VMAC A24113 OEM Compressor Mount Package for CR70 Installation Guide

Installation Manual for VMAC OEM
Compressor Mount Package for VR70
CAT 4.4 – A240113
www.vmacair.com
VMAC – Vehicle Mounted Air Compressors
VMAC Technical Support: 888-241-2289
VMAC Knowledge Base: https://kb.vmacair.com

Document #: 1901199
Changes and Revisions

Important Information

The information in this manual is intended for approved VMAC installers who have been trained in installation and service procedures and/or for anyone with mechanical trade certification who have the tools and equipment to properly and safely perform the service. Do not attempt this service without the appropriate mechanical training, knowledge, and experience.
Follow all safety precautions for mechanical work. Any fabrication for correct fit in equipment must follow industry standard “best practices”.

Notice
Copyright © 2023 VMAC Global Technology Inc. All Rights Reserved. These materials are provided by VMAC for informational purposes only, without representation or warranty of any kind, and VMAC shall not be liable for errors or omissions with respect to the materials. The only warranties for VMAC products and services are those set forth in the express warranty statements accompanying such products and services, if any, and nothing herein shall be construed as constituting an additional warranty. Printing or copying of any page in this document in whole or in part is only permitted for personal use. All other use, copying or reproduction in both print and electronic form of any part of this document without the written consent of VMAC is prohibited. The information contained herein may be changed without prior notice.
Printed in Canada

General Information

Introduction
This manual provides installation instructions for mounting the engine related compressor components. Read this manual prior to servicing or operating the compressor system.
Follow all safety precautions when servicing or operating the VMAC system.
Proper service and repair are important to the safety of the operator and the safe, reliable operation of the equipment. Always use genuine VMAC replacement parts.
The procedures described in this manual are the only approved methods of service and operation.
Torque Specifications
All fasteners must be torqued to specifications. Use manufacturers’ torque values when available. Apply Loctite 242 (blue) or equivalent on all fasteners subject to vibration.
Torque values below are typical to achieve 70% yield strength of the bolt with Loctite applied (or otherwise lightly lubricated).
This assumes the mating threads are of sufficient strength. Reduce values as needed based on thread engagement length and material.

Typical Maximum Tightening Torque – SAE

Grade| 5| 8
Pitch| Coarse| Fine| Coarse| Fine
1/4| ft-lb| 6| 7| 9| 10
Nm| 8| 10| 12| 13
5/16| ft-lb| 13| 14| 18| 20
Nm| 17| 19| 24| 27
3/8| ft-lb| 23| 26| 33| 37
Nm| 31| 35| 45| 50
7/16| ft-lb| 37| 41| 52| 58
Nm| 50| 55| 70| 79
1/2| ft-lb| 57| 64| 80| 90
Nm| 77| 86| 108| 122
9/16| ft-lb| 82| 91| 115| 129
Nm| 111| 123| 156| 175
5/8| ft-lb| 112| 128| 159| 180
Nm| 152| 173| 215| 244
3/4| ft-lb| 200| 223| 282| 315
Nm| 271| 302| 382| 427
Typical Maximum Tightening Torque – Metric

Class| 8.8| 10.9| 12.9
M5 x 0.8| ft-lb| 5| 7| 8
Nm| 7| 10| 12
M6 x 1.0| ft-lb| 8| 12| 15
Nm| 12| 17| 20
M8 x 1.25| ft-lb| 21| 30| 35
Nm| 29| 41| 48
M10 x 1.5| ft-lb| 42| 60| 70
Nm| 57| 82| 96
M12 x 1.75| ft-lb| 74| 106| 123
Nm| 100| 143| 167
M16 x 2.0| ft-lb| 183| 261| 305
Nm| 248| 354| 413

Ordering Parts
To order parts, contact the VMAC Inside Sales department. To assist in selecting the appropriate parts, please provide the VMAC compressor serial number, part number, description, and quantity. Contact VMAC Inside Sales by calling 1 (887) 912-6605 or by email to [email protected].

Safety

Important Safety Notice
The information contained in this manual is based on sound engineering principles, research, extensive field experience and technical information. Information is constantly changing with the addition of new models, assemblies, service techniques and running OEM changes. If a discrepancy is found in this manual, contact the VMAC OEM department prior to initiating or proceeding with installation, service or repair. Current information may clarify the issue. Anyone with knowledge of such discrepancies, who proceeds to perform service and repair, assumes all risks.
Only proven service procedures are recommended. Anyone who departs from the specific instructions provided in this manual must first assure that their safety and that of others is not being compromised, and that there will be no adverse effects on the operational safety or performance of the equipment.
VMAC will not be held responsible for any liability, consequential damages, injuries, loss or damage to individuals or to equipment as a result of the failure of anyone to properly adhere to the procedures set out in this manual or standard safety practices. Safety should be the first consideration when performing any service operations. If there are any questions concerning the procedures in this manual, or more information is required, please contact VMAC OEM department prior to beginning repairs.
Safety Messages
This manual contains various warnings, cautions and notices that must be observed to reduce the risk of personal injury during installation, service or repair and the possibility that improper installation, service or repair may damage the equipment or render it unsafe.

|

This symbol is used to call attention to instructions concerning personal safety. Watch for this symbol; it points out important safety precautions, it means, “Attention, become alert! Your personal safety is involved”.
Read the message that follows and be aware of the possibility of personal injury or death. As it is impossible to warn of every conceivable hazard, common sense and industry standard safety practices must be observed.

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| This symbol is used to call attention to instructions on a specific procedure that if not followed may damage or reduce the useful life of the compressor or other equipment.

NOTE

| This symbol is used to call attention to additional instructions or special emphasis on a specific procedure.

Safety Precautions

As it is impossible to warn of every possible hazard that may result from operating this system, common sense and industry standard safety practices must be observed.
Read this information before operating the compressor for the first time. Follow the information and procedures in this manual for operation, maintenance and repair. Observe the following items to reduce the chance of personal injury or equipment damage.
Proper service and repair are important to the safety of the service technician and the safe, reliable operation of the equipment. Always use genuine VMAC replacement parts.
The procedures described in this service manual are effective methods of service and repair. Some procedures may require the use of tools specially designed for a specific purpose. Anyone using a replacement part, service procedure or tool must first determine that neither their safety nor the safe operation of the equipment will be compromised by the replacement part, service procedure or tool selected.
Moving Parts Hazard

• Before performing service, disconnect the power source to prevent unexpected equipment
• Do not operate the system without guards in If the guards are damaged or missing, replace them before operating the equipment.

Electrical Hazard

• Ensure the ground point connection is connected to the equipment body/chassis to prevent the chance of injury.
• Ensure the equipment is grounded appropriately

Burn Hazard

• The compressor system gets very hot during operation, contact with the components or the oil can cause serious injury. Allow sufficient time for the system to cool prior to performing
• Never allow any part of your body to contact the compressor components until the system has cooled sufficiently.

Compressor Air and Oil Hazard

• The compressor system is under sufficient pressure that a leak could force the air/oil mixture through the skin directly into your This could cause serious injury or death.
• Ensure the system is completely depressurized before attempting maintenance or repair.
• Do not use compressed air to clean off clothing or skin, compressed air can penetrate the skin causing serious injury or death.
• Do not move or service the system while it is pressurized or operating.
• Components and hoses under pressure could separate suddenly and cause serious injury or death. If equipped, the air receiver tank must be drained prior to servicing the system.
• Never adjust or attempt to make any repairs to the system while the engine is running. Components and hoses under pressure could fail and cause serious injury or death.

Burst Hazard

• Serious injury or death may result from an air tank explosion.
• Never exceed manufacturer’s maximum air pressure rating.
• Do not repair components, only replace with approved parts.
• Do not tamper with, or disable factory safety equipment.

Personal Safety

• Vaporized oil is a respiratory hazard, do not breathe the compressor air.
• Always use the appropriate personal protective equipment, particularly eye and hearing protection when operating air powered equipment.

Main Bracket and Compressor Installation

Apply Loctite 242 (blue) to all fasteners.

• Mount the pulley (P/N 1800282) to the engine using six M12x30 bolts (P/N 1520624) and Loctite.
• Torque the six M12 bolts to 74 ft-lb (100 N•m) as per Table 1 on page 6.
• Mount the main bracket assembly (P/N 4800883) to the engine using four M12x80 bolts (P/N 1520682) and Loctite. Leave bolts finger tight.
• Install one M16x110 bolt and washer (P/N 1520683 and 1570233), this will press-in the bushing included in bracket assembly (P/N 5800200) until it contacts engine mount face.
• Torque the four M12 bolts to 74 ft-lb (100 N•m) as per Table 1 on page 6.
• Torque the M16 bolt to 183 ft- lb (248 N•m) as per Table 1 on page 6.
• Mount the compressor (P/N P120218) onto the main bracket using four M8x110 bolts (P/N 1540521) and Loctite.
• Torque all four compressor bolts to 19 ft-lb (25 N•m) as per Table 1 on page 6.
• Install the belt (P/N 1610378) and route as per the figure below.
• Remove the tensioner locking pin using a 3/8” drive to rotate the tensioner.

Ensure belt is located correctly on all tensioners, pulleys, and idlers.
Failure to mount the belt correctly could damage or throw the belt on start- up, creating a safety hazard and or personal injury.

Hose Routing

Illustrated Parts List

Engine Kit Components – A240113

Item #

| Part #| Qty|

Description

---|---|---|---
1| P120218| 1| ASSY, COMPRESSOR, VR70
2| 1610378| 1| BELT, K060559
3| 1800282| 1| PULLEY, CRANK, CAT C4.4, VR70
4| 4800883| 1| ASSY, BRACKET, MAIN, VR70, C4.4
4.1| 1100268| 1| BRACKET, MAIN, VR70, C4.4
4.2| 1300031| 1| IDLER, SERP, BACK,FLANGE,90MM
4.3| 1520571| 1| BOLT,HHCS FLHD PL, M10 X 1.5 X 30
4.4| 1570496| 1| WASHER, FENDER, 10MM X 30MM
4.5| 3300045| 1| TENSIONER 38507
4.6| 1520532| 1| BOLT, HHCS,G10.9,FLPL, M10X1.5X80
4.7| 5800200| 1| BUSHING, STEEL, 16.5ID, 26OD, 24L
5| 1700660| 1| HOSE, SILICONE, CAT4.4
6| 3801473| 1| FASTENER PACK, A240113
6.1| 1520683| 1| BOLT, HHCS, PL, M16 X 2.0 X 110
6.2| 1520682| 4| BOLT, HHCS, FL, PL, M12 X 1.75 X 80
6.3| 1520624| 6| BOLT, HHCS FL,LK,PL M12 X 1.75 X 30
6.4| 1570233| 1| WASHER, FLAT SAE, 5/8
6.5| 1540521| 4| BOLT, SHCS, PL, M8 X 1.25 X 110
7| 1901199| 1| INSTRUCTIONS/IPL, A240113

Compressor Assembly – P120218

Item #

| Part #| Qty|

Description

---|---|---|---
1| 9200636| 1| SUB ASSY, VR70, 3.21
2| 4900203| 1| FTG, 90, #8MORB-#8MJIC, VITON
3| 1540549| 7| BOLT,SHCS,M6 X 1 X 18,PLATED,G12.9
4| 4900128| 1| FTG, STR, #12MORB-#12MJIC, VITON
5| 9200510| 1| CAP, DISCHARGE, VR70
6| 9200610| 1| ASSY, INLET, 2.0” INTAKE
7| 5000165| 2| ELBOW,90, BRASS NPT-POLY, 1/8-3/16
8| 4300076| 1| PIPE FTG, PLUG SKT HEAD, 1/8
9| 1540550| 2| BOLT,SHCS,M8 X 1.25 X 50, G12.9 PLT
10| 1540530| 2| BOLT,SHCS,M8 X 1.25 X 55, G12.9 PLT
11| 5000020| 1| ELBOW, BRASS NPT-POLY, 1/8-1/4
12| P200035| 1| CLUTCH, COMPLETE 6 GROOVE
13| 5830004| 1| O-RING, VITON, 3 1/8 ID X 1/8
14| 5830112| 1| O-RING, VITON, 3 3/4 ID X 3/32
15| 3550794| 1| PROBE, ASSY, THERMISTOR. GT 150
16| 4900045| 1| PLUG, #8ORB, INTERNAL HEX
17| 4400295| 1| LABEL, VR70 NAME PLATE
18| 1500355| 2| SCREW, LONG U DRIVE, 2 – 3/16
19| 3600123| 1| VALVE, CHECK, 1/8 NPT

Inlet Valve Assembly – 9200610

Item #

| Part #| Qty|

Description

---|---|---|---
1| 9200592| 1| INLET VALVE, NO OIL PLUG
2| 5830070| 1| O-RING, VITON, 2 9/16 ID X 3/32
3| 3200545| 1| ADAPTER, INLET, 2″
4| 1500533| 4| SCREW, BUTTON HCS, 10-32 X 5/8 PL
5| A700137| 1| ACCESSORY PACK, REGULATOR ASSEMBLY
6| 5830130| 1| O-RING, VITON, 1 5/16 ID X 3/16
7| 5830002| 1| O-RING, VITON, 2 3/8 ID X 3/32
8| 4900045| 1| PLUG, #8ORB, INTERNAL HEX

Manufactured by
888-241-2289
877-740-3202
www.vmacair.com
[email protected]
[email protected]
www.kb.vmacair.com
1333 Kipp Road, Nanaimo, B.C., V9X 1R3 Canada

References

• VMAC - Vehicle Mounted Air Compressors | VMACAIR.com
• VMAC Knowledge Base

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