Vmac S700172 Owner's manual

C# 002354

VR70 Air Compressor

Installation Manual

John Deere JD6068

SYSTEM S700172

Installation Manual for

System S700172

John Deere 6068 VR70

General Information..................................................................... 3

Before You Start ....................................................................... 3

Part 1: System Identification and Warnings ............................ 4

Part 2: Air/Oil Separator Tank (AOST) Installation ................... 5

2.1 Preparing for Installation .................................................... 5

2.2 Tank Installation ................................................................. 7

Part 3: Manifold Installation ........................................................ 9

3.1 Installing the Bracket and Manifold .................................... 9

Part 4: Cooler Installation ........................................................... 11

Part 5: Installing the Compressor .............................................. 15

5.1 Main Bracket ....................................................................... 15

5.2 Installing Air End and Hoses .............................................. 17

4.3 Filling the System with Oil .................................................. 27

Part 6: Control System ................................................................ 29

6.1 Control Box and Wiring ...................................................... 30

6.2 Confirmation Test ............................................................... 31

Part 7: Finishing the Installation ................................................ 32

6.1 Before Starting the Engine Checklist.................................. 32

6.2 After Starting Engine Checklist ........................................... 32

Accessory Products from VMAC ............................................... 34

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Document #1930232

Installation Manual for VMAC System S700172

John Deere 6068 VR70

Changes and Revisions

Version

Revision Details

Revised by/date

Approved

Implemented

A ENGINEERING RELEASE RR 04NOV2014

MP/RD 10 Nov 2014

18 Nov 2014

B ECN 14-079: S700172

FASTENER PACK CHANGES RR 17NOV2014 MP/DB 19 Nov 2014 19 Nov 2014

Important Information

The information in this manual is intended for certified VMAC installers

who have been trained in installation procedures and for people with

mechanical trade certification who have the tools and equipment to

properly and safely perform the installation. Do not attempt this

installation if you do not have the appropriate mechanical training,

knowledge and experience.

Follow all safety precautions for underhood mechanical work. Any

grinding, bending or restructuring operations for correct fit in modified

vehicles must follow standard shop practices.

All hoses, tubes, and wires which are rerouted or shifted

during installation must be secure so that they do not

contact excessively hot areas or sharp edges. Where

possible follow the routing suggestions in this manual.

The VMAC warranty form is located at the back of this manual. This

warranty form must be completed and mailed or faxed to VMAC at the

time of installation for any subsequent warranty claim to be considered

valid.

To order parts, contact your VMAC dealer. Your dealer will ask for the

VMAC serial number, part number, description and quantity. To locate

your nearest dealer, call 1-888-241-2289.

VMAC recommends covering all hoses and wires for

protection.

All trademarks used in this manual are the property of the respective copyright holder.

The contents of this manual may not be reproduced in any form without the express

written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3.

Printed in Canada

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General Information

Before You Start

Read this manual before attempting installation so that you can

familiarize yourself with the components and how they fit on the

vehicle. Identify variations for different engine models and different

situations that are listed in the manual. Open the package, unpack

the components and identify them.

All fasteners must be torqued to specifications. Use manufacturers

torque values for OEM fasteners. Apply Loctite 242 or equivalent

on all engine-mounted fasteners. Torque values are with Loctite

applied unless otherwise specified.

STANDARD GRADE 8 NATIONAL COARSE THREAD

Size

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

Foot-pounds (ft-lb)

9

18

35

55

80

110

170

280

Newton meter (N•m)

12

24

47

74

108

149

230

379

STANDARD GRADE 8 NATIONAL FINE THREAD

Size

3/8

7/16

1/2

5/8

3/4

Foot-pounds (ft-lb)

40

60

90

180

320

Newton meter (N•m)

54

81

122

244

434

METRIC CLASS 10.9

Size

M8

M10

M12

M14

M16

Foot-pounds (ft-lb)

19

41

69

104

174

Newton meter (N•m)

25

55

93

141

236

Hose Information

Different frame designations will affect the tank mounting position. If

you have to move the tank, the lines may be too short. Measure the

hose shortfall and order a Hose Extender Kit. Depending on other

installed equipment, it might be necessary to move the air/oil

separator tank from its intended location. The hoses used in VMAC

compressor systems have a specific inner liner that is

compatible with our compressor oil. Use of hoses other than

those supplied or recommended by VMAC may cause

compressor damage and may void your warranty. Please contact

VMAC for replacement hoses and further information.

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Part 1: System Identification and

Warnings

□ 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 in customer inquiries and

ordering of parts

□ Mark and drill two 7/64-inch holes in a suitable location. This

location must be easily visible, such as beside the control box or

compressor. Secure the plate with the supplied self-tapping

screws

□ Place the S700172 belt routing and safety label beside the

control box in a visible location.

□ Complete the warranty form. The VMAC warranty form is located

within the system ID package as well as online at:

http://vmacair.com/support/warranty/

This warranty form must be completed and mailed or faxed to

VMAC at the time of installation for any subsequent warranty

claim to be considered valid.

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Part 2: Air/Oil Separator Tank

(AOST) Installation

2.1 Preparing for Installation

□ Remove the service panel on the alternator side of the

enclosure.

□ Remove the PTO offset housing, bracket, and associated oil

fittings (Figure 1) and plug/blank the ports (Figure 2).

Figure 1

REMOVE

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Figure 2

□ Remove the two bolts fastening the bottom of the corner post on

the housing to the frame (Figure 3).

Figure 3

INSTALL COVER

PLATE AND GASKET

PLUG

REMOVE

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2.2 Tank Installation

□ Install the BRACKET, TANK MOUNT (1200761) and fasten to

the frame using the supplied fasteners (Figure 4).

Figure 4

□ While pulling the enclosure corner post outward, slide the AOST

into position. It is recommended that the tank is installed with

the welded bracket initially pointing upward and then rotated into

position once the tank is in the mounting location.

□ Install the (4) supplied fasteners securing the welded bracket on

the AOST to the frame (Figure 5).

□ Install the C-Clamp over the end of the AOST and loosely secure

the clamp to the frame with the supplied fasteners.

□ Install and tighten the pinch bolt on the clamp.

□ Tighten the previously installed fasteners securing the c-clamp to

the bracket.

MOUNTING

HOLES

1200761

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Figure 5

The tank must be mounted below the level of the

compressor discharge with the arrow on the end cap

pointing vertically upwards.

□ Remove the oil drain plug on the AOST.

□ Install the remote-oil drain hose and ball-valve assembly.

WELDED MOUNTING

BRACKET

C-CLAMP

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Part 3: Manifold Installation

3.1 Installing the Bracket and Manifold

□ Secure the bracket (1200801) to the top engine block as shown

in Figure 6.

Figure 6

□ Attach the bracket (1200796) to bracket (1200801) and secure

1200796 to the bottom engine block. The bolt goes through the

MANIFOLD

MOUNTING HOLES

TOP ENGINE

BLOCK BOLTS

M8x25

1200801

1200796

BOTTOM

BLOCK BOLT

M8x35 + spacer

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bracket and the spacer before inserting into the block. See

Figure 6.

□ Secure the manifold assembly (4800641) to the bracket

(1200801) with the fasteners supplied as shown in Figure 6 and

Figure 7.

Figure 7

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Part 4: Cooler Installation

□ Remove the (2) engine mount bolts (see Figure 8) and install the

lower cooler bracket re-using the same bolts. Leave the bolts

loose at this point.

□ Install the upper cooler bracket on the engine block using 2x

M10x110 bolts. Tighten the fasteners to the torque specified.

Figure 8

UPPER COOLER

BRACKET

MOUNTING HOLES

LOWER COOLER

BRACKET

MOUNTING HOLES

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□ Install the cooler between the two brackets in the orientation

shown in Figure 9 using the supplied fasteners in (6) places and

tighten to specification.

Figure 9

□ Tighten the fasteners securing the lower bracket to the engine

mount.

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Figure 10

□ Attach green wire with ring terminal from the cooler fan harness

to the ground post of the alternator as indicated in Figure 10.

□ Attach orange wire with ring terminal from the cooler fan harness

to the 24v post of the alternator as indicated in Figure 10.

□ Blunt cut orange wire from the fan harness connects to an

ignition switched 24v source.

Note: See Figure 11 for cooler-fan wiring schematic.

GROUND POST

24v POST

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Figure 11

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Part 5: Installing the Compressor

5.1 Main Bracket

□ Add a notch to the top left corner of the engine mount to allow for

L-bracket clearance. See Figure 12 & Figure 13.

Figure 12

Figure 13

NOTCH

0.65”

1.05”

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□ Remove the 3 side engine mounts and attach the L-shaped

bracket as shown in Figure 14.

Note: Leave the rear bottom bolt tight to hold engine

during installation.

Figure 14

□ Remove the tensioner assembly and idler from the main bracket.

□ Apply Loctite and re-install the tensioner assembly and the idler

on the main bracket and torque fasteners to specification.

REMOVE

UPPER FRONT

ENGINE MOUNT

LOWER FRONT

ENGINE MOUNT

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□ Mount the main bracket to the upper and lower front engine

mounts as shown in Figure 14.

□ Apply loctite and install the provided M16 bolts in the two front

block mounts. Do not tighten.

□ Snug down the (2X) M16 x 50mm engine mount bolts and torque

to specifications.

5.2 Installing Air End and Hoses

□ Install crank pulley. The pulley mounts between the OEM crank

pulley and the OEM damper. Use loctite and six M10x25mm

bolts provided and torque to specifications.

□ Mount the compressor to the main bracket. Use the two

M8x20mm bolts provided to mount the clutch bracket to the front

of the main bracket as shown in Figure 15.

Figure 15

M8 BOLTS

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□ Apply loctite and install compressor to main bracket using the

three M8 bolts. These bolts are of varying lengths and the

positions are shown in Figure 16 . Torque to specifications.

Figure 16

M8X90MM BOLT

M8X100MM BOLT

M8X30MM BOLT

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Vmac S700172 Owner's manual

Vmac S700172 Owner's manual

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