UNDERHOOD 30-40 Clutch Replacement

Technical Support Subject UNDERHOODTM 30 & 40 Clutch Replacement Version Document Department Revision Details Revised by Tech Engineering Implemented A EXT-VL-010 Tech Document Release BDJ 30 Apr 2020 DB 1May 2020 N/A 1 May 2020 Knowledge Base: kb.vmacair.com Page 1 of 6 Email: tech@vmacair.com Web: www.vmacair.com Technical Support: 1(888)241-2289 Toll Free:1(800)738-8622 Fax: 1(877)740-3201 SYSTEM OR PARTS AFFECTED • All UNDERHOODTM 30 cfm (VR Lite) Compressor Systems • All UNDERHOODTM 40 cfm Compressor Systems INDEX Overview ............................................................................................1 Safety .................................................................................................2 Disassembly ......................................................................................2 Reassembly .......................................................................................4 OVERVIEW • Following is the procedure for removal and replacement of VMAC Clutch part numbers P200046 and P200048. • Compressor components are shown for reference purposes only and may not be exactly as shown (Figure 1). Figure 1 Small Circlip Large Circlip Field Coil Rotor assy. Armature assy. Shim stack 5 mm BoltTechnical Support Subject UNDERHOODTM 30 & 40 Clutch Replacement Version Document Department Revision Details Revised by Tech Engineering Implemented A EXT-VL-010 Tech Document Release BDJ 30 Apr 2020 DB 1May 2020 N/A 1 May 2020 Knowledge Base: kb.vmacair.com Page 2 of 6 Email: tech@vmacair.com Web: www.vmacair.com Technical Support: 1(888)241-2289 Toll Free:1(800)738-8622 Fax: 1(877)740-3201 SAFETY • It is impossible to warn of all the possible hazards that may result from operating, servicing, or repairing this system. Wear all appropriate Personal Protective Equipment and follow all industry standard safety practices. • Confirm that the system is depressurized and has cooled prior to performing any service work. • This information is intended for people with mechanical trade certification who have the tools and equipment to properly and safely perform the service or repair. Do not attempt to service or repair this system without the appropriate mechanical training, knowledge, and experience. Follow all safety precautions and industry standard “best practices”. DISASSEMBLY Some models allow clutch replacement with the compressor installed; others require compressor removal. Contact VMAC Technical Support for more information if you unsure what is necessary to complete your clutch replacement. • Remove the compressor from the vehicle (if necessary) and place the compressor in a vise with the clutch facing up. • Remove the 5 mm bolt from the clutch armature. • Using (x2) small flat bladed screwdrivers, pry up on opposite sides of the clutch armature to slide it off of the compressor shaft (Figure 2). Figure 2Technical Support Subject UNDERHOODTM 30 & 40 Clutch Replacement Version Document Department Revision Details Revised by Tech Engineering Implemented A EXT-VL-010 Tech Document Release BDJ 30 Apr 2020 DB 1May 2020 N/A 1 May 2020 Knowledge Base: kb.vmacair.com Page 3 of 6 Email: tech@vmacair.com Web: www.vmacair.com Technical Support: 1(888)241-2289 Toll Free:1(800)738-8622 Fax: 1(877)740-3201 As the clutch armature comes off, watch for shims or the shim stack, which may stick to the bottom the armature. • Remove the shim stack from the bottom of the armature and/or from the compressor input shaft. Set the shim stack aside for use during reassembly (Figure 3). Figure 3 Observe the installation orientation of the circlips that retain the rotor and the field coil. The wider tab must be clockwise in relation to the narrower tab. In this orientation the flat face of the circlip with sharp edges should be facing outwards and the tapered or rounded edge should be inwards towards the compressor. • Remove the upper, small circlip on the inside of the rotor assembly (Figure 4) and slide the clutch rotor assembly off of the end of the compressor cover housing. Use care when removing the clutch rotor assembly from the rotor shaft to prevent damage to the rotor shaft splines. Figure 4 • Remove the lower, large circlip securing the field coil assembly (Figure 4). Shim Stack Small Circlip Large CirclipTechnical Support Subject UNDERHOODTM 30 & 40 Clutch Replacement Version Document Department Revision Details Revised by Tech Engineering Implemented A EXT-VL-010 Tech Document Release BDJ 30 Apr 2020 DB 1May 2020 N/A 1 May 2020 Knowledge Base: kb.vmacair.com Page 4 of 6 Email: tech@vmacair.com Web: www.vmacair.com Technical Support: 1(888)241-2289 Toll Free:1(800)738-8622 Fax: 1(877)740-3201 • Cut the cable tie securing the field coil wire and remove the screw that secures the cable tie tab to the compressor body. Set the screw and tab aside for use later (Figure 5). Figure 5 • Remove the field coil. REASSEMBLY • Install the field coil ensuring the alignment pins are engaged (Figure 6) to prevent rotation of the field coil and secure it with the large circlip oriented as described previously (Figure 4). The field coil should have no rotational movement if installed properly. It is Imperative that the front cover and the field coil alignment pins fully engage to ensure that the clutch will not rotate during use. Figure 6 • Install the rotor assembly and secure it with the small circlip oriented as described previously. • Reinstall the cable tie tab and secure the field coil wire using a new cable tie (Figure 5). Field Coil Wire Cable Tie Tab Alignment Pin Alignment PinTechnical Support Subject UNDERHOODTM 30 & 40 Clutch Replacement Version Document Department Revision Details Revised by Tech Engineering Implemented A EXT-VL-010 Tech Document Release BDJ 30 Apr 2020 DB 1May 2020 N/A 1 May 2020 Knowledge Base: kb.vmacair.com Page 5 of 6 Email: tech@vmacair.com Web: www.vmacair.com Technical Support: 1(888)241-2289 Toll Free:1(800)738-8622 Fax: 1(877)740-3201 • Install the original shim stack on the input shaft. • Install the armature plate on the input shaft and install the bolt and washer without Loctite (Figure 7). Figure 7 • Check the gap between the rotor assembly and the armature with feeler gauges (Figure 8). Adjust the shim stack height as necessary to obtain the specified air gap: o Minimum gap 0.016 in (0.4 mm) o Maximum gap 0.023 in (0.6 mm) Figure 8Technical Support Subject UNDERHOODTM 30 & 40 Clutch Replacement Version Document Department Revision Details Revised by Tech Engineering Implemented A EXT-VL-010 Tech Document Release BDJ 30 Apr 2020 DB 1May 2020 N/A 1 May 2020 Knowledge Base: kb.vmacair.com Page 6 of 6 Email: tech@vmacair.com Web: www.vmacair.com Technical Support: 1(888)241-2289 Toll Free:1(800)738-8622 Fax: 1(877)740-3201 • When correct gap is achieved remove the bolt and washer. Apply Blue #242 Loctite to the threads of the bolt and secure the armature plate assembly with the bolt and washer (Figure 9). o Torque the bolt to 54 lb-in (6 N-m) Figure 9 • If the compressor was removed from the vehicle, re-install it as per the installation manual • Test clutch and compressor operation as per the Testing The Installation chapter in the installation manual. If there are any questions about this document, please contact VMAC Technical Support. Apply Loctite #242 and torque to 54 lb-in (6 N-m)