Lincoln Welder Compressor After-cooler and Air Dryer Owner s Manual A800071

Transcription

1 Lincoln Welder Compressor After-cooler and Air Dryer Owner s Manual A Safety Precautions... 3 Introduction... 4 Component Identification... 5 Required Tools... 5 Installation... 6 Testing the Installation Routine Maintenance Air Dryer Desiccant Filter Replacement Component Replacement General Procedures Removing the Air Dryer Assembly Purge Valve Replacement Regeneration Valve Replacement Turbo Valve Replacement Check Valve Replacement Heater Replacement Problem Diagnosis

2 Owner Manual - Document # Lincoln Welder Compressor After-cooler and Air Dryer Owner s Manual Changes and Revisions Version Revision Details Revised by/date Approved by/date Implemented 000 Original Manual Release SL Sept 29/08 MH 6 Oct Oct 2008 A ECN: CD Dec 15/08 MH 15 Dec Dec 2008 This manual provides operation instructions, specifications, maintenance schedules and warranty information for the VMAC compressor system and components as installed on the Lincoln Welder. The information in this manual is intended for people who have been trained in installation/repair procedures on this equipment and for people with mechanical trade certification who have the tools and equipment to properly and safely perform the procedures. Do not attempt any of these procedures if you do not have the appropriate mechanical training, knowledge and experience. To order parts, contact your VMAC dealer. Your dealer will ask for the VMAC serial number, part number, a description of the part and the quantity. Always refer to part numbers stamped on components when ordering replacements. To locate your nearest dealer, call Copyright 2008 All trademarks used in this manual are the property of the respective copyright holder. The contents of this manual may not be reproduced in any form without the express written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3. Printed in Canada 2

3 Safety Precautions This manual uses the following icons to highlight important information or safety issues: This symbol indicates additional, important information about procedures or operation of the system that should be observed as a best practice.! This symbol indicates hazardous personal situations or potential damage to equipment. Neither VMAC nor Lincoln will be liable for personal injury or damage to equipment caused by not following the procedures in this manual or not following safe work practices. Observe the following general safety rules: pay attention to operations, do not leave running equipment unattended follow safe work practices and wear the appropriate safety equipment, including eye and hearing protection avoid contact with drive belts and moving parts when the system is operating avoid contact with pressurized air, because if it penetrates your skin it can enter your bloodstream and kill you do not breathe compressed air, as vaporized oil is a respiratory hazard follow all safety precautions for mechanical work Observe these rules when operating the compressor: make sure that the equipment is placed in a safe position that will not cause a hazard to workers do not bypass or disable the oil temperature switch do not expose the tank or compressor to extreme heat use a regulator in the output line to precisely control the final air delivery pressure run the system at idle speed under no-load conditions for 2 to 3 minutes before turning the system off to allow system cooling and lubrication do not tamper with the pressure relief valve do not attempt to repair or modify any component 3

4 to prevent compressor explosion or fire, make sure that the air entering the compressor is free of flammable vapors prevent system leaks, as vaporized oil propelled by highpressure air is an explosive mixture Observe these rules when performing maintenance or service: do not attempt any maintenance or repair on the system unless you are qualified to do so use an approved lock-out or tag-out system to prevent operation of the equipment during service maintain proper service records for warranty and preventive maintenance procedures do not perform any service until the system has been completely blown-down (for a minimum of 1 minute) and you have verified that all air has been discharged, including pressure from areas behind one-way check valves and from auxiliary tanks do not attempt to repair or service a pressurized system do not attempt service on a system that has just been operated and is hot, as hot oil can cause serious burns do not start the engine while servicing the compressor on direct mounted systems; if the engine must be turned-over, ensure that air pressure cannot build and that oil cannot be pumped through the compressor system Introduction Air tools require clean, dry air. Water vapor in the air will damage tools and freeze in cold weather. An after-cooler reduces the temperature of the compressed air and condenses the water vapor into liquid. Most of the water is extracted and collected in a drain bottle. The drain valve in the bottle has a small discharge of air which increases with system pressure to discharge water from the aftercooler. The air then passes through an air dryer which removes any remaining water vapor. The water collects at the bottom of the air dryer which automatically expels the water with a small blast of air. 4

5 Component Identification Item Qty Part # Description Aftercooler with panel Replacement desiccant filter Turbo valve service kit Check valve service kit Regeneration valve service kit Purge valve service kit Hose assembly - Aftercooler to Air dryer Hose assembly - Air dryer to Supply valve Required Tools 1. Crescent wrench. 2. Phillips head screwdriver. 3. Socket set with 3/8, 7/16, 5/8 and 3/4 sockets. 5

6 Installation 1. Disconnect the battery. 2. Remove the sliding door and rails, case sides, and roof. Aftercooler Air Dryer 3. Remove the bracket mounting the compressed air supply valve below the control panel in the welder frame (note the position of the washer).! Observe all warnings in the Lincoln manual. 4. Pull the valve and hose out enough to disconnect the hose from the valve. 5. Pull the hose back into the welder and route the hose under the engine and out the left panel opening. The desiccant air dryer purge valve and discharge outlets protrude through the bottom of the dryer/purge tank assembly frame. Do not damage the fittings. 6

7 Inlet From Manifold Outlet To Air Dryer To Drain Valve 6. Place the air dryer assembly, purge tank end first, onto the fuel tank support frame from the left side of the welder (as viewed from the control panel). Make sure that the brass fittings are not damaged by contact with the frame. 7. Slide the air dryer/purge tank assembly into the welder and make sure that the fitting on the other end is lifted over the frame. The air dryer/purge tank assembly should sit on the fuel tank rails. 7

8 8. Position the fuel tank return line between the air dryer and the purge tank and make sure that the harness is not caught on the air dryer/purge tank assembly. 9. Insert four 1/4 x 1 inch bolts from underneath through the welder fuel tank frame and through the air dryer/purge tank assembly frame and install split lock washers and nuts. Before tightening, make sure that the air dryer/purge tank assembly clears the fuel tank. 10. Remove all but the bottom 2 screws on the existing panel. Loosen each bottom screw 1-2 turns. Hold the panel and lean it outward 6-8 by using (2) 8 cable ties connected together and looped through the upper right hole in the panel and through the nut on the machine. 11. Remove all connections going to the existing panel and then remove panel. 12. Remove the oil cooler from the old panel and reinstall on the new panel with existing hardware. This is best accomplished on a flat surface such as a work bench or table. 13. Place the after-cooler panel assembly as close as possible to the left access opening. 14. Attach hose from the air supply valve to the aftercooler inlet fitting and tighten. 8

9 15. Install the 90 fitting of the 67 inch (170 cm) hose to the inlet fitting on the air dryer. Route the hose along the frame, under the engine compartment shield and out the left access opening. Attach the hose to the bottom fitting on the after-cooler and tighten. 16. Lift the after-cooler and louvered panel into place and install it on the welder. 17. Route the 1/4 inch nylon hose from the filter to the bottom of the frame. Avoid kinks, sharp corners, hot components, or moving parts. 18. Attach the remaining supplied hose to the 90 fitting at the right hand side of the air dryer. 19. Route the hose down and along the frame to the front of the welder, insert it through the opening in the lower frame and attach it to the supply valve. Note the position of the wavy washer. 20. Attach the supply valve bracket to the frame. 21. Remove the 5 screws securing the control panel (2 on the top of the roof, 1 on each side panel, and 1 on the front of the control panel) and swing the panel down. 22. Locate the coiled up electrical harness from the bottom of the air dryer and route it to the electrical panel through the frame cutouts along with the other wires going to the control panel. 23. Connect the Ground wire to the center stud at the base of the control panel opening. 24. Connect the Power wire to the left stud at the base of the control panel opening. 25. Secure the air dryer heater harness to the main harness with tie straps 26. Close the control panel and fasten in place. 27. Check the routings of hoses, tubes and wiring. Use tie straps to secure them to prevent contact with hot surfaces, sharp corners, chafing, pinch points and moving parts. 28. Install all side panels. 29. Connect the battery. 9

10 Power Stud Ground Stud Testing the Installation 1. Connect an air tool to the discharge valve. 2. Start the welder (follow all start-up procedures in the S manual) and when it reaches operating temperature, turn the compressor switch on. 3. Activate the air tool to discharge air from the system, then stop using the tool. A loud, sudden discharge of air from the bottom of the air dryer should occur when the system reaches full pressure. 4. If you do not hear a loud, sudden discharge of air check the discharge pressure without any air tools attached. This pressure should be 150 psi. If the pressure is not correct, adjust the regulator according to the procedures in the S manual. A buildup of air pressure after use will trigger the air dryer to expel a blast of air, which will blow out any moisture collected by the air dryer. Long, continuous discharge of air pressure may cause water to build up in the air dryer. If water has built up in the air dryer, several purges will eventually clear the excess. 10

11 Routine Maintenance 700 hours or 2 years Replace the following air dryer components: desiccant filter purge valve regeneration valve check valve turbo valve Air Dryer Desiccant Filter Replacement 1. Remove the side panel and clean the area around the filter. 2. Remove the desiccant filter by turning it counterclockwise using a strap type filter wrench. 3. Remove and discard the O-ring from the threaded nipple mount. 4. Clean the surface of the air dryer and threaded nipple. 5. Apply a light coating of supplied grease to the new O-ring and install it onto the threaded nipple. 6. Apply grease to the seal of the desiccant filter. 7. Spin the filter onto the threaded nipple. When the desiccant filter s seal makes contact, tighten the filter an additional 1/2 turn. 11

12 Component Replacement General Procedures! It is important that you observe the general procedures listed previously in this manual to avoid damaging parts or components. Removing the Air Dryer Assembly 1. Disconnect the battery and remove the left side panel. Clean the area around the air dryer. 2. Disconnect the hose from the after-cooler to the air dryer. 3. Disconnect the hose from the air dryer reservoir to the discharge valve. 4. Remove the bolts securing the air dryer assembly to the fuel tank frame and slide the air dryer out part-way. 5. Unplug the air dryer heater harness. 6. Lift the air dryer assembly out of the welder. 7. Disconnect the nylon hose from the air dryer s control port. 12

13 Purge Valve Replacement 1. Follow the instructions for removing the air dryer assembly. 2. Remove the two bolts that attach the control port to the air dryer. 3. Use a thin blade to pry out the control port and discard the three O-rings. 4. Remove the purge valve using a probe inserted up through the discharge in the bottom into the valve spring. 5. Use a hooked probe pull out the filter screen form the bottom of the cavity and clean the cavity. 6. Lubricate the three new O-rings with the supplied grease. 7. Install the two thicker O-rings onto the control port first, then install the thinner O-ring. 8. Install the new filter screen into the cavity with the open end out. 9. Apply a light coating of lubricant to the O-ring seat of the purge valve and install the thin O-ring on the purge valve seat. 10. Install the purge valve by aligning the opening on the side of the valve with the exhaust port at the bottom of the air dryer. Do not dislodge the O-ring from its seat.! If the air dryer purge valve port does not line up with the exhaust port on the bottom the air dryer will not purge. 11. Install the control port. 13

14 12. Apply a light coating of grease to the threads of the retaining bolts, install the bolts securing the control port and torque to ft. lbs. (14-20 N m). 13. Connect the control hose, install the air dryer assembly, connect the air hoses and heater wiring. Regeneration Valve Replacement 1. Follow the instructions for removing the air dryer assembly. 2. Remove the three bolts mounting the air dryer to the air dryer frame. 3. Remove the regeneration valve nut from the air dryer and discard the O-ring, spring and spindle. 4. Clean the regeneration nut and cavity. 5. Lubricate the new O-ring with the supplied grease and install the O-ring onto the regeneration nut. 6. Install the spindle (with the spring pocket out), into the cavity and install the spring into the spindle. 7. Apply a light coating of grease to the threads of the regeneration nut, install the nut and torque to 60 ft. lbs. (81 N m). 8. Install the air dryer into the air dryer frame; connect all the hoses and wiring and install the assembly back into the welder. 14

15 Turbo Valve Replacement 1. Follow the instructions for removing the air dryer assembly. 2. Disconnect all the hoses from the air dryer s ports. 3. Remove the three bolts mounting the air dryer to the air dryer frame. 4. Remove the eight bolts from the bottom half of the air dryer and discard the gasket 5. Remove and discard the turbo nut from the inside of the bottom half of the air dryer. 6. Turn the housing over and the valve stop should fall out. Discard the stop. 7. Use a hooked probe to pull the valve out of the bottom of the cavity and discard the valve. 8. Clean the cavity, then lubricate the two new O-rings with the supplied grease and install them onto the valve. Install the valve into the cavity with the pointed end out. 9. Place the new valve stop on top of the valve with the concave side down. 15

16 10. Lubricate the new O-ring and install it onto the nut. Install the flat gasket into the nut, install the nut and torque to ft. lbs. (55-61 N m). 11. Place the new gasket onto the housing and align the holes. Install the housing and align the inlet port directly below the outlet port. Install the eight bolts and tighten to ft. lbs. (28-33 N m). 12. Install the air dryer into the air dryer frame; connect all the hoses and wiring and install the assembly back into the welder. Check Valve Replacement 16

17 1. Follow the instructions for removing the air dryer assembly. 2. Disconnect the hose from the air dryer outlet port and remove the outlet port nut from the air dryer. 3. Remove and discard the O-ring from the nut, the spring, spindle and ball from the cavity. Clean the cavity. 4. Lubricate the new O-ring with the supplied grease and install it onto the nut. 5. Place the ball into the cavity and position the spindle (with spring pocket out) into the cavity. 6. Install the spring into the spindle. 7. Lubricate the threads of the nut, install the nut and torque to 60 ft. lbs. (81 N m). 8. Connect the hose to the outlet port. 9. Connect all the hoses and wiring and install the assembly back into the welder. Heater Replacement 1. Follow the instructions for removing the air dryer assembly. 2. Remove the three bolts mounting the air dryer to the air dryer frame. 3. Remove the two screws securing the heater thermostat on the lower right side of the air dryer 17

18 4. Pull the thermostat out of the casting and clean the cavity. 5. Install the O-ring onto the thermostat housing. 6. Place the foam block on top of the thermostat. 7. Push the thermostat housing into the casting and secure it with the two screws. 8. Install the air dryer into the air dryer frame; connect all the hoses and wiring and install the assembly back into the welder. Problem Diagnosis SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Dryer will not exhaust Air leak at exhaust port during charge mode Air leak at exhaust port during standby mode Pressure will not build or is slow building Compressor cycles rapidly Water in air supply and no purge of air flow Air dryer frequently exhausts No pressure in control port hose Exhaust port blocked Purge valve stuck Air pressure in control port hose Purge valve stuck Worn purge valve Worn check valve No pressure in control port hose Purge valve stuck Worn purge valve Worn check valve Worn turbo valve Worn regeneration valve Saturated desiccant filter Worn check valve Worn turbo valve Replace governor valve Clear exhaust port Replace purge valve Replace governor valve Replace purge valve Replace purge valve Replace check valve Replace governor valve Replace purge valve Replace purge valve Replace check valve Replace turbo valve Replace regeneration valve Replace desiccant filter Replace check valve Replace turbo valve 18