vmacair S700196 VR70 OEM Component Package Instruction Manual

vmacair S700196 VR70 OEM Component Package

Product Information

Specifications

• Product Name: VMAC OEM Component Package
• Model Number: S700196
• Compatible Engine: STAGE V CUMMINS 4.5/6.7
• EOC: Yes
• Manufacturer: VMAC
• Website : www.vmacair.com

Product Usage Instructions

Installation

1. Ensure you are an approved VMAC installer who has received proper training in installation and service procedures. Alternatively, you should have mechanical trade certification and the necessary tools and equipment for safe installation.
2. Follow all safety precautions for mechanical work.
3. Any fabrication required for correct fit in equipment must follow industry standard best practices.

General Information

• This manual provides an overview of the system components and where to find installation instructions for the S700196 OEM Component Package. It is important to read this manual thoroughly before servicing or operating the compressor system.
• Always 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. Provide them with the VMAC compressor serial number, part number, description, and quantity to assist in selecting the appropriate parts. You can reach VMAC Inside Sales by calling 1 877-912-6605 or emailing sales@vmacair.com.

Safety

Important Safety Notice
Only use proven service procedures as recommended in this manual. If you deviate from the provided instructions, ensure that it does not compromise your safety or the safety of others. Additionally, confirm 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 damage the equipment or make it unsafe.

The following symbols are used throughout the manual:

• Attention Symbol: This symbol calls attention to instructions concerning personal safety. Pay close attention to these instructions as they involve your personal safety. Be aware of the possibility of personal injury or death.
• Procedure Symbol: This symbol calls attention to specific procedures that, if not followed, may damage or reduce the useful life of the compressor or other equipment.

Frequently Asked Questions (FAQ)

• Q: Who can install the VMAC OEM Component Package?
  A: The VMAC OEM Component Package should be installed by approved VMAC installers who have received proper training in installation and service procedures. Alternatively, individuals with mechanical trade certification and the necessary tools and equipment can also perform the installation.

• Q: How can I order parts for the VMAC OEM Component Package? A: To order parts, contact the VMAC Inside Sales department. Provide them with the VMAC compressor serial number, part number, description, and quantity to assist in selecting the appropriate parts. You can reach VMAC Inside Sales by calling 1 877-912-6605 or emailing sales@vmacair.com.

Installation Manual for VMAC OEM Component Package For S700196 – VR70, STAGE V CUMMINS 4.5/6.7, EOC
www.vmacair.com

• VMAC – Vehicle Mounted Air Compressors
• VMAC Technical Support: 888-241-2289
• VMAC Knowledge Base: https://kb.vmacair.com

Document #: 1901186 Changes and Revisions

Revision| Revision Details| Revised by| Checked by| Implemented
---|---|---|---|---
Eng.| Tech.| Qual.
Mech.| Elec.
A| ECN-21-185: Engineering Release| RRP| SJH| N/A| DSB| LPH| 26JUL2023

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

• VMAC – Vehicle Mounted Air Compressors
• VMAC Technical Support: 888-241-2289
• VMAC Knowledge Base: https://kb.vmacair.com

General Information

Introduction
This manual provides an overview of system components and where to find installation instructions for the S700196 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 sales@vmacair.com.

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.
| 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 start.
• Do not operate the system without guards in place. If the guards are damaged or missing, replace them before operating the equipment.

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| 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.

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| 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 service.
• Never allow any part of your body to contact the compressor components until the system has cooled sufficiently.

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| 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 bloodstream. 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.

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| 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.

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| 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.

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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 that allows VMAC to assist with parts and repairsInstall the supplied maintenance checklist decal in a visible place near the control box. Component Installation
Complete component installation instructions are provided with their respective packages as listed in Table 1 below:

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Compressor| 1901132| A240104| 1901132 Link
Belt Drive| 1901132| A240104| 1901132 Link
Separator Tank| 1901134| A230102| 1901134 Link
Coalescer| 1901134| A230102| 1901134 Link
Blow Down Solenoid| 1901134| A230102| 1901134 Link
Oil Cooler| 1901133| A270105| 1901133 Link
Controls| 1901131| A260104| 1901131 Link
Air Intake| 1901083| A220112| 1901083 Link

Table 1 – Component Installation Instructions Reference

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.

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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.
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|

• 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 dealer near you.

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.

• 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
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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

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| 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
Aeroquip- AQP™, Parker-PKR® , and Gates-GTS (CPE)™. properties of VMAC compressor oil and the high heat that our compressors generate. Examples:

Hose Routing

Figure 4 – Hose Routing

Illustrated Parts List

OEM Component Package – S700196

100” HOSE PACKAGE – A400100

• 888-241-2289
• 877-740-3202
• www.vmacair.com
• tech@vmacair.com
• warranty@vmacair.com
• www.kb.vmacair.com
• 1333 Kipp Road, Nanaimo, B.C., V9X 1R3 Canada

References

• VMAC Knowledge Base
• Required VMAC Hoses

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