Mangonel Vmac VR 7000 9016 Owner's Manual

Rotary screw compressor 1999 ford super duty f250-f550 6.8l triton v10 w/woac

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Summary of Contents for Mangonel Vmac VR 7000 9016

Page 5 ® ® ® ® ® ™ ™ ™ ™ ™...
Page 9 ™ ¤ ¥ ¦ § ¦ ¨ ¦ © © ¤ © © © ¤ ¦ © ¡ ¢ £ £ £ Type Grade 8 plated Class 10.9 unplated Size In Cast or In Cast or Steel Aluminum Steel Aluminum 7/16...
Page 12 ™ ¡ ¢ £ ¢ ¤ ¢ ¥ ¦ ¥ § ¨ ¦ © ¥ ¦ ¥ ¥ ¢ ¥ ¦ DATA LINK CONNECTOR Just to the side of the data link connector, find the light blue/pink NOTE 1: wire with the end temporarily ON SOME EARLY PRODUCTION covered with a plastic cap.
Page 13 ® ™ ™ ™ ™ ™...
Page 15 ™ ¤ ¥ ¦ § ¦ ¨ ¦ © © ¤ © © © ¤ ¦ © ¡ ¢ £ £ £ Description Location Weight Dimension Compressor and Inlet Valve Engine 55 lbs. 11” × 7” × 6½” Air/oil Tank Frame Rail 16.9 lbs.
Page 19 ® ™ ™ ™ ™ ™...
Page 22 ™ ¡ ¢ £ ¢ ¤ ¢ ¥ ¦ ¥ § ¨ ¦ © ¥ ¦ ¥ ¥ ¢ ¥ ¦ On-Off Rocker Switch Hours Display System Operation Light System Warning Lights NOTE NOTE NOTE...
Page 24 ™ A DIVISION OF MANGONEL CORPORATION Remove This Plug WARNING WARNING...
Page 25: System Adjustments
Part 4 System Adjustments System #9016 1999 FORD SUPER DUTY F250-F550 ® 6.8 L TRITON V10 W/WOAC ™ ™ ™ ™ ™ ROTARY SCREW COMPRESSOR...
Page 27: Engine Rpm Adjustment
™ A DIVISION OF MANGONEL CORPORATION System adjustments 4.1 General adjustment information • • Inlet control valve adjustment ¡ ¢ £ £ £ ¤ ¥ ¦ § § § Engine RPM adjustment ¨ Important precautions WARNING WARNING...
Page 28: Throttle Control Adjustment
™ A DIVISION OF MANGONEL CORPORATION 4.2 Throttle control adjustment ″. ¡ ¢ ″. £ ¤ ¥ ″. ¦ 3/8” VR7000 Throttle Controller Idle-down Screw OEM Throttle Housing Nut B 11/16” Nut A 7/32” VR7000 Pull Bracket ″ or ″ diameter orifice downstream from outlet air valve.
Page 29 ™ A DIVISION OF MANGONEL CORPORATION When the pressure has reached approximately 30 PSI below the maximum operating pressure (Figure 8), the engine speed should start to roll off and should reach base idle. (160-170 PSI range is the most common requirement for maximum operating pressure.) Set the idle-down pressure screw so that the engine starts to ramp down approximately 30 PSI below required maximum operating pressure.
Page 30 4.3 Inlet flow control valve adjustment Make all control valve adjustments with the engine turned off. Make sure that contaminants do not enter the system by making sure that you never operate the system with the air cleaner removed. Make sure that the system has been operated long enough to reach normal operating temperatures.
Page 31: System Maintenance
Part 5 System Maintenance System #9016 1999 FORD SUPER DUTY F250-F550 ® 6.8 L TRITON V10 W/WOAC ™ ROTARY SCREW COMPRESSOR...
Page 33: Routine Maintenance Procedures
™ A DIVISION OF MANGONEL CORPORATION System maintenance 5.1 Routine maintenance procedures ¡ ¢ £ £ £ compressor system contains no reed-valves or other easily fouled, fatigue-prone components. With proper maintenance, the need for premature repair or component replacement can be drastically reduced.
Page 34: Replace The Air Filter
™ A DIVISION OF MANGONEL CORPORATION 5.4 Replace the air filter If the system has been just operated, allow at least 30 minutes so that all air pressure can vent. Clean loose debris from the area around the compressor and the filter cover to prevent contamination.
Page 35: Replace The Oil Filter
™ A DIVISION OF MANGONEL CORPORATION 5.5 Replace the oil filter If the system has been operated, allow at least 30 minutes so that all air pressure can vent. Clean loose debris from the area around the compressor and the filter to prevent contamination.
Page 36: Change Compressor Oil
™ A DIVISION OF MANGONEL CORPORATION 5.6 Change compressor oil If the system has just been operated, allow at least 30 minutes so that all air pressure can vent. Clean loose debris from the area around the oil drain plug on the bottom of the air/oil...
Page 37 ™ A DIVISION OF MANGONEL CORPORATION Allow the system to pressurize and return to OEM base idle speed. Turn the compressor switch on the control unit to the “OFF” position. Allow the system to settle for approximately 10 minutes, then check the oil level through the sight glass.
Page 38 ™ A DIVISION OF MANGONEL CORPORATION Remove the housing from the tank. If the housing is stuck, gently tap it sideways with a soft-faced hammer to loosen it from the tank. Protect the housing from contamination by storing it in a clean, dry location.
Page 39 ™ A DIVISION OF MANGONEL CORPORATION Clean the screen filter with solvent, blow it out thoroughly with compressed air and replace it in the line. If the filter is plugged or damaged, replace it with a new filter. Check the inside of the tank for contamination and wipe it clean as required. Do not use flammable solvents to clean out the tank.
Page 40 ™ A DIVISION OF MANGONEL CORPORATION Turn the compressor switch on the control unit to the “OFF” position. Allow the system to settle for approximately 10 minutes, then check the oil level through the sight glass. The level must be between the minimum and maximum level indicators. Check...
Page 41: Problem Diagnosis
Part 6 Problem Diagnosis System #9016 1999 FORD SUPER DUTY F250-F550 ® 6.8 L TRITON V10 W/WOAC ™ ROTARY SCREW COMPRESSOR...
Page 43 ™ A DIVISION OF MANGONEL CORPORATION 6.1 Diagnosing system problems Problem diagnosis for the compressor systems should follow sound, ¡ ¢ £ £ £ recognized practice. Quick, accurate diagnosis of problems is possible by: • accurately identifying the problem by operating the system yourself •...
Page 44 ™ A DIVISION OF MANGONEL CORPORATION PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Frequent over-temperature Low oil level. Check oil on level ground, add as shut-down. required. Restriction in compressor oil Check for kinked or pinched oil lines. lines. Compressor oil filter plugged.
Page 45 ™ A DIVISION OF MANGONEL CORPORATION PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Power fuse blows. Short to ground in the control Locate and correct short. circuit. Incorrect fuse. Install 10 A fuse. Incorrect wiring. Repair wiring according to wiring diagram. PROBLEM...
Page 46 ™ A DIVISION OF MANGONEL CORPORATION PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Engine RPM over-revs Throttle controls not connected Check and correct connections. when compressor is properly. activated. PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Engine RPM does not Wiring fault. Check and correct wiring return to base idle.
Page 47: Repair Procedures
Part 7 Repair Procedures System #9016 1999 FORD SUPER DUTY F250-F550 ® 6.8 L TRITON V10 W/WOAC ™ ROTARY SCREW COMPRESSOR...
Page 49 ™ A DIVISION OF MANGONEL CORPORATION Repair procedures 7.1 System repair precautions The compressor and gearbox are manufactured and assembled as an integral unit. With proper routine maintenance and proper use, no service or repairs to the internal components of the compressor unit will be required for the life of this product.
Page 50 ™ A DIVISION OF MANGONEL CORPORATION Disconnect the wire connector between the clutch and the wiring harness. Remove the four (4) socket head cap screws holding the clutch stator in place on the front of the compressor gearbox (Figure 15).
Page 51 ™ A DIVISION OF MANGONEL CORPORATION Clean the mounting surface on the front of the compressor. Install the new stator on the compressor. Align the mounting holes and install the four (4) socket head cap screws. Tighten the screws. Clean the compressor clutch hub. Make sure that the woodruff key is in place.
Page 52 ™ A DIVISION OF MANGONEL CORPORATION Remove the clutch stator. Remove the seal retainer with the proper pin wrench. Do not use “alternate” tools as this can cause damage to the seal retainer (Figure 16). Press the seal out of the retainer using the correct tools.
Page 53 ™ A DIVISION OF MANGONEL CORPORATION Apply one drop of Loctite® 242 (blue) to seal retainer threads and gear case threads. Install the seal retainer and tighten it with the pin wrench. Install the stator on the compressor. Align the mounting holes and install the four (4) socket head cap screws. Tighten the screws.
Page 54 ™ A DIVISION OF MANGONEL CORPORATION 7.4 Replace the poppet seat O-ring If the system has just been operated, allow at least 30 minutes so that all air pressure can vent. Clean loose debris from the area around the compressor and the filter cover to prevent contamination.
Page 55 ™ A DIVISION OF MANGONEL CORPORATION Carefully insert the inlet valve piston so you do not damage the new seal. Install a new nitrile O-ring and replace the inner filter plate. Align the holes in the plate with those in the inlet valve body, insert and tighten the four (4) socket head cap screws.
Page 56: Illustrated Parts List
Part 8 Illustrated Parts List System #9016 1999 FORD SUPER DUTY F250-F550 ® 6.8 L TRITON V10 W/WOAC ™ ™ ™ ™ ™ ROTARY SCREW COMPRESSOR...
Page 59 ™ A DIVISION OF MANGONEL CORPORATION TRIT UNI T PART # DESCRIPTION ITEM 1206 VR7000 COMPRESSOR 92088 INLET CONTROL VALVE ASSEMBLY #2 PAPER FILTER ELEMENT 36037 36045 FILTER COVER 15221 ¼″ NC NUT 15374 ¼″ NC THREADED ROD x 3” LONG 15029 ¼″...
Page 60 ™ A DIVISION OF MANGONEL CORPORATION TRIT ITEM UNIT PART # DESCRIPTION 15161 ½ x 1¼ NC G8 FLANGELOCK BOLTS 14051 IDLER BOLT SPACER 13007 IDLER GRIB BACK 33015 BELT AUTO TENSIONER 5030 THROTTLE SPEED CONTROLLER FORD V10 17055 1/4 BRAKE POLY TUBE x 12”...
Page 62 ™ ™ ™ ™ ™ A DIVISION OF MANGONEL CORPORATION 1333 KIPP ROAD, NANAIMO, B.C. CANADA V9X 1R3 Telephone 250-754-6997 Fax 250-754-6972 Toll-Free 800-738-8622...