Installation and Operation Manual A / A G30 Cold Climate Kit

Transcription

1 Installation and Operation Manual A / A G30 Cold Climate Kit Contents General Information... 3 Important Safety Notice... 3 Safety Messages... 3 Torque Specifications... 4 Ordering Parts... 4 Recommended Accessory... 4 Parts List... 6 Safety Precautions... 7 Installation... 8 Heater Cartridge Installation... 8 Cold Climate Harness Installation Power Inverter Installation Best Practices Operation Fax:

2 Installation and Operation Manual A / A RAPTAIR-G30 Cold Climate Kit Document: Changes and Revisions Version Revision Details Revised by /date Checked by /date Reviewed by /date Implemented A Engineering Release MSP 9 March 2016 RDB 21 March 2016 JKR 21 March March 2016 Important Information The information in this manual is intended for certified VMAC installers who have been trained in installation procedures and for people with mechanical trade certification who have the tools and equipment to properly and safely perform the installation. Do not attempt this installation if you do not have the appropriate mechanical training, knowledge and experience. Follow all safety precautions for mechanical work. Any grinding, bending or restructuring operations for correct fit in modified trucks must follow standard shop practices. Notice Manuals are subject to change without notice. Registered Trademarks All trademarks mentioned in this manual are the property of their respective owners. Their use by VMAC is for identification of the manufacturers products only and does not imply any affiliation or endorsement by said companies. Loctite and Loctite 242 are registered trademarks of Henkel AG & Company KGaA. Permatex and Ultra Black are registered trademarks of ILLINOIS TOOL WORKS INC. Copyright 2016 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 2 Fax:

3 General Information 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 and service techniques. If a discrepancy is noted in this manual, contact VMAC prior to initiating or proceeding with installation, service or repair. Current information may clarify the issue. Any person with knowledge of such discrepancies who performs 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 performance or the operational safety 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 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 in this manual or require any more information on details that are not included in this manual, please contact VMAC before 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 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 or special emphasis on a specific procedure. Fax:

4 Torque Specifications All fasteners must be torqued to specifications. Use manufacturers torque values for OEM fasteners. Apply Loctite 242 or equivalent on all engine-mounted fasteners. Torque values are with Loctite applied unless otherwise specified. STANDARD GRADE 8 NATIONAL COARSE THREAD Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 Foot-pounds (ft-lb) Newton meter (N m) STANDARD GRADE 8 NATIONAL FINE THREAD Size 3/8 7/16 1/2 5/8 3/4 Foot-pounds (ft-lb) Newton meter (N m) METRIC CLASS 10.9 Size M6 M8 M10 M12 M14 M16 Foot-pounds (ft-lb) Newton meter (N m) Ordering Parts To order parts, contact your VMAC dealer. Your dealer will ask for the VMAC serial number, part number, description and quantity. To locate your nearest dealer, call or online at Recommended Accessory 600 W, 12 V Modified Sine Wave Power Inverter Part Number: A Fax:

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6 Parts List Item QTY Part # Description SLEEVE, HEATER HARNESS, G30, COLD CLIMATE KIT HEATER, 200W, ASSY HEATER, 400W, ASSY INSTR, COLD CLIMATE KIT, RAPTAIRG CLAMP, CABLE, 1/ CLAMP, STRAP 7/ TIE, NYLON MD, 6" NUT, M8 X 1.25 FL PL SEALANT, RTV HIGH TEMP, ULTRA 80ML (Only included with A500041) 6 Fax:

7 Safety Precautions Moving Parts Hazard Before performing service, disconnect the battery and disconnect the spark plug wire to prevent unexpected engine start. Do not operate the compressor without guards in place. If the guards are damaged or missing, replace them before operating the equipment. Burn Hazard The engine, exhaust and the compressor system get very hot during operation, contact with the components or the oil can cause serious injury. Allow sufficient time for the system to cool before performing service. Never allow any part of your body to contact the engine or compressor components. General Warnings Disconnect Spark plug wire before attempting any repair or service. Be attentive for unexplained changes in operation parameters and record any changes. Check compressor oil level and condition before starting the system. Do not add or change oil while the system is running. Use only approved oil. The compressor operates anytime the engine is running. Avoid contact with the compressor, hoses, or engine during operation. Keep hoses and wiring aware from sharp edges or moving components. Use only approved hoses and replacement parts. Do not modify the equipment. Do not operate the air compressor when fatigued or under the influence of alcohol or drugs. Know how to operate the compressor, fully read the manual. Check equipment before every use. Never bypass or disable any of the safety equipment. Never adjust or attempt to make any repairs to the compressor system while the engine is running. Components and hoses under pressure could fail and cause serious injury or death. Fax:

8 Installation Heater Cartridge Installation Ensure the system is cool, and the key is in the off position. Disconnect the battery and cover the terminals. Disconnect the spark plug wire. (Figure 1) Figure 1 Spark plug wire Remove the VMAC belt guard. (Figure 2) Figure 2 VMAC belt guard 8 Fax:

9 Remove the lower engine shroud. (Figure 3) Figure 3 Lower engine shroud Apply a liberal amount of Permatex RTV Ultra Black to the shaded area on the engine to bond the heater block to the engine. Slide the heater block into place. Ensure it sits flush against the cylinder head fins. (Figure 4) Figure 4 Installing the heater block Fax:

10 Slide the 400 W heater cartridge fully into the heater block. Fill the cavity and chamfer with a liberal amount of RTV Ultra Black to keep it in place. (Figure 5) Figure 5 Inserting the heater cartridge This cold climate kit uses 2 different heater cartridges. The 400 W cartridge is used on the engine and the 200 W cartridge is used on the compressor. Each cartridge is stamped with the output on the face of the cartridge. Push the heater cartridge wire behind the inside edge of the VMAC belt guard mounting plate and away from the edge of the lower engine shroud. (Figure 6) Mount 1/4 in P-clip Ensure wire is routed behind inner belt guard Figure 6 Heater cartridge wire routing 10 Fax:

11 Replace the lower engine shroud. Ensure the tabs properly mate with the engine. (Figure 7). Figure 7 Installing lower shroud Replace the VMAC belt guard. Route the heater cartridge harness through the supplied 1/4 in P-clip and bolt into place. (Figure 6) Install the 200 W heater cartridge into the compressor. Cover the face of the cartridge with Permatex RTV Ultra Black to hold it in place. (Figure 8) Figure 8 Installing the compressor heater Fax:

12 Route the heater cartridge wire through one of the supplied 1/4 in P- clips. Attach the P-clip to the fastener shown using Loctite 242. (Figure 9) Attach P-clip here Figure 9 Heater cartridge wire routing Cold Climate Harness Installation Route the main cold climate harness through one of the supplied 7/8 in P-clips. Attach the P-clip and the ground wire of the cold climate harness to the WHASP tank mount using the supplied nut. (Figure 10) Figure 10 Cold climate harness routing 12 Fax:

13 Route the main cold climate harness between the WHASP tank and the oil return hose and up towards the WHASP cooler. (Figure 11) Main cold climate harness Oil return hose Figure 11 Cold climate harness routing Route the main cold climate harness through the supplied 7/8 in P-clip and attach to the WHASP cooler using the supplied nut. (Figure 12) Main cold climate harness Figure 12 Cold climate harness routing Fax:

14 Route the cold climate heater harness through the supplied P-clip and attach to the top of the VMAC belt guard. (Figure 13) Figure 13 Cold climate harness routing Plug the compressor and heater cartridges into the main cold climate harness. Re-connect the spark plug wire. Re-connect the battery. Power Inverter Installation Best Practices Follow all installation instructions for the inverter. Mount the inverter in the cab whenever possible. If mounting in the cab is not practical, mount the inverter where it will be protected from the elements, such as a tool cabinet. Use a grounded, 3 prong extension cord suitable for 1000 W to connect between the inverter and the cold climate kit harness. Mount the breaker in a protected location near the battery. 14 Fax:

15 Operation VMAC recommends using an inverter rated for a minimum of 600 W continuous power if you are supplying your own. VMAC is unable to provide specific warming times as variables such as ambient temperature and how sheltered the RAPTAIR-G30 is will affect the time it takes to warm the compressor system. You may need to run the heaters for 30 minutes or more prior to starting the engine to allow sufficient time for the system to warm up. This can generally be accomplished while driving to work. Ensure the vehicle engine is running as the inverter s current draw is capable of draining the batteries quite rapidly. Turn the inverter switch on. Once the system has warmed sufficiently turn the inverter off. Special considerations may be required if operating the RAPTAIR-G30 at extreme temperatures. The RAPTAIR-G30 cold climate kit is not equipped with a timer or automatic shut off. Once the unit has warmed up, turn off or unplug the inverter. Alternatively, the cold climate kit can be connected to a switch allowing the heaters to be turned off while the inverter supplies power to other devices. Fax:

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