VMAC A800185 Air Aftercooler Owner’s Manual

A800185 Air Aftercooler
Owner’s Manual

A800185 Air Aftercooler

VMAC – Vehicle Mounted Air Compressors
VMAC Technical Support: 888-241-2289
VMAC Knowledge Base: kb.vmacair.com
Document: 1930225
Changes and Revisions

Additional Application Information

• For use with system between 80 cfm to 185 cfm*.
• For systems requiring between 70 cfm, see the VMAC Air Aftercooler 70 CFM (P/N: A800070).

Registered Trademarks
All trademarks mentioned in this manual are the property of their respective owners. VMAC’s use of manufacturers’ trademarks in this manual is for identification of the products only and does not imply any affiliation to, or endorsement of said companies.
Loctite®, Loctite® 242 and Loctite® 567 are registered trademarks of Henkel AG & Company KGaA.
Important Information
The information in this manual is intended for certified VMAC installers who have been trained in installation and service procedures and/or for anyone with mechanical trade certification who has the tools and equipment to properly and safely perform the installation or service. Do not attempt installation or service without the appropriate mechanical training, knowledge and experience.
Follow all safety precautions. Any fabrication for correct fit in modified vehicles must follow industry standard “best practices”.
Notice
Copyright © 2023 VMAC Global Technology Inc. All Rights Reserved. These materials are provided by VMAC for informational purposes only, without representation or warranty of any kind, and VMAC shall not be liable for errors or omissions with respect to the materials. The only warranties for VMAC products and services are those set forth in the express warranty statements accompanying such products and services, if any, and nothing herein shall be construed as constituting an additional warranty. Printing or copying of any page in this document in whole or in part is only permitted for personal use. All other use, copying or reproduction in both print and electronic form of any part of this document without the written consent of VMAC is prohibited. The information contained herein may be changed without prior notice.  Printed in Canada

Safety

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, service
techniques and running OEM changes. If a discrepancy is found in this manual, contact VMAC Technical Support prior to initiating or proceeding with installation, service or repair. Current information may clarify the issue. Anyone with knowledge of such discrepancies, who proceeds to perform 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 ensure that their safety and that of others is not being compromised, and that there will be no adverse effects on the operational safety or performance 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 anyone to properly adhere to the procedures set out in this manual or standard safety practices.
Safety should be the first consideration when performing any service operations. If there are any questions concerning the procedures in this manual, or more information is required, please contact VMAC Technical Support prior to beginning work.
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 attention to instructions concerning 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 aware of the possibility of personal injury or death. As it is impossible to warn of every conceivable hazard, common sense and industry standard safety practices must be observed.
This symbol is used to call attention to instructions on a specific procedure that if not followed may damage or reduce the useful life of the compressor or other equipment.
This symbol is used to call attention to additional instructions or special emphasis on a specific procedure.

Warranty

VMAC Standard Warranty (Limited)
For complete warranty information, including both VMAC Standard Warranty (Limited) and VMAC Lifetime Warranty (Limited) requirements, please refer to our current published warranty located at: www.vmacair.com/warranty
If you do not have access to a computer, please contact us and we will be happy to send you our warranty.
VMAC’s warranty is subject to change without notice.

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VMAC Lifetime Warranty (Limited)
A VMAC Lifetime Limited Warranty is offered on the base air compressor only and only on UNDERHOOD, Hydraulic Driven, Transmission Mounted, Gas and Diesel Engine Driven Air Compressors, Multifunction Power Systems, and other products as defined by VMAC, provided that (i) the purchaser fully completes and submits a warranty registration form within 3 months of purchase, or 200 hours of operation, whichever occurs first; (ii) services are completed in accordance with the Owner’s Manual; (iii) proof of purchase of applicable service kits are made available to VMAC upon request. The VMAC Lifetime Warranty is applicable to new products shipped on or after 1 October, 2015. Warranty Registration
Warranty registration for VMAC systems can be completed online or by filling in the form at the back of each system installation manual. Warranty registration must be completed and sent to VMAC at the time the system is put into service for any subsequent warranty claim to be considered valid. There are 4 ways the warranty can be registered with VMAC:
www.vmacair.com/warranty
warranty@vmacair.com
(877) 740-3202
VMAC – Vehicle Mounted Air Compressors 1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3
VMAC Warranty Claim Process
VMAC warranty work must be pre-authorized by VMAC. Claims are processed via our dealer network. If you are not a VMAC dealer, please select one to work with via our Dealer Locator: https://www.vmacair.com/dealer-locator/

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1. Communicate with VMAC Technical Support at 1-888-241-2289 or tech@vmacair.com to help diagnose/troubleshoot the problem prior to repair. VMAC technical support will require the VMAC System ID, and hours on the compressor.
2. VMAC will provide direction for repair or replacement of the failed components.
3. If requested, failed parts must be returned to VMAC for evaluation.
4. Dealers may login to the VMAC website to view the “VMAC Labour Time Guide” (under “Agreements”) to see the allowable warranty labour times.
5.  Warranty invoices must include the Service Ticket number, VMAC System ID#, hours on the compressor, and a detailed description of the work performed.
6.  VMAC Warranty does not cover consequential damages, overtime charges, mileage, travel time, towing/recovery, cleaning or shop supplies.
7. Dealers submit warranty claims on behalf of the Vehicle Owner/End User affected by the defective part(s). The dealer ensures that all warranty credits are refunded back to the Vehicle Owner/End User who made the initial warranty claim.

**** In order to qualify for Lifetime Warranty (Limited), the completed warranty registration form must be received by VMAC within 3 months of the buyer receiving the Product(s), or 200 hours of operation, whichever occurs first.
If the completed warranty registration form has not been received by VMAC within 3 months of the buyer receiving the Product(s), or 200 hours of operation, the “Standard” warranty period will be deemed to commence 30 days from the date of shipment from VMAC.
Failure to follow the warranty claim process may result in denial of the warranty claim.
VMAC Product Warranty Policies & Warranty Registration can be found on the VMAC website (see previous page for URL).

General Information

Optional Equipment Compatibility
While VMAC strives to design systems compatible with optional OEM equipment (such as running boards), it is impractical to develop systems that accommodate every OEM and aftermarket option or add-on. Whenever possible, VMAC
endeavors to advise of compatibility issues in the “Additional Application Information” section of the manual. Even when specific optional equipment is determined by VMAC to be incompatible, it does not preclude the vehicle upfitter
or end user from modifying the optional equipment to make it compatible with the installed VMAC system. VMAC does not warrant or accept responsibility or liability for the fitment, function, or safety of any products modified in any way not expressly outlined in the installation manual.
Before Starting
Note and label all parts that are removed from the vehicle as many of the OEM parts will be reused during the installation of the VMAC system.
Read this manual prior to beginning the installation to ensure familiarity with the components and how they will fit on the vehicle. Identify any variations from the application list such as vehicle model, engines, or optional equipment (e.g., dual alternator, active steering assist, etc.).
Open the package, unpack the components and identify them using the Illustrated Parts List (IPL) included in the Fastener Pack.
Hose Information
Depending on other installed equipment, it might be necessary to move the air/oil separation tank from its intended location. The hoses used in VMAC compressor systems have a specific inner liner that is compatible with VMAC compressor oil. Use of hoses other than those supplied or recommended by VMAC may cause compressor damage and may void your warranty. Please contact VMAC for replacement hoses and further information.
Ordering Parts
To order parts, contact a VMAC dealer. The dealer will ask for the VMAC serial number, part number, description and quantity. Locate the nearest dealer online at www.vmacair.com/dealer-locator or call 1-877-912-6605.

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Special Tools Required
• None
Torque Specifications
All fasteners must be torqued to specifications. Use manufacturers’ torque values for OEM fasteners.
The torque values supplied in Table 1 are intended for VMAC supplied components, or for use as a guide in the absence of a torque value provided by an OEM.
Apply Loctite 242 (blue) to all fasteners (except nylon lock nuts) unless otherwise stated.
Torque values are with Loctite applied unless otherwise specified.

Standard Grade 8 National Coarse Thread

Size (in)| 1/4| 5/16| 3/8| 7/16| 1/2| 9/16| 5/8| 3/4
Foot pounds (ft•lb)| 9| 18| 35| 55| 80| 110| 170| 280
Newton meter (N•m)| 12| 24| 47| 74| 108| 149| 230| 379
Standard Grade 8 National Fine Thread
Size (in)| 3/8| 7/16| 1/2| 5/8| 3/4
Foot pounds (ft•lb)| 40| 60| 90| 180| 320
Newton meter (N•m)| 54| 81| 122| 244| 434
Metric Class 10.9
Size (mm)| M6| M8| M10| M12| M14| M16
Foot pounds (ft•lb)| 5.| 19| 41| 69| 104| 174
Newton meter (N•m)| 6| 25| 55| 93| 141| 236

Table 1 — Torque Table

Illustrated Parts List

System Specifications

Air requirements: Between 80 cfm to 185 cfm.
Electrical requirements: 12V dc.
Connections: 1 in NPT (intake and discharge).
Optional accessory: A700143 Mounting Bracket Kit. System specification (cont.)
Minimum hose size: #12 (3/4 in) hose.
**** Minimum hose sizes when air volume is between 150 cfm and 185 cfm.

Table 2 — Minimum hose size
Recommended Wire Gauge
**** VMAC does not recommend installing the system in a location that would require a combined wire length greater than 50 ft (15.5 m).

Table 3 — Recommended wire size

Installation

Install the VMAC Air Aftercooler 70 CFM in a location that provides adequate air flow and easy accessibility.
The unit should have a minimum of 8 in of clearance on all sides. Ensure there is sufficient space to: remove the front panel, connect the air lines, connect the wiring, and access to the manual drain.
The manual drain function can be placed in a remote location by removing the drain valve and connecting a hose, rated for a minimum of 200 psi, between the aftercooler and the relocated drain valve.
The aftercooler must be mounted upright to allow the automatic drain to function as designed (Figure 2). Ensure the selected mounting location provides a minimum of 8 in of clearance on all sides of the Eliminator. Ensure the operator has easy access to the manual drain.

• Place the aftercooler in position and drill the mounting holes (Figure 1 on page 11).
• Fasten the rubber mount feet securely. If using the optional VMAC mounting brackets (P/N: A700143), install the aftercooler unit onto the brackets and fasten securely.
• Connect the supply line from the air source to the “Air In” fitting (see Table 2 on page 12 for recommended hose size). When tightening, support the fitting on the aftercooler with a wrench when tightening.
•  Connect the tool delivery line to the “Air Out” fitting, (see Table 2 on page 12 for recommended hose size). When tightening, support the fitting on the aftercooler with a wrench.
• Install the water separator and Filter, Regulator, Lubricator (FRL) combination unit in a position where the filters can be easily monitored and changed.
• Route the black nylon water drain tube from the air filter and water separator to a suitable drain location.

When installing the hose between the eliminator and the water separator, ensure the hose is routed above the height of the water separator to prevent water pooling in the hose.

• Connect the delivery line from the Eliminator to the water separator (it is best practice to install the largest hose available to reduce pressure drops across the system).
• Connect the red wire from the aftercooler through a 20 A fuse to a 12 V (constant) source using the recommended wire size (Table 3 on page 12).

To confirm a good ground, use an ohm meter to measure the resistance between the ground point and the negative battery terminal. Resistance should be less than 1 Ω.

• Connect the green wire to a good ground using the recommended wire size (Table 3 on page 12).

VMAC UNDERHOOD 150 Systems

• Connect the red wire from the aftercooler to a 12 V source (see page 12).
• Connect the green wire from the aftercooler to a good ground (see page 12).
•  Connect the white wire from the aftercooler to the white clutch wire coming from the VMAC compressor (Figure 3).

Universal Connection

• Connect the red wire from the aftercooler to a 12 V source (see page 12).
• Connect the green wire from the aftercooler to a good ground (see page 12).
• Connect the white wire to a power source through an on/off switch using 18 AWG wire.

Operation

In extreme cold temperatures, moisture in the drain lines can freeze within minutes, to prevent a blockage, open the manual drain immediately after use.
Daily Operation
At the end of each shift, shut the compressor system down and vent any stored air. Open the manual drain valve, on the side of the cooler, to drain the air line; this will prevent the water in the float bowl from freezing in cold temperatures which will cause the automatic water drain to fail. Leave the valve open until the compressor is started again.
Manual Drain
The VMAC air aftercooler has a manual drain valve to purge water from the ‘Air-In’ line entering the aftercooler.

**** 888-241-2289
877-740 -3202
www.vmacair.com
warranty@vmacair.com
 tech@vmacair.com
kb.vmacair.com
1333 Kipp Road, Nanaimo, B.C., V9X 1R3 Canada

References

• VMAC Knowledge Base
• VMAC - Vehicle Mounted Air Compressors | VMACAIR.com
• Find A Dealer - VMAC
• VMAC Warranty Policies & Warranty Registration
• Find A Dealer - VMAC

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