Vmac RAPTAIR60 Manual

VMAC –Vehicle Mounted Air Compressors
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Service Procedures for RAPTAIR60
500/1000 Hour Service Kits A500001/17 (RAPTAIR60)
General Service Information
Safety and Service Precautions
Observe these precautions when performing any service:
Never attempt to clean the air filter element with compressed air. Replace the air filter element.
To prevent damage to the oil filter, always use a proper filter wrench. Never over-tighten the filter, as this may damage
the seal or the filter. Apply a thin coating of compressor oil to the filter sealing gasket.
Never use any lubricant other than the supplied compressor oil, as other lubricants will damage the compressor and may
void warranty.
Do not overfill the system, as this can flood the oil level sight tube and make the system appear empty.
If the system has been operating, shut it off and wait at least 30 seconds for the air pressure to vent before performing
service.
You must make sure that there is no pressure left in the system. If there is a pressure gauge, make sure that
it is at zero before commencing service. If you are not sure, attach a tool or air nozzle to the air outlet and
make sure that there is no pressure.
If the system is cold, bring the engine to operating temperature and then operate the compressor system for a few
minutes to bring the compressor oil to operating temperature. This will also help to suspend contaminants in the oil so
that they can be removed from the system along with the old oil.
Observe all safety procedures relating to moving belts, hot oil and compressed air. Use all safety equipment to protect
yourself.
Check the old oil for any evidence of metal filings or contamination; if found, flush the tank, hoses and cooler. Metal
filings will damage the compressor.
Flushing Procedure
Component failure (such as a gearbox, compressor, hose or cooler core) can leave metal filings and other foreign materials
in the system. To flush the system, follow this procedure:
1. Before replacing any failed component, check all other system components for evidence of contamination and clean
thoroughly. Use compressed air to blow out lines and other components. Remove the oil filter and dump out oil from the
filter. If there is no metal in the oil filter, continue with the regular flush procedure, (continue to step 2).
If there is metal in the oil filter, look for metal in the return line to the compressor. If metal is found, the cooler must be
flushed before the new compressor is installed. As well, the lines from the tank to the cooler and cooler to compressor
need to be thoroughly checked / flushed or replaced before installing the new compressor.
2. Once the system has been cleaned as thoroughly as possible, replace the failed component and reconnect all lines and
fittings
3. Install a new oil filter and fill the system with VMAC compressor oil to the correct level.
4. Start the engine and engage the air system. Allow the system to pressurize and allow it to operate in no-load mode for
about 15 minutes without discharging any air.
5. Shut-down, allow the system to cool and change the oil and the oil filter. Refill with compressor oil to the correct level.
6. After 50 hours, replace the oil filter and top up the oil level.
Service Kit Contents
A 500 hour service kit will contain an air filter, oil filter and sufficient oil for the system, 1.06 USG (4 liters) for a RAPTAIR60.
A 1000 hour service kit will contain the same, with the addition of a Coalescing Filter, (Vmac # 3600079).
!

VMAC –Vehicle Mounted Air Compressors
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500 Hour Service Procedures
1. Check oil level in air/oil separator tank
The air compressor system holds 4 litres of oil, which includes enough to fill the oil filter. The filter holds 0.3 litres of oil. The
compressor holds about 0.5 litres of oil.
Check the level the oil has reached on the oil level sight tube.
OIL
LEVEL
MAX.
MIN.
OIL LEVEL
SIGHT TUBE
OIL LEVEL
Figure 1 –Checking Compressor Oil Level
Clean debris and dust from the area around the oil fill port of the air/oil separator manifold to prevent contamination.
Use a funnel inserted into the oil fill port in the air/oil separator manifold and pour in VMAC certified compressor oil.
Oil Fill Port
Replace the cap on the oil fill port and tighten.
Start the system following the start-up procedure in the User’s Manual
Allow the system to pressurize.
Turn off the system using the shutdown procedure in the User’s Manual
Wait 5 minutes then drain the air fully to depressurize the system.
Check for oil leaks.
Repeat until the oil level sight tube shows the oil level in the air/oil separator tank is in the operational range.

VMAC –Vehicle Mounted Air Compressors
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2. Replacing the Air Filter
This is a dual air filter for the Kubota engine and VMAC compressor. Follow all safety precautions. For ease
of service the air filter is located just under the roof of the RAPTAIR60 behind the service panel. The filter is
also equipped with a filter minder switch at the back, and is monitored by the control system.
Clean loose dust and debris from the area around the filter cover to prevent contaminants from entering the system.
Remove the air filter cover retaining clamps and the cover.
Remove the filter element from the air cleaner housing.
Immediately cover the air cleaner housing with a clean cloth to prevent contamination entering the intake hose and
compressor.
Do not use compressed air or perform any other tasks around the filter and cover until both are replaced.
Never clean the filter element with compressed air, as this will allow some contaminates into the compressor
system. Always replace the air filter element.
Clean the inside of the cover and the air cleaner housing with a clean, dry cloth.
Do not use flammable solvents to clean the inside of the cover. If a solvent has been used rinse the cover
thoroughly with water and dry it before installing the cover. Fire in the compressor can cause an explosion.
Remove the cloth from the air cleaner housing.
Place the filter into the air cleaner housing and secure the cover with the retaining clamps.
3. Replacing Compressor Oil
Follow all safety precautions.
Clean debris and dust from the area around the drain valve of the air/oil separator tank to prevent contamination.
Compressor Oil Filter
Compressor Oil
Drain Valve
Figure 2 - Oil Filter Location
Insert a hose over the air/oil separator tank’s drain valve outlet and open the valve to drain the oil into a container large
enough to hold at least 1-1/2 US Gallons (6 liters). After the oil has drained, close the valve.

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Dispose of the oil in accordance with the Environmental Protection Laws in your location.
Replace oil filter as in Section 4.
Clean debris and dust from the area around the oil fill port of the air/oil separator manifold to prevent contamination.
4 liters of VMAC certified oil is required to fill the system.
Unscrew and remove the oil fill port cap. Use a funnel inserted into the port and pour in the required amount of VMAC oil.
Follow the oil level checking procedure in Section 1.
4. Replacing the Compressor Oil Filter
Follow all safety precautions.
Clean debris and dust from the area around the air/oil separator tank and the filter to prevent contamination.
Remove the filter by turning it counterclockwise using a suitable filter wrench.
Check the filter to make sure that the threaded nipple did not unscrew with the filter. If it is in the filter,
remove it carefully to avoid thread damage, coat the threads that go into Separator Tank Base with a small
amount of Loctite blue and install it into the tank base.
If Compressor Oil Filter Nipple is
stuck in Oil Filter, remove and
Loctite into Tank Base before
installing Filter
Compressor Oil Filter
Compressor Oil Filter Nipple
Figure 3 –Compressor Oil Filter
Check the gasket-sealing surface of the air/oil separator tank for contamination, old gasket material or damage.
Make sure the new filter is a VMAC filter, part number 9200039. This oil filter is a high pressure oil filter, not
an automotive oil filter, which will rupture under high pressure.
Apply a thin coating of compressor oil to the filter sealing gasket.
Spin the filter onto the threaded nipple until the gasket contacts the sealing surface of the air/oil separator tank.
Tighten the filter an additional 3/4 to 1 turn to seat the sealing gasket.
Never over-tighten the filter, as this may damage the seal or filter.
Follow the oil level checking procedure in Section 1.

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1000 Hour Service Procedures
For 1000 Hour Service, perform the 500 Hour Service and also replace the Coalescing Filter as below:
5. Replacing the Coalescing Filter
Follow all safety precautions.
Compressor
Coalescing Filter
Air/Oil Separator
Tank
Figure 4 - Coalescing Filter Location
Clean debris and dust from the area around the air/oil separator tank and the filter to prevent contamination.
Remove the filter by turning it counterclockwise using a suitable filter wrench.
Do not use a screwdriver punched into the side of the filter, as this practice can damage the scavenging tube
and screen. See Fig. 5.
Scavenge Line inserts into
Coalescing Filter during
installation
Coalescing Filter
Scavenge Line
Figure 5 –Avoid Damaging the Scavenge Line
Check the filter to make sure that the threaded nipple did not unscrew with the filter. If it is in the filter,
remove it carefully to avoid thread damage, coat the threads that go into manifold block with a small amount
of Loctite blue and install it into the manifold block. Use caution when removing the filter so as to avoid
catching the scavenge screen orifice on the bottom of the scavenge tube on the lip of the coalescing filter.
This scavenge screen orifice is attached to the scavenge tube by a “push to connect” fitting, if the fitting has
come off of the tube re-insert the tube into the fitting ensuring that the tube is fully engaged.
Check the gasket-sealing surface of the manifold block for contamination, old gasket material or damage.

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Make sure the new filter is a VMAC filter, part # 3600079. This is a high-pressure filter. Use of other filters not
rated to the required pressure may cause the filter to rupture.
Apply a thin coating of compressor oil to the coalescing filter sealing gasket and coat the end of the threaded nipple, as
there is also an O-ring inside the coalescing filter.
Spin the filter onto the threaded nipple until the gasket contacts the sealing surface of the manifold block.
Tighten the filter an additional 3/4 to 1 turn to seat the sealing gasket.
Never over-tighten the filter, as this may damage the seal or filter.
Check the oil level following the oil level checking procedure in Section 1.
Document #1900924
Version
Revision Details
Revised by/date
Approved by/date
Implemented
A
Engineering Release
SAR 22 Sep 2011
SM/MH 5 Oct 2011
6 Oct 2011
B
ECN 12-028: revised as per markups
SAR 26 Jan 2012
SM 25 Jun 2012
04 Jul 2012
C
ECN 13-048: Updated for use on both
A500001 and A500017
CM 10 Jun 2013
MH/DB 04 Jul 2013
05 Jul 2013
Copyright 2011 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