Lincoln Repair 1900909 A

8/2/2019 Lincoln Repair 1900909 A

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VMAC Vehicle Mounted Air CompressorsToll Free:1-888-241-2289Fax: 1-250-740-3201

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Installation and Repair Manual forCompressor G4481/G6204Lincoln Air Vantage Welder

1.0 Information........................................................................... 4

2.0 Preparation......................................................................... 16

3.0 Compressor removal and reinstallation.......................... 16

4.0 Tank removal, and reinstallation G4481.......................... 17

5.0 Tank removal, and reinstallation G6204.......................... 17

6.0 Oil filter manifold removal and reinstallation ................. 18

7.0 G4481 earlier model .......................................................... 19

8.0 Cooler removal and reinstallation G4481........................ 19

9.0 Cooler removal and reinstallation G6204........................ 19

10.0 Completing the installation .............................................. 20

11.0 Component Failure Procedure......................................... 21

12.0 Servicing Intervals and Information ................................ 22


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VMAC Vehicle Mounted Air CompressorsToll Free:1-888-241-2289

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Install or Repair Manual Document 1900909Compressor G4481/G6204 For Lincoln Air Vantage Welder

Changes and Revisions

Version Revision Details Revised by/date Approved by/date Implemented

A Original manual issue SL Dec 09/2009 SC 8 Dec 2009 10 Dec 2009

Trademarks:

VMAC is a registered trademark of VMAC, Division of Mangonel CorporationLincoln is trademarks of The Lincoln Electric CompanyLoctite is registered trademarks of Loctite CorporationNotice: 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 theG4481/G6204 air compressor system. Proper and regular servicingprovide continuing high performance and long life at low cost. Formore information contact VMAC.

KEEP THIS MANUAL WITH THE WELDING/AIR COMPRESSORUNIT FOR USER REFERENCE

Torque Specifications

All fasteners must be torqued to specifications. Use manufacturerstorque values for OEM fasteners. Apply Loctite 242 or equivalent onall engine-mounted fasteners. Torque values are with Loctite appliedunless otherwise specified.

STANDARD GRADE 8 NATIONAL COARSE THREADSize 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 (Nm) 12 24 47 74 108 149 230 379

STANDARD GRADE 8 NATIONAL FINE THREAD

Size 3/8 7/16 1/2 5/8

Foot-pounds (ft-lb) 40 60 90 180 320

Newton meter (Nm) 54 81 122 244 434

METRIC CLASS 10.9Size M8 M10 M12 M14 M16

Foot-pounds (ft-lb) 19 41 69 104 174

Newton meter (Nm) 25 55 93 141 236


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1.2 Important Safety Notice

WHEN THE ENGINE IS RUNNING, EVEN WITH THE

COMPRESSOR OFF, THE COMPRESSOR WILL PRODUCEUP 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 soundengineering principles, research, extensive field experience andtechnical information. Information is constantly changing with theaddition of new models, assemblies and service techniques. If adiscrepancy is noted in this service manual, contact VMAC prior toinitiating or proceeding with service. Current information may clarifythe matter. Any person with knowledge of such discrepancies whoperforms service and repair assumes all risks.

Only proven service procedures are recommended. Anyone whodeparts from the specific instructions provided in this manual mustfirst assure that their safety and that of others is not beingcompromised and that there will be no adverse effects onperformance 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 ofthe failure of any person to properly adhere to the procedures set outin this manual or standard safety practices. Safety should be yourfirst consideration in performing service operations. If you have anyquestions concerning the procedures in this manual or require anymore 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 instructionsconcerning your personal safety. Watch for this symbol;

it points out important safety precautions, it meansattention, become alert! Your personal safety isinvolved. Read the message that follows and be alert tothe possibility of personal injury or death. Be alert; yoursafety is involved. While it is impossible to warn aboutevery conceivable hazard, let good common sense beyour guide.

This symbol is used to call your attention to instructions

on a specific procedure that if not followed may damageor reduce the useful life of the compressor.

This symbol is used to call your attention to additionalinstructions or special emphasis on a specific procedure.

Safety Precautions

Read this information before operating the compressor for the firsttime. Follow the information and procedures in this manual foroperation, maintenance and repair. Observe the following items toreduce the chance of personal injury or equipment damage.Follow all safety precautions for mechanical work. Moving drive beltsor fan blades are an extreme hazard. Stay clear of all moving partswhen the system is operating. Only qualified personnel shouldperform maintenance and repair on system components with thewelder/compressor shutdown.

Proper service and repair are important to the safety of the servicetechnician and the safe, reliable operation of the equipment. Alwaysuse genuine VMAC replacement parts; do not use a substitute.

The procedures described in this service manual are effectivemethods of service and repair. Some procedures may require the useof tools specially designed for a specific purpose. Anyone using areplacement part, service procedure or tool must first determine thatneither their safety nor the safe operation of the equipment will becompromised by the replacement part, service procedure or toolselected.


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This manual contains various warnings, cautions and notices thatmust be observed to reduce the risk of personal injury during serviceor repair and the possibility that improper service or repair may

damage the equipment or render it unsafe. Be aware that it isimpossible to warn of all the possible hazardous consequences thatmight result from failure to follow these instructions.

Fire and Explosion Hazards

Fire in the compressor can cause an explosion and flameprojection. Should this occur, there is potential for serious

injury or death.

Vaporized oil propelled by high-pressure air is an explosivemixture.

You must observe the following when operating the compressor:

constant vigilance is necessary around high-energyequipment

be attentive for unexplained changes in operationparameters 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 offlammable vapors

Personal Hazards

Follow all safe work practices. Wear the appropriate safetyequipment.

Do not breathe the compressor air. Vaporized oil is arespiratory hazard.


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Always use the appropriate personal protectiveequipment, particularly eye and hearing protectionwhen operating air-powered equipment.


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The compressor system is under sufficient pressure that aleak could force the oil/air mixture through the skin directlyinto your blood stream. This will cause death.

Even with the compressor turned off, if the engine isrunning the compressor can produce up to 50 PSI (414KPA) of pressure. Never work on the compressor systemwith the engine running. Never work on the compressorsystem while it is pressurized. Always ensure that thecompressor system has been depressurized prior to anyservicing or maintenance. Always allow a suitable length

of time for components to cool .

The compressor and the compressor system gets veryhot during operation, contact with the components orthe oil can cause serious burns.

The compressor system is protected from over pressurization by amechanical inlet control in the compressor that regulates air flow inresponse to the demand. There is also a 200 PSI (1,379 kPa)

pressure relief valve in the oil/air separation tank to protect thesystem from over pressurization.

VMAC certified and approved high performance synthetic oil is usedto lubricate the compressor and is the only approved lubricant.Any other oil may void the warranty. The oil/air separator tankremoves most of the oil from the compressed air and the coalescingseparating filter removes the remaining oil. The oil is passed througha replaceable filter to remove contaminants.

The compressor intake is equipped with a replaceable paper filterelement.


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Illustrated Parts Lists

New Model Cummins G4481 System

Old Model Cummins G4481 System

Kubota G6204 System


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Figure 1 New Model Cummins G4481 System Diagram


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Parts List For New Model Cummins G4481 System

Item QTY Part # Description1 1 1710619 Hose Assembly, Oil/Air Separator Tank to Cooler2 1 1710620 Hose Assembly, Oil Cooler to Manifold3 1 1710759 Tube, 1/4 Outside Diameter, Scavenge Line

(White), Manifold to Compressor4 1 9300058 Assembly, Bracket, Manifold5 1 P170002 Assembly, Compressor6 1 9300064 Inlet Valve, G44817 1 1710618 Hose Assembly, Discharge, Manifold to Supply

Valve

8 1 1710714 Tube, 1/4 Outside Diameter, Compressor On/Off(Red), Solenoid Valve to Inlet Valve

9 1 4800366 Assembly, Solenoid Valve10 1 3550685 Electrical Harness11 1 4800371 Assembly, Discharge Valve12 1 1710624 Hose Assembly, Supply, Compressor to Oil/Air

Separator Tank13 1 9300055 Assembly, Tank, Aluminum

14 1 1710627 Hose Assembly, Oil/Air Separator Tank to Manifold15 1 9300056 Assembly, Cooler16 1 1710619 Hose Assembly, Oil/Return, Manifold to

compressor17 1 1710622 Tube, 1/4 Outside diameter, System Pressure

(Black), Manifold to Inlet Control Valve18 1 1200366 Bracket, Compressor19 1 1200365 Bracket, Compressor20 1 1710623 Tube, 1/4 Outside Diameter, System Pressure

(Black), Manifold to Inlet Control Valve21 1 3800507 Fastener Pack S70003322 1 4800375 Assembly, Tube Oil Extension

23 1 4800390 Assembly Oil Dipstick


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Figure 2 Old Model Cummins G4481 System Diagram


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Parts List for Old Model Cummins G4481 System

Item QTY Part # Description1 1 1710619 Hose Assembly, Oil/Air Separator Tank to Cooler2 1 1710620 Hose Assembly, Oil Cooler to Manifold

3 1 1710621 Tube, 1/4 Outside Diameter, Scavenge Line(White), Manifold to Compressor

4 1 4800382 Assembly, Bracket, Manifold5 1 1710625 Tube, 1/4 Outside Diameter, Compressor

On/Off, (red) Solenoid to Manifold6 1 P170002 Assembly, Compressor7 1 1710626 Hose Assembly, 338 1 *9300016/

9300064

Assembly, Inlet Control Valve

9 1 4800366 Assembly, Solenoid Valve10 1 1710618 Hose Assembly, Discharge, Manifold to Supply

Valve11 1 3550685 Electrical Harness12 4800371 Assembly, Discharge Valve13 1 1710624 Hose Assembly, Supply, Compressor to Oil/Air

Separator Tank

14 1 1710623 Tube, 1/4 Outside Diameter, (Black) Compressorto Solenoid Valve15 1 9300031 Assembly, Tank, Steel16 1 1710627 Hose Assembly, Oil/Air, Separator Tank to

Manifold17 1 1200365 Bracket, Compressor18 1 1200366 Bracket, Compressor19 1 1710623 Tube, 1/4 Outside Diameter, (Black) Manifold to

Inlet Control Valve

20 1 1710619 Hose Assembly, Oil Return, Manifold toCompressor

21 1 9300022 Assembly, Cooler22 1 3800507 Fastener Pack S70003323 1 4800375 Assembly, Tube Oil Extension24 1 4800390 Assembly Oil Dipstick

* Please Note: 9300016 used on all units with serial number

S700033|0|S|A|006 to S700033|A|U|E|0089300064 used on all other units.


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Figure 3 - G6204 Kubota Type System


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Parts List for G6204 Kubota Type System

Item QTY Part # Description1 1 9300068 Assembly, Cooler

2 1 1752049 Hose Assembly, Oil Cooler to Manifold

3 1 1710622Tube 1/4 Outside Diameter, SystemPressure, (Black), Manifold to InletControl Valve

4 1 1751018Hose Assembly, Oil Return, Manifold toCompressor

5 1 1710759Tube, 1/4 Outside Diameter, ScavengeLine, (White), Manifold to Compressor

6 1 9300070 Assembly, Manifold7 1 1770057

Hose Assembly, Oil/Air Separator Tankto Manifold

8 1 9300071 Inlet Control Valve

9 1 1710714Tube, 1/4 Outside Diameter,Compressor On/Off, (Red), SolenoidValve to Inlet Valve

10 1 4800366 Assembly, Solenoid Valve11 1 9300077 Assembly, Tank, Aluminum12 1 3550685 Electrical Harness

13 1 1710760Tube, 1/4 Outside Diameter, (Black),Compressor to Solenoid Valve

14 1 1772030Hose Assembly, Supply, Compressor toOil/Air Separator Tank

15 1 4800527 Assembly, Discharge Valve

16 1 1752034

Hose Assembly, Oil/Air Separator Tank

to Cooler

17 1 1770079Hose Assembly, Discharge, Manifold toSupply Valve

18 1 P170024 Assembly Compressor19 1 3800700 Fastener Pack, S70006620 1200553 Bracket, Tank Brace


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2.0 PreparationBefore commencing work ensure that the unit is elevated andsupported safely to enable you to work underneath. If the unit has

just been used, ensure that all components are cool enough to workon and all air pressure has been discharged.

2.1 Disconnect battery.

2.2 Drain compressor system oil.

2.3 Drain coolant (if removing the cooler G4481 only).

2.4 Remove the unit side panels for good access. Label allhoses and air lines and wiring before disconnection.

3.0 Compressor removal andreinstallation

3.1 Disconnect the black, red and clear poly lines from the inletcontrol valve. Remove the inlet control valve from thecompressor (4 M8 socket head bolts). Take note of thediffering bolt lengths and orientation and ensure that they areinstalled in this manner when reinstalling the inlet valve.

Cover the inlet to the compressor rotors to preventdebris entering.

3.2 Remove the 3/4 air discharge hose from the compressor.

3.3 Disconnect the 1/2 oil return hose from the compressor tothe oil filter manifold, at the compressor end.

3.4 Remove the rear compressor support bracket from thecompressor and the engine bracket.

3.5 Loosen the two front compressor securing nuts on the

engine studs and slide the compressor back to allow nuts tobe removed.


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3.6 Remove the compressor by sliding it off the splines.


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3.7 To install the compressor, follow this procedure in reverseorder. Be sure to engage the splines correctly and ease thecompressor into position and support the rear of the

compressor. Fit new studs and nuts, use Loctite 242 on allengine fasteners.

4.0 Tank removal, andreinstallation G4481

To remove the tank will require loosening the engine

mounting bolts and lifting the engine slightly. This willallow just enough room for the tank to be maneuveredout.

4.1 Disconnect the wiring to the temperature probe at the tank

4.2 Disconnect the 1/2 oil return hose to the cooler.

4.3 Disconnect the 3/4 air discharge hose from the tank to thecoalescing filter/ manifold.

4.4 Disconnect the 3/4 air discharge hose connection from thecompressor to the tank and remove the hose, note theangled crimp end connection is at the compressor.

4.5 Support the tank and undo the four bolts locating the tank tothe frame brackets. Lift out the tank.

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

5.0 Tank removal, andreinstallation G6204

To remove the tank will require releasing the front floor

section on the radiator side of the machine to gainaccess.


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5.1 Disconnect the 1/2 oil return hose to the cooler, at the tank(label connection).

5.2 Disconnect the 3/4 discharge hose from the compressor atthe tank.

5.3 Disconnect the 3/4 tank air discharge hose to the filtermanifold at the tank.

5.4 Disconnect the temperature probe switch wiring at the tank.

5.5 Remove the four bolts locating the separator tank to themounting bracket.

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

6.0 Oil filter manifold removal andreinstallation

6.1 Disconnect and remove the 1/2 oil return hose to the top of

the oil filter.

6.2 Disconnect the 1/2 oil return hose from the side connectionon the oil filter.

6.3 Remove the air discharge hose from the coalescing filterto the shutoff valve.

6.4 Remove the white poly line to the fitting on the top of the oil

filter manifold.

6.5 Remove the black poly tube from the 90-degree fitting on topof the oil filter manifold.


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To release the poly tube from the fittings, push in ordown on the outer ring and pull the tube out.

6.6 Undo the two bolts holding the oil filter manifold bracket tothe engine front mount plate and remove the filters andmanifold.


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7.0 G4481 earlier modelProceed as above but remove the additional poly tubes from the 90-degree 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 andreinstallation G4481

8.1 Place a drain can under the cooler to catch the residuecoolant.

8.2 Disconnect the top and bottom coolant hoses from thecooler.

8.3 Disconnect the two oil hoses from the connections on thecooler. (label all the connections).

8.4 Undo the two bolts that hold the cooler to the engine mountbracket and remove the cooler.

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

9.0 Cooler removal and

reinstallation G6204Remove the panel carefully from the non-service side of the machinewhere the oil cooler is located. This will need to be supported as theoil cooler hoses, three sensors electrical wires and fan wiring will stillbe attached at this point.

9.1 Disconnect the red wire labeled, Line 405 and the two

black ground wires which connect to the welder wiringharness.


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9.2 Disconnect the oil hoses to the cooler, mark or note thecorrect connections for the top and bottom. Top oil hose ishot IN from the tank. Bottom is Cooled out to oil filter.

9.3 Remove the six bolts locating the cooler to the panel. Note

the six spacers between the cooler and the panel and keepthem for reinstallation.

9.4 Drain oil from the cooler.

To install the cooler, reverse this procedure. Make sure the sixspacers are installed between the cooler and the panel.

Hoses

Reassemble and fit new oil hoses and poly lines as required followingall the marked connections. It is important to have the hoses and polylines connected correctly for correct compressor function.Replacement hoses should be clear of all moving or hot systemcomponents.

Do not route the hoses adjacent to objects which could

abrade the hoses causing failure of the hose andpotential 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 MUSTbe flushed with 4 liters of compressor oil and the systemmust be run to temperature. Then re-drain the oil andchange 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 thecompressor. Set up the system as per operators manual Lincoln AirVantage 500 System Flushing Procedure.

When adding oil to the system it should be taken into

account that there will be residual oil remaining invarious components. If the system is overfilled oil carry-over may result.

Approximate Component amounts.

System Component S700033 S700066

Compressor 200ml, 200ml

Compressor to tank discharge hose 400ml 400ml

Oil Filter Coalescing filter unit 400ml 400mlTank 3.5 L 3.0L

Cooler 500ml 1L

Total 5L 5L

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

11.0 Component Failure ProcedureThe following procedure should be followed in the event ofcomponent failure, such as compressor, gearbox, tank, hose orcooler core. In short, any component failure which could introduceforeign material into the oil system.

1. Prior to the replacement of any failed components, check allother system components for evidence of contamination and

thoroughly clean as far as is practical. This may involve blowingout lines / compressor with compressed air etc.

2. When all reasonable precautions have been made to remove anyforeign materials from the oil system, install the replacementcomponent and reconnect all lines.

3. Add 4L of VMAC compressor oil to the system. The VMAC oilhas 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. withoutdischarging any compressed air from service air lines.


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5. Perform a 500hr service.

12.0 Servicing Intervals and

InformationRegular service intervals are 500 hours. Use service kit P/N A700100this includes:

VMAC Part Number Description

3600037 Air Filter

9200039 Oil Filter

A700091 VR High Performance Oil 1 L

A700094 VR High Performance Oil 4 L

Heavy Duty or extreme dust environment

VMAC Part Number Description

A700136 Remote Heavy Duty Air Filter (complete unit)

A700138 Remote Heavy Duty Air Filter w/Cyclone-70CFM

Heavy Duty or extreme dust environment service intervals

Change

Stock (small) Air Filters = 50 hours. of compressor use.

Heavy Duty Air Filters = 250 hours. of compressor use.

Oil = 250 hours. of compressor use.

Oil Filters = 250 hours. of compressor use.

Coalescent Filter = 250 hours. of compressor use.

Check / Inspect

Inspect air filter for contamination every 5 days whether compressor

has been used or not.


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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).

Documents

Lincoln Repair 1900909 A