Mea VR40 Owner's manual

VR40 ENGINE MOUNTED COMPRESSOR
SYSTEM
OWNER OPERATORS’ MANUAL

Document No 3000-D0001-01
THIS PAGE IS LEFT BLANK
PURPOSELY.

Document No 3000-D0001-01
MEA Product Registration Form
THIS FORM MUST BE COMPLETED AND
RETURNED WITHIN 30 DAYS OF INSTALLATION
OR
WARRANTY WILL BE VOID

Document No 3000-D0001-01
MEA Product Registration Form
This form must be completed and returned to MEA at the time of
Installation. Warranty will be void if this form is not received by MEA
within 30 days of installation.
MEA Dealer Information
Company Name: _____________________________________________________________
City: _______________ State: ___________________ Country : ___________________
MEA Installer Information
Company Name: ______________________________________________________________
City: _______________ State: ___________________ Country: ___________________
Installation Date: _______ / ________ / ______
Day Month Year
Owner Information
Company Name: ______________________________________________________________
Address: ____________________________________________________________________
City: _______________ State: ___________________ Country: ___________________
Postcode: _________________________ Phone #: ________________________________
Product Information
MEA Serial Number: __________________________________________________________
Model Number: _______________________________________________________________

Document No 3000-D0001-01
TABLE OF CONTENTAIR
Introduction ............................................................................................................................. 4
Safety Messages .................................................................................................................... 4
Important Safety Notice ...........................................................................................................5
Safety Precautions .................................................................................................................. 7
Personal Hazards ................................................................................................................... 8
System Identification and Warnings.....................................................................................9
System Specifications ........................................................................................................ 10
System Components .......................................................................................................... 11
Compressor .......................................................................................................................... 12
Control Panel ........................................................................................................................ 12
Throttle control ...................................................................................................................... 13
Hoses ................................................................................................................................... 13
Operating Principles........................................................................................................... 14
Oil Separation and Cooling ................................................................................................... 14
Filtration ................................................................................................................................ 15
Belt Alignment and Tensioning ..............................................................................................15
Pressure Regulation and Engine Speed Control .................................................................. 16
Safety Devices .......................................................................................................................17
Hose Protection .................................................................................................................... 17
System Operation ............................................................................................................... 18
Control Box Features............................................................................................................. 18
AutomaticOver-TemperatureShutdown ...............................................................................18
Operating Instructions ........................................................................................................... 19
Cold Environment Operation ................................................................................................. 20
Diesel Particulate Filter Warning (DPF) ................................................................................. 20
Stationary Elevated Idle Control (Ford Applications Only) ............................................. 21
SEIC Restart Delay ............................................................................................................... 21
Problem Diagnostics and Troubleshooting ..................................................................... 22
Maintenance........................................................................................................................ 25
Routine Maintenance ............................................................................................................ 25
Maintenance Schedule ......................................................................................................... 25
Oil Level Maintenance .......................................................................................................... 26
Inspecting the Drive Belt ....................................................................................................... 27
Inspecting the Muffler ............................................................................................................ 27
Inspecting the Pressure Relief Valve ................................................................................... 27
Replacing the Air Filter ......................................................................................................... 28
Replacing the Oil Filter ......................................................................................................... 29
Changing Compressor Oil .................................................................................................... 31
Changing the Coalescing Filter ............................................................................................. 32
Setup, Performance Testing,……………………................................................................. 33

Document No 3000-D0001-01
Dear Customer,
Thank you for your valued support.
Please find enclosed the following information for your
convenience:
•Commissioning Sheet
•VR40 Owner’s Manual
•General MEA Brochure
For further information, technical support, service or sales,
please phone us on [phone].
Thank you,
Mobile Energy Australia

Document No 3000-D0001-01
Installation Test Report
Customer: ________________________________________ Job #: _________________________
Compressor Serial
Number
Control unit
Model of truck VIN Number
Type of speed control
PTO serial number
Engine Speed settings
Engine Speed volts Base
Voltage (circle 1) System
Settings
Operating temperature Type of cooler
System Checks (As Applicable)
Oil Level
Emergency stop
PTO Kick out
Handbrake warning buzzer
Checked OK
System checked for leaks
Checked OK
Remote Fan Operation _______________________________________________________
Sign: ____________________________________Date: ___________________________________
8060
VR70
8070
Pred. 40
8080
Pred. 60
80100
AHBI
HK400
Dynaset
Infinity
BCU
Can bus
Murphy
Analogue
Manual
Electronic
Reverse rotator
Min
Max
Min
Max
ISUZU
.5vdc
HINO
.8vdc
Air Pressure
Oil Pressure
Oil Flow
Remote
Water
Front Mount
Integrated
Checked OK
Tested OK
Tested OK
Tested OK

Document No 3000-D0001-01
1. INTRODUCTION
This manual provides operation instructions, specifications, adjustment, maintenance, and
Warranty information for the VMAC VR40 UNDERHOOD air compressor.
SAFETY WARNINGS
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.
This symbol is used to call your attention to additional instructions involving
explosion hazards.
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.

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INTRODUCTION - Continued
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.
Follow all safety precautions for mechanical work. Moving fan belts and fan blades are an
extreme hazard. Stay clear of all moving parts when the system is operating. Only qualified
personnel should perform maintenance and repair on system components and only while the
system is properly shut down.
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; do not use
any substitutes.
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.
VMAC –Vehicle Mounted Air Compressors
This manual contains various warnings, cautions, and notices that must be observed to reduce
the risk of personal injury during service or repair and the possibility that improper service or
repair may damage the equipment or render it unsafe. Be aware that it is impossible to warn
of all the possible hazardous consequences that might result from failure to follow these
instructions.
MEA 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 MEA before beginning any work.
Fire in the compressor system can cause an explosion and flame
projection. Should this occur, there is potential for serious injury or death.
Vaporized oil propelled by high-pressure air is an explosive mixture.

Document No 3000-D0001-01
2. SAFETY PRECAUTIONS
Avoid all contact with pressurized air, if it penetrates your skin, it can
enter your bloodstream and cause serious bodily harm or even death. Do
not breathe the compressor air. Vaporized oil is a severe respiratory
hazard.
Vaporized oil propelled by high pressure air is an explosive mixture. To
prevent compressor explosion or fire, make sure that the air entering the
compressor is free of flammable vapours.
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 contact with drive belts and stay clear of all moving parts when the system is
operating.
•Follow all safety precautions for under hood 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.
•Do not perform any service until the system has been completely depressurized and you
have verified that all air has been discharged from the compressor system and any
connected receiver tanks.
•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 always be in park (for automatic transmissions) or neutral (for manual
transmissions) with the park brake fully applied before starting the compressor and during
compressor operation
•Use a regulator in the output line to precisely control the final air delivery pressure
•Do not bypass the park brake or DDC (drive disable circuit) connections
•Do not operate the compressor while driving
•Do not tamper with or remove the pressure relief valve
Personal Hazards
Follow all safe work practices. Wear the appropriate safety equipment.
Do not breathe the compressor air. Vaporized oil is a respiratory hazard.
Always use the appropriate personal protective equipment,
particularly eye and hearing protection when operating air-powered
equipment.

Document No 3000-D0001-01
SAFETY PRECAUTIONS - Continued
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.
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.
Never perform maintenance procedures on the system until the
compressor has been shut down for at least 5 minutes to ensure the
system is fully depressurized. After 5 minutes open the discharge valve
to ensure the system is depressurized. Failure to depressurize the
system could cause parts to separate explosively. Flying parts could
cause serious injury or death. Air/oil mixture could be sprayed out with
sufficient force to penetrate the skin, which could cause serious injury
or death.
The engine, exhaust and the compressor system get very hot during
operation, contact with the components or the oil can cause serious
burns. Allow enough time for the system to cool before performing
service.
Components and hoses under pressure could separate suddenly, fly out
and cause serious injury or death. If equipped, the auxiliary air tank must
be drained before servicing any components in the compressor system
System Identification and Warnings
Ensure that the safety and operational instruction decal is affixed in an obvious location so
that it can be seen by vehicle operators. A good spot for this is usually on the inside of the
door, on the panel underneath the steering wheel, or next to the compressor control panel.
To alert any technicians that may service the vehicle, affix the servicing caution/contact label
in the engine compartment near the hood latch in a visible location. Thoroughly clean the
selected area before affixing the label.

Document No 3000-D0001-01
3. SYSTEM SPECIFICATIONS
System Specifications
Model:
•VR 40 UNDERHOOD Air Compressor
Compressor Type:
•Oil injected rotary screw
Drive System:
•Front End Auxiliary Drive (FEAD)
Control:
•Electric on/off 12V clutch control
Maximum Air Delivery:
•Up to 40 CFM and 150 PSI/10 bar depending on installation and engine speed
Pressure Regulation:
•Intake valve is operated via a pressure regulator and pressure switch. Theswitch increases
and decreases the engine RPM to suit air demand
Engine Controls:
•OEM supplied control box to start and stop compressor. engine RPM adjusts automatically
depending on air demand
Safety Features:
•200 PSI (13 bar) relief valve in separator tank
•rapid blow-down valve to relieve system pressure on shutdown
Lubrication:
•MEA certified and approved synthetic oil
Filters:
•Air filter: paper-type replaceable
•Oil filter: spin-on type high pressure
•Coalescing filter: spin-on type
The VR 40 consists of the following components:
•Oil separator tank
•Compressor
•Control panel
•Throttle control
•Air/oil discharge hose
•Oil return hose
•1/4” scavenge oil return line

Document No 3000-D0001-01
SYSTEM SPECIFICATIONS - Continued
Control Panel
OEM digital control panel starts and stops compressor, displays critical information such as
operational hours, faults, and compressor status
Throttle control
Is achieved through an MEA supplied speed control unit seamlessly integrated into the
vehicles ECU
Hoses
The VR 40 has three main hoses and 2 control tubes
•Discharge hose (compressor to separator tank)
•Cooler hose (tank to oil cooler)
•Return hose (cooler to compressor)
•PTFE oil scavenge tube (separator to compressor)
•PTFE regulator pressure tube (separator to regulator)
Air Compression
The VR40 systems use a VMAC designed and built oil 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 meshing rotor lobes.
Cooled oil is injected into the rotors during compression to lubricate and cool the rotors and
bearings also sealing the rotor lobes to allow for efficient compression.
As the rotors rotate, the meshing lobes compress the volume of the trapped air/oil mixture
before sending it down the discharge line to the separator tank where the air/oil mixture is
separated by gravity.
Partially clean air moves on to the coalescing filter for further air/oil separation down to less
than 3mg/m3.
Excess oil in the coalescing filter is sucked back into the compressor via the scavenge tube.

Document No 3000-D0001-01
SYSTEM SPECIFICATIONS - Continued
Filtration and Cooling
The hot oil from the compressor flows through a high-pressure spin on oil filter and exits the
separator tank to the oil cooler (radiator).
The cooled oil is then returned to the compressor via the oil return hose.
Belt Alignment and Tensioning
The VR40 system may be driven by serpentine belt that runs off the engine crank pulley.
Depending on the system the compressor may be driven by a belt with 8 ribs or less.
For proper alignment always ensure the belt is centred on the clutch grooves, i.e., if the system
uses a 4-rib serpentine belt it should be centred on the middle 4 grooves with 2 unused
grooves showing on either side of the belt.
Belt maintenance and service should be performed per the OEM’s maintenance schedule.
Systems with a dedicated serpentine auxiliary belt are equipped with an automatic tensioner
and do not require manual adjustment. Check pulley alignment to ensure proper belt
operation.
Additional Belt Information
Where necessary, MEA provides a replacement for the belt in the compressor service kit.
The OEM belt and any brackets removed during compressor installation should be kept with
the vehicle. In the event of a compressor failure, the MEA supplied belt and brackets can be
replaced with the OEM belt and brackets to ensure the vehicle remains operable.
Pressure Regulation and Engine Speed Control
The system uses a pressure regulator to regulate the air intake valve. The system pressure
supply’s the signal to operate the regulator which in turn opens and closes the intake valve
poppet.
Connected inline with the regulator is a pressure switch that opens when it senses regulated
pressure. This switch sends a signal to the engine speed controller that increases or
decreases the engine RPM depending on air demand.
These control devices provide the following benefits:
•quick response to air flow demands
•reduction of standby noise
•reduction of cooling system load
•fuel conservation when not using air

Document No 3000-D0001-01
SYSTEM SPECIFICATIONS - Continued
Safety Devices
A 200 PSI (13 Bar) pressure relief valve is installed in the separator tank to prevent system
over pressure.
The system is also equipped with an automatic rapid blow-down system to discharge system
pressure on shutdown.
The system makes use of the OEM safetycircuits when available or adds safety circuits where
required. These circuits prevent the operation of the high idle system if certain conditions are
not met. This both protects the vehicle and ensures that the engine will not automatically go
to high idle, should the compressor system be inadvertently activated at an inappropriate time.
The compressor system is equipped with a thermostatic switch, if the compressor oil
temperature exceeds 140°C it will disengage the compressor and drop the engine to base
idle.
An indicator light on the control box will illuminate to show that an over-temperature event has
occurred, and a fault code will be generated to track the occurrence.
A 20A 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. Hose 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
•If any hoses appear damaged, replace hoses prior to failure.
System Operation
Control Box Features
The control panel is not weather-proof. It should be installed either inside the cab or
inside a cabinet on the service body (if equipped).
The control box has the following features:
•Large ON/OFF push button with green indicator light
•Compressor hour meter display
•Over-temperature warning light
•Fault code display

Document No 3000-D0001-01
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 automatic transmission in park or neutral 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 all compressor air system outlets.
5. Activate the compressor using the ON button on the control panel.
Engine RPM will increase to the set speed. The system will build pressure until it reaches 150
PSI/10 Bar (less if the pressure set point has been reduced).
After reaching operating pressure there is a brief delay and the engine RPM will drop to high
idle.
Re-starting the compressor immediately after shutdown may cause belt slippage and
compressor clutch damage.
Cold Environment 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) onthe instrument panel or message
centre. 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.
Elevated Idle Control
Always ensure that the transmission is in park or neutral with the park brake applied
before starting the engine or operating the system.

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TROUBLE SHOOTING

Document No 3000-D0001-01
TROUBLE SHOOTING –Continued

Document No 3000-D0001-01
TROUBLE SHOOTING - Continued

Document No 3000-D0001-01
TROUBLE SHOOTING –Continued