Vanair ADHD Powertech, Installation, Operation, Maintenance And Parts List Manual

Page 1: ...g operating or servicing this equipment Failure to comply with the operation and maintenance instructions in this manual WILL VOID THE EQUIPMENT WARRANTY NOTE Use only Genuine Vanair Parts Inspect and...

Page 2: ...acement parts will be incurred by customer Factory installed units will also include warranty on the installation for one year Warranty will commence upon receipt of the Warranty Registration Card If...

Page 3: ...2 Fire and Explosion 1 4 1 3 Moving Parts 1 5 1 5 Hot Surfaces Sharp Edges and Sharp Corners 1 6 1 5 Toxic and Irritating Substances 1 7 1 6 Electrical Shock 1 8 1 7 Safety Decals 1 9 1 7 Section 2 D...

Page 4: ...2 8 Electrical System Functional Description 2 9 2 8 Section 3 Specifications 3 0 3 1 Compressor Specifications 3 1 3 1 Lubrication Guide Compressor 3 2 3 1 Application Guide 3 3 3 2 Section 4 Operati...

Page 5: ...6 5 6 2 Compressor Oil Change and Filter Replacement Procedure 6 5 1 6 2 Compressor Oil Change Procedure 6 5 1 1 6 2 Compressor Oil Filter Element Replacement 6 5 1 2 6 3 Air Filter Maintenance 6 5 2...

Page 6: ...8 1 8 1 Discharge System 8 2 8 2 Enclosure 8 3 8 4 Instrument Panel 8 4 8 6 Inlet Valve Assembly 8 5 8 8 Oil Cooling System electric 125 185 CFM 8 6 8 10 Above Deck Compressor Air Inlet and Parts 8 7...

Page 7: ...xle Weight Rating GPM Gallons per Minute GVWR Gross Vehicle Weight Rating HC Hydraulic Cooled HD Hydraulic Drive ICFM Inlet Cubic Feet per Minute PSI Pounds per Square Inch PSIG Pounds per Square Inch...

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Page 9: ...e the air compressor with a known unsafe condition Tag the air compressor and render it inoperative by disconnecting the battery so others who may not know of the unsafe condition will not attempt to...

Page 10: ...and the shutoff throttle valve when an air hose exceeding 1 2 13mm inside diameter is to be connected to shut off throttle valve to reduce pressure in case of failure per OSHA Standard 20 CFR 1926 302...

Page 11: ...and personal protective equipment per OSHA Standard 29 CFR 1910 242 b or any applicable Federal State and Local codes standards and regulations L DO NOT engage in horseplay with air hoses as death or...

Page 12: ...oded Keep all terminals clean and tight G Turn off battery charger before making or breaking connections to the battery H Keep grounded conductive objects such as tools away from exposed live electric...

Page 13: ...nts Tag the battery connection so others will not unexpectedly reconnect it F When adjusting the controls it may require operation of the equipment during adjustment DO NOT come in contact with any mo...

Page 14: ...s servicing personnel areas or towards the air intake of any portable or stationary compressor F Fuels fluids coolants lubricants and battery electrolyte used in the compressor are typical of the indu...

Page 15: ...to exposed live parts of the electrical system C Attempt repairs only in clean dry and well lighted and ventilated areas D Stay clear of the compressor during electrical storms It can attract lightni...

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Page 17: ...rvice Department 2 2 Sullair Compressor Unit Functional Description Vanair compressors feature the Sullair compressor unit a single stage positive displacement fluid lubricated type compressor This un...

Page 18: ...properly filtered it then flows on to the compressor unit where it lubricates seals and cools the compression chamber as well as lubricates the bearings and gears 2 4 Compressor Discharge System Func...

Page 19: ...DESCRIPTION Section 2 Pg 03 Figure 2 1 Compressor Discharge and Cooling and Lubrication System...

Page 20: ...e receiver on shutdown when the compressor is being run in parallel with other compressors tied to a large air system A pressure relief valve located on the wet side of the separator is set to open if...

Page 21: ...trucks engine to run at full speed The rising sump pressure begins to pass air through the minimum pressure orifice Modulation 100 to 115 PSIG Should less than the rated capacity of air be used the se...

Page 22: ...ting piping The air filter is a two stage dry element type filter This filter is capable of cleaning extremely dirty air However in such cases frequent checks of the air filter will be required See Se...

Page 23: ...e monitors the temperature of the air fluid mixture leaving the compressor unit The normal reading should be approximately 180 F to 210 F The reset button cancels and or resets over pressure over temp...

Page 24: ...wing is a list of flows and pressures for the appropriate compressor model C F M Nominal Air Pressure PSIG Compressor Speed R P M H P Min Recom System Pressure Oil Flow G P M 85 100 1460 23 3 2300 20...

Page 25: ...brication Guide Compressor IMPORTANT The compressor oil must be of a recommended type that is inspected and replace together with the oil and air filters in accordance with this manual CAUTION DO NOT...

Page 26: ...ditions condensed moisture may emulsify with the oil forming a milky color The fluid should be changed if this condition develops IMPORTANT DO NOT mix different types of fluids Combinations of differe...

Page 27: ...de the receiver tank at various load and unload conditions HOUR METER Indicates the cumulated hours of operation Useful for planning and logging service schedules COMPRESSOR DISCHARGE TEMPERATURE GAUG...

Page 28: ...to air demand SYSTEM BLOWDOWN VALVE Vents sump pressure to the atmosphere at shutdown 4 3 Initial and Routine Start Up Procedures The following procedure should be used to make the initial start up of...

Page 29: ...due to the rating of the Vanair supplied hydraulic motor 5 2 Installation Refer to Section 5 4 for dimensions A location on the truck is the first thing that needs to be determined Some of the concern...

Page 30: ...INSTALLATION Section 5 Pg 02 5 2 1 RECEIVER TANK INSTALLATION 1 Always install tank with drain plug at bottom 2 Do not install tank above height of compressor...

Page 31: ...INSTALLATION Section 5 Pg 03 5 3 Wire Diagram 266551_r1_ TP...

Page 32: ...INSTALLATION Section 5 Pg 04 5 4 Dimensions Diagram 263620_r1_ TP...

Page 33: ...cessary amount If the addition of fluid becomes too frequent a simple problem has developed which is causing this excessive loss See the Troubleshooting Section 7 2 Troubleshooting Guide under Excessi...

Page 34: ...ter element For element replacement see procedure for servicing the fluid filter in this section Fill the sump with fluid according to specifications in Section 3 6 5 1 1 Compressor Oil Change Procedu...

Page 35: ...the new gasket 4 Hand tighten the new element until the new gasket is seated in the gasket groove 5 Continue tightening the element by hand an additional 1 2 to 3 4 turn 6 Restart the compressor and...

Page 36: ...fer duct work between the air filter and compressor unit to be sure all clamps and joints are tight and there are no cracks in the ducting 2 The air filter mounting clamps and bolts must be tight to h...

Page 37: ...LOW DIRT OUT WITH COMPRESSED AIR 5 At this time clean or replace the element Part No 263931 Cleaning instructions follow 6 Install the element back into the body and replace the wingnut Tighten secure...

Page 38: ...ior to installation See 6 5 2 4 Air Filter Element Inspection 6 5 2 4 Air Filter Element Inspection 1 Place a bright light inside the element to inspect for damage or leak holes Concentrated light wil...

Page 39: ...act with the metal surface of the bolt ring and cover DO NOT use gasket sealer as it can insulate the staples causing the element not to be properly grounded for operation 7 Replace the sump cover and...

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Page 41: ...sually noticeable by discoloration or a burnt odor Should your problem persist after making the recommended check consult your nearest Vanair representative or Vanair Manufacturing Inc 7 2 Troubleshoo...

Page 42: ...r replace valve Defective Pressure Relief Valve Replace pressure relief valve INSUFFICIENT AIR DELIVERY Plugged Air Filter Replace Plugged Air Fluid Separator Replace separator element and also change...

Page 43: ...ompressor or from the Serial Number Plate located on the compressor Figure 8 1 Figure 8 1 Serial Plate Location Table 8A Recommended Spare Parts List Key No Description Part Order No 1 Oil Filter Repl...

Page 44: ...Section 8 Pg 02 8 2 Discharge System 9 34 26 34 9 43 13 32 43 6 15 27 36 24 6 41 20 21 22 23 20 18 41 1 6 3 6 P I 42 5 A B 4 28 37 39 37 17 30 19 40 38 14 44 1 33 12 11 2 A B 39 37 17 40 38 35 29 35...

Page 45: ...FPT x 1 4 MPT 269788 2 21 Sight Glass 1 4 FPT 269789 1 22 Valve Check 1 4 NPT Male 269893 1 23 Tee 1 4 MPT x 1 4 FPT x 1 4 MJIC 270115 1 24 Valve Blowdown 1 4 Piston 270807 1 25 Elbow Pipe Street 1 2...

Page 46: ...PARTS LIST ILLUSTRATION Section 8 Pg 04 8 3 Enclosure 263612...

Page 47: ...1 6 Panel End 263469 1 7 Panel Side R H 263471 1 8 Panel Side L H 263472 1 9 Panel Roof 263473 1 10 Angle Receiver Tank Mtg 263484 2 11 Capscrew Hex HD 1 4 20 x 829104 075 2 12 Capscrew Hex HD 5 16 18...

Page 48: ...PARTS LIST ILLUSTRATION Section 8 Pg 06 8 4 Instrument Panel 5 2 1 7 3 3 4 6 14 AMP FUSE VANAIR P N 260066 8 266579_r0...

Page 49: ...al Panel Overlay 261349 1 3 Switch High Temp Shutdown 260625 1 4 Gauge Temperature 266331 1 5 Gauge Pressure 261974 1 6 Gauge Hour Meter 040035 1 7 Elbow 1 4T x 1 8P Push on 261309 1 8 Coupling Pipe G...

Page 50: ...PARTS LIST ILLUSTRATION Section 8 Pg 08 8 5 Inlet Valve Assembly 265400_r0...

Page 51: ...w Socket Head M6 x 50 265400 005 2 6 Spring Inlet Check 265400 006 1 7 Stem Inlet Valve 265400 007 1 8 Valve Inlet Check 265400 008 1 9 Screw Socket Head M6 x 16 265400 009 5 10 O Ring Viton 3 1 4 x 3...

Page 52: ...PARTS LIST ILLUSTRATION Section 8 Pg 10 8 6 Oil Cooling System Electric 125 185 CFM 3 7 5 5 2 1 4 6 8 7 267870_r0...

Page 53: ...Cooler Oil 125 185 CFM 261992 1 3 Guard Cooler 125 185 EC 261968 1 4 Fan and Motor Assy 12V 264856 1 24V 265057 1 5 Elbow Swivel 90 3 4 FPT x 3 4 MPT 048429 2 6 Screw Hex Self Thread 1 4 x 3 4 834204...

Page 54: ...PARTS LIST ILLUSTRATION Section 8 Pg 12 8 7 Above Deck Compressor Air Inlet and Parts 6010092ID_r0...

Page 55: ...ng X Female Pipe Swivel 260105 009 1 4 Elbow 1 4t X 1 8p Push On 261309 2 5 Elbow 90 Deg Push On 1 4t X 1 4p 261310 2 6 Adapter 1 1 2 Pipe X 1 1 2 O Ring 261938 016 1 7 Tubing Flex 3 Air Intake 262090...

Page 56: ...PARTS LIST ILLUSTRATION Section 8 Pg 14 8 8 Above Deck Hydraulic Drive 6100047ID_r0...

Page 57: ...ng 263252 1 5 Motor Hyd 3 2 Cid 263365 1 5a Motor Hyd 4 5 Cid 263366 1 Ns Kit Bolt Package 264911 100 1 6 Hub Taper Lock E20 Htl Rexnord 408012 2 7 Bushing Taper Bore 1610 1 Bore 408014 1 8 Element Co...

Page 58: ...PARTS LIST ILLUSTRATION Section 8 Pg 16 8 9A Decal Locations 1 of 2 2 3 9 1 4 10 8 5 6 DO NOT REMOVE OR COVER ANY SAFETY DECAL Replace any safety decal that becomes damaged or illegible 7...

Page 59: ...PARTS LIST ILLUSTRATION Section 8 Pg 17 8 9B Decal Locations 2 of 2 1 DO NOT REMOVE OR COVER ANY SAFETY DECAL Replace any safety decal that becomes damaged or illegible 2 3 4 5...

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Page 61: ...__________ Generator Panel N A Location ________________________________________ Service Valve Locations _____________________________________________ Muffler Modifications ___________________________...

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Page 64: ...300 North Michigan City IN 46360 Phone 219 879 5100 800 526 8817 Service Fax 219 879 5335 Parts Fax 219 879 5340 Sales Fax 219 879 5800 www vanair com Printed in the U S A Specifications Subject to Ch...