Vmac VR70, VR150 Owner's Manual

VR70 & VR150 UNDERHOOD

AIR COMPRESSOR

OWNERS MANUAL

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VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622 Local: 1-250-740-3200
Fax: [phone]

1

Table of Contents

Accessory Products from VMAC ............................................... 3

Introduction .................................................................................. 4

Ordering Parts .............................................................................. 4

Important Safety Notice .............................................................. 4

Safety Messages .......................................................................... 5

Safety Precautions ...................................................................... 6

Installation Instructions .............................................................. 8

System Specifications ................................................................ 9

Operating Principles.................................................................... 10

Oil Separation and Cooling ....................................................... 10

Filtration ..................................................................................... 10

Belt Alignment and Tensioning ................................................. 11

Pressure Regulation and Engine Speed Control ...................... 11

Safety Devices .......................................................................... 11

Line Protection .......................................................................... 12

Special Installation Notes .......................................................... 12

System Operation ........................................................................ 13

Cold Climate Operation ............................................................. 14

Control Box Features and Operation ........................................ 15

Automatic Shutdown ................................................................. 19

Adding Oil to the System ........................................................... 19

Adjusting the System .................................................................. 20

Adjusting the Pressure Regulator ............................................. 22

Electronic Throttle Control Adjustment ..................................... 23

Routine Maintenance................................................................... 25

Maintenance Schedule .............................................................. 25

Inspect the Drive Belt ................................................................ 26

Inspect the Muffler ..................................................................... 26

Inspect the Pressure Relief Valve ............................................. 27

Replacing the Air Filter .............................................................. 27

Replacing the Oil Filter .............................................................. 28

Changing Compressor Oil ......................................................... 29

Changing the Coalescing Filter ................................................. 31

Problem Diagnostics / Troubleshooting ................................... 34

VMAC Warranty ............................................................................ 39

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622 Local: 1-250-740-3200

Fax: [phone]

2

Owner Manual - Document #1930060
VR70 and VR150 Systems
Changes and Revisions

Version

Revision Detai

ls Revised

Approved

Implemented

00 Initial draft, revised to completion IB 27 Jan 2004 SC 16 Mar 2004 16 Mar 2004
a Added coalescing information IB 19 Apr 2005 SM 27 Apr 2005 29 Apr 2005
b Warranty information change IB 18 Apr 2006 SM 19 Apr 2006 20 Apr 2006
c ECN 06-220 Coalescing spring IB 25 Oct 2006 SM 28 Oct 2006 30 Oct 2006
d ECN 07-009 phone & general IB 10 Jan 2007 RD 26 Jan 2007 29 Jan 2007
e ECN 07-099 lack of use failure IB 18 Jun 2007 SC 18 Jun 2007 24 Jun 2007
f ECN 08-242 General updates SL 15 Oct 2009 SC/SM 22Sep2010 22 Sep 2010
g ECN 12-003 General updates SR 06 Jan 2012 SJC 17 JAN 2012 19 JAN 2012
h ECN 12-169 PRV and muffler RK 10Dec 2012 MH 12 Dec 2012 17 Dec 2012
h Cor: warranty info & card MP 23Sep 2016 N/A 26 Sept 2016

Manuals are subject to change without notice.

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

Copyright 2017

The contents of this manual may not be reproduced in any form

without the express written permission of VMAC.

Printed in Canada

1333 Kipp Road, Nanaimo, BC V9X 1R3

1-800-738-8622

VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622 Local: 1-250-740-3200
Fax: [phone]

3

Accessory Products from VMAC

The following accessory products for your VR compressor system
are available from VMAC. For more information or to order these
products, call toll free 1-800-738-8622 or local 250-740-3200.

Eliminator Aftercooler

Part Number A800070

Removes up to 80% of moisture from
compressed air. Quick installation, automatic
drain and compact design

Filter Regulator Lubricator

Part Number A700151

Removes lubricants, water and dirt from the air
stream. Adds atomized tool oil to lubricate tools.
Reduces pressure for longer tool life.

Hose Reel

Part Number A700007

Secure, compact, retractable hose storage in a
sturdy reel.

Air Receiver Tank

Part Number A300010

Thirty-five gallon capacity in a compact tank,
complete with fittings and a gauge.

DE-ICING

HEATER

De-icer Kit

Part Number A700031

Insulated rope heater prevents freezing of lines
and regulator in freezing conditions.

Service Kits

VR150 200 hour Part Number A700059
VR150 400 hour Part Number A700060
VR70 200 hour Part Number A700019
VR70 400 hour Part Number A700020

Using OEM service products will extend the life
of your system. Includes oil, filters, seals and O­rings. 200 hour and 400 hour service interval kits
are available

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622 Local: 1-250-740-3200

Fax: [phone]

4

Introduction

This manual provides operation instructions, specifications,
adjustment, maintenance, and warranty information for the VMAC
VR70 and VR150 underhood air compressor, and VMAC Electronic
Throttle Controller.

Ordering Parts

To order parts, contact your VMAC dealer. Your dealer will ask for
the VMAC serial number, part number, a description of the part and
the quantity. To locate your nearest dealer, call 1-800-738-8622.

Important Safety Notice

The information contained within 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 and service techniques. If a
discrepancy is noted in this manual, contact VMAC prior to initiating
or proceeding with service. Current information may clarify the
matter. Any person with knowledge of such discrepancies who
performs any work on the system, 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
performance or the operational safety of the equipment.

VMAC will not be held responsible for any liability, injuries, loss or
damage to individuals or to equipment as a result of the failure of any
person to properly adhere to the procedures set out in this manual or
standard safety practices. Safety should be your first consideration in
performing service operations. If you have any questions concerning
the procedures set out in this manual or require any more
information on details that are not included in this manual, please
contact VMAC before beginning any work.

VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622 Local: 1-250-740-3200
Fax: [phone]

5

Safety Messages

This symbol is used to call your attention to instructions
concerning your 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 alert to
the possibility of personal injury or death. Be alert; your
safety is involved. While it is impossible to warn about
every conceivable hazard, let good common sense be
your guide.

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

This symbol is used to call your attention to additional
instructions involving fire hazards.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622 Local: 1-250-740-3200

Fax: [phone]

6

Safety Precautions

Observe the following general safety rules:

Pay attention to operations; do not leave the vehicle

unattended.

Follow safe work practices and wear the appropriate safety

equipment when operating air-powered equipment,
particularly eye and hearing protection.

Avoid all contact with pressurized air, because if it
penetrates your skin it can enter your bloodstream and
cause serious bodily harm or even death.

To prevent compressor explosion or fire, make sure that
the air entering the compressor is free of flammable
vapors.

To prevent compressor explosion or fire, make sure that
correct servicing procedures and intervals are
observed.

Vaporized oil propelled by high-pressure air is an
explosive mixture.

Do not breathe the compressor air. Vaporized oil is a
severe respiratory hazard.

Avoid contact with drive belts and stay clear of all
moving parts when the system is operating.

Follow all safety precautions for underhood mechanical

work.

Follow safety procedures for the type of work being

completed.

Observe these rules when operating the compressor:

Do not bypass or disable the oil temperature sensor.
Do not expose the tank or compressor to extreme heat.

VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622 Local: 1-250-740-3200
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7

Do not perform any service until the system has been

completely blown-down and you have verified that all air has

been discharged.
Do not try to repair or service a pressurized system
Maintenance and repair on system components should only

be performed by qualified personnel
The vehicle must be in park (for automatic transmissions) or

neutral (for manual transmissions) with the park brake or air

spring brake fully applied before starting the compressor and

at all times during compressor operation
Use a regulator in the output line to precisely control the final

air delivery pressure
Run the system at idle speed under no-load conditions for 1

minute before turning the system off to allow system cooling

and lubrication
Do not bypass the park brake or DDC connections
Do not operate the compressor while driving
Do not tamper with the pressure relief valve
Do not attempt to repair or modify any component

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622 Local: 1-250-740-3200

Fax: [phone]

8

Installation Instructions

Detailed information provided in a separate publication, Installation
Manual for the Underhood Air Compressor, which provides specific

information for each different application.
This information includes torque tables, recommendations and other

important information for correct installation. The information in the
installation manual is intended for use by trained, professional
technicians with the knowledge, tools, and equipment to do the job
properly and safely. Installation should not be performed by persons
without the appropriate skills.

Do not attempt to install any of these systems without
the appropriate installation manual.

Ensure that the safety and operational instruction decal is affixed in
an obvious location so that vehicle operators can easily see it.

VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622 Local: 1-250-740-3200
Fax: [phone]

9

System Specifications

Model: VR70 and VR150 Underhood Air Compressor
Type: rotary screw
Drive System: front end auxiliary drive
Control: electric on/off 12V clutch control
Maximum Air Delivery:

VR70 70 CFM and 175 PSI / 1207 KPA
VR150 150 CFM and 175 PSI / 1207 KPA

Pressure Regulation: mechanical inlet control valve modulates flow

in response to demand

Engine Controls: throttle control to modulate between idle and upper

limit RPM to maintain air requirements

NOTE: Some trucks have onboard computers that must
be programmed by the OEM dealer to permit operation
of the electronic throttle control.

Safety Features:

200 PSI / 1379 KPA relief valve in oil/air tank
temperature safety sensor in compressor
rapid blow-down valve to discharge system pressure on

shutdown (10-15 seconds)
drive disable circuit (DDC)

Lubrication: VMAC certified and approved synthetic oil
Filters:

paper-type replaceable air filter
spin-on type high pressure oil filter
coalescing separator element

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622 Local: 1-250-740-3200

Fax: [phone]

10

Operating Principles

These systems use a flooded-lobe, rotary screw compressor. The
oil-filled compressor housing contains two rotors.

Compression occurs when inlet air (at normal atmospheric pressure)
enters a chamber where it is trapped between the rotating rotor
lobes.

A lubricated pitch line provides sealing. As the lobes mesh, they
reduce the volume of the air, compressing it to the desired pressure.

Oil Separation and Cooling

The system has a two-stage air/oil separator. The first separation
stage consists of baffles, which perform mechanical separation. The
second stage uses an integral serviceable coalescing element.

A liquid-to-liquid cooler connected to the engine cooling system cools
the oil. This maintains the oil temperature in an optimal performance
range that increases system durability and reduces the temperature
of the compressed air.

Filtration

The rotary screw compressor is designed and machined to exacting
tolerances. Foreign particles entering the system will drastically
damage or shorten the life expectancy of the compressor and will
result in damage to bearings, gears, rotors and the inside of the
housing.

The system is equipped with a replaceable paper element air inlet
filter, spin on cartridge type high pressure capable oil filter and a
scavenge screen filter.

These system filters enhance performance and extend component
life by reducing damage from dust and other debris. Proper filter
maintenance is the key to long compressor life.

VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622 Local: 1-250-740-3200
Fax: [phone]

11

Belt Alignment and Tensioning

This system is equipped with automatic belt tensioning and does not
require manual adjustment. Always check pulley alignment to ensure
proper belt operation. All components are designed and machined
for precision, some variation in mounting holes may still occur.

Pressure Regulation and Engine Speed Control

The system uses two control systems; an inlet control valve
incorporating a mechanical pressure regulator and an engine speed
control that automatically adjusts engine RPM to respond to air
consumption demand. These control devices provide the following
benefits:

instant response to air flow demands
reduction of standby noise
reduction of cooling system load
fuel conservation when not using air

For information an adjustment, please refer to the section titled
“Adjusting the System”

An external regulator is recommended for operation at pressures
lower than 145 PSI / 999.7 KPA.

Safety Devices

A 200 PSI / 1379 KPA pressure relief valve in the tank to prevent
system over pressure. The system is also equipped with an
automatic rapid blow-down system to discharge system pressure on
shutdown.

There is a switch which only permits operation when the mechanical
or air park brake is applied. Vehicles with automatic transmission are

fitted with a “Drive Disable Circuit”, (DDC) which disables the throttle

control and prevents engine speed increase when the vehicle is in
gear.

The compressor is equipped with an oil temperature sensor which
stops system operation should the temperature become excessive.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622 Local: 1-250-740-3200

Fax: [phone]

12

A fuse protects the system. If the fuse blows
continuously, there is an electrical problem that will not
be solved by a higher fuse rating. Exceeding the rating

can cause component damage.
Do not disable or bypass the over-temperature

shutdown circuit. Failure of the shutdown system could
result in equipment damage, injury or death.

Line Protection

To prevent damage to the lines, observe the following:

Always ensure that the hoses are secure, do not allow the

hoses to dangle under the vehicle

Always ensure that the hoses do not get pinched in steering

or suspension components

Make sure to keep the hoses away from hot surfaces, such

as turbocharger housings or exhaust system components
Hoses should not be bent tightly around sharp metal edges
Ensure that hoses are kept away from fan blades or belts
If the hoses are secured in a bundle, protect them from

abrasion by insulating them from each other using rubber

padding or plastic loom

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 may 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 VR tank blow-down from draining the
auxiliary tank and to prevent moisture from entering the VMAC tank.

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 water
from clogging the line.

VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622 Local: 1-250-740-3200
Fax: [phone]

13

System Operation

Diesel Particulate Filter Warning (DPF)

When engine driven or PTO driven equipment is run on vehicles with
DPF for extended periods of time, particulate may build up in the
filter. All vehicles with a DPF have a warning light (or message) on
the instrument panel or message center. Run time until filter build up
depends on many variables and is the responsibility of the operator
to monitor. It is suggested that if equipment is run for extended
periods of time (over 1 hour) without driving, the vehicle DPF
warning system must be checked after 1 hour and every 15 min
thereafter. If the DPF warning light or message appears, see the
vehicle owner’s manual for methods of cleaning or regenerating.

Operating Instructions

The vehicle must not be parked on grades exceeding 15 º in slope
as this may affect lubrication and air/oil separation.

1. Place the manual transmission in neutral or the automatic
transmission in park and fully apply the park brake.

2. Start and run the vehicle long enough for the engine to stabilize
at base idle and reach normal operating temperature.

3. Close the hood (if open).

4. Close all compressor air system outlets.