Viper Diesel 100 PSI Rotary Screw Air Compressor

100 PSI ROTARY SCREW AIR COMPRESSOR

OPERATOR’S MANUAL & PARTS LIST

NOTE

This publication contains the latest information available at the time of preparation. Every effort has been made to ensure accuracy. However, Vanair

Manufacturing, Inc. takes no responsibility for errors or consequential damages caused by reliance on the information contained herein.

Vanair Manufacturing, Inc. reserves the right to make design change modifications or improvements without prior notification.

Read this manual before installing, 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 Vanair Vanguard™

Premium Synthetic Oil and

Genuine Vanair Parts. Inspect and replace damaged components before operation.

Substituting non-Vanguard™

Oil or non-genuine Vanair filter components WILL VOID THE

COMPRESSOR WARRANTY!

Vanair Manufacturing, Inc.

10896 West 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

NOTE

Making unauthorized modifications to the system components WILL VOID THE

WARRANTY!

Always inform Vanair

Manufacturing, Inc., before beginning any changes to the

Viper Diesel system.

KEEP THE MANUAL

WITH THE VEHICLE

©2014 Vanair Manufacturing, Inc.

All rights reserved.

P/N: 090053-OP_r0

Effective Date:

01-2014

WARRANTY: VIPER GAS/DIESEL ENGINE & VIPER HYDRAULIC AIR COMPRESSORS

The rotary screw compressor unit is warranted for life when adhering to the prescribed maintenance schedule.

The hydraulic motor on the hydraulic Viper is warranted for two (2) years. This warranty does not cover damage caused by accident, misuse or negligence. If a compressor unit is disassembled the warranty is void. Any disassembly of major components must be approved by Vanair to avoid voiding of warranty. All other parts including the compressor unit shaft seal are warranted for twelve (12) months subject to the same conditions mentioned previously. Any and all such claims for warranty consideration must be coordinated prior to work being performed through the Warranty-Service Department at the address below. Do not return parts without prior authorization.

Warranty is limited to the supply of replacement parts failing within the warranty period. Credit for labor required to refit replacement parts is NOT included. All warranted parts are to be shipped PREPAID to VANAIR. Replacement parts will be shipped back to the customer by VANAIR via ground shipment. Cost to expedite delivery of replacement parts will be incurred by customer.

Warranty will commence upon receipt of the Warranty Registration Card. If the Warranty Registration Card is not received within six (6) months, the warranty commencement date shall be thirty (30) days from the date of shipment from VANAIR. Records of warranty adherence are the responsibility of end user.

This statement of warranty is expressly in lieu of and disclaims all other express warranties, implied warranties of merchantability and fitness for a particular purpose and all other implied warranties which extend beyond the description on the face hereof. In no event shall Vanair be responsible for special, indirect, incidental, consequential or punitive damages of any kind, including without limitation, lost profits or other monetary loss, whether or not any such matters or causes are within Vanair's control or due to negligence or other fault of Vanair, its agents, affiliates, employees or representatives.

This warranty shall be void and VANAIR shall have no responsibility to repair, replace or repay the purchase price of defective or damaged parts resulting from the use of or repair of replacement parts or fluids not of VANAIR'S manufacture or from buyer's failure to store, install, maintain and operate the compressor according to the recommendations contained in the Manual.

All claims under the Warranty shall be made by contacting VANAIR Warranty-Service Department.

Please note that engines are warranted separately by the engine manufacturer.

Register Your Warranty Online at www.vanair.com under the Support Tab!

Or Call: (800) 526-8817 • Fax: (219) 879-5800

Mail to: 10896 W 300 North • Michigan City, IN 46360

Effective February 11, 2013

DIESEL VIPER 100 PSI TABLE OF CONTENTS

TABLE OF

CONTENTS

WARRANTY ............................................... BEHIND COVER

TABLE OF CONTENTS...................................................... I

WARRANTY CLAIMS PROCEDURE ................................ V

CLAIMS PROCESS FOR WARRANTED PARTS..................................................................................... V

PROCEDURE ........................................................................................................................................... V

SECTION 1: SAFETY .....................................................1

1.1

1.2

1.3

1.3.1

GENERAL INFORMATION......................................................................................................1

DANGERS, WARNINGS, CAUTIONS AND NOTES...............................................................1

SUMMARY OF DANGERS, WARNINGS CAUTIONS AND NOTES.......................................1

DANGERS ....................................................................................................................................................... 1

1.3.2

1.3.3

WARNINGS ..................................................................................................................................................... 1

CAUTIONS ...................................................................................................................................................... 2

1.4

1.3.4

SAFETY DECALS ........................................................................................................................................... 3

DISPOSING OF MACHINE FLUIDS .......................................................................................3

SECTION 2: SPECIFICATIONS ..........................................5

TABLE 2A: SPECIFICATIONS FOR VIPER DIESEL 100 PSI ROTARY SCREW COMPRESSOR ..........5

TABLE 2B: PRIME LUBRICANT CHARACTERISTICS.............................................................................6

SECTION 3: INSTALLATION..............................................7

3.1

3.2

MACHINE PACKAGE RECEIPT/INSPECTION............................................................................7

INSTALLATION INSTRUCTIONS.................................................................................................7

FIGURE 3-1: DIMENSION DIAGRAM - PART 1 OF 2..............................................................................8

FIGURE 3-1: DIMENSION DIAGRAM - PART 2 OF 2..............................................................................9

Continued on next page...

VANAIR MANUFACTURING, INC.

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090053-OP_r0 (JAN-2014)

PAGE - I

TABLE OF CONTENTS DIESEL VIPER 100 PSI

SECTION 4: OPERATION ................................................ 11

FIGURE 4-1: MAIN MACHINE COMPONENT LOCATIONS ................................................................. 10

4.1

GENERAL DESCRIPTION ..........................................................................................................11

4.2

INSTRUMENTATION ..................................................................................................................11

4.2.1

DIGITAL DISPLAY SCREEN................................................................................................................................11

4.2.2

SCROLL SELECTOR ROCKER SWITCH ..........................................................................................................11

4.2.3

ON/START AND STOP SELECTION ROCKER SWITCH .................................................................................. 11

4.3

4.4

4.5

4.6

INITIAL START-UP PROCEDURE..............................................................................................11

SUBSEQUENT START-UP PROCEDURE ................................................................................ 12

SHUTDOWN PROCEDURE....................................................................................................... 12

CONTROLLER GUIDE............................................................................................................... 12

4.6.1

HOME SCREEN.................................................................................................................................................. 12

4.6.2

SPLASH SCREEN .............................................................................................................................................. 13

4.6.3

ADJUSTING USER SETTINGS.......................................................................................................................... 13

4.6.3.1

PARAMETERS.............................................................................................................13

4.6.3.2

AUTO SHUTDOWN ................................................................................................... 13

4.6.3.3

AUTO CRANK............................................................................................................. 13

4.6.3.4

SLEEP STATE TIMER ................................................................................................13

4.6.4

SETTING PRESSURE .........................................................................................................................................13

4.7

4.8

4.6.5

SAFETY .............................................................................................................................................................. 13

4.6.6

SERVICE INTERVALS ........................................................................................................................................ 13

OPERATING CONDITIONS ....................................................................................................... 14

EXTREME CONDITIONS........................................................................................................... 14

SECTION 5: MAINTENANCE ........................................... 15

5.1

5.2

GENERAL INFORMATION ........................................................................................................ 15

ROUTINE MAINTENANCE SCHEDULE.................................................................................... 15

5.3A

MAINTENANCE SCHEDULE TABLE - COMPRESSOR INTERVALS....................................... 17

5.3B

MAINTENANCE SCHEDULE TABLE - ENGINE INTERVALS ................................................... 18

5.4

5.5

REPLACEMENT PARTS............................................................................................................ 21

PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES................................................ 21

5.5.1

ADJUSTING THE ENGINE SPEED..................................................................................................................... 21

5.6

5.7

SERVICING THE SYSTEM FUSES AND CIRCUIT BREAKER ................................................ 21

STORAGE AND INTERMITTENT USE...................................................................................... 22

5.7.1 INTERMITTENT USE................................................................................................................................................ 22

Continued on next page...

PAGE - II

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DIESEL VIPER 100 PSI TABLE OF CONTENTS

SECTION 5: MAINTENANCE (CONTINUED)

5.7.2 LONG TERM STORAGE .......................................................................................................................................... 22

SECTION 6: TROUBLESHOOTING .................................23

6.1.

6.2

GENERAL INFORMATION.........................................................................................................23

TROUBLESHOOTING GUIDE....................................................................................................24

6.3

EXTREME CONDITION OPERATION........................................................................................28

6.3.1

HIGH MOISTURE CONDITION: EMUSLIFICATION OF OIL IN

ROTARY SCREW COMPRESSOR SYSTEMS .................................................................................................... 28

TABLE 6.3A HIGH MOISTURE CONDITION OPERATION......................................... 29

6.3.2

COLD WEATHER OPERATION........................................................................................................................... 29

TABLE 6.3B COLD WEATHER OPERATION.............................................................. 30

6.3.3

HIGH TEMPERATURE OPERATION................................................................................................................... 30

TABLE 6.3C HIGH TEMPERATURE OPERATION.................................................................... 31

6.3.4

HIGH DUST CONTENT OPERATION ................................................................................................................. 31

TABLE 6.3D HIGH DUST CONTENT OPERATION................................................................... 31

6.3.5

HIGH ALTITUDE OPERATION ............................................................................................................................ 32

SECTION 7: ILLUSTRATED PARTS LIST .......................33

7.7

7.8

7.9

7.9

7.4

7.4

7.5

7.6

7.2

7.2

7.3

7.3

7.1

PARTS ORDERING PROCEDURE ............................................................................................33

TABLE 7A: RECOMMENDED SPARE PARTS LIST...............................................................................34

TABLE 7B: MACHINE OPTIONS LIST ....................................................................................................34

TABLE 7C: MAINTENANCE TRACKING LOG ........................................................................................35

COMPRESSOR REPLACEMENT PARTS (1 OF 2) ...................................................................36

COMPRESSOR REPLACEMENT PARTS (2 OF 2) ...................................................................38

ENGINE AND DRIVE PARTS (1 OF 2).......................................................................................40

ENGINE AND DRIVE PARTS (2 OF 2).......................................................................................42

COOLING SYSTEM (PART 1 OF 2) ...........................................................................................44

COOLING SYSTEM (PART 2 OF 2) ...........................................................................................46

CANOPY AND FRAME PARTS ..................................................................................................48

INSTRUMENT PANEL................................................................................................................50

ELECTRICAL SYSTEM ..............................................................................................................50

FUEL TANK ASSEMBLY ............................................................................................................52

DECAL LOCATIONS (PART 1 OF 2) (TYPICAL) .......................................................................54

DECAL LOCATIONS (PART 2 OF 2) (TYPICAL) .......................................................................56

7.10

WIRING DIAGRAM .....................................................................................................................58

7.11

SCHEMATIC FLOW DIAGRAM ..................................................................................................59

7.12

HOSE INSTALLATION GUIDE....................................................................................................60


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PAGE - III

TABLE OF CONTENTS DIESEL VIPER 100 PSI

BLANK PAGE

PAGE - IV

090053-OP_r0 (JAN-2014)


(800) 526-8817 • www.vanair.com

VIPER DIESEL 100 PSI WARRANTY PROCEDURE

WARRANTY CLAIMS

PROCEDURE

C

LAIMS PROCESS FOR

WARRANTED

V

ANAIR PARTS

This process must be used by owners of

Vanair

®

equipment in situations where a warranted item needs repair or replacement under the terms of the purchase warranty.

Do not return items to Vanair without prior authorization from the Vanair Warranty

Administrator.

P

ROCEDURE

:

When a customer needs assistance in troubleshooting a system and/or returning parts, follow the steps below.

1.

Locate the machine’s serial number:

The machine package serial number plate is located inside the machine compartment on the floor near to the engine air filter mounting location (see Figure W-1).

The engine and the compressor also have individual serial numbers respectively (see

Figure W-1). For engine warranty issues, consult the Engine Operator’s Manual for the engine’s limited warranty details. For particular compressor unit issues, the compressor serial number may be needed.

In any case, engine and/or compressor issues can be confirmed using the machine serial number as found in Figure W-1.

2.

Have a list of the symptoms/condition/ malfunctions along with any applicable temperature and pressure readings, and also the number of operational hours available:

Note that the above information will also need to be included on the Return Material


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090053-OP_r0 (JAN-2014)

Authorization Form (per Step #6); this form is necessary for warranty processing if the warranty claim is deemed valid by the service case review.

3.

Contact the Vanair

®

Service Department by phone (1-219-879-5100) to speak with a Service Technician.

4.

Vanair Service will troubleshoot the problem based on the information provided by the customer, and attempt to return the unit to service as quickly as possible.

5.

If the unit cannot be returned to service, and Vanair determines this matter is a warranty issue, the Service Technician will assign an RMA (Return Material

Authorization) number that will provide for the return of the item to Vanair for analysis and a final determination as to the item’s warranty status.

NOTE

The RMA number must be placed on the outside of the package being returned.

6.

Warranty Claims are solicited via a

Return Material Authorization (RMA)

Form. This form can be obtained via download from the web site, or requested directly from the Vanair Service

Department:

Once a current form has been obtained, follow the instructions given on the form to fill in the information needed. This form is used for the purpose of soliciting a warranty case.

All of the field information except for the bottom section block fields, which includes

PAGE - V

WARRANTY PROCEDURE

VIPER DIESEL 100 PSI

Engine Serial Number

Compressor Unit

Serial Number

Stamped On

Casing

NOTE

Machine serial number also displays on instrument panel at startup, on the hours screen.

Machine Serial Number

800-526-8817 www.vanai r.com

MODEL NUMBER

SERIAL NUMBER

MAXIMUM PRESSURE

COMPRESSOR INPUT RPM

260940

Figure W-1: Machine Serial Number Location

Disposition of Goods

, Notifications and

Additional Notes

, will be required.

Customers have 30 days after the RMA number is issued to return the item. If the part is not returned within this period, the

RMA is void and any claims will be denied.

NOTE

All labor claims or invoices must be approved by the Vanair Warranty

Administrator prior to starting repair work along with the cost of the repair. All paper work associated with the returned item and warranty repair cost must reference the RMA number issued against the part, and be forwarded to Vanair within 30 days of the completion of work.

Before sending a warranty part to a customer, Vanair

®

will need a P.O. or credit card number to cover the cost of the part and shipping. After the part is analyzed and deemed to be covered under warranty,

Vanair will issue credit to the customer. All parts eligible for warranty must have the

RMA number on the invoice at the time of purchase.

No items can be returned “freight collect”.

Freight costs will be addressed at the time the claim is closed. The customer pays any additional costs for warranty parts delivered through expedited services (i.e., Next Day,

Second Day).

VANAIR WILL NEVER ACCEPT ANY

INVOICES FOR PARTS RETURNED: ANY

PARTS RETURNED VIA INVOICE WILL BE

RETURNED FREIGHT COLLECT: NO

PARTS ARE TO BE RETURNED FREIGHT

COLLECT!

Vanair Mfg., Inc. strives to continuously improve its customer service. Please forward any questions, comments, or suggestions to

Vanair Service (219-879-5100, ext. 400) or email us ([email protected]).

PAGE - VI

090053-OP_r0 (JAN-2014)


(800) 526-8817 • www.vanair.com

VIPER DIESEL 100 PSI SECTION 1: SAFETY

SECTION 1:

SAFETY

1.1 GENERAL INFORMATION

IMPORTANT

harm. When you see the international warning symbol, pay extremely careful

attention, and follow the given instructions or indications to avoid any possible hazard.

Read this manual before operating or servicing the Viper Diesel compressor system. Failure to do could result in damage equipment, bodily injury, or death

The products provided by Vanair

®

Manufacturing, Inc., are designed and manufactured for safe operation and maintenance. But it is ultimately the responsibility of the users and maintainers for safe use of this equipment. Part of this responsibility is to read and be familiar with the contents of this manual before operation or performing maintenance actions.

1.2 DANGERS, WARNINGS,

CAUTIONS AND NOTES

These boxes are labeled clearly with the title block listing either Danger, Warning,

Caution, or other non-safety issue. They draw attention to specific issues that are pertinent to the safe and correct operation of the machine.

The symbols shown and defined in Section

1: Safety are used throughout this manual and on the machine to call attention to, and identify, possible hazards.

The international warning symbol (shown below) is used on all decals, labels and signs that concern information pertaining to bodily

1.3 SUMMARY OF WARNINGS,

CAUTIONS AND NOTES

These boxed inserts are placed throughout this manual in the sections where they apply.

This subsection is a general summary of their contents.

1.3.1 DANGERS

• Keep tools or other conductive objects away from live electrical parts.

• Never touch electrical wires or components while the machine is operating. They can be sources of electrical shock.

1.3.2 WARNINGS

• DO NOT EVER use this compressor as a breathing air source. Vanair Manufacturing

Inc., disclaims any and all liabilities for damage or loss due to fatalities, personal injuries resulting from the use of a Vanair compressor to supply breathing air.

• DO NOT perform any modifications to this equipment without prior factory approval.

• DO NOT install this compressor in a confined space that lacks proper ventilation and airflow; breathing and cooling air circulation must not be compromised.

• DO NOT operate the compressor or any of its systems if there is a known unsafe condition. Disable the equipment by disconnecting it from its power source.

Install a lock-out tag to identify the


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PAGE - 1

SECTION1: SAFETY VIPER DIESEL 100 PSI

equipment as inoperable to other personnel.

• DO NOT operate the compressor with any by-pass or other safety systems disconnected or rendered inoperative.

• DO NOT operate the equipment while you are under the influence of alcohol or drugs.

• DO NOT operate the equipment while you are feeling ill.

• DO NOT attempt to service the equipment while it is operating.

• Before performing maintenance, or replacing parts, relieve the entire system pressure by opening a service valve which will vent all pressure to the atmosphere: remove all electrical power.

• DO NOT use the compressor for purposes other than for which it is intended. High pressure air can cause serious and even fatal injuries.

• DO NOT operate the compressor outside of its specified pressure and speed ratings. (See

Section 2:

Specifications or refer to the equipment data plate.)

•

DO NOT use flammable solvents or cleaners for cleaning the compressor or it parts.

• DO NOT operate the compressor in areas where flammable, toxic, or corrosive fumes, or other damaging substance can be ingested by the compressor intakes.

• Keep arms, hands, hair and other body parts, and clothing away from fans, drive shafts, and other moving parts.

• DO NOT wear jewelry, unbuttoned cuffs, ties, or loose-fitting clothing when you are working near moving/rotating parts.

• ALWAYS confine long hair when working near moving/rotating parts.

• NEVER operate the equipment while wearing a headset to listen to music or the radio.

• Wear personal protective equipment such as gloves, work shoes, and eye and hearing protection as required for the task at hand.

• DO NOT operate the compressor with any guards removed or damaged, or other safety devices inoperative.

PAGE - 2

• DO NOT operate the compressor in enclosed or confined spaces where ventilation is restricted or closed-off.

• Ensure that hoses connected to service valves are fitted with correctly sized and rated flow limiting devices which comply with applicable codes. Pressurized broken or disconnected hoses can whip causing injuries or damage.

• Over speed is hazardous! NEVER tamper with the governor components or settings to increase the maximum speed. Severe personal injury and equipment damage can result if operated at speeds above the maximum.

• DO NOT use tools, hoses, or equipment that have maximum ratings below that of this compressor.

• Keep metal tools, and other conductive objects away from live electrical components.

• Before performing maintenance or repair operations on the compressor, ensure that all power has been removed and been locked out to prevent accidental application.

• DO NOT assume that because the compressor is in a STOPPED condition that power has been removed.

• Use this compressor only to compress atmospheric air. Use of this equipment as a booster pump and/or to compress any other gaseous or aerosol substance constitutes improper use. It can also cause damage or injuries. Such misuse will also void the warranty.

• Install, operate, and maintain this equipment in full compliance with all applicable OSHA, other Federal, state, local codes, standards, and regulations.

• When lifting objects, be aware of proper lifting techniques to avoid injury.

• ALWAYS read and follow safety related precautions found on containers of hazardous substances.

• DO NOT play with compressed air. It can cause serious injury.

1.3.3 CAUTIONS

• Check all safety devices for proper operation on a routine basis.

• Ensure that no tools, rags, or other objects are left on compressor drive systems or near intakes.

090053-OP_r0 (JAN-2014)


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VIPER DIESEL 100 PSI SECTION 1: SAFETY

• Keep the equipment clean when performing maintenance or service actions. Cover openings to prevent contamination.

• DO NOT operate the compressor if cooling air is not available (fan/cooler not operating) or if lubricant levels are below their specified minimum levels.

• Ensure all plugs, hoses, connectors, covers, and other parts removed for maintenance actions are replaced before applying power to the compressor.

• Avoid touching hot surfaces and components.

• Ensure that electrical wiring, terminals; hoses and fittings are kept in serviceable condition through routine inspections and maintenance. Replace any damaged or worn components.

• DO NOT install safety devices and/or replacement parts other than authorized

Vanair

®

replacement parts.

• Keep personnel out of line with, and away from discharge opening of valves, hoses and tools.

• Immediately clean up any lubricant or spills.

1.3.4 SAFETY DECALS

Safety decals are placed onto, or located near, system components that can present a hazard to operators or service personnel. All pertinent decals listed in Section 7.9, Decal

Locations are located near a component, which is subject to respect in terms of safety precautions. Always heed the information noted on the safety decals.

WARNING

DO NOT REMOVE OR COVER ANY

SAFETY DECAL. Replace any safety decal that becomes damaged or illegible.

1.4 DISPOSING OF MACHINE

FLUIDS

Always dispose of machine fluids under the guidance of all applicable local, regional and/ or federal law.

Vanair

®

encourages recycling when allowed.

For additional information, consult the container label of the fluid in question.


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090053-OP_r0 (JAN-2014)

PAGE - 3

SECTION 1: SAFETY VIPER DIESEL 100 PSI

BLANK PAGE

PAGE - 4

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VIPER DIESEL 100 PSI SECTION 2: SPECIFICATIONS

SECTION 2:

SPECIFICATIONS

TABLE 2A: SPECIFICATIONS FOR VIPER DIESEL 100 PSI ROTARY SCREW COMPRESSOR

GENERAL SYSTEM

INFORMATION

SPECIFICATION

ENGINE

Diesel 25HP

I

Engine Speed

Engine Oil Capacity

Fuel Consumption

Fuel Tank Capacity

Fuel Type

Idle Speed: 2200 RPM

II

// Full Speed: 3600 RPM

Four (4) Quarts 15W40 (Refer to Engine Operator’s Manual for Extreme

Conditions)

1.25 GPH at Full Engine Speed / Load Nine (9) Hour Runtime (one gallon/hour @ 60% Duty Cycle)

Nine (9) Gallons

Diesel Fuel

III

Operating Temperature Limits

COMPRESSOR

Air Compressor Capacity

Inlet Control

Air Filter

+20 °F (-7°C) to 120 °F (49 °C)

IV

Single Stage, Oil Injected Rotary Screw

80 CFM

Electric

Pleated Paper, Dry Type

Table continued on next page

I

For specification and requirements regarding the Kubota

®

25 HP Diesel Engine, refer to the Engine Operator’s

Manual. IMPORTANT: Do not adjust the engine speed without first consulting the Vanair

®

Service Department

(refer to Section 5.5.1).

II

Idle speed: 48 CFM @ 100 PSIG @ 2200 RPM.

III

Vanair recommends: Diesel Fuel Specification Type and Sulfur Content % (ppm) used must be compliant with all applicable emission regulations for the area in which the engine is operated.

Engine manufacturer recommends a fuel sulfur content of less than 0.10% (1000 ppm). For fuels with a high sulfur content 0.50% (5000 ppm) to 1.0% (10000 ppm) a more frequent engine oil and oil filter change schedule is needed

(approximately half). DO NOT USE fuels with a sulfur content greater than 1.0% (10000 ppm). For additional information on fuel for this engine, consult Section 6.3 (Extreme Condition Operation), and the Engine Operator’s

Manual.

IV

With cold weather option kit temperature range expands to: -40 °F (-40 °C). Refer to Section 7, Table 7B for options list.

NOTE: Specifications are subject to change without notice.


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PAGE - 5

SECTION 2: SPECIFICATIONS VIPER DIESEL 100 PSI

TABLE 2A: SPECIFICATIONS FOR VIPER DIESEL 100 PSI ROTARY SCREW COMPRESSOR (cont.)

GENERAL SYSTEM

INFORMATION

SPECIFICATION

COMPRESSOR (specifications continued from previous page)

Oil Filter

Spin-on Style

Oil Capacity / Type

Air End - 1.2 Gallons (Approximately 5 Quarts) // Machine - 1.5 Gallons

(6 Quarts) (Vanguard™ Premium Synthetic Oil)

200 PSIG

Safety Relief Valve Setting

Operating Temperature Range

(ambient)

-20 °F (-29 °C) to 120 °F (49 °C)

Operating Pressure Range

60-100 (Maximum) PSI; Pressure setting is set at factory to 100 PSI, but

may be adjusted downward accordingly.

Electrical System

Cooling System

12 VDC

Air to Oil Heat Exchanger

Instrumentation Display

Hour, Fuel, Compressor Temperature, Pressure, RPM

NOTE: Compressor adjustment should be set in accordance with rated RPMs.

NOTE: Specifications are subject to change without notice.

TABLE 2B: PRIME LUBRICANT CHARACTERISTICS

Viscosity

178 SUS (38 cst) at 100 °F (38 °C)

Flashpoint

Pour Point

Contains

457 °F (236 °C)

-49 °F (-45 °C)

Rust and Oxidation Inhibitors and Detergents

PAGE - 6

090053-OP_r0 (JAN-2014)


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VIPER DIESEL 100 PSI SECTION 3: INSTALLATION

SECTION 3:

INSTALLATION

3.1 MACHINE PACKAGE

RECEIPT/INSPECTION

Upon receipt of the machine package, inspect the exterior of the shipping crate for signs of shipping/transit damage. Any damage should be reported immediately to the shipping company. Open the lid and inspect the component parts and supports to ensure that there has been no internal movements of assemblies or components which may have caused damage. To install the Viper Diesel Compressor System, refer to the following sections.

NOTE

Contact Vanair

®

at

(219) 879-5100 / (800) 526-8817

Service Fax: (219) 879-5335 www.vanair.com

to report missing items, incorrect part numbers, or other discrepancies.

3.2 INSTALLATION INSTRUCTIONS

DANGER

DO NOT install in enclosed spaces.

WARNING

ELECTRICAL HAZARD! Be sure the battery is disconnected before starting the installation.

NOTE

In order to prevent accidental damage to vehicle components (fuel tanks, lines, brake lines, wiring harnesses), note their location before drilling any holes.

Refer to Figure 3-1 (parts 1 and 2), and the following procedure:

1. Position the machine so that there is no restriction of cooling air through the enclosure (minimum of 12 inches from front access side; minimum of six inches from rear side, and approximately 2.5 inches from nonvented, width panel side). Cooling air enters the enclosure through the front and rear panels, passes through the cooler, and exits through vents in the end shroud.

2. Ensure that adequate height and clearance exists to allow for the hood to open (minimum of 49.9 inches from mounting surface), and a clear passage for service allowance to the maintenance access panel located at the back.

3. Mounting surface or support should be adequate for the weight of the machine and should be level for normal operation.

Mounting holes for four (4) 1/2” hold down bolts are provided. Refer to

Section 7, Illustrations and Parts Lists

for additional installation and system schematic drawings.

4. Service connections are conveniently grouped at the end of the unit in the base frame.

5. Electrical connections (system designed for 12VDC negative ground).

Ensure all supply hoses and electrical wiring are correctly specified, adequately supported and do not touch or rest on any sharp edges.

Wiring should be protected with split loom to prevent corrosion and consequently, loose due to down time.


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PAGE - 7

SECTION 3: INSTALLATION VIPER DIESEL 100 PSI

3.3 INSTRUMENT PANEL

RELOCATION

The Viper Diesel 100 PSI compressor allows for the instrument panel to be mounted at either the front or back side of the machine package canopy. If desired, the instrumentation panel can be re-located if it better-suits the vehicle’s mounting allowance space, or the compressor’s functions (see

Figure 3-1, Part 1 of 2, for optional panel location). Please note that if relocating the panel to re-apply any zip ties that were cut to re-establish the cable wire to the new location. Tying the wire at intervals may be needed to secure the panel cable away from moving objects or sharp edges during operation.

PAGE - 8

DISCLAIMER

If machine package is to be mounted within a confined space such as beneath a canopy, the area must be determined to allow for adequate air flow to take place for cooling purposes. Consult factory for assistance in ensuring adequate air flow before mounting the machine.

NOTE

The dimensions listed in this diagram are the minimum required clearance distances needed for properly cooling the machine. Additional clearance room may be desired for easier access for control and/or maintenance functions.

050846_r3_1of2

Figure 3-1: Dimension Diagram - Part 1 of 2

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VIPER DIESEL 100 PSI SECTION 3: INSTALLATION


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Figure 3-1: Dimension Diagram - Part 2 of 2

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050846_r3_2of2

PAGE - 9

SECTION 4: OPERATION VIPER DIESEL 100 PSI

G

H

J

K

L

M N

Z

P

F

E

D

C

Q

R

Y

X

W

U

T

V

S

AA

B

A

KEY

A

B

C

D

DESCRIPTION

BATTERY

DIESEL FUEL PORT CAP

COMPRESSOR UNIT

COMPRESSOR AIR FILTER

KEY

K

DESCRIPTION

ENGINE OIL FILL PORT CAP

L

COOLER ASSEMBLY -

OIL COOLER RADIATOR

M

COOLER ASSEMBLY - ENGINE

RADIATOR

E

RELAY

N

RADIATOR FILL PORT CAP

F

FUSES

G

PRESSURE RELIEF VALVE

H

ENGINE EXHAUST MUFFLER

J

LIFTING BAIL

P

COOLING FAN ASSEMBLY

Q

COOLANT RECOVERY TANK

R

RADIATOR DRAIN VALVE

S

ENGINE OIL DRAIN OUTLET / TUBE

I

Orifice located in-line/behind sight glass.

II

There is an oil dipstick indicator located on either side of the engine.

KEY DESCRIPTION

T

ENGINE AIR FILTER

U

COMPRESSOR OIL DRAIN OUTLET

/ TUBE

V

COMPRESSOR OIL FILL PORT CAP

W COMPRESSOR AIR / OIL

SEPARATOR

X

SCAVENGE LINE SIGHT GLASS

I

Y

COMPRESSOR OIL FILTER

Z

ENGINE OIL FILTER

AA ENGINE OIL LEVEL / DIP STICK

INDICATOR

II

Figure 4-1: Main Machine Component Locations

PAGE - 10

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VIPER DIESEL 100 PSI SECTION 4: OPERATION

SECTION 4:

OPERATION


Refer to Figure 4-1. The Vanair

®

Viper

Diesel 100 PSI compressor has a comprehensive array of controls and indicators for optimum machine performance. Understanding the correct operation of the system will help to distinguish between a properly functioning system, and a system that may be indicating the beginning of a malfunction. The information in the Operation Section will help the operator to recognize and interpret the readings to assure that the system is performing optimally.

NOTE

Before starting the Vanair Viper Diesel

100 PSI compressor, read this section thoroughly and familiarize yourself with the controls and indicators - their purpose, location and use.

NOTE

If start-up and shut-down procedures are not followed, damage to the system and its components may occur.

4.2 INSTRUMENTATION

Refer to

Figure

4-2. The standard instrument panel for the Viper Diesel 100 PSI compressor features a digital display screen with scrolling and operational rocker switches.

4.2.1 DIGITAL DISPLAY SCREEN

The air pressure readout monitors service air pressure and incorporates an over-pressure shutdown function.

4.2.2 SCROLL SELECTOR ROCKER

SWITCH

The scroll selector rocker switch allows the operator to navigate through the settings and displays related to the machine’s functions during operation.

4.2.3 ON/START AND STOP SELECTION

ROCKER SWITCH

The ON/START AND STOP selection rocker switch is used to turn the machine on and off.

4.3 INITIAL START-UP

PROCEDURE

The following procedure should be used to make the initial start-up of the compressor.

1. Position the compressor on a level surface so that proper amounts of liquid can be added, if required.

2. Check engine and compressor oil levels and add oil if necessary.

3. Fill fuel tank.

4. Connect air hose/piping to discharge.

5. Press and hold Start button for one (1) second to turn on display.

6. Press and hold Start button a second time for one (1) second to start Engine cranking sequence.

7. Allow the machine to sufficiently warm-up before operating.


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KEY DESCRIPTION

A

INSTRUMENT PANEL MODULAR DIS-

PLAY SCREEN: Display contains four lines,

20 characters/line.

B

SCROLL SELECTOR ROCKER SWITCH

C

ON/START AND STOP SELECTION

ROCKER SWITCH

A B C

Figure 4-2: Controller Panel

8. After the initial run, shut down machine and top off compressor oil sump, as required. Inspect for any leaks, and tighten any loose fittings.

4.4 SUBSEQUENT START-UP

PROCEDURE

On subsequent starts, follow the procedure explained below:

1. Check engine and compressor oils and add oil, if necessary.

2. Fill the fuel tank.

3. Press and hold Start button for one (1) second to turn on display.

4. Press and hold Start button a second time for one (1) second to start Engine cranking sequence.

5. Allow the machine to warm up sufficiently before operating.

4.5 SHUTDOWN PROCEDURE

1. Allow engine to run at idle for approximately five (5) minutes.

2. Press the STOP button; NOTE: Allow the compressor to blow down prior to restarting.

IMPORTANT

In case of emergency where immediate shutdown is required, this procedure is not necessary.

Press the STOP button immediately.

4.6 CONTROLLER GUIDE

Refer to Figure 4-2 for controller panel display features. The electronic controller supplied in the Diesel Viper package has been designed to work in conjunction with the linear actuator that operates the speed control. When used properly, they will reduce fuel consumption, remind the user when periodic service is due, extend the useful life of the package, and help diagnose any problems that may arise during the life of the compressor system.

4.6.1 HOME SCREEN

The home screen displays the basic information required during each state the

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VIPER DIESEL 100 PSI SECTION 4: OPERATION

package can exist in. Before startup, it displays fuel level and a message that helps instruct the user how to start the engine.

While the engine is in its cranking sequence, it displays a message describing what it is doing (glow plugs, warm-up period, etc.).

During regular operation, it displays engine

RPM, compressor pressure and temperature, fuel level, and hours of operation. After shutdown, it displays the blowdown timer required to elapse before engine can be restarted.

4.6.2 SPLASH SCREEN

When the display first turns on, it displays the manufacturer information, software version, current hours, and serial number of the machine. To access this screen after the display goes to the home screen, press the

Up or Down button while at the home screen and it can be accessed like the adjustable parameters.

4.6.3 ADJUSTING USER SETTINGS

The Diesel Viper controller has several settings that can be adjusted to suit each user's specific requirements. The following parameters can be adjusted as follows:

4.6.3.1 P

ARAMETERS

Parameter Name

Auto Shutdown (min.)

Auto Crank

Sleep State Timer (min.)

Setting Limits

(Increment)

0-30 (1)

On/Off

0-15 (5)

Default

5

On

10

1. After the display is turned on, from the home screen press the Up or Down buttons on the control panel to toggle between each parameter.

2. Press ON/START to select a parameter to adjust.

3. Use the Up and Down buttons to cycle between available settings.

4. Press ON/START to confirm the parameter setting. This will return view access to the home screen.

4.6.3.2 A

UTO

S

HUTDOWN

When enabled, auto shutdown will turn off the compressor package until air demand is needed again.

4.6.3.3 A

UTO

C

RANK

When enabled (ON/OFF, default to ON), auto crank will apply the appropriate length of glow plugs, crank the engine until it starts, and allow for a brief warm-up period before making air.

When off, manual crank by depressing ON/OFF switch.

4.6.3.4 S

LEEP

S

TATE

T

IMER

The sleep state timer is the length of time that the package can be “asleep” before it will turn off completely to reduce battery draw and reduce the possibility of accidental restart when no one is around.

4.6.4 SETTING PRESSURE

Refer to Section 2, Specifications for pressure range. When the machine is running, the Up and Down buttons adjust the pressure set point.

4.6.5 SAFETY

The controller is designed with the user's safety in mind. There are several safety conditions that must be met to run the compressor package. The pressure transducer and temperature thermistor on the compressor must be plugged in and functional for the package to run. The alternator connector must be plugged in for the package to run. The hood must remain closed until after the engine has started. If any unsafe condition is present before the package is started or during its operation, the controller will alert the user with a message on the display. Once the problem is corrected, the message can be cleared by holding the Up button.

4.6.6 SERVICE INTERVALS

The controller will remind the user of periodic service intervals. Once the package has


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PAGE - 13


been serviced, the message can be cleared by holding the Up button.

4.7 OPERATING CONDITIONS

1. Operate only in well-ventilated areas.

Exhaust fumes can be lethal.

2. Ensure there are no obstructions on cooling air intakes at both ends of the machine.

3. Do not leave anything resting on top of the machine. Hot engine exhaust and cooling air will generate high heat.

4. Be sure to leave sufficient room around the machine for cooling air. See Figure

3-1.

5. Operate machine with top cover closed to avoid engine exhaust fumes and heat from being deflected.

6. Refer to specifications for operating parameters, speeds, etc.

4.8 EXTREME CONDITIONS

When operating in extreme cold or hot conditions, in the presence of high humidity, or at a high altitude, extra attention should be given to any indication that could lead to a serious problem. Preventative safeguards exist that can minimize the possibility of malfunctions that are prone to occur under certain ambient conditions. Refer to Section

6.3, Extreme Condition Operation, for additional information on variable ambient operating conditions, and adjustment adaptations that can be made accordingly.

PAGE - 14

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VIPER DIESEL 100 PSI SECTION 5: MAINTENANCE

SECTION 5:

MAINTENANCE


A strict maintenance program is the key to long life for the Viper Series Compressor

System package. Below is a program that, when adhered to, should keep the package in top operating condition. Refer to Table

5.3A, Table 5.3B, and Section 5.5, Parts

Replacement and Adjustment Procedures

for detailed descriptions of specific compressor system components. Refer to

Table 7A in Section 7 for part order information.

WARNING

To avoid accidental system start-ups during periods of maintenance, disconnect the positive (+) cable to the battery terminal, and place the wire aside, or tape the contact end so that it cannot accidentally contact the battery post.

NOTE

Operating the machine package in a severe environment requires more frequent service intervals.

5.2 ROUTINE MAINTENANCE

SCHEDULE

Vanair

®

Manufacturing, Inc. considers the maintenance schedule given in Section 5.3,

Maintenance Schedule Table (5.3A for

compressor; 5.3B for engine), to be part of the warranty agreement with the customer.

This maintenance regimen must be followed in order to protect the warranty of the machine package.

WARNING

DO NOT remove caps, plugs and/or other components when compressor is running or pressurized. Stop compressor and depressurize system prior to maintenance of system. Relieve the entire system pressure by opening the air tank drain/vent valve, if equipped, which will vent all pressure to the atmosphere.

Wear personal protective equipment such as gloves, work boots, and eye and hearing protection as required for the task at hand.

Refer to Figure 5-1. Open fill cap SLOWLY

(contents under pressure) to make sure all pressure has been relieved.

A

C

A

B

KEY DESCRIPTION

A

COMPRESSOR FILL CAP

B

FILL CAP BLEED VENT GROOVE: Open/crack cap slightly to allow bleed vent to relieve air pressure before removing cap.

C

OIL FILL LEVEL: Full indication is equal to bottom inside thread of oil fill port.

Figure 5-1: Compressor Pressure Relief Check


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SECTION 5: MAINTENANCE VIPER DIESEL 100 PSI

NOTE

Follow the prescribed periodic maintenance (PM) schedule as recommended. Perform the required PM schedule at recommended intervals.

Failure to follow this prescribed periodic maintenance at the recommended intervals will impair the package safety, performance characteristics, shorten the package’s life, and will negatively affect the warranty coverage of the package.

Vanair

®

Manufacturing, Inc. especially requires that a consistent service regimen be established for engine oil changes, and engine and compressor air filter servicing.

The following schedule is designed so that many of the other maintenance tasks are completed when the engine and compressor air filters are serviced, and the engine oil is changed.

WARNING

Follow all applicable safety recommendations as outlined in Section

1: Safety of this manual.

Please take a moment to acquaint yourself with the service schedule presented in

Section 5.3 (5.3A for compressor; 5.3B for

engine) to assist the customer in establishing a maintenance routine log.

For assistance in obtaining routine maintenance or replacement parts, consult

Section 7.1, Parts Ordering Procedure, and Table 7A: Recommended Spare Parts

List.

PAGE - 16

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0 wo

00 rs r T o

1 ea ery

) y (2 urs

Ev

Ho ne

00 r r O

5 ea

o

) y ery

(1 urs

Ev

00 urs

1

Ho ery Ev

Y IL DA

Ho s

0 t 5

Hour

Firs


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PAGE - 17


2) o ( ars

tw ye ery Ev rs ou H 00 5 ery Ev rs ou H 00 4 ery Ev rs ou H 00 2 ery Ev ar rs

Ye ou

1)

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PAGE - 18

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2) o ( ars

tw ye ery Ev rs ou H 00 5 ery Ev rs ou H 00 4 ery Ev rs ou H 00 2 ery ar rs

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PAGE - 19


2) o ( ars

tw ye ery Ev rs ou H 00 5 ery Ev rs ou H 00 4 ery Ev rs ou H 00 2 ery ar rs

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PAGE - 20

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5.4 REPLACEMENT PARTS

Replacement parts should be purchased through your local Vanair

®

representative or where the Viper Diesel 100 PSI Air

Compressor System was purchased. If, for any reason, parts are not available in this manner, they can be purchased through

Vanair directly.

NOTE

For assistance when ordering new replacement parts, consult Section 7.1,

Parts Ordering Procedure, and Table 7A:

Recommended Spare Parts List.

NOTE

If additional spare parts are being stored for future use, make certain that they are stored in proper containers that allow for protection against contamination, and kept in a clean area of moderate temperature reading. For information on storing the machine package for periods of non-use, consult Section 5.7.2, Long

Term Storage.

outside of specified speeds, consult the

Vanair Service Department.

NOTE

Do not tamper with the RPM setting to increase the maximum engine speed.

Overspeed is hazardous and will void the engine warranty.

5.6 SERVICING THE SYSTEM

FUSES AND CIRCUIT

BREAKER

Consult Section 7.7, Electrical System,

(FUSE LAYOUT diagram insert) to determine the location of the specific fuses.

Refer to Figure 5-2 for reference location of the 50A circuit breaker.

NOTE

Refer to the Engine Operator’s Manual for detailed maintenance and replacement procedures for the engine.

C A B


10896 West 300 North


Telephone: (800) 526-8817

(219) 879-5100

Service Fax: (219) 879-5335

Parts Fax: (219) 879-5340


5.5 PARTS REPLACEMENT

AND ADJUSTMENT

PROCEDURES

5.5.1 ADJUSTING THE ENGINE SPEED

The Viper Diesel was designed in such a way that the governor speeds should not need to be adjusted. Should the unit operate

KEY DESCRIPTION

A

50 AMP CIRCUIT BREAKER - AUTO RESET

B

ENGINE STARTER (Location reference)

C

ENGINE OIL FILTER (Location reference)

Figure 5-2: 50A Circuit Breaker Location


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5.7 STORAGE AND

INTERMITTENT USE

5.7.1 INTERMITTENT USE

If the unit is not used very regularly always treat the fuel with a fuel stabilizer.

Check all belts and hoses for signs of deterioration such as visible surface cracks, stiffness or discoloration.

5.7.2 LONG TERM STORAGE

Disconnect the battery cable that is connected to the positive (+) side of the battery.

Cover the unit with a tarp or plastic to prevent the accumulation of dust, but leave the bottom open for air circulation.

Fill the fuel tank with fuel and fuel stabilizer to prevent moisture build-up in the tank.

PAGE - 22

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VIPER DIESEL 100 PSI SECTION 6: TROUBLESHOOTING

SECTION 6:

TROUBLESHOOTING


The information contained in this section has been compiled from years’ worth of information gathered from the field. It contains symptoms and usual causes for the most common types of problems that may occur. All available data concerning the trouble should be systematically analyzed before undertaking any repairs or component replacement.

A visual inspection is worth performing for almost all problems and may avoid unnecessary additional damage to the machine. The procedures which can be performed in the least amount of time and with the least amount of removal or disassembly of parts should be performed first.

WARNING

Before starting, performing maintenance, or replacing parts, relieve the entire system pressure by opening a service valve, which will vent all pressure to the atmosphere.

Although Vanair

®

strives to anticipate situations that may occur during the operation life of the machine package, the Troubleshooting

Guide may not cover all possible situations.

Be aware that additional troubleshooting information may be found in other sources, such as the Engine Operator’s Manual.

Should the situation remain unresolved after exhausting available sources, contact the

Vanair Service Department at:

Phone: 800-526-8817 (toll free)

Phone: 219-879-5100

Fax: 219-879-5335

NOTE

When contacting the Vanair Service

Department, please have machine serial number on hand to quickly expedite service. See below for machine serial plate location.

Figure 6-1: Machine Serial Plate Location

NOTE

Machine serial number also displays on instrument panel at start-up, on the hours screen.


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6.2 TROUBLESHOOTING GUIDE

Fault/Malfunction

Machine does not start

Fault:

Freq Sensor Error,

Machine Will Not Run

Engine will not crank

Engine will not start

Improper Control Operation:

Engine does not speed up

Possible Cause Corrective Action

Controller is not receiving input from alternator connector

Check connection/continuity.

During extremely cold weather, use of heater pads c an be required to get engine to spin fast enough to generate a usable signal. If no heater pads are installed, change crank sequence to Manual Crank

(refer to Section 4.6.3.1, Parameters).

ENGINE

Faulty battery connection.

Battery out of power

Check for proper battery connections and battery charge.

Recharge or replace battery.

Control module fuse blown Check fuse; refer to Section 7.7.

Machine hood shutdown safety switch prevents start-up of engine

Close hood panel or check if roof switch is faulty.

Faulty starter or starter solenoid

Faulty 50A circuit breaker

Low fuel and/or oil supply

Pinched fuel line

Plugged fuel filter(s)

Replace.

Replace; refer to Figure 5-2.

Check fuel gauge. Replenish as necessary.

Consult the Engine Operator’s Manual for additional information on engine maintenance.

Replace or reroute if necessary.

Low battery voltage

Replace if necessary. Refer to the Engine

Operator’s Manual for additional information on engine maintenance.

Recharge or replace if necessary.

Loose connections; tighten connections.

Plugged engine air filter

Dirty connections; clean connections.

Replace engine air filter. Refer to Engine

Operator’s Manual.

Defective oil pressure switch Check continuity, and replace if necessary.

Defective engine temperature switch Check continuity, and replace if necessary.

Poor ground connection

Speed control actuator stuck

Check and clean/renew connection.

Lubricate; replace speed control actuator if necessary.

Engine speed control lever stuck Free lever and lubricate if necessary.

Continued on next page

PAGE - 24

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Fault/Malfunction Possible Cause

ENGINE (CONTINUED)

Fuel filter partly plugged mproper Control Operation:

Engine does not speed up

(continued)

Improper Control Operation:

Engine does not slow down

Engine stops during operation

Fault:

Low Engine Oil Press

Gradual loss of engine power

Speed control actuator stuck

Engine speed control lever stuck

Engine stops during operation

Faulty pressure tranducers

Oil filter plugged.

Fault:

Engine High Temp Shutdown

Located too close to obstruction

Engine oil filter plugged

Engine radiator plugged

Fault with engine cooling system

Ambient temperature too high

Faulty temperature switch

Low oil level

Engine shutdown switch activated

Faulty oil pressure switch

Contaminated fuel

Engine air filter contaminated

Fuel filter(s) contaminated

Low fuel level

Overload

Corrective Action

Replace fuel filter. Refer the Engine


Auxiliary fuel pump may be needed for remote fuel tank.

Lubricate; replace speed control actuator if necessary.

Free lever and lubricate if necessary. Refer to Engine Operator’s Manual.

Check and replace, if necessary.

Replace oil filter.

Move further from obstruction.

Replace engine oil filter. Refer to the Engine


Clear debris/dirt from engine radiator.

Consult Engine Operator’s Manual.

Consult Section 6.3.3, High Temperature

Operation.

Replace.

Check engine oil level; replenish as necessary. Consult the Engine Operator’s

Manual for additional information on engine maintenance.

Confirm that access door is properly in place. Replace faulty engine shutdown switch.

Replace.

Drain and replace fuel supply.

Check air filter. Replace if necessary (refer to the Engine Operator’s Manual).

Check fuel filters. Refer to the Engine

Operator’s Manual for additional information on engine maintenance.

Add fuel.

Reduce load; check load use, and reduce



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Fault/Malfunction Possible Cause Corrective Action

Gradual loss of engine power

(continued)

Fault:

Cmpr High Temp Shutdown

ENGINE (CONTINUED)

Engine not warmed up Allow engine to warm up.

For additional information concerning an engine problem, consult the Engine Operator’s Manual.

COMPRESSOR

Compressor overheats Low compressor oil level Check oil level and refill to proper level if necessary (ensure machine is parked on a level surface).

Obstructed cooler fins

Insufficient air flow over cooler

Clear/clean if required.

Check for obstructions (frame, body, etc.) to cooling air flow.

Compressor will not build up pressure

Defective temperature thermistor

Compressor oil filter plugged

Defective compressor thermal valve

Low compressor oil level

Check sensor; replace if necessary.

Replace compressor oil filter.

Replace valve.

Check oil level and refill to proper level if necessary (ensure machine is parked on a level surface).

Air demand too high

Compressor capacity too low to accommodate demand

Compressor air filter plugged

Check for leaks and take corrective action.

Check air tools for wear, damage, or malfunctions. Replace or repair.

Substitute larger capacity compressor system.

Check air filter. Replace if necessary.

Engine does not speed up: input RPM too slow

Check engine speed control actuator.

Engine speed control lever stuck Free lever and lubricate if necessary.

Consult the Engine Operator’s Manual.

Service valve is open Close service valve.

Pressure transducer is malfunctioning Replace as necessary.

Inlet valve fails to open

Inlet valve frozen shut

Leak in air control line

Check for proper operation with an auxiliary air source. Replace if necessary.

Repair/replace inlet valve.

Repair/replace inlet valve.

Check for leaks and take corrective action.


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Compressor system overpressures

Fault:

Cmpr High Press Shutdown or safety relief valve

No service air output (See also

Compressor will not build up pressure

)

Low service air output (See also

Compressor will not build up pressure

)

Compressor stalls

Excess amount of oil in air discharge

COMPRESSOR (CONTINUED)

Unload solenoid valve defective Replace solenoid valve.

Restricted or plugged bleed orifice

Damaged/kinked control line

Clean if soiled; if ice is present, clear and remove.

Check line for damage (wear, kinks, etc.).

Re-route, re-tie or replace if necessary.

Control line connections are not properly seated/poor connection quality

Check lines for proper seating/ensure line ends have been cut cleanly and are square

(DO NOT use wire cutters: use a loom cutting tool or a clean, sharp razor blade).

Valve will need to be dis-assembled to check; consult with Service Department.

Inlet valve Teflon “O” ring popped out of groove

Inlet valve piston is stuck in open position.

Check for proper operation with an auxiliary air source—replace or rebuild inlet valve.

Compressor shaft seal is leaking

Minimum pressure/check valve is malfunctioning

Replace shaft seal with available kit.

Rebuild or replace check valve.

Pressure transducer is malfunctioning Check transducer for proper operation; replace if necessary and check controls.

Defective safety valve

Plugged coalescer

Replace safety valve.

Replace coalescer element.

If equipped, OSHA valve/velocity fuse, not functioning properly

Reset or replace OSHA valve.



Clogged compressor air filter

Solenoid valve sending continuous signal to inlet valve

Incorrect compressor speed

Check air filter. Replace if necessary.

Rebuild or replace solenoid valve if defective.

Adjust engine speed. Refer to Section

5.5.1, Adjusting the Engine Speed.



Idle speed is set too low

Machine not on level surface

Adjust idle speed; consult factory.

Move machine to level surface.



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Excess amount of oil in air discharge (continued)

COMPRESSOR (CONTINUED)

Compressor oil level too high The correct oil level is between the bottom of the oil port threads (low level) to the top lip of the port’s threads (high level). Drain excess oil to correct level.

Scavenger system not operating Inspect scavenger line for obstructions or leaks. Replace if necessary (refer to Figure

4-1). Remove the scavenge sight glass to access the orifice.

Replace the coalescer element.

Coalescer element plugged or damaged

Moisture accumulating in air tank Excessive moisture in the compressed air

System oil appears to be cloudy or milky

Excessive moisture in system oil; defective thermal valve

Drain water from air tank (if applicable to installation).

Check/replace thermal valve. Consult factory for assistance.

6.3 EXTREME CONDITION

OPERATION

When operating in extreme cold or hot conditions, in the presence of high humidity, or at a high altitude, extra attention should be given to any indication that could lead to a serious problem. Engine power and compressor air output will be reduced at high altitude or hot ambient temperatures.

Machine review and maintenance check schedules should be more frequent than the normal suggestions given in the

Maintenance Schedule Tables (Table

5.3A, and Table 5.3B in Section 5).

Become acquainted with the situationadjusted operation approaches given in this section before operating the power system package in any type of extreme ambient condition. For additional operation information consult the Engine Operator’s

Manual, or visit the engine manufacturer’s web site given in that manual.

6.3.1 HIGH MOISTURE CONDITION:

EMULSIFICATION OF OIL IN ROTARY

SCREW COMPRESSOR SYSTEMS

Consult the information in Table 6.3A for preventative and/or repair measures. If machine is operating in a high moisture environment, water contamination may persists after following the regular preventative maintenance schedule and standard operating procedures.

PAGE - 28

090053-OP_r0 (JAN-2014)


(800) 526-8817 • www.vanair.com


TABLE 6.3A HIGH MOISUTRE CONDITION OPERATION

Symptom Cause Prevention / Corrective Action

Emulsification of oil in compressor system:

• Compressor oil is milky white in color

• Compressor oil is broken down and lacks lubricity.

• Compressor oil may develop solid chunks or clumps

Operating the compressor system for short periods of time:

• Short cycling prevents the temperature of the oil from attaining a high enough temperature capable of vaporizing the moisture droplets.

RECOMMENDED CHANGES:

If the problem is not corrected by standard operating practices and regular preventative maintenance, consider the following:

• Raise the average temperature of the compressor oil.

Operating the compressor system unloaded without air flow from the service line for long periods of time:

• This can keep the oil temperature from getting hot enough to vaporize the moisture droplets, preventing the moisture from being able to escape the system. Additionally, there is no path for the moisture to escape the system.

• Change the operating procedure to allow for the compressor oil temperature to reach 180 °F before discharging any air. If the compressor isn't discharging any air, it's not ingesting any potentially humid air.

It will build pressure upon initial startup, but then it will run closed and allow it to heat up.

REPAIR/MAINTENANCE:

Refer to Section 5 of the Operator's Manual for inspection, cleaning, and repair instructions.

The thermal valve is faulty and activating the cooling fan too soon:

• This prevents the oil from attaining a high enough temperature capable of vaporizing the moisture droplets.

1. Once the compressor oil becomes emulsified, it must be replaced along with the oil filter. Depending on the severity, other parts might also need to be replaced.

The air filter is saturated with water:

2. Check that the separator element is in good, working condition.

3. Check that the scavenge line is working properly.

• This forces moisture to be ingested by the compressor.

Any of the above causes will be exacerbated in especially humid environments.

If the system is badly contaminated, Vanair

® recommends a lube flush that will help clean out any remaining contamination throughout the system. Consult Vanair Service Department for lube flush instructions.

Check the moisture drain frequently on the air tank reservoir, to alleviate moisture build-up.

6.3.2 COLD WEATHER OPERATION

Consult the information in Table 6.3B for preventative and/or repair measures. The

Diesel Viper’s 25HP engine runs on diesel fuel, which can be more difficult to start in cold weather. Once the engine is started, the air density becomes larger and the intake efficiency also becomes higher. More output can be expected in cold areas. When the temperature is very low, extra care must be taken regarding fuel and oil changes in their viscosity, freezing of water contained in the piping, or of water adhering on the filter.

Diesel fuel may gel at very cold temperatures.


(800) 526-8817 • www.vanair.com

090053-OP_r0 (JAN-2014)

PAGE - 29


TABLE 6.3B COLD WEATHER OPERATION

Symptom

Water freezes in the fuel line

Lubrication oil viscosity increases

Diesel fuel turns to a gel-like consistency at temperatures around 0°F (-18°C)

Cause Prevention / Corrective Action

WATER

Water in the fuel can freeze at temperatures below 32°F (0°C), blocking fuel lines.

At an extremely cold temperature, the viscosity of lubrication oil may increase and the torque of starter may exceed its permissible value, hindering proper starting.

GELLING

The diesel forms wax crystals when the temperatures drop below 15°F

(-9°C).

As it gets colder, these wax crystals turn to gel. This thicker substance cannot pass the fuel filter, so the engine may run intermittently, or may not start at all.

• Park the vehicle or equipment indoors when not in use.

• Use a block heater or glow plugs.

• Maintain the battery; this will make it easier to start a diesel engine in cold weather.

• In below zero temperatures a fuel line deicer product may need to be used.

• Check the fuel filter regularly to insure that it contains no water.

• Vanguard™ Premium Synthetic Oil is suitable for use from -40°F to 110°F

(-40°C to 43°C).

• For additional engine precautions, consult the Engine Operator’s Manual.

• Vanair

®

recommends installation of the cold weather heater option kit. Consult

Vanair for details.

• Keep the fuel tank full to prevent condensation from forming inside the tank and lessen the chances of water getting in the fuel line.

• The standard recommendation of 15W-40 engine oil is suitable for temperatures down to -4°F (-20°C). If temperatures are consistently below 30°F (-1°C), it is recommended that 5W-30 oil be used. If temperatures are below -25°F (-32°C), a highperformance, fully synthetic oil, such as

AMSOIL 5W-30 should be used which is suitable to temperatures of -55°F (-48°C).

6.3.3 HIGH TEMPERATURE OPERATION

Consult the information in Table 6.3C for preventative and/or repair measures. Reduce load duty cycle to less than 60% when operating in ambient temperatures above

104°F (40°C).

Extra care should be taken to keep the engine and air compressor clean and to not restrict the air flow around the unit. Consult

PAGE - 30

090053-OP_r0 (JAN-2014) the Engine Operator’s Manual for fuel, lubrication oil and cooling requirements under extreme temperatures.

When operating the machine in high temperature areas, precautions should be taken to prevent overheating. At the minimum, all coolers, including air passage ways around the coolers, should be free of debris and dirt. The fan, driven by the engine,


(800) 526-8817 • www.vanair.com


is designed to run continuously to assure a constant flow of cooling air.

The operator should be aware that high temperatures can influence engine performance, which can directly effect some machine function capacity outputs.

TABLE 6.3C HIGH TEMPERATURE OPERATION


Overheating/high compartment temperatures

Diminished engine performance

High ambient temperatures, confined spaces, soundproof cases and other reasons. Among these the most important factor is the temperature of the intake and cooling air.

• Extra care should be taken to keep the engine and air compressor clean and to not restrict the air flow around the unit.

• Consult the Engine Operator’s Manual for fuel, lubrication oil and cooling requirements under extreme temperatures.

• At the minimum, all coolers, including air passage ways around the coolers, should be free of debris and dirt. The fan, driven by the engine, is designed to run continuously to assure a constant flow of cooling air.

The operator should be aware that high temperatures can influence engine performance, which can directly effect some machine function capacity outputs.

6.3.4 HIGH DUST CONTENT OPERATION

Consult the information in Table 6.3D for preventative and/or repair measures. When the machine is to be used in continuously dusty environments, special care must be taken with the engine’s air cleaner and radiator.

TABLE 6.3D HIGH DUST CONTENT OPERATION


Overheating

System contamination

Stalling

Machine components exposed to frequent or constant dust interaction, can result in diminished system performance, or machine cessation.

• The intake air must be cleaned with the air cleaner—inspect the air filter frequently for dust build-up and replace as needed.

• Ensure that the radiator and oil cooler fins are kept clean to prevent overheating.

• If the machine is not being used for an extended period of time, an additional precaution, such as covering the machine with a tarp, will help to keep the inside of the machine free of dust particle accumulation.

• For extreme cases of high dust content environments, machine fluids may need to be replaced at more frequent intervals. Adjust maintenance schedule accordingly.


(800) 526-8817 • www.vanair.com

090053-OP_r0 (JAN-2014)

PAGE - 31


6.3.5 HIGH ALTITUDE OPERATION

Engine horsepower will decrease by 3.5% for every 1,000 feet over 6,000 feet increase in altitude. At high altitude overall unit performance will deteriorate, and care will need to be taken not to overload the engine.

SECTION 6: TROUBLESHOOTING

PAGE - 32

090053-OP_r0 (JAN-2014)


(800) 526-8817 • www.vanair.com

VIPER DIESEL 100 PSI SECTION 7: ILLUSTRATED PARTS LIST

SECTION 7:

ILLUSTRATED PARTS LIST

7.1 PARTS ORDERING PROCEDURE

Part orders should be placed through the distributor from whom the unit was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the address or phone numbers below.

When ordering parts always indicate the Serial Number of the machine package. This can be obtained form the

Bill of Lading for the machine package, or from the compressor unit serial number plate. See Figure 7-1 for location of machine package serial plate. Consult Table

7A: Recommended Spare Parts List on the next page for a listing of replacement parts.


10896 West 300 N.


Telephone: (800) 526-8817

(219) 879-5100

Service Fax: (219) 879-5335

Parts Fax: (219) 879-5340



(800) 526-8817 • www.vanair.com

NOTE

Machine serial number also displays on instrument panel at start-up, on the hours screen.

Figure 7-1: Machine Package Serial Number Plate Location

090053-OP_r0 (JAN-2014)

PAGE - 33

SECTION 7: ILLUSTRATED PARTS LIST VIPER DIESEL 100 PSI

TABLE 7A: RECOMMENDED SPARE PARTS LIST

KEY NO.

PART NUMBER DESCRIPTION QTY

1

2

3

4

5

6

7

8

9

10

15

16

17

18

19

11

12

13

14

264626-1GAL

272026-001

272026-002

272026-003

270764

RC77662

269136

KIT1154

KIT1175

KIT1176

EN270451-007

267306

260246

263532

264316

264695

267880

III

ROUTINE/SCHEDULED MAINTENANCE ITEMS

Vanguard Premium Oil (One [1] Gallon)

I

Element, Compressor Coalescing Air/Oil Separator Spin-on Style

Element, Compressor Oil Filter

Element, Compressor Air Filter

Element, Engine Air Filter Replacement

Filter, Engine Fuel

Filter, Engine Oil

KIT (FULL) MAINTENANCE ITEMS

Kit, Maintenance for Engine Filters

Kit, Maintenance for Compressor - Initial 50 Hours

Kit, Maintenance for Compressor - Annual / 500 hours

NON-ROUTINE MAINTENANCE ITEMS

Belt, Engine Replacement

II

Breaker, Circuit Replacement

Relay, NO/NC Weatherproof with Resistor

Fuse, A to 5A Tan

Fuse, A to 25A Clear

Fuse, Block 4-Way ATC

Fuse, ATC 20A Yellow

Battery, Replacement

Kit, Shaft Seal

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Consult Factory

I

Use only Vanair

®

Vanguard™ Premium Synthetic Oil and Genuine Vanair Parts. Inspect and replace damaged components before operation. Substituting non-Vanguard™ Oil or non-genuine Vanair filter components WILL VOID THE COMPRESSOR

WARRANTY!

II

This belt replaces the engine alternator belt only. For full engine belt coverage, consult factory.

III

Due to shipping regulations pertaining to lead acid batteries, Vanair recommends procuring a replacement battery from a localized source. Two possible replacement models include: BatteriesPlus® no. SLi96R, and NAPA battery no. BAT 7590.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

TABLE 7B: MACHINE OPTIONS LIST

KEY NO.

PART NUMBER

1

2

3

4

5

6

032894

032895

032905

MA273477

032896-030, 032896-060, 032896-120

032901

DESCRIPTION

Aftercooler 12VDC

Cold Weather 12VDC Pad

Cold Weather 120VAC Pad

Heater, Engine Block 120VAC

Remote Control Module

Bolt-on Fork Pockets


QTY

1

1

1

1

1

1

IMPORTANT

If additional spare parts are being stored for future use, ensure that they are stored in proper containers that allow for protection against contamination, and kept in a clean area of moderate temperature reading. For information on storing the machine package for periods of non-use, consult Section 5.7.2, Long Term Storage.

IMPORTANT

Use only approved Vanair

®

Vanguard™ Premium Synthetic

Oil and Genuine Vanair Parts. Inspect and replace damaged components before operation. Substituting non-Vanguard

Oil or non-genuine Vanair filter components will VOID THE

COMPRESSOR WARRANTY!

PAGE - 34

090053-OP_r0 (JAN-2014)


(800) 526-8817 • www.vanair.com


TABLE 7C: MAINTENANCE TRACKING LOG

DATE DESCRIPTION OF MAINTENANCE

SECTION 7: ILLUSTRATED PARTS LIST

PART(S) REPLACED


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090053-OP_r0 (JAN-2014)

PAGE - 35


7.2 COMPRESSOR REPLACEMENT PARTS (1 OF 2)

PAGE - 36

090053-OP_r0 (JAN-2014)

6010114ID_r7_1of2


(800) 526-8817 • www.vanair.com



ITEM DESCRIPTION

PART

NUMBER

QTY ITEM DESCRIPTION

PART

NUMBER

QTY

1 ELBOW, 1/4T x 1/8P PUSH-

ON

2 CONNECTOR, 1/8P x 1/4T

PUSH ON

3 TUBING, PLASTIC 1/4 WHITE

4 CLAMP, HOSE SUPPORT

1.25 ID

5 LOOM, FLEX-GARD 1/4 ID

261309

261316

261322

261546

262751

1

1

2 ft

3

2 ft

19 MOUNT, RUBBER ARMOR

PLATED 200# GREEN

20 THERMISTOR, TEMP. 3/8

BSPP

21 CONNECTOR, 37DEG FLR x

G3/4

22 ELBOW, 90 DEG. SWIVEL #12

FJIC x #12 MJIC MOD

23 BUSHING, TAPER BORE

1610 28MM

24 ELEMENT, TORSIONAL

COUPLING

25

DECAL, SEPARATOR

272442

272444

272754

272755

273661

2

1

1

1

1

6 VALVE, RELIEF 200 PSIG,

1/2" NPT

7 ELBOW,90 DEG. MJIC x

MBSPP 1/2

8 ADAPTER, FEMALE PIPE x

BSPP 1/8

9 ADAPTER, MJIC x MBSPP 1/2 x 1/2

10 WASHER, SEALING

11 VANGUARD, BULK

12 WASHER, SNUBBING

RUBBER MOUNT

TRANSDUCER, PRESSURE

13

14

COMPR, RSE3GDSS223

15 BRACKET, COMPRESSOR

FILTER SIDE


REAR SIDE

263704

263747-006

263748-001

264312-008

264449-002

264626

264829

267363

272026

272231

272232

1

2

2

1

1

1 gal

4

1

1

1

1

26 DECAL, OIL FILTER

273750

273818

273819

1

1

1

27 SUPPORT, COMPRESSOR

W/ HOLE

28 PLUG, PIPE 1/8

29 CAPSCREW, HEX HEAD M10

X 25

30 CAPSCREW, S.H. M8x1.25 x

35mm

273821

807800-005

828010-025

829308-035

1

1

4

6

31 CAPSCREW, HEX GR8 1/2-13 x 3

32

SCREW, SER WASH 5/16-18 x 1

829408-300

829705-100

2

8

33 WASHER, LOCK INTERNAL

3/4

837412-055 1

WASHER, LOCK METRIC M10 838810-220 4

34

17 SUPPORT, COMPRESSOR 272233 1 35 WASHER, FLAT METRIC M10 838910-220 4

18 HOUSING, D902 AL. W/

STARTER COVER

272437 1

36

BULKHEAD, 1/2 FNPT x #8

MJIC

862008-050 1


ITEM

A

B

C

D

COMMONLY REPLACED PARTS

DESCRIPTION PART NUMBER QTY

ELEMENT, COALESCING

(SEPARATOR)

272026-001

1

ELEMENT, OIL FILTER

ELEMENT, AIR FILTER

VANGUARD OIL

272026-002

272026-003

264626-1GAL

1

1

1


(800) 526-8817 • www.vanair.com

090053-OP_r0 (JAN-2014)

PAGE - 37



PAGE - 38

090053-OP_r0 (JAN-2014)

6010114ID_r7_2of2


(800) 526-8817 • www.vanair.com




PART

NUMBER

QTY ITEM DESCRIPTION

PART

NUMBER

QTY

1 ELBOW, 1/4T x 1/8P PUSH-

ON

2 CONNECTOR, 1/8P x 1/4T

PUSH ON

3 TUBING, PLASTIC 1/4 WHITE

4 CLAMP, HOSE SUPPORT

1.25 ID

5 LOOM, FLEX-GARD 1/4 ID

261309

261316

261322

261546

262751

1

1

2 ft

3

2 ft


PLATED 200# GREEN

20 THERMISTOR, TEMP. 3/8

BSPP

21 CONNECTOR, 37DEG FLR x

G3/4

22 ELBOW, 90 DEG. SWIVEL #12

FJIC x #12 MJIC MOD

23 BUSHING, TAPER BORE

1610 28MM

24 ELEMENT, TORSIONAL

COUPLING

25

DECAL, SEPARATOR

272442

272444

272754

272755

273661

2

1

1

1

1

6 VALVE, RELIEF 200 PSIG,

1/2" NPT

7 ELBOW,90 DEG. MJIC x

MBSPP 1/2

8 ADAPTER, FEMALE PIPE x

BSPP 1/8

9 ADAPTER, MJIC x MBSPP 1/2 x 1/2

10 WASHER, SEALING

11 VANGUARD, BULK

12 WASHER, SNUBBING

RUBBER MOUNT

TRANSDUCER, PRESSURE

13

14

COMPR, RSE3GDSS223


FILTER SIDE


REAR SIDE

263704

263747-006

263748-001

264312-008

264449-002

264626

264829

267363

272026

272231

272232

1

2

2

1

1

1 gal

4

1

1

1

1

26 DECAL, OIL FILTER

273750

273818

273819

1

1

1

27 SUPPORT, COMPRESSOR

W/ HOLE

28 PLUG, PIPE 1/8

29 CAPSCREW, HEX HEAD M10

X 25

30 CAPSCREW, S.H. M8x1.25 x

35mm

273821

807800-005

828010-025

829308-035

1

1

4

6


32

SCREW, SER WASH 5/16-18 x 1

829408-300

829705-100

2

8

33 WASHER, LOCK INTERNAL

3/4

837412-055 1

WASHER, LOCK METRIC M10 838810-220 4

34

17 SUPPORT, COMPRESSOR 272233 1 35 WASHER, FLAT METRIC M10 838910-220 4

18 HOUSING, D902 AL. W/

STARTER COVER

272437 1

36

BULKHEAD, 1/2 FNPT x #8

MJIC

862008-050 1


ITEM

A

B

C

D

COMMONLY REPLACED PARTS

DESCRIPTION PART NUMBER QTY

ELEMENT, COALESCING

(SEPARATOR)

272026-001

1

ELEMENT, OIL FILTER

ELEMENT, AIR FILTER

VANGUARD OIL

272026-002

272026-003

264626-1GAL

1

1

1


(800) 526-8817 • www.vanair.com

090053-OP_r0 (JAN-2014)

PAGE - 39


7.3 ENGINE AND DRIVE PARTS (1 OF 2)


PAGE - 40

090053-OP_r0 (JAN-2014)

6100051ID_r8_1of2


(800) 526-8817 • www.vanair.com



ITEM DESCRIPTION PART

NUMBER

262704

QTY ITEM DESCRIPTION PART

NUMBER

825702-083

QTY

1 WASHER, NYLON FLAT 1/4 3 33 NUT, HEX LOCKING #10-32 2

2 CLAMP, EXHAUST 1 1/2

3 WASHER, SNUBBING RUBBER

MOUNT

4 CLAMP, HOSE #28

5 STRAP, GROUND 8" w/ 3/8

HOLES

6 FILTER, AIR 6"

GASKET, MUFFLER REPLCMT

7

KUBOTA 902

8 HOSE, FLEX 1-3/4" I.D.

262906-150

264829

265560

267498

269660

269961

2

1

2

4

1

1

34 CAPSCREW, HEX 8mm 1.25 x 40


828008-040

829104-100

36 CAPSCREW, HEX GR5 1/4-20 x 1-1/4 829104-125

37 CAPSCREW, HEX GR5 1/4-20 x 1-1/2 829104-150

38 CAPSCREW, HEX GR5 5/16-18 x 1 829105-100

39 CAPSCREW, HEX GR5 5/16-18 x 1-1/4 829105-125

1

1

3

2

4

6

9 BRACKET, THROTTLE ADJ

10 GUARD, FAN

11 ELBOW, EXHAUST

12 SPACER, COMPRESSOR

13 ACTUATOR, LINEAR 2"

STROKE, 30#, 12V

14 FAN, 15.50" DIA PUSHER

15 SPACER, FAN

16 BRACKET, MUFFLER

17 EXHAUST, ENGINE OUT

18 ELBOW, EXHAUST OUT BACK

19 BRACKET, ENGINE STARTER

SIDE

20 BRACKET, ENGINE THROTTLE

SIDE

21 SUPPORT, ENGINE FRONT


PLATED 200# GREEN

23 SUPPORT, ENGINE REAR

24 SUPPORT, TOWER

25 CAPSCREW, HEX 10 MM 1.25 x

25 MM

26 BRACKET, THROTTLE

EXTENSION

27 SPRING, EXTENSION

THROTTLE

28 BRACKET, ACTUATOR ROD

29 CAPSCREW, S.H. 10-32 x 1/2

ZINC

30 ADAPTER, FLYWHEEL

COUPLING

31 NUT, HEX 5/16-18

32 NUT, HEX LOCKING 1/4-20

270698

272019

272074

272127

272158

272160

272165

272166

272168

272174

272211

272228

272229

272230

272442

272516

272553

272864

273300

273302

273307

273310

273660

825205-273

825504-145

1

1

1

1

1

1

1.5 ft

1

1

1

1

1

1

1

2

1

1

12

1

1

1

2

1

6

2

40 CAPSCREW, S.H. M8x1.25 x 20mm





45 SCREW, SER WASH 5/16-18 x 1

46 WASHER, FLAT 1/4

47 WASHER, FLAT 5/16

48 WASHER, LOCK 1/4

49 WASHER, LOCK 5/16

50 WASHER, LOCK METRIC M8


52 WASHER, FLAT METRIC M8


54 HOSE, FUEL LINE 5/16"

55 EXHAUST, KUBOTA

56 ENGINE DIESEL, 25 HP, HZ SHAFT

57 U-BOLT, 3/8-16 X 3 1/2 WD X 5 1/16

58 CLAMP, HOSE, T-BOLT STYLE, 13mm

SS

59 DRAIN, ENGINE OIL

60 TIES, THERMAL STAINLESS

61 HEADER WRAP, HIGH TEMP 2" WIDE

62 OIL, DIESEL 15W-40

63 HOSE, ANA300D ENGINE OIL DRAIN

829308-020

829308-040

829308-045

829308-050

829408-300

829705-100

838908-180

FA38355

FI273012

HA42205

PR81122

SE271475

TU273011


1

838204-071

838205-071

838504-062

838505-078

838808-200 9

838810-220 12

2

8

4

4

838910-220 12

842315-031 2.0 ft

EN270396

EN270451

FA270399

1

1

2

2

1

2

2

8

2

4

1

4

32 ft

4.0 qt

1

ITEM

A

B

C

COMMON REPLACEMENT PARTS

DESCRIPTION

ELEMENT, AIR FILTER

ELEMENT, FUEL FILTER

ELEMENT, OIL FILTER

PART NUMBER

270764

RC77662

269136


(800) 526-8817 • www.vanair.com

090053-OP_r0 (JAN-2014)

PAGE - 41




PAGE - 42

090053-OP_r0 (JAN-2014)

6100051ID_r8_2of2


(800) 526-8817 • www.vanair.com



ITEM DESCRIPTION PART

NUMBER

262704

QTY ITEM DESCRIPTION PART

NUMBER

825702-083

QTY

1 WASHER, NYLON FLAT 1/4 3 33 NUT, HEX LOCKING #10-32 2

2 CLAMP, EXHAUST 1 1/2

3 WASHER, SNUBBING RUBBER

MOUNT

4 CLAMP, HOSE #28

5 STRAP, GROUND 8" w/ 3/8

HOLES

6 FILTER, AIR 6" 90DEG

GASKET, MUFFLER REPLCMT

7

KUBOTA 902

8 HOSE, FLEX 1-3/4" I.D.

262906-150

264829

265560

267498

269660

269961

2

1

2

4

1

1

34 CAPSCREW, HEX 8mm 1.25 x 40


828008-040

829104-100

36 CAPSCREW, HEX GR5 1/4-20 x 1-1/4 829104-125

37 CAPSCREW, HEX GR5 1/4-20 x 1-1/2 829104-150

38 CAPSCREW, HEX GR5 5/16-18 x 1 829105-100

39 CAPSCREW, HEX GR5 5/16-18 x 1-1/4 829105-125

1

1

3

2

4

6

9 BRACKET, THROTTLE ADJ

10 GUARD, FAN

11 ELBOW, EXHAUST

12 SPACER, COMPRESSOR

13 ACTUATOR, LINEAR 2"

STROKE, 30#, 12V

14 FAN, 15.50" DIA PUSHER

15 SPACER, FAN

16 BRACKET, MUFFLER

17 EXHAUST, ENGINE OUT

18 ELBOW, EXHAUST OUT BACK

19 BRACKET, ENGINE STARTER

SIDE

20 BRACKET, ENGINE THROTTLE

SIDE

21 SUPPORT, ENGINE FRONT


PLATED 200# GREEN

23 SUPPORT, ENGINE REAR

24 SUPPORT, TOWER

25 CAPSCREW, HEX 10 MM 1.25 x

25 MM

26 BRACKET, THROTTLE

EXTENSION

27 SPRING, EXTENSION

THROTTLE

28 BRACKET, ACTUATOR ROD

29 CAPSCREW, S.H. 10-32 x 1/2

ZINC

30 ADAPTER, FLYWHEEL

COUPLING

31 NUT, HEX 5/16-18

32 NUT, HEX LOCKING 1/4-20

270698

272019

272074

272127

272158

272160

272165

272166

272168

272174

272211

272228

272229

272230

272442

272516

272553

272864

273300

273302

273307

273310

273660

825205-273

825504-145

1

1

1

1

1

1

1.5 ft

1

1

1

1

1

1

1

2

1

1

12

1

1

1

2

1

6

2






45 SCREW, SER WASH 5/16-18 x 1

46 WASHER, FLAT 1/4

47 WASHER, FLAT 5/16

48 WASHER, LOCK 1/4

49 WASHER, LOCK 5/16





54 HOSE, FUEL LINE 5/16"

55 EXHAUST, KUBOTA

56 ENGINE DIESEL, 25 HP, HZ SHAFT

57 U-BOLT, 3/8-16 X 3 1/2 WD X 5 1/16

58 CLAMP, HOSE, T-BOLT STYLE, 13mm

SS

59 DRAIN, ENGINE OIL

60 TIES, THERMAL STAINLESS

61 HEADER WRAP, HIGH TEMP 2" WIDE

62 OIL, DIESEL 15W-40

63 HOSE, ANA300D ENGINE OIL DRAIN

829308-020

829308-040

829308-045

829308-050

829408-300

829705-100

838908-180

FA38355

FI273012

HA42205

PR81122

SE271475

TU273011


1

838204-071

838205-071

838504-062

838505-078

838808-200 9

838810-220 12

2

8

4

4

838910-220 12

842315-031 2.0 ft

EN270396

EN270451

FA270399

1

1

2

2

1

2

2

8

2

4

1

4

32 ft

4.0 qt

1

ITEM

A

B

C

COMMON REPLACEMENT PARTS

DESCRIPTION

ELEMENT, AIR FILTER

ELEMENT, FUEL FILTER

ELEMENT, OIL FILTER

PART NUMBER

270764

RC77662

269136


(800) 526-8817 • www.vanair.com

090053-OP_r0 (JAN-2014)

PAGE - 43


7.4 COOLING SYSTEM (PART 1 OF 2)


PAGE - 44

090053-OP_r0 (JAN-2014)

6020067ID_r5_1of2


(800) 526-8817 • www.vanair.com



ITEM DESCRIPTION PART NUMBER

12

13

14

15

8

9

10

11

4

5

6

7

1

2

3

CONNECTOR, #12 MSAE x #8 MJIC

ELBOW, 90 DEG #8 MJIC x #12 MSAE

NUT, HEX #6-32 KEPS

CLAMP, EXHAUST 1 1/2

SEAL, RUBBER "D" TRIM-LOK 1" X 1"

COOLER, ENGINE/COMPRESSOR

SHROUD, COOLER

BRACKET, COOLER SUPPORT BACK SIDE

BRACKET, COOLANT TANK MTG BOTTOM

BRACKET, COOLANT TANK MTG CLIP

BRACKET, COOLER / EXHAUST SUPPORT

HOSE, RADIATOR TOP

HOSE, RADIATOR BOTTOM

BRACKET, BELT GUARD

BRACKET, HOOD SWITCH

16

17

18

19

NUT, HEX FLANGE 5/16-18

SCREW, SER WASH 5/16-18 x 0.75

SCREW, MACHINE #6-32 x 1

SWITCH, HOOD SAFETY NO/NC 15A-125V. AC

825305-283

829705-075

831600-100

CO81774

20

21

CLAMP, HOSE, #20, 1.75DIA.

GASKET, SEAL AND TRIM

FA47720

PR35734


260387-132

260403-115

261595-632

262906-150

264138

270843

272169

272171

272172

272173

272797

272816ID

272817ID

272996

273289

QTY

1

1

1

1

1

1

1

1

1

1

2

2

4.750 ft

1

1

4

17

2

1

4

5.063 ft


(800) 526-8817 • www.vanair.com

090053-OP_r0 (JAN-2014)

PAGE - 45




PAGE - 46

090053-OP_r0 (JAN-2014)

6020067ID_r5_2of2


(800) 526-8817 • www.vanair.com




12

13

14

15

8

9

10

11

4

5

6

7

1

2

3

CONNECTOR, #12 MSAE x #8 MJIC

ELBOW, 90 DEG #8 MJIC x #12 MSAE

NUT, HEX #6-32 KEPS

CLAMP, EXHAUST 1 1/2

SEAL, RUBBER "D" TRIM-LOK 1" X 1"

COOLER, ENGINE/COMPRESSOR

SHROUD, COOLER

BRACKET, COOLER SUPPORT BACK SIDE

BRACKET, COOLANT TANK MTG BOTTOM

BRACKET, COOLANT TANK MTG CLIP

BRACKET, COOLER / EXHAUST SUPPORT

HOSE, RADIATOR TOP

HOSE, RADIATOR BOTTOM

BRACKET, BELT GUARD

BRACKET, HOOD SWITCH

16

17

18

19



SCREW, MACHINE #6-32 x 1

SWITCH, HOOD SAFETY NO/NC 15A-125V. AC

825305-283

829705-075

831600-100

CO81774

20

21

CLAMP, HOSE, #20, 1.75DIA.


FA47720

PR35734


260387-132

260403-115

261595-632

262906-150

264138

270843

272169

272171

272172

272173

272797

272816ID

272817ID

272996

273289

QTY

1

1

1

1

1

1

1

1

1

1

2

2

4.750 ft

1

1

4

17

2

1

4

5.063 ft


(800) 526-8817 • www.vanair.com

090053-OP_r0 (JAN-2014)

PAGE - 47


7.5 CANOPY AND FRAME PARTS


A

PAGE - 48

B

A

B

090053-OP_r0 (JAN-2014)

6030060ID_r6


(800) 526-8817 • www.vanair.com


7.5 CANOPY AND FRAME PARTS

ITEM

18

19

20

21

14

15

16

17

22

23

24

25

26

5

6

7

8

1

2

3

4

9

10

11

12

13

DESCRIPTION

BULKHEAD, 90 DEG. 3/4

WASHER, NYLON 5/16-18

SCREW, TRUSS HD 5/16-18x3/4 SS

LATCH, SENTRY PANEL

CLIP, TOOL ZINC 3/4 TO 1-1/8

HOOD, CANOPY

BAFFLE, SHROUD

PANEL, OPEN SIDE

PANEL, REAR SIDE

PLATFORM, VIPER DIESEL

DOOR, FRONT ACCESS

PLATE, COVER INST. OPENING

HOSE, AIR OUT LOWER

INSULATION, ACOUSTICAL FOAM, HOOD

INSULATION, ACOUSTICAL FOAM, BAFFLE

INSULATION, HEAT SHIELD


SCREW, ROUND HD #10-24 x 0.75

WASHER, LOCK INTERNAL 1"

BULKHEAD, 3/4 FNPT x #12 MJIC

NUT, LOCK, M6 X 1.0 PITCH

STUD, BALL, .39DIA. X .55LG.

GAS SPRING, 6 STROKE, 20#

HINGE, 2" X 2", BLACK

PLUG, PLASTIC, 1-3/8 DIA, RIBBED BLACK


PART NUMBER


272713-001

272713-002

272713-006

829705-075

831602-075

837414-100

862012-075

FA55272

FA58724

HA72205

HA88014

PR273179

PR35734

250006-058

262943

262945

267124

272059

272250

272251

272253

272254

272256

272257

272535

272693-008

QTY

2

2

1

8

1

1

1

6

4

2

2

1

24.022 ft

2

1

1

1

1

17

17

4

1

1

1

1

1


(800) 526-8817 • www.vanair.com

090053-OP_r0 (JAN-2014)

PAGE - 49



OPTIONAL

LOCATION

7.7 ELECTRICAL SYSTEM


6040049ID_r1

PAGE - 50

090053-OP_r0 (JAN-2014)

6060080ID_r8


(800) 526-8817 • www.vanair.com




3

4

1

2

WASHER, NYLON 5/16-18

SCREW,TRUSS HD 5/16-18x3/4 SS

MODULE,CONTROL AUTO SPD CTRL

PLATE, COVER INST. OPENING

262943

262945

272527

272535


QTY

1

1

8

8

7.7 ELECTRICAL SYSTEM

ITEM DESCRIPTION PART NUMBER QTY

13

14

15

9

10

11

12

7

8

5

6

3

4

1

2

RELAY, NO/NC WEATHERPROOF w/ RESISTOR

FUSE, ATO 5 AMP TAN

FUSE, ATO 25 AMP CLEAR

FUSE, BLOCK 4-WAY ATC

INSULATOR, BATTERY TERM RED 466

FUSE, ATC 20 AMP YELLOW

WEDGELOCK, DEUTSCH W4S

PLUG, SEALING

CONNECTOR, DEUTSCH DTP06-4S

BRACKET, BATTERY HOLD DOWN

WD, DIESEL VIPER

HARNESS, DIESEL VIPER

CABLE, BATTERY NEGATIVE

CABLE, BATTERY POSITIVE

BATTERY, 12V LEAD-ACID AUTOMOTIVE 600 CCA

260246

263532

264316

264695

267208

267880

268907

269055

269415

272213

272618

272621

272735

272736

273937

I

16

17

18

19

TERMINAL, BATTERY POST


SCREW, MACHINE #10-32 x 3/4

WASHER, FLAT #10

273940

829705-150

831702-075

838202-045

3

3

2

2

20

21

WASHER, LOCK #10


838502-047

PR35734

3

2.740 ft

I

This part number is invalid for spare or replacement part reorders. Due to shipping regulations pertaining to lead acid batteries, Vanair

®

recommends procuring a replacement battery from a localized source. Two possible replacement models include: BatteriesPlus

®

no. SLi96R, and NAPA battery no. BAT 7590.

1

1

1

1

1

1

1

1

4

1

2

1

1

1

1



(800) 526-8817 • www.vanair.com

090053-OP_r0 (JAN-2014)

PAGE - 51


7.8 FUEL TANK ASSEMBLY


PAGE - 52

090053-OP_r0 (JAN-2014)

6140011ID_r5


(800) 526-8817 • www.vanair.com


7.8 FUEL TANK ASSEMBLY


13

14

15

16

9

10

11

12

17

18

19

20

5

6

7

8

1

2

3

4

SCREW, TRUSS HD 1/4-20UNC X 3/4LG S.S.

TERMINAL, DEUTSCH 0462-201-16141

PLUG, DEUTSCH DT06-2S

WEDGELOCK, DEUTSCH W2S

CLAMP, HOSE, #24, 1"-2" DIA.

TANK, FUEL 9 GALLON

NECK, FUEL FILL DIESEL TETHERED, NO VENT

SUPPORT, FUEL NECK



HOSE, FUEL LINE 5/16" X 18" LG.

TUBE, FUEL PICK UP

SENDER UNIT, FUEL LEVEL, 5.50 LG

VALVE, CHECK INLINE 3/16 TUBING

CLAMP, HOSE, T-BOLT STYLE, 13mm SS

CLAMP, HOSE, T-BOLT STYLE, 10M

PUSH - ON, MALE ADAPTER, 1/4 MALE X 3/16 PUSH

CAP, DIESEL VENTED TETHERED

HOSE, 1-1/2 DIA. FUEL x 12-1/2" LONG

HOSE, 3/16DIA. HT, FUEL X 30 LG.


262953

263582

268902

268903

270493

272236

272855

272865

825305-283

829704-075

842315-031

A1270398

CO22750

CO273306

FA38355

FA91153

FI92363

HA271677

TU269928

TU28641

QTY

1

1

2

4

4

3

1.5 ft

1

1

1

1.04 ft

2.5 ft

2

1

1

1

4

2

1

1


(800) 526-8817 • www.vanair.com

090053-OP_r0 (JAN-2014)

PAGE - 53


7.9 DECAL LOCATIONS (PART 1 OF 2) (TYPICAL)

PAGE - 54

WARNING



090053-OP_r0 (JAN-2014)

6110013ID_r5


(800) 526-8817 • www.vanair.com



ITEM

1

DESCRIPTION

DECAL, ENGINE OIL DRAIN

PART

NUMBER

part of kit decal

QTY

1


12 DECAL, WARNING PLUGS

PART

NUMBER

264378

2

3

4

DECAL, DIESEL FUEL ONLY

DECAL, COMPRESSOR OIL

DRAIN

PLATE, SERIAL VANAIR part of kit decal part of kit decal

260940

1

1

1

5

6

7

8

DECAL, CONNECT AIR HOSE

DECAL, DO NOT USE AIR

DECAL, HOT PARTS

DECAL, ROTATING PARTS

9 DECAL, SULFURIC ACID

10 DECAL, CARBON MONOXIDE

11 DECAL, EXPLOSIVE FUEL

261885

261886

264372

264374

264375

264376

264377

1

1

3

2

1

2

1

I

Graphic for 19 and 20 are exact in content, but different in size.

13 DECAL, WARNING FAN

GUARD

14 DECAL, WARNING ELECTRIC

TAMPER

15 DECAL, CAUTION AUTO-

START

16

17

DECAL, READ MANUAL

DECAL, ROTARY SCREW OIL

264383

271510

272041

272424

272501

18 DECAL, WIRING DIAGRAM 272672

19 DECAL, VIPER DIESEL LARGE 272850-001

20 DECAL, VIPER DIESEL SMALL 272850-002

21 DECAL, MAINTENANCE 272852

22 DECAL, QUICK START GUIDE 273312


QTY

2

1

1

3

2

1

1

2

1

1

2

6 7

2

1

MODEL NUMBER

SERIAL NUMBER

MAXIMUM PRESSURE

COMPRESSOR INPUT RPM

800-526-8817 www.vanair.com

3

4

260940

5

8

10


(800) 526-8817 • www.vanair.com

9

Decal Identification continued on page 57

090053-OP_r0 (JAN-2014)

PAGE - 55



PAGE - 56

WARNING



090053-OP_r0 (JAN-2014)

6110013ID_r5


(800) 526-8817 • www.vanair.com



ITEM

1

DESCRIPTION

DECAL, ENGINE OIL DRAIN

PART

NUMBER

part of kit decal

QTY

1


12 DECAL, WARNING PLUGS

PART

NUMBER

264378

2

3

4

DECAL, DIESEL FUEL ONLY

DECAL, COMPRESSOR OIL

DRAIN

PLATE, SERIAL VANAIR part of kit decal part of kit decal

260940

1

1

1

5

6

7

8

DECAL, CONNECT AIR HOSE

DECAL, DO NOT USE AIR

DECAL, HOT PARTS

DECAL, ROTATING PARTS

9 DECAL, SULFURIC ACID

10 DECAL, CARBON MONOXIDE

11 DECAL, EXPLOSIVE FUEL

261885

261886

264372

264374

264375

264376

264377

1

1

3

2

1

2

1

I

Graphic for 19 and 20 are exact in content, but different in size.

13 DECAL, WARNING FAN

GUARD

14 DECAL, WARNING ELECTRIC

TAMPER

15 DECAL, CAUTION AUTO-

START

16

17

DECAL, READ MANUAL

DECAL, ROTARY SCREW OIL

264383

271510

272041

272424

272501

18 DECAL, WIRING DIAGRAM 272672

19 DECAL, VIPER DIESEL LARGE 272850-001

20 DECAL, VIPER DIESEL SMALL 272850-002

21 DECAL, MAINTENANCE 272852

22 DECAL, QUICK START GUIDE 273312


QTY

2

1

1

3

2

1

1

2

1

1

2

11

12

13

14

16


(800) 526-8817 • www.vanair.com

15

18

17

21

090053-OP_r0 (JAN-2014)

19 & 20

22

PAGE - 57


7.10 WIRING DIAGRAM


PAGE - 58

090053-OP_r0 (JAN-2014)

272618_r7


(800) 526-8817 • www.vanair.com


7.11 SCHEMATIC FLOW DIAGRAM



(800) 526-8817 • www.vanair.com

090053-OP_r0 (JAN-2014)

273387_r2

PAGE - 59


7.12 HOSE INSTALLATION GUIDE


1. Hose is weakened when installed in twisted position. Pressure in twisted hose tends to loosen fitting connections. Design so that machine motion produces bending rather than twisting.

2. Ample bend radius should be provided to avoid collapsing of line and restriction of flow.

3. Exceeding minimum bend radius will greatly reduce hose assembly life.

4. Use elbows or other adapters as necessary to eliminate excess hose length and to insure neater installation for easier maintenance.

5. When hose assembly is installed in a flexing application, remember that metal hose fittings are not part of the flexible portion. Allow ample free length for flexing.

6. When properly routing, use clamps to secure the hose in its proper position.

PAGE - 60

090053-OP_r0 (JAN-2014)


(800) 526-8817 • www.vanair.com

BLANK PAGE

Vanair Manufacturing, Inc.

10896 West 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 Change

Without Prior Notice

050846

JAN-2014

Viper Diesel 100 PSI Rotary Screw Air Compressor

100 PSI ROTARY SCREW AIR COMPRESSOR

OPERATOR’S MANUAL & PARTS LIST

NOTE

NOTE

Vanair Manufacturing, Inc.

NOTE

TABLE OF

CONTENTS

Continued on next page...

Continued on next page...

BLANK PAGE

WARRANTY CLAIMS

PROCEDURE

LAIMS PROCESS FOR

WARRANTED

ANAIR PARTS

P

:

NOTE

NOTE

NOTE

SECTION 1:

SAFETY

1.1 GENERAL INFORMATION

IMPORTANT

1.2 DANGERS, WARNINGS,

CAUTIONS AND NOTES

1.3 SUMMARY OF WARNINGS,

CAUTIONS AND NOTES

1.3.1 DANGERS

1.3.2 WARNINGS

1.3.3 CAUTIONS

1.3.4 SAFETY DECALS

WARNING

1.4 DISPOSING OF MACHINE

FLUIDS

BLANK PAGE

SECTION 2:

SPECIFICATIONS

SECTION 3:

INSTALLATION

3.1 MACHINE PACKAGE

RECEIPT/INSPECTION

NOTE

3.2 INSTALLATION INSTRUCTIONS

DANGER

WARNING

NOTE

3.3 INSTRUMENT PANEL

RELOCATION

DISCLAIMER

NOTE

SECTION 4:

OPERATION

4.1 GENERAL INFORMATION

NOTE

NOTE

4.2 INSTRUMENTATION

4.2.1 DIGITAL DISPLAY SCREEN

4.2.2 SCROLL SELECTOR ROCKER

SWITCH

4.2.3 ON/START AND STOP SELECTION

ROCKER SWITCH

4.3 INITIAL START-UP

PROCEDURE

4.4 SUBSEQUENT START-UP

PROCEDURE

4.5 SHUTDOWN PROCEDURE

IMPORTANT

4.6 CONTROLLER GUIDE

4.6.1 HOME SCREEN

4.6.2 SPLASH SCREEN

4.6.3 ADJUSTING USER SETTINGS

4.6.4 SETTING PRESSURE

4.6.5 SAFETY

4.6.6 SERVICE INTERVALS

4.7 OPERATING CONDITIONS

4.8 EXTREME CONDITIONS

SECTION 5: