vmacair DM00014 Vehicle Mounted Air Compressors Installation Guide
- June 15, 2024
- vmacair
Table of Contents
- vmacair DM00014 Vehicle Mounted Air Compressors
- Product Information
- Frequently Asked Questions
- VMAC – Vehicle Mounted Air Compressors
- Safety
- Warranty
- General Information
- Preparing for Installation
- Inverter
- Air Receiver Tank
- Recommended Accessories
- Testing the Installation
- Digital Throttle Control
- Adjusting the Pressure Regulator
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)
vmacair DM00014 Vehicle Mounted Air Compressors
Product Information
Specifications
- Product: VMAC System
- Model Number: DM00014
- Website: www.vmacair.com
Installation Manual for VMAC System
The VMAC System is a vehicle-mounted air compressor designed for various applications. It is equipped with a side power take-off (PTO) option and throttle control. It is compatible with the Aisin AS69RC transmission with PTO.
Safety
Important Safety Notice:
- Only follow proven service procedures mentioned in this manual.
- Ensure that your safety and the safety of others is not compromised.
- Adherence to the procedures in this manual and standard safety practices is essential.
- Contact VMAC Technical Support for any questions or additional information.
Safety Messages
This manual contains important safety messages that must be observed during installation, service, or repair to reduce the risk of personal injury and equipment damage. The following symbols are used:
- Safety Symbol 1: This symbol indicates instructions concerning personal safety. Pay attention to these instructions as they involve personal injury or death risks.
- Safety Symbol 2: This symbol indicates instructions that, if not followed, may damage or reduce the useful life of the compressor or other equipment.
- Safety Symbol 3: This symbol indicates additional instructions or special emphasis on a specific procedure.
Warranty
VMAC offers a limited warranty for the VMAC System. For complete warranty information, including requirements for both VMAC Standard Warranty (Limited) and VMAC Lifetime Warranty (Limited), please refer to our current published warranty located at: www.vmacair.com/warranty.
Frequently Asked Questions
Q: Can the VMAC System be used with any vehicle?
A: The VMAC System is designed for vehicle-mounted applications. However, compatibility may vary depending on the vehicle’s specifications. Please refer to the product manual or contact VMAC Technical Support for more information.
Q: What should I do if I have questions about the installation or usage of the VMAC System?
A: If you have any questions or need assistance with the installation or usage of the VMAC System, please contact VMAC Technical Support at 888-241-2289 or visit the VMAC Knowledge Base at kb.vmacair.com.
®
Installation Manual for VMAC System
DM00014
2019+ Ram 3500 4500 Chassis Cab 6.7 L Cummins Diesel with PTO
www.vmacair.com
VMAC – Vehicle Mounted Air Compressors
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Document: 1930399 Changes and Revisions
Revision
Revision Details
K
ECN: 23-203 Update AOST instructions
Revised by MSP
Checked by Eng.
Tech. Qual. Mech. Elec. MRH N/A RDB LPH
Implemented 21 Sept. 2023
Additional Application Information
· 2019+ Ram 3500 4500 Chassis Cab equipped with 6.7 L Cummins Diesel
Aisin AS69RC transmission with PTO.
· Must have factory PTO prep package (RPO Production code LBN, passenger
side PTO option).
· Note that this VMAC system may be equipped with either a digital or analog
throttle control.
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. Eaton Aeroquip® is a registered trademark of EATON AEROQUIP
INC. RAM® is registered trademark of FCA US LLC. Cummins® is registered
trademark of Cummins Inc. New LineTM is a trademark of New Line Hose and
Fittings.
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 © 2020 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
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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.
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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.
VMAC Lifetime Warranty (Limited)
A VMAC Lifetime Limited Warranty is offered
AIR INNOVATED
on the base air compressor only and only on
UNDERHOOD, Hydraulic Driven, Transmission Mounted, Gas and Diesel Engine Driven Air
LIFETIME
Compressors, Multifunction Power Systems, and other products as defined by VMAC, provided that (i) the purchaser fully completes and submits a
WARRANTY
TRUST SERVICE VALUE
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
The VMAC warranty registration form is located near the back of this manual. This warranty registration form must be completed and sent to VMAC at the time of installation for any subsequent warranty claim to be considered valid.
There are 4 ways the warranty can be registered with VMAC:
[email protected]
877-740-3202 VMAC – Vehicle Mounted Air
Compressors 1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3
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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/
1. Communicate with VMAC Technical Support at
1-888-241-2289 or
[email protected] 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 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).
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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 warranty 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
· Pneumatic fan wrench (Lisle 43300 or equivalent) · 6 mm ball end hex driver.
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
Size (mm)
Metric Class 10.9
M6
M8
M10
M12
M14
M16
Foot pounds (ft·lb) 4.5
19
41
69
104
174
Newton meter (N·m)
6
25
55
93
Table 1 — Torque Table
141
236
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System Identification, Warranty Registration and Warning Labels
Preparation for installation is very important. Missing a step or an item can
cause problems in the installation or damage to components.
Check off each item as it is completed so that no steps are
missed.
Review the contents of the system using the illustrated parts list to ensure
all
components are present and in the correct quantity. If any components are
missing, have the system ID ready and call VMAC Technical Support at
888-241-2289.
The VMAC warranty form must be completed and returned to VMAC at the time of
installation for any subsequent warranty claim to be considered valid.
Complete the warranty form. The VMAC warranty form is located at the back of
this manual, as well as online at:
www.vmacair.com/warranty
The System Identification Plate must be attached to the vehicle at the time of
installation. This plate provides information that allows VMAC to assist with
parts and repairs.
Locate a conspicuous area in the engine bay (where the tag will be easily
noticed) to install the System ID tag.
Mark and drill (×2) 7/64 in holes and secure the plate with the supplied self-
tapping screws (Figure 1).
Figure 1 — System Identification Plate
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As part of the installation process, ensure that the safety and operational
instruction decal is affixed in an obvious location so that it can be seen by
vehicle operators. A good spot for this is usually on the inside of the door
or on the panel underneath the steering wheel (Figure 2).
Figure 2 — Operating Instruction label
To alert any technicians that may service the vehicle, affix the servicing
caution/
contact decal in a conspicuous area in the engine bay (where the decal will be
easily noticed) (Figure 3).
Figure 3 — Advisory label
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Preparing for Installation
Ensure the VMAC Warranty Registration has been completed and the System
Identification Plate and Operating Instruction Label are installed prior to
proceeding (Please see page 8 for details).
Do not use a test light to probe for power on vehicle circuits, the increased
current draw of the test light may damage components!
Vehicles equipped with RAM’s Vehicle System Interface Module (VSIM), skip, to
page 11.
Identify the “PARK”/”NEUTRAL” wire.
Locate the 10 pin connector plugged into the transmission range sensor on the
driver side of the transmission (Figure 4).
Range sensor
Figure 4 — Locate range sensor
Locate the yellow wire with blue stripe going to pin 9 in the transmission
range
sensor connector (Figure 5).
Pin 9
Figure 5 — View from front of connector
To verify pin 9 is the “PARK”/”NEUTRAL” wire, turn the ignition key to “RUN”
but
do not start the engine.
Using a multimeter, verify the voltage is between 0 V – 2 V while the gear
selector is in “PARK” or “NEUTRAL”, and approximately 12 V in all other gears.
Mark the “PARK”/”NEUTRAL” wire for identification later. Turn the ignition key
to “OFF”.
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Disconnect the negative terminal from the batteries.
Ensure the vehicle is supported safely with appropriately rated jack stands.
Raise the front of the vehicle and support it appropriately. Remove the air
box assembly. Cover the intake tube to prevent any
contaminants from entering the system.
Drain the coolant into a clean container and set it aside for use later.
Due to variations in service body design and other equipment, VMAC is unable
to recommend mounting locations for the remote air filter housing.
Determine a location for the remote air filter. Determine the approximate
remote air filter duct length: · Refer to page 47 for air filter mounting
guidelines. · For optimum performance, the duct length should be minimized. ·
The kit includes 8 ft. of hose, which can be cut to length. · Longer hose may
be purchased from VMAC, or a hose supplier (VMAC P/N:
1700650, New Line P/N: NL6025-200).
Possible remote air filter location
Approximate location of compressor inlet
Figure 6 — Determine remote air filter location
If the flexible hose has been extended, test the system once installation is
complete as extending the hose may affect compressor performance.
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Installing the PTO and Compressor
Apply Loctite 242 (blue) to all fasteners.
It is extremely important to ensure that contaminants do not enter the PTO
port on the transmission.
Refer to the “PTO Installation Alternative” bulletin on the RAM Body Builder’s
Guide for detailed instructions on accessing the PTO access panel on the
passenger side of the cab. https://www.ramtrucks.com/ram-commercial/body-
builders-guide.html
Remove the passenger seat, and doorsill guards to allow the vinyl floor mat to
be lifted.
Fold the floor mat toward the rear of the cab to expose the PTO access hatch.
Remove the fasteners and sealer from the PTO access hatch (Figure 7).
Front of vehicle
Figure 7 — PTO access hatch
Optional: Remove the passenger side inner fender. This provides much better
access for the PTO install.
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Remove the nuts from the exhaust flange and set them aside for later (Figure
8).
Remove (×3) exhaust flange nuts
Figure 8 — Exhaust flange
Disconnect the exhaust from the turbo outlet (Figure 9).
Use care when disconnecting the exhaust components to prevent damaging the
gaskets (forward gasket OEM P/N: 6807 1676AA, rear gasket OEM P/N:
52122213AB).
Disconnect exhaust
Figure 9 — Turbo outlet
Remove the exhaust support bracket.
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With the exhaust pipe disconnected, push the pipe toward the front of the
vehicle to clear the studs in the flange, rotate it toward the frame, and
secure it in place with a ratchet strap (Figure 10 and Figure 11).
Figure 10 — Shift exhaust forward
Figure 11 — Rotate exhaust
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Remove the inlet and O-ring from the compressor and cover the opening of the
compressor to prevent any contaminants from entering the system (Figure 12).
Figure 12 — Remove intake
Insert the compressor through the PTO access hole (or up from the bottom of
the vehicle), slide it toward the rear of the vehicle, and set it on the
transmission cross member.
Secure the compressor in place to prevent it from falling while the PTO is
installed.
Install the PTO clocking ring in the orientation shown (see Chelsea manual for
torque specifications) (Figure 13).
Clock hole with bolt
Clock hole with bolt
Figure 13 — PTO Clocking ring orientation
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Using the (×3) flat head fasteners, install the PTO flange adapter; torque the
fasteners to specification (Figure 14).
Figure 14 — PTO flange adaptor
Follow the mechanical portion of the OEM PTO installation instructions (272
Series for 2013+ Aisin AS69RC transmission).
The PTO electrical installation will be covered in “Installing the Control
Components” and differs from the OEM PTO instructions.
Apply a generous amount of spline grease to the compressor input shaft.
Install the compressor onto the PTO (Figure 15).
(×2) M10 × 1.5 × 55 mm bolts
1/2 in × 3 1/2 in G8 bolt
Figure 15 — Mount compressor to PTO
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Remove the covering from the compressor opening and reinstall the inlet and
O-ring onto the compressor (Figure 16).
Figure 16 — Install inlet
Remove the (×2) transfer case fasteners (Figure 17).
(×2) Transfer case fasteners
Figure 17 — Remove fasteners
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Apply Loctite 242 (blue) to the transfer case fasteners, removed in the
previous
step, and install the air intake support bracket (Figure 18).
Figure 18 — Install air intake support bracket
Install the rubber air intake hose coupler onto the inlet and secure it using
a
gear clamp (Figure 19).
Figure 19 — Install intake hose
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Install the compressor side metal intake tube and secure the intake tube to
the
support bracket using a gear clamp (Figure 20).
Figure 20 — Install compressor side metal intake tube
Install the rubber air intake hose coupler onto the compressor side intake
tube
and secure it with a gear clamp (Figure 21).
Figure 21 — Install intake hose
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Standard Cab
Install the filter side metal intake tube and secure it using a gear clamp
(Figure 22).
Figure 22 — Install filter side metal intake tube
Secure the filter side intake tube to the cross member using the supplied
P-clip,
bolt, and washer (Figure 23).
OEM threaded hole
Figure 23 — Secure filter side intake tube
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Extended Cab and Crew Cab
Install the filter side metal intake tube and secure it using a gear clamp
(Figure 24).
Figure 24 — Install filter side metal intake tube
Install the rubber air intake hose coupler onto the intake tube and secure it
with
a gear clamp (Figure 25).
Figure 25 — Install intake hose extension
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Install the metal intake tube extension and secure it using a gear clamp (Figure 26)
Figure 26 — Secure filter side intake tube extension
Secure the intake tube extension to the cross member using the supplied
P-clip,
bolt, and washer (Figure 27).
OEM threaded hole
Figure 27 — Secure filter side intake tube
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Installing the Oil Cooler
Apply Loctite 242 (blue) to all fasteners.
Install the supplied 4.5 in hose onto the short oil cooler spigot using one of
the
supplied hose camps. Leave the hose clamp loose to allow adjustment (Figure
28).
Figure 28 — Install modified hose
Fit the other hose clamp onto the hose, leaving it loose. Remove the OEM
fastener securing the radiator brace and set it aside (Figure 29).
Radiator (for reference only)
Radiator brace
Passenger side body mount (for reference only)
Remove OEM fastener
Figure 29 — Remove OEM fastener
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Install the radiator brace and oil cooler bracket using the OEM fastener
retained
from the previous step; leave the fastener finger tight (Figure 30).
Radiator brace Figure 30 — Install cooler bracket
Install the bottom fastener into the backing strap, leaving the nut finger
tight
(Figure 31).
Install fastener in orientation shown
Figure 31 — Install backing strap
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Use extreme care while deflecting the transmission cooler hoses to prevent
damaging them, or the radiator.
While stabilizing the transmission cooler hoses at the radiator, gently
deflect
the hoses upward to provide room for the oil cooler (Figure 32).
Shift hoses upward
Figure 32 — Deflect hoses
Install the supplied flex hose onto the engine spigot (Figure 33).
Install flex hose
Figure 33 — Install flex hose
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Mount the cooler onto the cooler bracket, fitting the hoses loosely onto the
cooler spigots (Figure 34).
Figure 34 — Mount cooler
Install the top cooler bracket fastener finger tight (Figure 35).
Install top fastener
Figure 35 — Install top fastener
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Install the (×2) bottom cooler fasteners (Figure 36).
Install fasteners
Figure 36 — Install bottom cooler fasteners Once the cooler has been mounted,
verify that there is adequate clearance between the cooler and the fender,
and/or the charge air cooler ducting. If the cooler is contacting either of
these components, ensure adequate vibration isolation (such as a length of
coolant hose secure in place) is used to prevent wear to any VMAC and/or OEM
components.
Adjust the coolant hoses to ensure they are not kinked or restricted, and
tighten
the hose clamps.
Torque the fasteners securing the cooler and bracket to specification. Remove
and discard the plug from the passenger side of the cylinder head
(Figure 37).
Remove coolant vent plug
Figure 37 — Coolant vent plug
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Apply Loctite 567 (thread sealant) to each end of the pipe nipple and install
the
brass bushing and the tee fitting.
Apply Loctite 567 (thread sealant) to the threads of the brass bushing and
install the assembly into the cylinder head with the tee facing toward the
passenger side of the vehicle (Figure 38).
Figure 38 — Install pipe nipple
Apply Loctite 567 (thread sealant) to the hose barb and install it onto the
tee
fitting (Figure 39).
Hose barb
Figure 39 — Install hose barb
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Connect the supplied 10 mm ID coolant hose to the hose barb and secure it
using the supplied gear clamp (Figure 40).
Figure 40 — Install coolant hose
Route the hose forward to the corner of the air box, then down toward the
frame mount on the passenger side.
Secure the hose to the barb connector on the VMAC oil cooler using the
supplied gear clamp.
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Installing the Air Oil Separator Tank (AOST)
Dependent upon other installed equipment, it may be necessary to move the AOST
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 the warranty.
The AOST must be level for proper air/oil separation, and to ensure that the
oil level will display accurately in the sight glass.
Apply Loctite 242 (blue) to all fasteners.
Installing the AOST
The AOST will mount to the passenger side frame rail behind the body mount
(Figure 41).
Front of vehicle
Figure 41 — AOST installed (Standard Duty Chassis Shown)
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The AOST mounting hardware and instructions are chassis specific. This kit
includes the hardware required for both installations, Any parts not called
out may be discarded.
Visually identify whether the vehicle is equipped with the “standard duty” or
“heavy duty” chassis.
For “standard duty” chassis, turn to page 32 (Figure 42).
Figure 42 — Standard Duty Chassis
For “heavy duty” chassis, turn to page 34 (Figure 43).
Figure 43 — Heavy Duty Chassis
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Standard Duty Chassis
Insert one of the M10 × 1.5 × 30 fasteners into the bracket and thread the
through frame spacer onto it. Using the remaining M10 fastener and snubbing
washer, mount the front tank bracket to the vehicle frame (Figure 44).
Snubbing washer
Front of vehicle
Through frame spacer
M10 × 1.5 × 30 fastener
M10 × 1.5 × 30 fastener
Figure 44 — Installing the AOST
Using the (×2) 3/8 in × 6 in bolts, install the rear tank mount and backing
strap
where the frame begins to narrow, behind the transmission cross member. Leave
the bolts finger tight to allow for minor adjustments (Figure 45).
(×2) 3/8 in lock washer
Front of vehicle
3/8 in × 6 in bolt
3/8 in flange lock nut
3/8 in × 6 in bolt (through lower hole)
Figure 45 — Installing the AOST
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Remove the tank clamp pinch bolts (Figure 46).
(×4) 5/16 in × 1 in bolt
(×2) Tank clamp lock nut
(×4) 5/16 in lock nut
(×4) 5/16 in washer
(×2) Pinch bolt
Figure 46 — Install AOST (AOST not shown for clarity)
Install the tank clamps over the front of the tank and slide them toward the
centre of the tank.
Install the tank onto the tank mounts (Figure 46):
Adjust the tank in the straps to bring the front of the tank close to (but not
touching) the cab mount.
*Install the (×2) 3 in × 1/4 in pinch bolts into the mounting clamps. Rotate the tank so that the directional arrow on the blowdown cap, at the rear
of the tank, is pointing upward.
AOST orientation is critical. The arrow on the blowdown cap at the rear of the
tank must be pointing up to prevent compressor failure due to oil starvation,
or oil in the discharge air.
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Heavy Duty Chassis
Using the (×2) 3/8 in × 4 1/2 in bolts, install the front tank mount and
backing
strap (the lower fastener is installed between the radius arm and the frame).
Leave the bolts finger tight to allow for minor adjustments (Figure 47).
(×2) 3/8 in lock washer
3/8 in flange lock nut
Radius arm mount
3/8 in × 4 1/2 in bolt
Front of vehicle
3/8 in × 4 1/2 in bolt (through upper hole)
Figure 47 — Installing the AOST
Using the (×2) 3/8 in × 6 in bolts, install the rear tank mount and backing
strap
where the frame begins to narrow, behind the transmission cross member. Leave
the bolts finger tight to allow for minor adjustments (Figure 48).
(×2) 3/8 in lock washer
Front of vehicle
3/8 in × 6 in bolt
3/8 in flange lock nut
3/8 in × 6 in bolt (through lower hole)
Figure 48 — Installing the AOST
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Remove the tank clamp pinch bolts (Figure 49).
(×4) 5/16 in × 1 in bolt
(×2) Tank clamp lock nut
(×4) 5/16 in lock nut
(×4) 5/16 in washer
(×2) Pinch bolt
Figure 49 — Install AOST (AOST not shown for clarity)
Install the tank clamps over the front of the tank and slide them toward the
center of the tank.
Install the tank onto the tank mounts (Figure 49):
Adjust the tank in the straps to bring the front of the tank close to (but not
touching) the cab mount.
*Install the (×2) 3 in × 1/4 in pinch bolts into the mounting clamps. Rotate the tank so that the directional arrow on the blowdown cap, at the rear
of the tank, is pointing upward.
AOST orientation is critical. The arrow on the blowdown cap at the rear of the
tank must be pointing up to prevent compressor failure due to oil starvation,
or oil in the discharge air.
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Installing the Regulator
Remove the OEM nut from the passenger side brace and set it aside (Figure 50).
Remove OEM nut
Figure 50 — Install regulator
Gently lift the brace and install the regulator assembly onto the OEM stud
(Figure 51).
OEM nut
OEM brace stud
Figure 51 — Install regulator
Reinstall the brace and secure it using the OEM nut retained earlier (Figure
51).
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Hose Requirements
Only attempt to shorten the supplied hose if there is access to the
appropriate equipment. Do not attempt to cut the hose and splice it using hose
clamps.
VMAC Compressor oil will degrade rubber lined hoses, use only hoses with an
AQP elastomer type liner. Contact VMAC Technical Support at
1-888-241-2289 for further information.
The PTFE tubes and AQP elastomer lined hoses are specifically designed to work
with VMAC compressor oil and at compressor operating temperatures.
Based on the desired location of the AOST, the hose lengths provided with this
system may not be ideal. VMAC suggests first trying to adjust the AOST within
its mounts to take up any excess slack in the hoses. If this is not effective,
the hoses can be shortened or replaced as necessary, or hose extenders can be
used.
VMAC recommends shortening these hoses as a preferred alternative to coiling
up and securing the excess. Shorter hose length will maximize system
performance.
Avoid using 90° fittings wherever possible as they cause flow restrictions and
negatively impact performance.
The following hoses are included with this compressor kit:
· 3/4 in × 76 in (oil fill hose). · 3/4 in × 89 in (discharge hose). · 3/4 in
× 20 in (discharge hose extension for extended cab). · 3/4 in × 33 in
(discharge hose extension for crew cab). · 1/2 in × 68 in (oil return hose). ·
1/2 in × 99 in (oil supply hose). · 1/4 in (PTFE tube) × 47 in. · 1/4 in
(black air brake tube) × 62 in. · 3/16 in (PTFE tube) × 87 in.
If longer hoses are required:
To order parts, contact a VMAC dealer. The dealer will ask for the VMAC serial
number, part number, description and quantity. See page 6 for ordering
information.
· Eaton Aeroquip hoses with an “AQP” type inner liner are required. · OTC
fittings are required for the VMAC supplied hose. · Push-lock fittings are
suitable if FC332 hose is used. · If Push-lock fittings are being used, do not
use hose clamps as they will
damage the hose and cause leaks.
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Connecting the Hoses
When routing hoses, ensure cap plugs are installed so that contaminants do not
get in the line. Take care when routing hoses, as a hose failure may damage
the compressor and/or cause injury.
All hoses, tubes and wires that are installed, rerouted or shifted during the
installation must be secured so that they do not contact any hot, sharp or
moving parts. Use rubber coated P-clips wherever possible. Follow the routing
suggestions in this manual and cover all hoses with plastic loom.
Ensure there is sufficient slack in the hose routing to allow for normal engine movement.
PTFE Tubing, Loom, and Push-To-Connect Fittings
PTFE tubing should only be cut using proper tubing cutters. Side cutters,
utility
knives, etc. will deform the tube, preventing a proper seal (or leave sharp
edges which cut the internal O-ring).
When applying loom to the PTFE tube, leave approximately 1 in between the
loom and the fitting.
Ensure the tube is clean, cut at 90° and that there are not sharp edges.
Lubricate the tube and firmly push it into the fitting so that the tube fully
seats
in the fitting.
Slide the collet out, away from the body of the fitting to lock the tubing in
place. Ensure the tube does not have any “play” to prevent the O-ring from
wearing.
Cut the tube squarely, using only proper tubing cutters as side cutters
will deform the tube.
Slide the collet out once the tube is fully inserted
O-ring
Figure 52 — Push-to-connect fittings
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Install the supplied fitting onto the AOST (Figure 53).
Figure 53 — Install fittings Beginning at the straight fitting, apply the
supplied heat wrap to:
The longest 3/4 in hose. *The longer 1/2 in hose. Connect the 90° fitting on the longer 1/2 in hose to the driver side fitting of the
oil cooler (Figure 54).
From AOST
To compressor
Figure 54 — Install hoses
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Route the hose along the top of the frame rail, to the inside of the inner
fender,
and connect it to the compressor (Figure 55).
Figure 55 — Connect compressor oil supply hose
To prevent damaging the compressor temperature sensor, use care when
tightening the oil supply line.
Connect the 90° fitting on the longer 3/4 in discharge hose to the fitting on
the
front of the AOST and route it toward the rear of the vehicle (Figure 56).
Figure 56 — Install discharge hose
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Install the M12 to M6 adapter into the threaded hole in the body cross member
(Figure 57).
M12 to M6 adaptor
Figure 57 — Install adaptor bolt
Route the discharge hose over the frame and secure the hose to the cross
member
using one of the supplied P-clips, the washer, and the M6 fastener (Figure
58).
Figure 58 — Route discharge hose
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Route the hose over the air intake tube, securing it to the OEM frame mounting
tab using the remaining P-clip, M8 fastener, and M8 nut (Figure 59).
Air intake tube Figure 59 — Route discharge hose
Connect the discharge hose to the 45° fitting on the compressor (Figure 60).
Figure 60 — Connect discharge hose
Using cable ties, apply heat wrap to the oil return and discharge hoses where
they connect to the compressor.
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Connect the 90° fitting on the shorter 1/2 in hose to the passenger side
fitting
of the oil cooler.
Route the hose along the frame, behind the inner fender, then down the inside
of the frame. Pass the hose to the outside of the frame near the lower radius
arm mount and connect it to the lower fitting on the AOST (Figure 61).
Secure hose to frame with cable tie Figure 61 — Install oil return hose
Using cable ties, secure the hose to the frame near the lower radius arm .
From under the vehicle at the AOST, route the straight end of the shorter 3/4
in
hose toward the oil cooler, following the same path as the 1/2 in hose.
From the oil cooler, route the 3/4 in hose up toward the top of the radiator
(Figure 62).
Figure 62 — Install oil fill hose
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Remove and discard the OEM fastener at the top passenger side of the radiator
(Figure 63).
Remove OEM fastener
Figure 63 — Oil fill hose
Using the supplied P-clip and fastener, secure the oil fill hose to the to the
radiator (Figure 64).
Figure 64 — Oil fill hose
Affix the oil fill decal in a conspicuous area near the oil fill plug.
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A 3/4 in 45° fitting is supplied with this kit and can be used as necessary to
assist in routing the discharge hose.
Routing the 3/4 in oil fill hose around the body mount, connect the 45°
fitting to
the Tee on the AOST (Figure 65).
Figure 65 — Connect oil fill hose
Apply the split loom to the (×2) PTFE tubes and the black air brake tube.
Install the black air brake tube 1/4 in PTFE tube onto the straight fitting on
the
remote regulator (Figure 66).
Black 1/4 in air brake tube
Figure 66 — Connect remote regulator tubes
3/16 in PTFE tube
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Install the translucent 3/16 in PTFE tube onto the 90° fitting on the remote
regulator (Figure 66).
Route the PTFE tubes along the firewall toward the passenger side fender;
securing the PTFE tubes to the degas bottle coolant hoses.
From the degas coolant hoses, route the PTFE tubes down the inner fender to
the VMAC oil hoses.
Once the PTFE tubes reach the frame, route them alongside the oil supply hose
installed earlier. Secure the PTFE tubes to the oil supply hose using cable
ties.
Using the supplied P-Clip and nut, secure the 3/4 in oil fill hose to the
shock
tower stud to keep it away from the turbocharger (Figure 67).
Secure P-clip to shock
tower stud
Figure 67 — Secure hoses away from turbocharger
Bundle the rest of the VMAC hoses together and secure them to the 3/4 in oil
fill hose, keeping them away from the turbocharger using cable ties.
Connect the PTFE tubes to the indicated fittings (Figure 68).
1/4 in PTFE tube
(from AOST)
Black 1/4 in air brake tube
1/4 in PTFE tube
(to inlet)
3/16 in PTFE tube (from remote regulator)
Inlet
AOST
Figure 68 — Connect remote regulator tubes
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Installing the Air Intake
Locate a suitable location to mount the air filter body and identify the
routing
for the flexible hose. This location should be:
· Away from heat sources, pinch points, moving components or components that
might have to be removed for vehicle maintenance.
· Higher than the inlet control valve (where possible). · Where cool air will
enter the filter (high temperature air reduces compressor
performance).
· Away from water, exhaust, flammable or explosive gases, fuel tank breathers,
fuel lines, fuel tanks or propane lines.
· Where holes drilled in the vehicle (or equipment panels) do not compromise
safety or weather protection.
· In a position where there is enough room to service the air cleaner. · Where
the air filter dust ejector (short spigot with a split rubber boot) points
downward and where ejected dust will not build up or compromise any other
equipment (Figure 69).
Air intake
Dust ejector
Body panel
Mounting option “A”
Mounting option “B”
Mounting option “C”
Figure 69 — Installing the remote air intake housing
Clean the selected mounting location.
Drill the remote air filter mounting holes (Figure 70).
Figure 70 — Installing the remote air intake housing
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Mount the remote air filter onto the vehicle using suitable fasteners. Align
the air cleaner for best fit and ensure the dust ejector port on the cleaner
body (short spigot with a split rubber boot) is pointing down.
Tighten the mounting clamp bolts. Reinstall any air cleaner parts removed for
installation. Install the supplied rain hat. Install the flexible hose onto
the intake tube using the supplied gear clamp
(Figure 71).
Compressor air inlet
Flexible hose
Figure 71 — Installing the air intake
Route the flexible hose to the remote air filter assembly.
Ensure the hose is adequately supported to prevent it from being snagged by
road hazards. Secure the hose away from hot, sharp or moving components using
rubber coated P-clips or cable ties (not supplied) as required.
Secure the hose to the remote air filter assembly using the supplied gear
clamp.
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Adding Oil to the System
The VMAC supplied and approved compressor oil must be used in this system.
Failure to use this special oil will result in damage to the compressor and
will void warranty. Do not overfill the system. Overfilling the system with
oil can flood the sight glass window and make the system appear empty.
Lower the vehicle from the axle stands. Ensure the vehicle is parked on level
ground. Remove the oil filter from the AOST and discard the cardboard warning
tag. Apply a light film of compressor oil to the filter gasket and thread the
filter onto
the AOST until the gasket makes contact. Tighten the filter an additional 3/4
to 1 turn after the gasket contacts the base.
Remove the plug from the oil-fill hose located in the engine bay on the
passenger side of the radiator (Figure 72).
Oil fill plug
Figure 72 — Oil fill hose location
Using a funnel, fill the AOST with the supplied oil. When dry, the system will
take approximately 5 L (5.2 qt) of oil.
Allow a few minutes for the oil to drain into the AOST. Check the level at
the sight glass at the front of the AOST. Continue adding oil until the level
is correct.
Replace the oil fill cap and tighten.
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Installing the Control Components
Best Practices
· 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 .
· Route all wires to ensure they will not contact hot, sharp or moving parts
(including the park brake mechanism, steering column, and pedals).
· Before drilling any holes ensure there are no OEM wires, hoses, or
components that may be damaged.
· Do not use a test light to probe for power on vehicle circuits, the
increased
current draw of the test light may damage components.
· VMAC recommends using only sealed crimp and solder butt connectors for
all electrical connections.
· To ensure a durable connection, use only good quality crimping tools. ·
Apply loom to all wiring:
Use high temperature loom in areas where high temperatures may be expected.
Use spiral loom in areas with high vibration.
In-line Butt Splice Connections
· Cut the wire approximately 2 in from the connector. · Strip approximately
3/8 in from the end of both sides of the cut wire, as well as
from the end of the wire being spliced in-line.
· Twist the wire to be spliced in-line, together with the “live” side of the
wire (not
the wire attached to the connector).
· Slide the butt connector onto the twisted wires and crimp it. · Insert the
“connector side” of the wire into butt connector and crimp it. · Lightly tug
the wires to ensure they are properly crimped. · Using a heat gun, carefully
apply heat to the butt connectors to seal the
connection.
Tying into OEM connectors
Some OEM connectors may have locking tabs that must be disengaged prior to
inserting a crimped connector.
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Analog Throttle Control Wire Schematic
Figure 73 — Analog throttle control and interface cable connections
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Under Deck
Pressure Switch
Battery
PTO Solenoid
Remote Regulator
Black 3-Pin Connector
Compressor
PTO Harness
Violet Red
Black
Black
Red
To Ground
Red
Control Box
Purple (see page 59)
Heater
Green 4-Pin
Connector
Red
Red Green
Inverter
Orange Orange
Red Red
White Pink
To Ground
White Green
White 4 – Pin Interface Connector
Connect to PTO F425 Pink wire (Part of upfitter jumper harness)
Connect to key switched 12 V (e.g. Pink wire with Yellow stripe at PDC in
engine bay)
Black Red Blue
Red Red
Connect to “PARK” / “NEUTRAL wire identified earlier (0 V “PARK”; 12 V other gears)
Blue To Ground
Green
Throttle Control
Connect to accelerator Pedal
To OEM connector from Accelerator pedal
Connect to Crank Position Sensor (Brown wire with Light Blue stripe)
51
Digital Throttle Control Wire Schematic
Figure 74 — Digital throttle control and interface cable connections
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Control Box and PTO Indicator Panel
Mount the PTO indicator panel on the dashboard or beside the Control Box.
Install the control box in a convenient location in the cab, positioned so
that
the wire harness will reach the compressor. The most common location for the
control box is between the driver side seat and the door.
*If mounting in the standard location: Remove the plastic trim panel from
the doorsill and the kick panel on the driver side.
Throttle Control
Plug the 4 harnesses into the throttle control. Using cable ties, secure the
throttle control under the dashboard, to the right of
the steering column, ensuring the connectors easily reach the accelerator
pedal and the adjusting screws, or the buttons and LED lights, are accessible.
Digital throttle control only: Cut the loop of grey wire from the black module
on
the DTC main harness (Figure 75).
Cut loop
Inverter
Figure 75 — Disable pull up harness
Due to slight variances in manufacturing and/or optionally installed
equipment, it may be necessary to mount the inverter in an alternate location.
If an alternate location is required, ensure the selected location will
provide adequate clearance for ventilation, and that the supplied harnesses
can be routed to the compressor without contacting hot, sharp, or moving parts
(including the park brake mechanism, steering column, and pedals).
Loop the cable ties through the inverter bracket, leaving them as loose as
possible (Figure 76).
Figure 76 — Prepare inverter bracket
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Cable ties
53
Locate the mounting stud on the driver side of the steering column under the
dashboard, remove the nut and set it aside (Figure 77). Remove nut
Steering column Figure 77 — Mount inverter onto bracket
Install the bracket in the orientation shown using the OEM nut (Figure 78).
Figure 78 — Mount inverter onto bracket
Slide the inverter into the bracket and tighten the cables ties to secure it
(Figure 78).
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See the Ram body builder bulletin for specific instructions on circuit F425 and the upfitter jumper harness: PTO Quick Start Information
Route the following wires into the engine compartment via a grommet in the
firewall:
Grey wire with the green 4 pin connector (temperature sensor). Grey wire with the black 3 pin connector (pressure sensor). Red wire from the white 4 pin interface (key switched 12 V). Orange wires, with black 3-pin connector (PTO heater cable). Red and green 14 AWG wires (PTO inverter power wires). Analog throttle control only: White wire from the throttle control
(tachometer signal).
Vehicles not equipped with VSIM only: Long blue wire (disregard if
connecting via VSIM).
Cover all of the engine compartment wires with plastic loom.
Connecting the Wiring
Route the bundled wires downward from the firewall grommet and along the
frame.
Once at the frame, route the orange harness, and the grey cable with green
connector, to the air compressor following the transmission cross member
toward the air discharge hose.
Connect the orange harness to the heater in the compressor body. Connect the
grey cable with green connector to the temperature sensor in the
compressor.
Route the PTO pressure switch, and solenoid power harness, over the
transmission, securing them as necessary with cable ties.
Connect the PTO pressure switch and solenoid plugs to the solenoid and
pressure
switch at the top of the PTO. Unplug the OEM cable from the accelerator pedal
and plug it into the matching connector from the throttle control. Plug the
cable from the throttle control into the matching connector on the accelerator
pedal.
Route the red and green wires running from the inverter to the driver side
battery. Connect the green wire to the negative battery terminal clamp.
Connect the red wire with the fuse holder to the positive battery terminal
clamp.
Ensure the fuse holder is protected and readily accessible for servicing.
Route the bundled wires along the firewall, over the engine, toward the remote
regulator assembly installed earlier.
Secure the wire bundle to the cowl using cable ties. Connect the black 3 pin
connector to the pressure sensor on the remote regulator.
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Vehicles not equipped with VSIM:
Unplug the connector from the park brake switch. Connect the black wire with
the piggyback connector from the interface cable
to the connector on the park brake switch.
Connect the OEM park brake connector to the piggyback connector. Route the
long blue wire to the transmission range sensor on the driver side of
the transmission. Splice the blue wire to the “PARK/NEUTRAL” wire identified
near the beginning of the installation:
Aisin AS69RC Transmission: Pin 9. *68RFE Transmission: Pin 4.
VSIM equipped vehicles
Splice the black wire from the VMAC 4 pin interface connector to the dark
green
wire with white stripe at pin 11 of the brown 16 cavity VSIM connector.
Splice the blue wire from the VMAC throttle control to the yellow wire with
dark
blue stripe at pin 7 of the grey 24 cavity VSIM connector.
Analog Throttle Control:
Route the white wire running from the throttle control to the Crank Position
Sensor (CKP sensor) on the driver side of the engine near the crank pulley
(Figure 79).
Unplug CKP Sensor harness
Figure 79 — Crank Position Sensor Location
Splice the white wire from the throttle control to the brown wire with light
blue
stripe that is connected to the CKP sensor plug (Figure 80).
Pin 3 Brown / light
blue wire
Pin 1
Figure 80 — Crank Position Sensor Connector (looking into front of connector)
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Digital Throttle Control:
Locate the OBD II port (generally located under the dashboard, beneath the
steering wheel column).
Remove the fasteners securing the OBD II port to the dashboard; this provides
easier access to the wires at the back.
Peel back the tape on the harness a few inches.
The wires populating pins 6 and 14 are a twisted pair (brown and yellow
wires).
Splice the light blue wire from the throttle control to the wire at pin 6
(brown
wire at the time of writing) of the OBD II port (Figure 81).
Figure 81 — OBD II connector
Splice the grey wire from the throttle control to the wire at pin 14 (yellow
wire
at the time of writing) of the OBD II port (Figure 81).
Connecting to Key Switch 12 V Supply
The instructions provided below can be used in cases where no upfitter
switched power circuits (minimum 10 A free) are available.
Locate the Power Distribution Center (PDC) fuse box under hood of the vehicle
(Figure 82).
Figure 82 — Locate PDC
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Remove the PDC housing from the bracket by simultaneously squeezing the (×4)
latches and pulling the PDC housing up out of the bracket (Figure 83).
Figure 83 — Remove PDC
The OEM recommended key switched power source is a pink wire with yellow
stripe. Dependant on the vehicle’s date of manufacture, this wire may be
located on connector C7 at pin 9, or on connector C5 at pin 7.
Locate the connector containing the pink wire with yellow stripe on the bottom
of the PDC housing. While holding the release, pull the locking lever down and
pull the connector out of the fuse box.
Splice the red wire from the control box to the pink wire with yellow stripe
(pin 7 / connector C5, or pin 9 / connector C7).
Use 1/4 in wire loom (not supplied) or equivalent protection to cover the
wires,
and secure the VMAC key switched wire to the OEM harness with a cable tie.
Reinstall the PDC into its holder.
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Upfitter Vehicle Controls
It is the responsibility of the installer or upfitter to ensure that third
party vehicle control systems are not able to affect engine speed while the
PTO system is in use. Any change to engine speed while the PTO system is
activated could cause component damage which could result in injury or death.
All third party vehicle control systems intended to activate the PTO system
must do so via the VMAC Control Box. Refer to the electrical schematic on page
51 or page 52.
This section is intended as a general guideline. Refer to the third party
vehicle control manufacturer’s documentation for specific installation
instructions.
The following steps are only applicable to vehicles equipped with third party
vehicle control systems. On vehicles with additional control systems (such as
crane remotes), the DTM70 can be activated/deactivated remotely much like a
standard PTO using these controls. In order to activate the PTO and VMAC
Control Box with third party vehicle controls (e.g. crane remote):
Connect the purple wire from the VMAC Control Box to the PTO activation
circuit on the third party vehicle controls. The VMAC Control Box requires a
+12 V DC latching input.
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Air Receiver Tank
If an air receiver tank will be used with this system, a check valve (not
supplied) must be installed to prevent damage to the system. Once a check
valve is installed, pressure in the air receiver tank will not be relieved
when the compressor system blows down. This is normal operation. Prior to
performing any service work on the system, discharge any stored air in the air
receiver tank.
If an air receiver tank will be used with this system, the following
installation procedure must be used to prevent damage to the system.
The VMAC compressor system will automatically depressurize when it is
shutdown, therefore the hose from the VMAC AOST to the air receiver tank must
have a check valve installed; this prevents blow back and moisture from the
receiver tank entering the AOST
While the air receiver tank can be installed at any height in relation to the
AOST, the discharge hose running from the AOST must be installed as high as
possible on the air receiver tank to prevent problems with condensation that
may have accumulated in the receiver tank (Figure 84).
Drain the condensed water from the receiver tank daily.
Install the line to the receiver tank as high as possible
Check valve
Air Receiver Tank
AOST
Figure 84 — Air receiver tank
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Recommended Accessories
While the compressor system will function without the following accessories,
VMAC strongly recommends their use for optimal performance.
See the “Accessory Product” section of this manual on page 70 for a list of
products available for purchase through VMAC.
Receiver Tank
An air receiver tank provides a buffer as it gives the compressor time to
react by increasing the engine speed and producing air before the tool stalls.
It also has the advantage of lowering the duty cycle of the compressor system.
Pressure Gauge
While not critical to system performance, a pressure gauge is important for
fine tuning the system and simplifies any potential troubleshooting. Install a
200 psi pressure gauge downstream of the air discharge valve.
Pressure Regulator and/or Lubricator or FRL
The compressor can produce air pressures up to approximately 175 psi (1206
kPa). It is the responsibility of the user to know the pressure and air flow
requirements of the tools powered by the air compressor system.
An appropriate air pressure regulator and lubricator can be installed
downstream of the air discharge valve. Failure to regulate the air pressure
may cause damage to the tool.
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Completing the Installation
Check all wiring, hoses and tubes to ensure that they will not contact any hot
or moving components and will not interfere with the operation of the vehicle.
Secure all wiring, hoses and tubes with cable ties and loom as required.
Pull any excess wiring back into the cab and tie it up and out of the way
under
the dash with cable ties.
Replace all dash panels and covers removed during installation. Reinstall the
exhaust components disconnected earlier in the installation. Reinstall the air
box, ensuring the electrical connector is reconnected. Fill the radiator with
the saved coolant. Connect the batteries.
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Testing the Installation
Safety Test
Ensure the following has been completed:
Place the automatic transmission in “PARK” and apply the park brake. Turn the
ignition “ON” but do not start the engine.
Check the control box to see if it is illuminated. If there is no display,
there is no
power to the control box.
Press the “ON” button. The green LED should come on.
On systems equipped with VMAC’s Digital Throttle Control, the “PRK BRAKE” LED
will remain illuminated at all times, regardless of park brake position.
Release the park brake. The green LED on the display box should flash and the
display will flash “PARK BRAKE”. Apply the park brake again and press the “ON”
button. The green LED should come on.
Press the “OFF” button. Turn the ignition “OFF”.
The engine must be running to complete the final steps in the safety test.
This will be done after the pre-start checks have been completed.
Place the vehicle in a safe operating position and adequately block the
wheels. Ensure that there are no people around the vehicle before beginning
the test
Before Starting the Engine Checklist
Ensure the following has been completed:
Verify that the compressor oil level at the AOST sight glass is correct.
Verify that the vehicle coolant level is correct. Perform a final inspection
of the installation to ensure everything has been
completed.
Check all wiring for security and protection. Ensure nothing is touching the
compressor body.
Install the VMAC Air Test Tool (P/N: A700052) with the 70 cfm (0.190 in)
orifice
installed and the ball valve closed.
Ensure all of the compressor outlets are closed. Ensure the parking brake is
engaged and the transmission is in “PARK”. Start the engine.
After Starting the Engine Checklist
Check for any leaks. Close and latch the hood. Allow the vehicle to reach
operating temperature. Turn on the compressor.
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Analog Throttle Control
When the VMAC system is first engaged, the engine speed should increase to
between 1,600 rpm and 2,000 rpm, then decrease to between 1,000 rpm and 1,100
rpm.
Digital Throttle Control
The VMAC digital throttle is a “slow ramp” throttle. Each time the system is
powered on, it will quickly increase engine speed to 1,500 rpm; then increase
to maximum VMAC rpm over 8 seconds (provided the system has not reached full
system pressure before maximum VMAC rpm is reached).
After the initial slow ramp, the throttle will respond normally to air demand
When the VMAC system is first engaged, the engine speed should increase to
1,500 rpm and then drop down to VMAC base idle (approximately 1,000 rpm) once
system pressure is reached.
With the system running, check for:
Coolant leaks. Compressor oil leaks. Allow the compressor to run until the system reaches full system pressure. Engine speed should reduce to between 900 rpm to 1,100 rpm. Turn off the compressor. Shut down the engine. Check the compressor oil level after the engine has been shut down and the oil
level has had time to stabilize.
Ensure any stored air is drained from the system prior to adding oil.
Add oil as necessary to bring the level to the “FULL” line in the sight glass
and
check for leaks.
Start the engine. Turn on the compressor and allow it to build to full system
pressure.
Analog Throttle Control:
With the brake pedal firmly depressed, shift the truck into “REVERSE”:
The engine speed reduces to OEM base idle (Approximately 650 rpm). The green LED on the control box remains illuminated. *The orange PTO indicator remains illuminated. Repeat these steps in all gear selector positions to ensure the engine speed
does not increase unless the gear selector is in “PARK” or “NEUTRAL”
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Digital Throttle Control
With the brake pedal firmly depressed, shift the truck into “REVERSE”:
The engine speed reduces to OEM base idle (Approximately 650 rpm). The green LED on the control box remains illuminated. The orange PTO indicator remains illuminated. The “STATUS” and “PRNDL” LED’s on the digital throttle control will turn off
and engine speed will reduce to base idle.
Shift the vehicle back into “PARK”. Cycle the compressor off, then on again to reset the safety parameters. Repeat these steps in all gear selector positions to ensure the engine speed
does not increase unless the gear selector is in “PARK” or “NEUTRAL”.
Allow the compressor to run until the system reaches full system pressure.
Confirm all air valves are closed and the system has no air leaks. Turn off
the compressor. Ensure any stored air is drained from the system.
Final Testing
Ensure the following has been completed:
Operate the system with an air tool (or the VMAC Air Test Tool with the
appropriate orifice installed) for at least 1/2 hour (1 hour preferred).
Road test the vehicle for approximately 14 miles (20 km). Observe the DTM
operation to ensure that nothing is rubbing or contacting hot
components.
Check all components, connections and fasteners once the engine is turned off
and the system has cooled.
Check the coolant level after the engine has been operated. Check the
compressor oil level after the engine has been shut down and the oil
level has had time to stabilize.
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Performance Testing and System Adjustments
Performance Testing and System Adjustment
System operation can be tested using the tools that will be operated by the
system or by using the VMAC Test Tool (A700052) with the 70 cfm (0.190 in)
orifice in the outlet to simulate tool use (Figure 85).
JIC Adapters
Orifice
Ball valve
Install orifice here
Figure 85 — A700052 VMAC Air Test Tool
Disconnect all downstream equipment (hose reels, etc.) and connect the test
tool directly to the discharge fitting on the AOST.
Ensure there are no leaks in the test tool. The system may not idle down if
there are leaks in the lines or fittings.
Install the VMAC test tool at the AOST outlet with the 70 cfm (0.190) orifice.
Ensure that the ball valve is closed. Place the transmission in “PARK” and
fully apply the park brake. Allow the engine to run until it is at operating
temperature. Turn on the air compressor system and allow it to operate until
the oil is warm. Observe the pressure gauge. Pressure should be approximately
150 psi.
Open the ball valve on the test tool and observe the engine tachometer:
Analog throttle control: Engine speed should increase to approximately
2,000 rpm 2,500 rpm.
*Digital throttle control: Engine speed should increase to approximately
2,600 rpm.
Close the air valve slowly to allow the system pressure to rise. When the
pressure reaches 150 psi (factory setting), the system will close the inlet
valve poppet and reduce the engine speed to VMAC base idle (approximately
1,000 rpm).
Once the system pressure is at maximum, slowly open the ball valve on the
test tool until the pressure on the gauge begins to drop. Engine speed should
ramp up when the pressure drops to approximately 140 psi. This value can be
adjusted via the “IDLE DOWN PRESSURE” (analog throttle) / “RAMP UP PRESSURE”
(digital throttle) adjustment.
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Adjusting the Pressure Regulator
Never adjust the pressure regulator to exceed 175 psi (1205 kPa). At 200 psi
(1379 kPa), the pressure relief valve at the AOST will activate, resulting in
rapid air loss, which may cause component damage, injury or death.
Prolonged operation above 175 psi / 1205 kPa may damage the pressure
regulator.
The pressure regulator is adjusted to limit maximum air pressure to a safe
level. As air pressure and flow are related, this adjustment is also very
important for optimum performance.
Install the test tool in the tank outlet with the ball valve closed. Ensure
that the oil level is correct and the system is at operating temperature.
Operate the system until it reaches full pressure. Observe the pressure on the
gauge.
Loosen the lock nut on the regulator (Figure 86). Pressure can be adjusted
within a range of 145 psi (999.7 kPa) 175 psi (1205
kPa), dependent upon requirements.
Rotate the setting bolt clockwise to increase pressure. Rotate counter
clockwise
to decrease pressure. Tighten the lock nut once adjustments are complete.
Open the ball valve to allow air to flow and the pressure to drop. Close the
valve and observe the pressure to ensure that the adjustment is correct.
Regulated pressure
Lock nut
Setting bolt
Bleed hole
System pressure
Figure 86 — Air regulator
Test the system after any adjustments are made to verify it is operating
properly.
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Digital Throttle Control Operation and Adjustments
The VMAC digital throttle is a “slow ramp” throttle. Each time the system is
powered on, it will quickly increase engine speed to 1,500 rpm; then increase
to maximum VMAC rpm over 8 seconds (provided the system has not reached full
system pressure before maximum VMAC rpm is reached).
After the initial slow ramp, the throttle will respond normally to air demand.
The throttle control is configured at the factory for optimum performance at
maximum cfm. In applications where maximum cfm is not required, or noise is a
concern, the throttle control can be adjusted to reduce the maximum VMAC rpm.
Safety features
The throttle control has built in safety features that will disable the system
if an unsafe condition is detected, or either of the lock out parameters is
not met (the vehicle must be in “PARK” and the park brake must be engaged).
If an unsafe condition is detected, the “STATUS” LED will turn off, and engine
speed will return to idle. Once all unsafe conditions have been removed, the
system must be cycled off, then on again to reset it. Once the system powers
up, the “STATUS” LED will illuminate, and the system will operate normally.
Figure 87 — Throttle control
If the vehicle is placed into gear, the “STATUS” LED and the PRNDL LED will
turn off and the throttle control will deactivate. This will reduce engine
speed to base idle.
In order to activate the system again, re-engage the appropriate lockout and
cycle the VMAC “OFF” then “ON” via the control box.
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The “PRK BRAKE” LED will remain illuminated at all times, regardless of park
brake position.
MAX RPM
The cfm produced by the system is directly related to engine speed; this
system delivers 70 cfm at 2,600 rpm. Maximum VMAC rpm can be adjusted between
1,000 rpm and 2,650 rpm (in 50 rpm increments) via the “” or “” buttons in the
“MAX RPM” column.
If the system is at full system pressure while the rpm is being adjusted, the
engine speed will increase to the new value for 4 seconds, then return to base
idle.
RAMP UP PRESSURE
“RAMP UP PRESSURE” is the amount of pressure the system will drop before the
engine speed is increased to generate air; as air continues to be used and the
pressure drops, engine speed will increase until maximum VMAC rpm is achieved.
“RAMP UP PRESSURE” is set to 140 psi (10 psi below the factory default maximum
system pressure of 150 psi). This allows for a small amount of air use without
the need to increase engine speed.
“RAMP UP PRESSURE” should only be adjusted if the maximum system pressure is
changed (via the inlet regulator). To maintain proper performance, and rapid
response to air demand, ensure the “RAMP UP PRESSURE” is set at no more than
20 psi below the maximum system pressure.
The “RAMP UP PRESSURE” can be set to “100 PSI”, “120 PSI”, “140 PSI”, or “160
PSI via the “” or “” buttons in the “RAMP UP PRESSURE” column; an LED will
illuminate beside the setting that has been selected.
Factory Reset
The throttle control can be reset to factory default values via a button
inside the throttle control box.
To perform a factory reset, turn the system on and allow the engine speed to
drop to VMAC base idle (approximately 1,000 rpm). Using a paper clip (or
similar object), push and hold the factory reset button for 5 seconds. All of
the LED lights will illuminate for several seconds while the settings revert
to their defaults. Once the LED’s return to their normal state, the system is
ready for use again.
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Accessory Products from VMAC
Compressor Service Kits
200 Hour or 6 Month Service Kit Part number: A700229 Includes 6 L VMAC high
performance compressor oil, oil filter, air filter, and next service due
decal.
400 Hour or 1-Year Service Kit Part number: A700230 Includes 6 L VMAC high
performance compressor oil, oil filter, air filter, coalescing filter,
pressure relief valve, muffler, and next service due decal.
Air Aftercooler
Part number: A800070 Improves tool performance and extends the life of air
tools; removes up to 80% of water from compressed air; includes automatic
water drain.
· Max air flow: 70 cfm / 175 psi. · Port size: 3/4 in NPT inlet and outlet. ·
Electrical: 12 V. · Dimensions: 17 in (43.2 cm) L × 8.0 in (20.3 cm) W
× 14.5 in (36.8 cm) H .
· Weight: 35 lb (15.8 kg).
Filter Regulator Lubricator (FRL) 70 cfm
Part number: A700151 Extends the life of air tools; filter removes
contaminants from the compressed air, adjustable regulator can reduce air
pressure going to tools, lubricator adds atomized tool oil to the air stream
to lubricate air tools (Tool oil not included).
· Max air flow: up to 70 cfm / 150 psi. · Port size: 3/4 in NPT inlet and
outlet.
1/2 in × 50 ft Hose Reel
Part number: A700007 Spring-loaded 1/2 in × 50 ft hose reel; steel
construction; full flow shaft and swivel for maximum performance.
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VMAC De-icer Kit
Part number: A700031 Cold climate heater package for operating VMAC
compressors in cold climates; proven at temperatures of -30 °C (-22 °F).
Requires 12V DC at 10A.
10 Gallon, 200 psi Air Receiver Tank w/ Mounting Feet
Part number: A300047 Air receiver tanks are used for lowering compressor duty
cycle and removing water from compressed air. Recommended for optimum
operation of VMAC Hydraulic Air Compressors, VMAC Diesel Driven Air
Compressors, UNDERHOOD40, UNDERHOOD70 (including Green Series Air
Compressors), DTM70/ DTM70-H, and VMAC Multifunction Power Systems, which
include standby mode; ASME certified; includes fittings, 200 psi pressure
relief valve, tank drain, and 200 psi pressure gauge.
· Max pressure: up to 200 psi. · Dimensions: 30 in (76.2 cm) L × 10 in (25.4
cm) D. · Weight: 33 lb (15 kg).
35 Gallon, 200 psi Air Receiver Wing Tank
Part number: A300010 Air receiver tanks are used for lowering compressor duty
cycle and removing water from compressed air. Recommended for optimum
operation of VMAC Diesel Air Compressors, Hydraulic Air Compressors,
UNDERHOOD40, UNDERHOOD70 (including Green Series Air Compressors),
DTM70/DTM70-H, and VMAC Multifunction Power Systems, which include standby
mode; ASME certified; includes fittings, 200 psi pressure relief value, tank
drain, and 200 psi pressure gauge.
· Max pressure: up to 200 psi. · Dimensions: 73 3/4 in (187.3 cm) L × 14 in
(35.6 cm) D. · Weight: 95 lb (43.1 kg).
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Notes
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Notes
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Notes
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Notes
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Warranty Registration
This form must be fully completed and returned to VMAC at the time the vehicle
is put into service. Warranty may be void if this form is not received by VMAC
within 3 months of receiving the vehicle, or 200 hours of operation, whichever
occurs first.
VMAC’s Warranty policy and registration can be viewed online at:
www.vmacair.com/warranty
Product Information
System Identification Number: D M Compressor Serial Number: P
Owner / End User Information
Company Name:
City:
State / Province:
Phone: ( )
Email Address:
Date vehicle was put into service:
/ /
Day
Month Year
Installer Information
Installer Company Name: City:
State / Province:
Submitted by
Name: Email:
Phone: ( )
Vehicle Information (Optional)
Unit:
Year:
Make:
Model:
Vehicle Identification Number:
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Manufactured by
®
1333 Kipp Road, Nanaimo, B.C., V9X 1R3 Canada