 8 NATIONAL COARSE THREAD Size 1 4 5 16 3 8 7 16 1 2 9 16 5 8 Foot pounds ft lb 9 18 35 55 80 110 170 280 Newton meter 12 24 47 74 108 149 230 379 STANDARD GRADE 8 NATIONAL THREAD Size 3 8 7 16 1 2 5 8 Foot pounds ft lb 40 60 90 180 320 Newton meter 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 25 55 93 141 236 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 11 2 1 Maintenance Schedule The following maintenance schedule should be adhered to to assure good performance and long service life The hours indicated are those displayed on the compressor hour meter Service should be performed at the l
19. ir operated equipment is securely connected to the pressure 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 While in auto turn the compressor ON OFF switch to the ON position Wait for the engine to idle down to the low idle state The clutch may be engaged in high idle but it is recommended that the compressor clutch be engaged in as low an RPM as is practical to extend clutch service life 2 2 8 Slowly open the supply valve The compressor will supply compressed air as demand requires VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 13 2 3 Shutdown Procedure 2 3 1 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 2 3 4 Allow the engine to return to the low idle state 2 3 5 Shutdown the engine according to the instructions in the Lincoln
20. lator and or lubricator AN 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 may 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 airflow 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 clutch is disengaged draining the high pressure air and reducing the load on the engine VMAC recommends the use of certified and approved high performance synthetic oil is used to lubricate the compressor 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 replaceable filter to remove contaminants The compressor air intake is equipped with a replaceable paper filter element System Components OIL COOLER BLOWDOWN SOLENOID
21. n 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 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 ZN 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 at least 5 minutes to ensure the system is fully depressurized After 5 minutes open the discharge 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 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 Allow sufficient time for the system to cool before performing service Components and hoses under pressure could separate suddenly and fly out and cause serious injury or death If equipped the auxiliary air tank must be drained before servicing any components in the compressor system Pressure regu
22. nnector brass NPT poly 1 8 1 4 18 1 5000162 Connector brass NPT poly 3 16 1 8 19 1 1200616 Bracket brace 20 2 1570067 Washer SAE 5 16 21 1 3600123 Valve Check 1 8 NPT 22 5 3500156 Tubing PVC alpha black 2 100 23 1 P200035 Clutch Complete 6 Groove VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 31 Item Qty Part Description 1 1 1100187 Bracket main Cummins B3 3 2 1 3300036 Tensioner 3 5400396 Loctite 242 blue Main Bracket Assembly Drive components Item Qty Part Description 1 1 4800566 Pulley crank Cummins B3 3 2 1 1650270 Belt 47 5 3 1 3400072 Spacer fan 32 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 4 4 Pressure Switch Assembly 4800565 Pressure Switch Assembly Item Qty Part Description 1 1 5000178 Connector Brass Bulkhead 1 8 2 1 1200628 Bracket Pressure Switch 3 1 5000162 Connect Brass NPT POLY 3 16 1 8 4 3501068 Switch Pressure N C 2PSI 5 A R 5400579 Loctite 567 Threadsealant High Temp VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 33 4 5 Solenoid Assembly 4800562 Solenoid Assembly Item Qty Part Description 1 1
23. on 2 4 2 10 Change compressor air filter Follow all safety precautions For ease of service the air filter is located on the roof of the welder The filter is also equipped with a filter minder 2 10 1 Clean loose dust and debris from the area around the filter cover to prevent contaminants from entering the system 2 10 2 Remove the air filter cover retaining clamps and the cover 2 10 3 Immediately cover the air intake to prevent contamination entering the intake hose and compressor Do not use compressed air or perform any other tasks around the filter and cover until both 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 before installing the cover Fire in the compressor can cause an explosion 2 10 5 Remove the protecting cover from the compressor air intake 2 10 6 Place the filter into the cover and secure it with the retaining clamps VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 22 Fax 1 250 740 3201 2 11 coalescing filter MANIFOLD BM COALESCING FILTER Do not use a screwdri
24. ressors 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 18 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 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 liters 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 19 Dispose of the accordance with the Environmental Protection Laws in your location 2 8 A Remove and replace the oil filter at this time following procedure number 2 9 2 8 5 Clean debris and dust from the area around the oil level dipstick of the oil air separator tank to prevent contamination 5 liters of certified or approved synthetic oil is required to fill the system Contact VMAC for information 2 8 6 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 7 Follow the oil level checking procedure in Section 2 4 2 9 Change compressor oil fil
25. romised by the replacement part service procedure or tool selected VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 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 gt mixture You must observe the following when operating the compressor e Constant vigilance is necessary around high energy equipment e attentive for unexplained changes in operation parameters and record any changes e Never bypass or disable the oil thermistor 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 Always use the appropriate personal protective equipment particularly eye and hearing protection whe
26. ter VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 20 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 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 1 Check the filter to make sure that the threaded nipple did not Threaded Nipple Check Surface 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 VMAC filter part number 9200039 This oil filter is a high pressure oil filter not an automotive oil filter which will rupture under high 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 VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 21 2 9 6 Tighten the filter an additional 3 4 to 1 turn to seat the sealing gasket 1 Never over tighten the filter as this may damage the seal or filter 2 9 7 Follow the oil level checking procedure in Secti
27. ver punched into the side of the filter as this practice can damage the internal scavenging tube and Screen THREADED NIPPLE DISCHARGE FITTING SCAVENGING TUBE VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Local 250 740 3200 Fax 1 250 740 3201 23 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 Use caution when removing the filter so as to avoid catching the scavenge screen orifice on the bottom of the scavenge tube on the lip of the coalescing filter This scavenge screen orifice is attached to the scavenge tube by a push to connect fitting if the fitting has come off of the tube re insert the tube into the fitting ensuring that the tube is fully engaged 1 Check the filter to make sure that the threaded nipple did not 2 11 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 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 4 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 an O ring inside the coalescing filter 2 11 5 Spin the filter onto the threade
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