Airworks Hydraulic Supply Units: Vortex Hyper-Pak

Submitted by admin on Thu, 12/17/2009 - 05:56

Features and Benefits

Features:

·         Tier 4 Certified

·         Safety Shutdown Protection

·         Electric Fuel Pump

·         Integral Oil Cooler

·         Powder Coated Finish

·         Wired Remote Controls

·         Hour Meter

·         Oil Containment System

·         Multi-positional Exhaust

 

Benefits:

·         Power levels to satisfy all of your hydraulic requirements

·         Less weight, less fuel, more poser, easy to transfer

·         Size: 18”W x 26”L x 23”H and Weight: from 7kg/164 lbs

·         Diesel powered

·         Replaces traditional PTO (decreased chassis wear/run time)

·         Engine Specs: Kubota, Diesel

·         Pump Style Options: Gear, Vane, Piston

 

 

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Operating Principles

  • Engine power is provided to operate a hydraulic pump. Supplying hydraulic power for operation of equipment, optional features may include an A/C generator, an air conditioning compressor and a 110 amp alternator.
  • An optional liquid to liquid cooling system is used to maintain hydraulic oil temperature. This system uses the cooling system of the prime mover to act as a heat sink for heat transfer and may also use an air to oil cooler.

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System Operation

  1. Important: Read and understand operation manual before installation.
  2. Trace base size and mount hole locations onto cardboard and use as template to drill holes to mount compressor in suitable location. Use caution when drilling; check below for obstacles.
  3. Allow for proper fitting, hose wire routing. Allow for proper ventilation and service access.
  4. Mount compressor to service body. Securely fasten.
  5. Run supply and return lines to truck diesel fuel tank. Use the auxillary pick up provisions on tank. Note: Do not cut into the truck engine lines. Consult vehicle manufacturer for proper procedure.
  6. Use caution to prevent rubbing/pinching on hose when vehicle in motion.
  7. Electric fuel pump on Vortex may need to be relocated near to fuel tank on long hose runs.
  8. An electric auxillary fuel pump is available for high lifts and long runs (see parts lists).
  9. Run battery cable from Vortex to truck battery. Install a 150 amp circuit breaker in system, near battery; size cable properly for length of run.
  10. Mount Vortex control panel in accessible location.
  11. If connecting truck cooling system to Vortex, use Airworks’ Cold Weather Package, P/N ATA020.
  12. An auxillary booster water pump is available for long run and high mounting locations. Use Airworks’ P/N ATA015.

Installation Notes

The stock fuel pump on the Vortex is not capable of drawing fuel from long distances. If the installation of the Vortex is more than 6 (six) feet from the fuel tank, the pump should be relocated closer to the fuel tank. An auxillary fuel pump is available from Airworks, part number ATA014 for long runs or high lift.

Restrictions in the air line such as 45 degree and 90 degree fittings should be limited to 3 or less. Too many direction changes or elbows may lead to loss of flow.

When installing the Vortex in a confined location, direction of airflow through the unit should be considered. A source of fresh air in and a place to vent the warm air out is critical to the proper operation of the compressor and engine.

When connecting the battery cables to the Vortex, it is recommended to use a minimum 4 gauge wire with a 150 amp breaker in line. Due to the rubber mounting bases on the Vortex, it is recommended that the unit is grounded to a clean, paint free spot on the Vortex engine and to battery.

Vortex Starting Procedure

  1. Turn ignition key to the left and hold for 15 seconds. This primes the fuel pump and engages the glow plugs. Never hold key in this position for longer than 15 seconds as damage to the glow plugs could result.
  2. Now turn the key to the right crank position. When engine has started release key.
  3. When engine has reached operating temperature, engage the compressor switch. This will allow compressor to start.
  4. When pressure reaches preset pressure (150 to 170 psi) unit will idle down.
  5. System is now ready for use.

Vortex Shutdown Procedure

  1. Switch compressor button off.
  2. Vortex will slow down.
  3. Turn key to off position.
  4. Engine will stop
Observe the Following General Safety Rules
  1. Read and understand operation manual, before operating machine. Installer to ensure manual and all safety decals are delivered with unit on completion of product installation.
  2. Follow safe work practices and wear the appropriate safety equipment when operating air-power equipment.
  3. Avoid contact with the drive system. Do not operate with panels removed.
  4. Vaporized oil propelled by high pressure air is an explosive mixture.
  5. Do not breathe the compressor air. Vaporized oil is a respiratory hazard.
  6. Components are hot during and following operation; use caution.
  7. Disconnect all power before any servicing.
  8. Do not attempt to service compressor while under pressure; remove fill cap and filters slowly.
When operating the compressor:
  1. Do not bypass any of the units safety shut down devices.
  2. Do not expose the unit to extreme heat.
  3. Do not repair or service a pressurized system.
  4. Maintenance and repairs are to be performed by qualified personnel only.
  5. Do not tamper with the pressure relief valve.
  6. Do not attempt to modify any component.
  7. Do not operate with cover or doors removed.

Safety Features

  1. Temperature safety shut down on engine and hydraulic system (optional)
  2. High pressure shutdown on hydraulic system (optional)
  3. Low oil pressure shut down on engine

Lubrication and Filters

  1. Use only Airworks certified and approved engine and compressor oils and filters
  2. Compressor may be under pressure; ensure pressure is released and unit is unloaded before servicing, remove fill cap slowly – stop if pressure is present
  3. Oil filters are spin-on type
  4. Air filters are paper type replaceable

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Routine Maintenance

During the warranty period you must follow the maintenance schedule and use only Airworks genuine replacement parts to maintain your system and warranty.

The most critical aspect of maintenance is proper air filtration and clean oil. If any particles enter the compressor through the air inlet, they can contaminate roller bearings, gears and rotors in the compressor. Contamination will cause severe and rapid damage to components.

Ensure Vortex is completely unloaded before servicing. Clean Areas to be serviced. Remove fill cap and filters slowly.

Maintenance Schedule

The following maintenance schedule should be observed to assure good performance and long service life. The hours indicated are those displayed on the unit’s hour meter.

For replacement parts please order the indicated part numbers from an authorized dealer.

250 Hours – Change engine oil and oil filter. Change compressor oil, oil filter, and air filter.

  • V14 - Airworks Service Kit P/N VHP14025
  • V20 - Airworks Service Kit P/N VHP20025
  • V44 - Airworks Service Kit P/N VHP44025

Inspect all components for loose or rubbing parts and repair as required.

500 Hours – Change engine oil, oil filter, fuel element, fan belt and air cleaner element. Replace fan belt, if required.

  • V14 - Airworks Service Kit P/N VHP14050
  • V20 - Airworks Service Kit P/N VHP20050
  • V44 - Airworks Service Kit P/N VHP44050

Inspect all components for loose or rubbing parts and repair as required.

Inspect pump drive coupler.

Check coolant strength.

Engine Speed Control

The system uses two control systems. One, a factory set air pressure switch and the other, an engine speed control. This allows for instant response to air demands based on air flow and reduction of load on the cooling system.

Adjusting the System

If insufficient airflow is developed under high demand conditions, check the engine RPM.

The throttle control is preset for maximum delivery by the system at all airflow demands within the unit’s abilities at the factory, but in some instance may require minute adjustment by the user. This is done by adjusting the linkage on the throttle control to increase or decrease the diesel RPM.

Consult your Airworks dealer before attempting adjustment.

Hydraulic flow and system pressure are related.

A system testing and adjustment tool is available from Airworks (ATT001).

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Troubleshooting

Quick accurate diagnosis of problems will help to effect repairs in a timely fashion and should involve the following:

  1. Understand the operational characteristics of the system to better determine the problem.
  2. Run the system, if possible, to determine the problem.
  3. Do not perform test procedures that are harmful to people or equipment.
  4. Perform repairs using the correct parts and procedures.
  5. Consult your local dealer or Airworks Compressors Corp.
Symptom:

Vortex does not produce adequate flow or pressure
Check and correct the following:

  1. Hydraulic oil level is correct
  2. Coupling between engine and compressor is intact
  3. Engine RPM is set to spec.
Symptom:

Frequent over-temperature shut downs
Check and correct the following:

  1. Check engine and hydraulic oil levels
  2. Check engine coolant level, while unit is cool
  3. Check engine and pump hoses for kinks
  4. Check engine and Vortex over temp shut down temp probes
  5. Check for adequate air circulation around unit
  6. Check heat exchanger not fouled
  7. Check oil filters not plugged
  8. Fan belt is properly adjusted
Symptom:

Engine stalls when pump starts
Check and correct the following:

  1. Engine fuel filter plugged
  2. Fuel pump functioning
  3. Hydraulic pump is under pressure
  4. Operating speed is too low
  5. Positive air shut off tripping (optional – not on all units)
Symptom:

Diesel engine turns but will not start
Check and correct the following

  1. Adequate fuel supply
  2. Glow plugs not used/faulty
  3. Hydraulic pump issue
  4. Fuel filter restricted/valve off
  5. Positive air shut off tripped (optional – not on all units)
  6. Fuel pump operation

Caring for Your Vortex

Your Vortex is designed to provide many thousands of hours of working life. By following the listed procedures you will ensure this happens and protect your investment and warranty.

Every 25 hours
  • Check fluid level
  • Check for loose or rubbing components
Every 100 hours
  • As above plus
  • Clean air filter element
  • Check fan belt tension
  • Check fuel filter
Every 250 hours
  • As above plus
  • Service engine oil and filters
  • Check radiator hoses and clamps
  • Check air intake hose
  • Inspect coupler on engine and compressor, replace if required
  • Check hoses for rubbing and/or wear
Every 500 hours
  • As above plus
  • Service engine oil and filters
  • Check radiator hoses and clamps
  • Check air intake lines
  • Replace the fuel filter element
  • Clean the radiator external fins
  • Replace the fan belt
Every 750 hours
  • Check the valve clearance
Every 2 years
  • Replace radiator hoses and clamps
  • Change radiator coolant
  • Replace air intake hose

Warranty Policy

General Provisions and Limitations

  1. Airworks Compressor Corp. warrants to each original retail purchaser (here after the buyer) of its new diesel drive air compressor system from Airworks or its authorized dealers that such products are free from manufacturers defects in material and workmanship.
  2. No warranty is made with respect to:
    1. Any products which in Airworks judgment have been subject to negligence, accident or improper storage, installation, application, operation or maintenance, or have been altered or repaired in such a way that effects the product adversely.
    2. Components or accessories manufactured, warranted and serviced by other than authorized dealer.
    3. Consequential damage(s) caused by Products failure.
    4. Any product(s) if other than Airworks genuine components are used in the Product and/or installation
    5. Normal wear and tear
    6. Paint and cosmetic items
  3. The warranty period will commence upon installation of the product. The returned warranty registration form marks the date of installation. If the warranty registration form has not been received by Airworks with in 2 months from the date of purchase then the warranty period will be deemed to commence 30 days from date of shipment from Airworks.
  4. The units are warranted for two (2) years or two thousand (2000) hours, whichever occurs first, against manufactures defects in materials and workmanship.
  5. Replacement parts, electrical components and cosmetic items (at Airworks discretion) shall be warranted for a period of six (6) months or three hundred (300) hours, whichever occurs first.
  6. Airworks Obligation
    1. Airworks obligation is limited to repairing or at Airworks option, replacing; during normal business hours at an authorized service facility of Airworks, any component, which in Airworks judgment is proven to be defective as warranted.
    2. Airworks obligation is limited to Product(s) proven to be warranted. No liability is accepted for any consequential damages, injuries or expenses directly or indirectly related to the Products failure.
    3. Airworks is not responsible for any costs incurred due to lost time or travel related to warranty issues.
    4. Airworks is not responsible for time required to service or repair product die to mounting location.
    5. Airworks is not responsible for return shipping to Airworks of failed components.
    6. Airworks will be responsible for ground shipment or replacement of validated warranty parts.
    7. Airworks is to be contacted prior to any possible warranty repairs are undertaken for warranty consideration.
  7. Buyers Obligations
    1. You, the buyer, are obligated to notify your dealer within 10 days of any defect and return defective part within 30 days of notification.
    2. The buyer must prepay all the costs associated with the warranty claim and submit receipts/invoices to your dealer for evaluation.
    3. The buyer must return components returned under this agreement to your dealer, designated by Airworks, for evaluation, to establish a claim under this warranty.
    4. Buyer shall maintain and service Airworks products in accordance with this manual.
    Warranty Registration Validations

    A warranty registration is supplied to the buyer with the product that must be returned to Airworks at time of installation.

    Disclaimer and Warranty Service
    1. Any labour costs incurred in excess of Airworks set labour rates are not covered.
    2. Any travel time or labour costs incurred by unauthorized personnel are not covered by this warranty.
    3. Any related service/repair costs incurred due to mounting location and accessibility are not covered by this warranty.
    4. This warranty is in lieu of all other warranties expressed or implied
    5. All warranty claims must be pre-authorised by Airworks and components returned prepaid using the assigned RGA number.

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    FAQ

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