VMAC S700199 OEM Component Package User Manual

VMAC S700199 OEM Component Package

Product Information

Specifications

• Product Name: VMAC OEM Component Package
• Model Number: S700199 – VR70, CAT 4.4L
• Manufacturer: VMAC
• Website: https://vmacair.com

General Information

This manual provides an overview of the system components and where to find installation instructions for the VMAC S700199 OEM Component Package. It is important to read this manual before servicing or operating the compressor system.Please follow all safety precautions when servicing or operating the VMAC system. Proper service and repair are crucial for the safety of the operator and the 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.

Ordering Parts

To order parts, please contact the VMAC Inside Sales department. When contacting them, provide the VMAC compressor serial number, part number, description, and quantity. You can reach VMAC Inside Sales by calling 1 877-912-6605 or by email at [email protected].

SafetyImportant Safety Notice

Only proven service procedures are recommended. If you deviate from the specific instructions provided in this manual, ensure that your safety and the safety of others are not compromised and that there will be no adverse effects on the operational safety or performance of the equipment.

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. Improper installation, service,or repair may also damage the equipment or render it unsafe.

The following symbols are used in this manual:

• Attention, become alert! Your personal safety is
  involved: This symbol is used to call attention to instructions concerning personal safety. Read the message that follows and be aware of the possibility of personal injury or death. While it is impossible to warn of every conceivable hazard, common sense and industry standard safety practices must be observed.

• Procedure may damage or reduce useful life:
  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.

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

Product Usage Instructions

Before proceeding with the installation or service of the VMAC OEM Component Package, ensure that you have received appropriate mechanical training, possess the necessary knowledge, and have therequired experience. If you do not meet these criteria, do not attempt the installation or service without assistance from a qualified professional.

Installation

Follow these steps to install the VMAC OEM Component Package:

1. Ensure that you have read and understood all the instructions in this manual.
2. Gather all the necessary tools and equipment required for the installation.
3. Refer to the specific installation instructions provided for each system component included in the package.
4. Follow industry standard best practices when fabricating any parts for correct fit in the equipment.
5. Ensure that all safety precautions for mechanical work are followed.

Service

Follow these steps to perform service on the VMAC OEM Component Package:

1. Ensure that you have read and understood all the instructions in this manual.
2. Gather all the necessary tools and equipment required for the service.
3. Refer to the specific service instructions provided for each system component included in the package.
4. Follow industry standard best practices when performing service tasks.
5. Always use genuine VMAC replacement parts.

Operation

To operate the VMAC OEM Component Package, follow these guidelines:

1. Ensure that you have read and understood all the instructions in this manual.
2. Make sure that all installation and service procedures have been completed successfully.
3. Refer to the specific operation instructions provided for each system component included in the package.
4. Follow industry standard best practices for safe and efficient operation.

FAQ

Q: Where can I find installation instructions for the VMAC S700199 OEM Component Package?

A: The installation instructions for each system component included in the package can be found in this manual. Please refer to the specific installation instructions provided for each component.

Q: How can I order parts for the VMAC OEM Component Package?

A: To order parts, please contact the VMAC Inside Sales  department. Provide them with the VMAC compressor serial number,part number, description, and quantity. You can reach VMAC Inside Sales by calling 1 877-912-6605 or by email at [email protected].

Q: What should I do if I encounter a safety issue during the installation or service?

A: If you encounter a safety issue during the installation or service of the VMAC OEM Component Package, stop the procedureimmediately. Ensure your safety and the safety of others before proceeding. If necessary, consult a qualified professional for assistance.

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.

General Information

This manual provides an overview of system components and where to find installation instructions for the S700199 OEM Component Package. 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.

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.

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

Safety Precautions

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.

System ID

| The System Identification Number Plate must be attached to the equipment at the time of installation. This plate provides information that allows VMAC to assist with parts and repairs
---|---

• Mark and drill two 7/64-inch holes in a suitable location. Secure the plate with the supplied screws.
• Install the supplied maintenance checklist decal in an easy to access location.

Component Installation

Complete component installation instructions are provided with their respective packages as listed in Table 1 below:

Component| Install

Manual #

| Install Instructions with

Package #

| Links
---|---|---|---
Hoses| 1901137| S700199| _1901137_ Link
Compressor| 1901199| A240113| _1901199_ Link
Belt Drive| 1901199| A240113| _1901199_ Link
Separator Tank| 1901134| A230102| _1901134_ Link
Coalescer| 1901134| A230102| _1901134_ Link
Blow Down Solenoid| 1901134| A230102| _1901134_ Link
Oil Cooler| 1901133| A270101| _1901133_ Link
Controls| 1901131| A260104| _1901131_ Link
Air Intake| 1901083| A220112| __1901083 Link

Special Installation Notes

| If you intend to use an auxiliary air tank with this system, you must observe the following installation procedure. Failure to observe this procedure will result in damage to the system.

•            The line from the VMAC tank to the auxiliary air tank must have a check valve installed to prevent blow-back from the auxiliary tank and to prevent moisture from entering the VMAC tank, see Figure 3.

•            The line to the auxiliary tank must not be installed in the bottom of the tank. It must be installed as high as possible to prevent sludge from the bottom of the tank from interfering

with proper check valve functions.

---|---

Operational Limitations

The system must not be operated in excess of 15⁰ from horizontal, as this will affect lubrication and air/oil separation.

Maintenance Schedule

| During the warranty period, you must follow the maintenance schedule and use only original genuine VMAC replacement parts to maintain your system and your 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 the rotors in the compressor.

Contamination will cause severe, rapid damage to components.

| Never run the compressor without the recommended air filter and filter cover installed.
| You must use VMAC certified and approved synthetic compressor oil.

Failure to use this oil will result in damage to the compressor and will void your warranty.

Maintenance Schedule

The following maintenance schedule listed in Table 2 should be observed to assure good performance and long service life. The hours indicated are:

• engine hours where the compressor is directly mounted to the engine.
• actual compressor operating hours where the compressor is equipped with a clutch to disengage operation from the engine.

Service should be performed at the lesser of the two intervals, hours, or calendar months, whichever occurs first. For replacement part numbers, check the appropriate Illustrated Parts List for your application or call a local VMAC dealer.

A700091

4L Oil: A700094

Every 6 months

or 500 hours

| Replace air filter, oil filter, and change oil.|

Contact VMAC Sales

Yearly or

every 1000 hours

| Replace air filter, oil filter, coalescing element and change oil.|

Contact VMAC Sales

Table 2 – Maintenance Schedule

Diagnostics and Trouble Shooting

| Read the “Safety Precautions” section prior to performing any work on the system (on page 5).

Wear appropriate Personal Protective Equipment and follow all industry standard safety practices.

---|---
| For the following tests, isolate the air-oil separation tank from all downstream (customer supplied) equipment.

Problem diagnosis should follow sound, recognized practices. Quick and accurate diagnosis of problems should involve the following:

• Follow industry standard safety practices.
• Accurately identify the problem by operating the system (provided it is safe to do so).
• Determining the possible causes for the problem by understanding how the system operates.
• Isolating the potential causes by accurate testing using the correct and recognized procedures.
• Performing proper repairs using the correct procedures and the recommended replacement parts.
• Performing proper post repair testing to ensure that the repairs were effective.
• Electrical testing should be performed according to the processes described in the troubleshooting charts and in conjunction with any documentation provided by VMAC.

Accessing Diagnostic Mode and Retrieving Logged Error Messages

• Turn the system “ON” but do not start the drive system for the compressor such that the control box receives power without running the compressor.
• Press and hold the “OFF“ button on the control box until “DIAGNOSTICS” message is displayed.
• Press the “OFF” button to scroll down, press the “ON” button to scroll up.
• When the end is reached, “NO SVC NEEDED” message will be displayed.
• To exit diagnostic mode, press both the “OFF” and “ON” buttons simultaneously.

Digital Control Box Information and Warning Messages

Warning/Information Message| Warning/Information Description| Compressor State
---|---|---
HRS:XXXX:XX| Main screen hour meter| On/Off.
Park Brake| System interlock is not applied or bad signal| Off.
HRS:XXXX500HRSVC| 500HR service is needed.| On/Off.
HRS:XXXX1000HRSVC| 1000HR service is needed.| On/Off.
COMP TOO COLD| Compressor too cold for operation (<-25C).| On.
TEMP XXXF/XXXC| Displays elevated temperature 130°C (266°F) to 150°C (300°F).| On/Off.
Wait xx Seconds| A 30 second countdown to allow for

compressed air blow down.

| Off.

01

|

OVER TEMP

|

Compressor is too hot.

| •  Low compressor oil level.

•  Faulty or crushed cooler hoses.

•  Exceeded cooling capacity of the compressor cooling system.

•  OEM changes in cooling

•  Non-standard application

02

|

TEMP PROBE SHORT

|

Compressor temperature probe wires shorted or failed.

| •  Faulty temperature probe.

•  Crushed temperature probe wires

•  Pinched or bare wires that are grounded

03

| TEMP PROBE OPEN| Compressor temperature probe circuit open.| •  Disconnected temperature probe.

•  Faulty temperature probe.

•  Broken temperature probe wires.

04

|

BATTERY LOW

|

Power supply voltage between connection A and G is less than 11 V.

| •  Faulty power or ground wire connection.

•  Bad fuse.

•  Broken or poorly crimped electrical connectors.

•  Equipment power supply system

issues.

05| CLUTCH HIGH| Current draw on the clutch is too high (5 A – 10 A).| • Faulty clutch.

•  Broken or pinched clutch wire.

06

|

CLUTCH LOW

| Current draw on the clutch is too low (below 2 A).| •  Faulty clutch.

•  Broken or pinched clutch wire.

•  Disconnected clutch wire.

07

| CLUTCH SHORT| Current draw on the clutch is too high (above 10 A).| • Faulty clutch.

•  Clutch wire shorted to ground or pinched.

Automatic Shutdown

If the compressor oil gets too hot, the over-temperature circuit will disengage the clutch, preventing operation of the system. The red indicator light on the control box will illuminate, indicating a problem.

• Press the “OFF” button on the control box.
• Allow a few minutes for the system to vent pressure and for the oil to drain back to the tank, then check the oil level through the sight-glass on the tank. The oil level must be checked with the vehicle on a level surface.
• If the oil level is low, check for and repair any leaks, then add oil until the correct level is reached.

Limp Mode

Limp mode was created to provide a way to bypass the temperature sensor in case of a sensor failure. This mode is an emergency mode and should be used with extreme caution.

How to activate

• Press and hold the “OFF” button on the control box until the “DIAGNOSTICS” screen appears (approximately 5 seconds). Release the “OFF” button and the screen will display “E01 xxxx xx xx” message.
• Press the “OFF” button again. The screen message “NO TEMP PROBE?“ will appear.
• To disable the temperature probe, press the “ON” button. “TEMP PROBE DIS” message will appear. This indicates that the temperature probe has been disabled.
• Press both the “ON” and “OFF” buttons simultaneously to exit.

While in “Limp Mode”, the main menu screen will display “NO TEMP PROBE?” message with a red LED then “CHECK OIL” message and the green LED and then the hours. The display will toggle between these messages approximately every second. The clutch and throttle will be on for 1 minute then off for 1 minute while in “Limp Mode”. Once the system is shut off via the “OFF” button, the control box will operate normally.

Diagnostic charts

Compressor does not run.

| Oil temperature too high.| Turn compressor off, allow to cool for 30 minutes, retry.
Oil level too low.| Add oil as necessary.

No power to clutch.1

| Apply 12V to the clutch and check for voltage between the clutch stator housing and the engine. If voltage is

present, ground the stator.

Faulty clutch stator windings.1

| With the compressor button “OFF” check the resistance between the clutch wire and ground. Resistance should be between 2.5 Ω – 3 Ω. If outside of this range, replace the

clutch.

Low air pressure.

| Air demand too high.| •  Reduce air consumption. • Install air

receiver tank.

Drive system speed too low.| Adjust Drive system speed control.
Pressure regulator set too low.| Adjust pressure regulator to 150 psi.
Excessive air pressure (significantly greater than 175 psi.)| Pressure regulator set too high.| Reduce system pressure by adjusting pressure regulator.
Pressure control tube blocked or frozen.| Clear PTFE tube. • Install VMAC De- icer kit (A700031).

System pressure higher than tool requires.

| No downstream pressure

regulator installed.

| Install downstream pressure

regulator.

Aftermarket pressure regulator set too high.| Adjust pressure regulator to desired pressure.
Oil drips from drive system connection after shutdown.|

Front shaft seal leaking

|

Contact VMAC Technical Support.

Oil blows out of compressor air filter on compressor shutdown.

| Shutting the drive system off before system has built to full

system pressure.

| Stop air demand and allow the engine speed to drop to base idle

prior to turning the compressor off.

Normal operation (remote mounted air filters only).

| It is normal for a small amount of oil to be present in the remote air filter hose once the compressor is shut

down. This oil will be drawn back into the compressor upon startup.

Missing, damaged, or dislodged inlet poppet O-ring.| Contact a VMAC dealer or VMAC Technical Support.

Excessive oil in the air stream (oil carry over).

| Compressor was shut down while building air.| Stop air demand and allow drive system speed to drop to base idle

prior to turning the compressor off.

Equipment placed on a grade greater than 15°.| Level the equipment and run the

system. Oil carry over may take up to 40 minutes to dissipate.

High oil level.| Correct oil level.
Failed coalescing filter.| Replace coalescing filter.
Clogged scavenge screen.| Clean scavenge screen.
Poor fit between coalescing filter and AOST/poor seal at O-rings.| Replace parts as necessary.
Drive system stalls when compressor is activated.| System is under pressure.| Allow sufficient time for blowdown.
Blowdown valve not working.| Replace blow-down valve.
Drive system rpm setting too low or speed control not set correctly.| Readjust rpm and speed control settings for optimum operation.
Symptom| Possible Cause| Corrective Action
---|---|---
Frequent over-temp shutdowns.| Low oil level.| Check oil on level ground, add as required.
Restriction in the compressor oil

hoses.

| Check for kinked or pinched oil

hoses.

Heat exchanger not functioning

or is fouled with deposits.

| Remove and clean or replace heat

exchanger.

Frequent relief valve operation.| Pressure control line plugged or frozen.| Remove pressure control line, clear obstructions. (Blow out.)
Relief valve defective.| Replace relief valve.

Hose Connections

Refer to the following sections for diagrams and further reference regarding the following connection line installations. For hose specification, please see the Hoses manual.

| VMAC uses hoses and tubing that have been specifically specified for the application and may differ from standard hosing and tubing. For current and complete details on hose types and sizes, see VMAC Technical Support Bulletin regarding VMAC hoses on the online

knowledge base: https://kb.vmacair.com/help/required-vmac- hoses

---|---

| Hoses for VMAC systems require a temperature rating of -40°C to 150°C (-40°F to 302°F) or greater. Pressure rating must be a minimum of 300 psi operating (working) pressure.

Lines for compressed air vary in size depending on air output. For VR90 and lower air flow systems, ¾” hose with #12 JIC connections are used. For VR130 and larger systems, 1” hose with #16 JIC

connections are used.

| VMAC air compressor systems require the use of hoses with special liners to stand up to the unique properties of VMAC compressor oil and the high heat that our compressors generate. Examples:

Aeroquip- AQP™, Parker-PKR® , and Gates-GTS (CPE)™.

Hose Routing

Illustrated Parts List

OEM Component Package – S700199

100” HOSE PACKAGE – A400100

VMAC – Vehicle Mounted Air Compressors

• VMAC Technical Support: 888-241-2289
• VMAC Knowledge Base: https://kb.vmacair.com

References

• VMAC Knowledge Base
• Required VMAC Hoses

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