Installation and Repair Manual for Compressor G4481/G6204 Lincoln Air Vantage Welder

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 Information ........................................................................... 4 Preparation......................................................................... 16 Compressor removal and reinstallation.......................... 16 Tank removal, and reinstallation G4481.......................... 17 Tank removal, and reinstallation G6204.......................... 17 Oil filter manifold removal and reinstallation ................. 18 G4481 earlier model .......................................................... 19 Cooler removal and reinstallation G4481........................ 19 Cooler removal and reinstallation G6204........................ 19 Completing the installation .............................................. 20 Component Failure Procedure ......................................... 21 Servicing Intervals and Information ................................ 22

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Install or Repair Manual Document 1900909 Compressor G4481/G6204 For Lincoln Air Vantage Welder Changes and Revisions
Version A Revision Details Original manual issue Revised by/date SL Dec 09/2009 Approved by/date SC 8 Dec 2009 Implemented 10 Dec 2009

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 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

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Serial Number Breakdown Description

X - 2009

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1.0 Information
1.1 Forward
This manual provides replacement or repair instruction for the G4481/G6204 air compressor system. 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

Torque Specifications All fasteners must be torqued to specifications. Use manufacturers torque values for OEM fasteners. Apply Loctite 242 or equivalent on all engine-mounted fasteners. Torque values are with Loctite applied unless otherwise specified.
STANDARD GRADE 8 NATIONAL COARSE THREAD Size 1/4 5/16 3/8 7/16 1/2 Foot-pounds (ft-lb) 9 18 35 55 80 Newton meter (Nm) 12 24 47 74 108 STANDARD GRADE 8 NATIONAL FINE THREAD Size 3/8 7/16 Foot-pounds (ft-lb) 40 60 Newton meter (Nm) 54 81 METRIC CLASS 10.9 Size Foot-pounds (ft-lb) Newton meter (Nm) M8 19 25 M10 41 55 1/2 90 122 M12 69 93 9/16 110 149 5/8 180 244 M14 104 141 5/8 170 230 280 379 320 434 M16 174 236

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1.2 Important Safety Notice

WHEN THE ENGINE IS RUNNING, EVEN WITH THE COMPRESSOR OFF, THE COMPRESSOR WILL PRODUCE UP TO 50 PSI (414 kPa) OF COMPRESSED AIR. NEVER WORK ON THE COMPRESSOR SYSTEM WITH THE ENGINE RUNNING. ALWAYS ALLOW PRESSURE TO DRAIN FOR A MINIMUM OF 5 MINUTES, OPEN THE SUPPLY VALVE AND TRIGGER ANY TOOLS ATTACHED TO DEPRESSURIZE THE SYSTEM BEFORE SERVICING THE COMPRESSOR AND COMPONENTS.

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. 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.

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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 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 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.
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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 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 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. 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.
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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. Even with the compressor turned off, if the engine is running the compressor can produce up to 50 PSI (414 KPA) of pressure. Never work on the compressor system with the engine running. Never work on the compressor system while it is pressurized. Always ensure that the compressor system has been depressurized prior to any servicing or maintenance. Always allow a suitable length of time for components to cool . The compressor and the compressor system gets very hot during operation, contact with the components or the oil can cause serious burns. 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. VMAC certified and approved high performance synthetic oil is used to lubricate the compressor and is the only approved lubricant. Any other oil may 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.

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Illustrated Parts Lists New Model Cummins G4481 System Old Model Cummins G4481 System Kubota G6204 System

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2 1

3
4

16

17
5 15

19
14

7 8 20

13 12

11

10

21

22

23

Figure 1 New Model Cummins G4481 System Diagram

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Parts List For New Model Cummins G4481 System

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Part # 1710619 1710620 1710759 9300058 P170002 9300064 1710618 1710714 4800366 3550685 4800371 1710624 9300055 1710627 9300056 1710619 1710622 1200366 1200365 1710623 3800507 4800375 4800390

Description Hose Assembly, Oil/Air Separator Tank to Cooler Hose Assembly, Oil Cooler to Manifold Tube, 1/4 Outside Diameter, Scavenge Line (White), Manifold to Compressor Assembly, Bracket, Manifold Assembly, Compressor Inlet Valve, G4481 Hose Assembly, Discharge, Manifold to Supply Valve Tube, 1/4 Outside Diameter, Compressor On/Off (Red), Solenoid Valve to Inlet Valve Assembly, Solenoid Valve Electrical Harness Assembly, Discharge Valve Hose Assembly, Supply, Compressor to Oil/Air Separator Tank Assembly, Tank, Aluminum Hose Assembly, Oil/Air Separator Tank to Manifold Assembly, Cooler Hose Assembly, Oil/Return, Manifold to compressor Tube, 1/4 Outside diameter, System Pressure (Black), Manifold to Inlet Control Valve Bracket, Compressor Bracket, Compressor Tube, 1/4 Outside Diameter, System Pressure (Black), Manifold to Inlet Control Valve Fastener Pack S700033 Assembly, Tube Oil Extension Assembly Oil Dipstick

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11

3 4

20 5 19 21 18 6 7

17 16

14 15 13

10 11 12

22

23

24

Figure 2 Old Model Cummins G4481 System Diagram

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Parts List for Old Model Cummins G4481 System Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Part # 1710619 1710620 1710621 4800382 1710625 P170002 1710626 *9300016/ 9300064 4800366 1710618 3550685 4800371 1710624 1710623 9300031 1710627 1200365 1200366 1710623 1710619 9300022 3800507 4800375 4800390 Description Hose Assembly, Oil/Air Separator Tank to Cooler Hose Assembly, Oil Cooler to Manifold Tube, 1/4 Outside Diameter, Scavenge Line (White), Manifold to Compressor Assembly, Bracket, Manifold Tube, 1/4 Outside Diameter, Compressor On/Off, (red) Solenoid to Manifold Assembly, Compressor Hose Assembly, 33 Assembly, Inlet Control Valve Assembly, Solenoid Valve Hose Assembly, Discharge, Manifold to Supply Valve Electrical Harness Assembly, Discharge Valve Hose Assembly, Supply, Compressor to Oil/Air Separator Tank Tube, 1/4 Outside Diameter, (Black) Compressor to Solenoid Valve Assembly, Tank, Steel Hose Assembly, Oil/Air, Separator Tank to Manifold Bracket, Compressor Bracket, Compressor Tube, 1/4 Outside Diameter, (Black) Manifold to Inlet Control Valve Hose Assembly, Oil Return, Manifold to Compressor Assembly, Cooler Fastener Pack S700033 Assembly, Tube Oil Extension Assembly Oil Dipstick

* Please Note: 9300016 used on all units with serial number S700033|0|S|A|006 to S700033|A|U|E|008 9300064 used on all other units.

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5 1 2 4 6

3
18 16 8

13 10

14 12
17 20

15

19

Figure 3 - G6204 Kubota Type System

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Parts List for G6204 Kubota Type System Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Part # 9300068 1752049 1710622 1751018 1710759 9300070 1770057 9300071 1710714 4800366 9300077 3550685 1710760 1772030 4800527 1752034 1770079 P170024 3800700 1200553 Description Assembly, Cooler Hose Assembly, Oil Cooler to Manifold Tube 1/4 Outside Diameter, System Pressure, (Black), Manifold to Inlet Control Valve Hose Assembly, Oil Return, Manifold to Compressor Tube, 1/4 Outside Diameter, Scavenge Line, (White), Manifold to Compressor Assembly, Manifold Hose Assembly, Oil/Air Separator Tank to Manifold Inlet Control Valve Tube, 1/4 Outside Diameter, Compressor On/Off, (Red), Solenoid Valve to Inlet Valve Assembly, Solenoid Valve Assembly, Tank, Aluminum Electrical Harness Tube, 1/4 Outside Diameter, (Black), Compressor to Solenoid Valve Hose Assembly, Supply, Compressor to Oil/Air Separator Tank Assembly, Discharge Valve Hose Assembly, Oil/Air Separator Tank to Cooler Hose Assembly, Discharge, Manifold to Supply Valve Assembly Compressor Fastener Pack, S700066 Bracket, Tank Brace

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2.0 Preparation
Before commencing work ensure that the unit is elevated and supported safely to enable you to work underneath. If the unit has just been used, ensure that all components are cool enough to work on and all air pressure has been discharged. 2.1 2.2 2.3 2.4 Disconnect battery. Drain compressor system oil. Drain coolant (if removing the cooler G4481 only). Remove the unit side panels for good access. Label all hoses and air lines and wiring before disconnection.

3.0 Compressor removal and reinstallation

3.1 Disconnect the black, red and clear poly lines from the inlet control valve. Remove the inlet control valve from the compressor (4 M8 socket head bolts). Take note of the differing bolt lengths and orientation and ensure that they are installed in this manner when reinstalling the inlet valve. Cover the inlet to the compressor rotors to prevent debris entering. 3.2 3.3 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 rear compressor support bracket from the compressor and the engine bracket. 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.
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3.4

3.5

3.6

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3.7

To install the compressor, follow this procedure in reverse order. Be sure to engage the splines correctly and ease the compressor into position and support the rear of the compressor. Fit new studs and nuts, use Loctite 242 on all engine fasteners.

4.0 Tank removal, and reinstallation G4481

To remove the tank will require loosening the engine mounting bolts and lifting the engine slightly. This will allow just enough room for the tank to be maneuvered out. 4.1 4.2 4.3 Disconnect the wiring to the temperature probe at the tank Disconnect the 1/2 oil return hose to the cooler. Disconnect the 3/4 air discharge hose from the tank to the coalescing filter/ manifold. Disconnect the 3/4 air discharge hose connection from the compressor to the tank and remove the hose, note the angled crimp end connection is at the compressor. Support the tank and undo the four bolts locating the tank to the frame brackets. Lift out the tank.

4.4

4.5

To install the tank, follow this procedure in reverse order.

5.0 Tank removal, and reinstallation G6204

To remove the tank will require releasing the front floor section on the radiator side of the machine to gain access.

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5.1

Disconnect the 1/2 oil return hose to the cooler, at the tank (label connection). Disconnect the 3/4 discharge hose from the compressor at the tank. Disconnect the 3/4 tank air discharge hose to the filter manifold at the tank. Disconnect the temperature probe switch wiring at the tank. Remove the four bolts locating the separator tank to the mounting bracket.

5.2

5.3

5.4 5.5

To install the tank, follow this procedure in reverse order.

6.0 Oil filter manifold removal and reinstallation

6.1 Disconnect and remove the 1/2 oil return hose to the top of the oil filter. Disconnect the 1/2 oil return hose from the side connection on the oil filter. Remove the air discharge hose from the coalescing filter to the shutoff valve. Remove the white poly line to the fitting on the top of the oil filter manifold. Remove the black poly tube from the 90-degree fitting on top of the oil filter manifold. To release the poly tube from the fittings, push in or down on the outer ring and pull the tube out. 6.6 Undo the two bolts holding the oil filter manifold bracket to the engine front mount plate and remove the filters and manifold.
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6.2

6.3

6.4

6.5

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7.0 G4481 earlier model

Proceed as above but remove the additional poly tubes from the 90degree fittings on the side of the oil filter manifold. (Used for blowdown function). To install the Oil filter manifold, follow this procedure in reverse order.

8.0 Cooler removal and reinstallation G4481

8.1 Place a drain can under the cooler to catch the residue coolant. Disconnect the top and bottom coolant hoses from the cooler. Disconnect the two oil hoses from the connections on the cooler. (label all the connections). Undo the two bolts that hold the cooler to the engine mount bracket and remove the cooler.

8.2

8.3

8.4

To install the Oil cooler, follow this procedure in reverse order. Ensure the oil hoses are fitted to the correct connections on the cooler.

9.0 Cooler removal and reinstallation G6204

Remove the panel carefully from the non-service side of the machine where the oil cooler is located. This will need to be supported as the oil cooler hoses, three sensors electrical wires and fan wiring will still be attached at this point. 9.1 Disconnect the red wire labeled, Line 405 and the two black ground wires which connect to the welder wiring harness.

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9.2

Disconnect the oil hoses to the cooler, mark or note the correct connections for the top and bottom. Top oil hose is hot IN from the tank. Bottom is Cooled out to oil filter. Remove the six bolts locating the cooler to the panel. Note the six spacers between the cooler and the panel and keep them for reinstallation. Drain oil from the cooler.

9.3

9.4

To install the cooler, reverse this procedure. Make sure the six spacers are installed between the cooler and the panel. Hoses Reassemble and fit new oil hoses and poly lines as required following all the marked connections. It is important to have the hoses and poly lines connected correctly for correct compressor function. Replacement hoses should be clear of all moving or hot system components. Do not route the hoses adjacent to objects which could abrade the hoses causing failure of the hose and potential failure of the compressor.

10.0 Completing the installation

1. Reconnect all wiring and hoses. 2. Tighten all fasteners to recommended torque figures. 3. Fill the system with correct level of oil. 4. Tighten coolant hoses and refill the cooling system. If old hoses or any old components are used they MUST be flushed with 4 liters of compressor oil and the system must be run to temperature. Then re-drain the oil and change the oil filter. Refill the system with another new 5 liters of compressor oil.

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Close the shut off valve and run the unit to warm up and then run the compressor. Set up the system as per operators manual Lincoln Air Vantage 500 System Flushing Procedure. When adding oil to the system it should be taken into account that there will be residual oil remaining in various components. If the system is overfilled oil carryover may result. Approximate Component amounts.
System Component Compressor Compressor to tank discharge hose Oil Filter Coalescing filter unit Tank Cooler Total S700033 200ml, 400ml 400ml 3.5 L 500ml 5L S700066 200ml 400ml 400ml 3.0L 1L 5L

This oil should be drained out as much as possible, If necessary, remove components to complete draining process.

11.0 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 component failure which could introduce foreign material into the oil system. 1. 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. 2. When all reasonable precautions have been made to remove any foreign materials from the oil system, install the replacement component and reconnect all lines. 3. Add 4L of VMAC compressor oil to the system. The VMAC oil has been proven to be most effective in the removal of any debris from the system. 4. Run the system for about 15min in a no load state i.e. without discharging any compressed air from service air lines.
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5. Perform a 500hr service.

12.0 Servicing Intervals and Information

Regular service intervals are 500 hours. Use service kit P/N A700100 this includes:
VMAC Part Number 3600037 9200039 A700091 A700094 Description Air Filter Oil Filter VR High Performance Oil 1 L VR High Performance Oil 4 L

Heavy Duty or extreme dust environment

VMAC Part Number A700136 A700138 Description Remote Heavy Duty Air Filter (complete unit) 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 Oil Oil Filters Coalescent Filter Check / Inspect Inspect air filter for contamination every 5 days whether compressor has been used or not. = 250 hours. of compressor use. = 250 hours. of compressor use. = 250 hours. of compressor use. = 250 hours. of compressor use.

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Before each use 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). Each 250 Hrs Check Flange stud Torque (compressor to PTO studs).

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