Vmac S700182 Owner's manual

Brand: Vmac

Model: S700182

Type: Owner's manual

Vmac S700182 is an OEM component package that provides compressed air for various applications. It is compatible with S700182 VR70, STAGE V CUMMINS 4.5/6.7 vehicles. The package includes essential components such as air compressors, air tanks, and hoses, providing a complete air system solution for your vehicle. With its robust design and reliable performance, Vmac S700182 ensures efficient and convenient access to compressed air, making it ideal for tasks that require pneumatic tools or equipment.

www.vmacair.com

Installation Manual for VMAC OEM

Component Package For S700182 -

VR70, STAGE V CUMMINS 4.5/6.7

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

Table of Contents

Table of Contents ......................................................................................................1

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

Safety .......................................................................................................................4

Safety Precautions .....................................................................................................5

System ID ..................................................................................................................7

Component Installation ...........................................................................................8

Maintenance Schedule ............................................................................................9

Diagnostics and Trouble Shooting ...........................................................................10

Hose Routing ...........................................................................................................15

Illustrated Parts List .................................................................................................16

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

Document #: 1901135

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

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

Revision

Revision Details

Revised by

Checked by

Implemented

Eng.

Tech.

Qual.

Mech.

Elec.

ECN-19-213: Engineering Release

NDB

PID

N/A

DSB

LPH

10DEC2020

ECN-20-246: Part number updates

NDB

PID

N/A

DSB

LPH

02FEB2021

ECN-21-136: Updated System ID section and

added Hose Connections

RRP

SJH

N/A

DSB

LPH

13JAN2022

ECN-22-158: Added hose routing and links to

A-kit manuals

SJH

RRP

N/A

LPH

11JAN2023

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 S700182 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.

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.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.

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.

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

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.

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 service.

• Never allow any part of your body to contact the compressor

components until the system has cooled sufficiently.

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

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.

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.

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

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 on the side of the compressor belt guard as

per Figure 3. Secure the plate with the supplied screws.

□ Install the supplied maintenance checklist decal on the front of the compressor

belt guard as per Figure 3.

Figure 2 - Maintenance Checklist Decal

Figure 3 – System ID Mounting Location

Figure 1 - System Identification Plate

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

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

S700182

1901137 Link

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

A270101

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 below.

The line to the auxiliary tank must not be installed in the bottom of the tank but must be

installed as high as possible to prevent sludge from the bottom of the tank from interfering

with proper check valve functions.

Figure 4 - Auxiliary Tank Installation

Operational Limitations

The system must not be operated in excess of 15⁰ from horizontal, as this will affect

lubrication and air/oil separation.

Install the line as high as

possible, NOT on the

bottom of the auxiliary tank

Tank

One-way check valve Auxiliary Tank

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

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 dealer near you.

Schedule

Action

Related Service Kits

Daily or

every 8 hours

Check oil level and add oil

if necessary.

1L Oil: 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

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

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.

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

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.

Error

Code

Display

Fault

Possible Problem(s)

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

TEMP PROBE

SHORT

Compressor temperature probe

wires shorted or failed.

• Faulty temperature probe.

• Crushed temperature probe wires

• Pinched or bare wires that are

grounded

TEMP PROBE

OPEN

Compressor temperature probe

circuit open.

• Disconnected temperature probe.

• Faulty temperature probe.

• Broken temperature probe wires.

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.

CLUTCH HIGH

Current draw on the clutch is too

high (5 A – 10 A).

• Faulty clutch.

• Broken or pinched clutch wire.

CLUTCH LOW

Current draw on the clutch is too

low (below 2 A).

• Faulty clutch.

• Broken or pinched clutch wire.

• Disconnected clutch wire.

CLUTCH

SHORT

Current draw on the clutch is too

high (above 10 A).

• Faulty clutch.

• Clutch wire shorted to ground or

pinched.

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

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.

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

Diagnostic charts

Symptom

Possible Cause

Corrective Action

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.

1 – Clutch component installed on belt driven systems only.

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

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)™.

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

Hose Routing

Figure 5 – Hose Routing

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

Illustrated Parts List

OEM Component Package – S700182

Item #

Part #

Qty

Description

4800811

IDENTIFICATION, SYSTEM, GENERIC OEM

1930060

MANUAL, OWNERS GENERIC, VR70 & 150

1901135

INSTRUCTIONS, OEM PKG INSTL

1901137

INSTRUCTION, HOSE CONNECTIONS

A230102

PACKAGE, VR70, SEPARATION SYS

A240104

ENG PKG, STG5 CUMMINS 4.5/6.7, VR70

A220112

PKG, AIR INTAKE, 70CF, 12FT

A260104

CONTROL PKG & HARNESS, OEM

A270101

PKG, COOLER, A-L, VR70, 12V, OPEN

A400100

PKG, HOSE, PTFE, 100”

4500131

VALVE,THERMO,1/2 NPT,160F

1901141

INSTRUCTIONS/IPL, A270103

Item 1 - 4800811

Item 2 - 1930060

Item 3 - 1901135

Item 4 - 1901137

Item 5 - A230102

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

Item 6 - A240104

Item 7 - A220112

Item 8 - A260104

Item 9 - A270101

Item 10 - A400100

Item 11 - 4500131

Item 12 - 1901141

100”

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: https://kb.vmacair.com

100” HOSE PACKAGE – A400100

Item #

Part #

Qty

Description

1700570

100 IN

TUBE, TEFLON, PTFE,1/4"OD

1700571

100 IN

TUBE, TEFLON,PTFE, 3/16"OD X 1/8"ID

1700581

2 @ 100 IN

LOOM, SPLIT PLASTIC, 1/4, HIGH TEMP

A400100 - 100” HOSE PACKAGE

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Vmac S700182 Owner's manual

Brand: Vmac

Model: S700182

Type: Owner's manual

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Vmac S700182 Owner's manual

Vmac S700182 Owner's manual

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