VMAC V910041 150 Underhood Air Compressors Owner’s Manual

VMAC V910041 150 Underhood Air Compressors

Product Information: 150 UNDERHOOD TM AIR COMPRESSORS

Specifications

• Model: 150 UNDERHOOD TM AIR COMPRESSORS
• Installation Manual: V910041
• Website: www.vmacair.com

Product Usage Instructions

Installation
To install the 150 UNDERHOOD TM AIR COMPRESSOR, please follow the steps below:

1. Ensure that the vehicle is turned off and the engine is cool.
2. Locate a suitable mounting location for the compressor. It should be securely attached to the vehicle’s engine.
3. Refer to the VMAC knowledge base article EXT-ACC-002 for specific instructions on mounting the compressor in the midship location.
4. If your vehicle has dual alternators, you will need to use the VMAC accessory A900023 and a single alternator belt (VMAC P/N: 1610101, Ford P/N: JK6-805/LC3Z-8620-C or Gates P/N: K060802).
5. Follow the detailed installation instructions provided in the installation manual V910041.

Safety

Please adhere to the following safety precautions when using the 150 UNDERHOOD TM AIR COMPRESSOR:

• Only use proven service procedures as recommended in the manual.
• Ensure that your safety and the safety of others is not compromised when deviating from the provided instructions.
• VMAC will not be held responsible for any liability, damages, injuries, or equipment loss resulting from failure to follow the procedures in this manual or standard safety practices.
• Prior to performing any service operations, prioritize safety and contact VMAC Technical Support if you have any questions or need additional information.

Warranty

The 150 UNDERHOOD TM AIR COMPRESSOR comes with a VMAC Standard Warranty (Limited). 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.

FAQ

Q: Are there any additional accessories required for dual alternator vehicles?
A: Yes, for dual alternator vehicles, you will need to use the VMAC accessory A900023 and a single alternator belt (VMAC P/N: 1610101, Ford P/N: JK6-805/LC3Z-8620-C or Gates P/N: K060802).

Q: Where can I find more information or support?
A: For more information or support, you can contact VMAC Technical Support at 888-241-2289 or visit the VMAC Knowledge Base at kb.vmacair.com.

150 UNDERHOOD TM AIR COMPRESSORS
Installation Manual for VMAC System
V910041
2023+ Ford Super Duty F250 ­ F600 7.3 L Gas
www.vmacair.com

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Document: 1930481 Changes and Revisions

Revision

A

Initial release

Revision Details

Revised by MSP

Checked by Eng.
Tech. Qual. Mech. Elec. MSP ASE KRM LPH

Implemented 2 Jun. 2023

Additional Application Information

· 2023+ Ford Super Duty F250 ­ F550, 7.3 L Gas. · Single battery application only. Dual battery vehicles will require accessory A900023. · Single alternator application only. See VMAC knowledge base article: EXT-UH-002.
Dual alternator vehicles will require VMAC accessory A900023 and single alternator
belt, VMAC P/N: 1610101 (Ford P/N:JK6-805/LC3Z-8620-C or Gates P/N: K060802).
· Passenger side running board is only compatible when the Air Oil Separator Tank is
mounted in the “midship location”, see VMAC knowledge base article: EXT- ACC-002.
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. Posi-TapTM is a trademark owned by Swenco® Products, Inc. Eaton Aeroquip® is a registered trademark of EATON AEROQUIP INC. Ford® and Super Duty® are registered trademarks of Ford Motor Company.

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

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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

UNDERHOODTM, 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:

www.vmacair.com/warranty

warranty@vmacair.com
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 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 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 removal set (such as Lisle® 43300) or a manual fan
pulley holder (such as KD Tool® KD3900).
· Torque angle meter (such as Lisle® 28100 torque angle meter).
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

141

236

Table 1 — Torque Table

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Preparing for Installation
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.
When dissembling engine components, cover the openings to prevent debris from entering the system.
Apply Loctite 242 (blue) to all fasteners (except nylon lock nuts) unless otherwise stated.
The VMAC system uses the OEM single alternator belt to run the OEM FEAD components. Vehicles converted from dual alternator systems will need to purchase this belt separately (Ford P/N: JK6-805/LC3Z-8620-C or Gates P/N: K060802).
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.
Disconnect the battery(s).
Dual battery vehicles only (Figure 1):
Remove driver side battery. *Remove the driver side battery cable run tray.

Cable run tray

Figure 1 — Remove battery and cable run tray (dual battery vehicle only)

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If lifting the vehicle, ensure it is supported safely with appropriately rated jack stands.
Remove the lower bumper/air dam, or lift vehicle to improve access. Drain the coolant into a clean container and set the coolant aside for use later. Remove the top radiator cross member cover. Remove the air intake tube and resonator assembly (Figure 2).
Figure 2 — Remove the air intake assembly
Disconnect the upper hose assembly from the radiator and secure it out of the
way toward the rear of the engine compartment (Figure 3).

Figure 3 — Shift coolant hose assembly (single battery degas bottle shown)

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Disconnect the vacuum system components, and hoses from the degas bottle. Remove the degas bottle.
Dual battery vehicles only:
Remove and discard the degas bottle and battery tray. Keeping the power steering lines connected, remove the power steering
reservoir from the driver side of the fan shroud.
Temporarily tie the power steering reservoir up and out of the way of the
shroud.
The power steering reservoir cap will leak if the reservoir is not kept upright.
Remove the lower fan shroud. Disconnect the radiator fan harness and mounting bracket. Disconnect the harness mounted to the underside of the fan shroud. Remove fan and fan shroud as an assembly. Remove the OEM FEAD belt. Remove the idler from the alternator bracket.
Single alternator vehicles:
Disconnect and remove the alternator.
Dual alternator vehicles:
Disconnect and remove the upper alternator (this alternator will not be
reused).
Disconnect and remove the lower alternator (this alternator will be reused). *Remove the support bracket (Figure 4).

Remove support bracket
Figure 4 — Remove mounting bracket (dual alternator only)
Remove the alternator mounting bracket.

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Remove the upper coolant hose assembly (Figure 5).

Figure 5 — Removing upper coolant hose
Remove the lower coolant hose support brackets (Figure 6).

Remove passenger side coolant hose

Remove hose support brackets

Figure 6 — Removing lower coolant hoses (viewed from under vehicle)
Disconnect and remove the passenger side lower coolant hose (Figure 6).

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Disconnect the bypass cooling circuit hose (Figure 7).
Disconnect bypass hose

Figure 7 — Removing driver side lower coolant hose
Cut the hose 1/4 in behind the molded cuff and remove the bypass Tee
assembly (Figure 8).
1/4 in

Figure 8 — Removing driver side lower coolant hose

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Modifying the Hoses, Installing the Cooler
Being careful not to damage the hose, remove the molded cuff and separate
the hose (Figure 9).
Cut cuff

Retain

1/4 in

Figure 9 — Driver side coolant hose modification
Measure 1/4 in from the cuff and cut the hose to remove the male connector
(Figure 9).
Being careful not to damage the hose or the connector, remove the molded cuff
on the passenger side lower coolant hose and separate the 45° quick connect (Figure 10).

Remove quick connect

Figure 10 — Passenger side coolant hose modification

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Insert the 45° quick connect into the short end of the supplied 120° bent hose
(Figure 11).

Figure 11 — Coolant hose modification
Insert the supplied hose coupler halfway into the other end of the hose
(Figure 11).
Measure 5 1/2 in from the female quick connect and cut the hose (Figure 12).

5 1/2 in

Figure 12 — Coolant hose modification

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Using cable ties, secure the supplied anti abrasion sleeve to the hose
(Figure 13).

Figure 13 — Coolant hose modification
Install the cooler bracket onto the black front crossmember, below the body
coloured radiator support (Figure 14).

Radiator support
Figure 14 — Install cooler
Mount the cooler to the cooler bracket (Figure 15).

Crossmember

Figure 15 — Install cooler

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Connect the passenger and driver side radiator hoses, and tubes to the VMAC
cooler. Route the hose assembly between the cross member and the radiator support (Figure 16, Figure 17, Figure 18).

Figure 16 — Install coolant hoses assembly
Anti-abrasion sleeve
Figure 17 — Radiator side anti-abrasion sleeve (Coolant assembly removed from vehicle for clarity)

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P/N: 1710900

To degas

P/N: 1720722

45° quick connect

To engine

P/N: 1720735

Modified passenger side coolant hose

Modified driver side coolant hose

Figure 18 — Cooler hose schematic

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Apply loom to the supplied 5/8 in hose. Using a gear clamp, secure the 5/8 in hose to the steel bypass line coming off of
the engine and route it toward the body coloured radiator support (Figure 19).

Hose section removed for
clarity
Figure 19 — Connect coolant bypass hose
Route the hose along the bottom of the body coloured radiator support, and over
to the cooler spigot (Figure 19).
Connect the hose to the small spigot on the passenger side of the cooler using a
hose clamp (Figure 19).
Using the supplied P-clips and fasteners, secure the hose to the clip nuts in the
body coloured radiator support (Figure 19).
Adjust all connections as necessary to ensure the hose is not pinched, kinked,
or twisted, and that all of the joints are engaged securely.
Rotate the steering to the right hand lock and ensure there is adequate
clearance between the hose assembly and the pitman arm. If necessary, rotate the steel tube to provide adequate clearance.
Secure all the connections with the supplied hose clamps.

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Being careful not to damage the connector, cut the molded cuff from the hose
and set the quick connect aside for use later (Figure 20).
Top radiator connection
Figure 20 — Remove quick connect
Measure 13 1/2 in along the outside radius and cut the hose square (Figure 21).

13 1/2 Figure 21 — Upper coolant hose modification

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Slide the supplied abrasion mesh onto the hose and secure it in place using
cable ties (Figure 22).
Reinstall the engine side of the modified upper coolant hose (Figure 22).
Place abrasion mesh
Figure 22 — Upper coolant hose modification
Secure the upper coolant hose toward the rear of the engine bay out of the
way.

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Modifying the Fan Shroud
Due to manufacturing variances, it may be necessary to remove more material from the fan shroud. After the vehicle is assembled inspect the area to ensure there is enough clearance.
Upper Coolant Hose Modification
Remove the shaded portion of the shroud to provide clearance for the upper
coolant hose (Figure 23, Figure 24 ).

Figure 23 — Fan shroud modification

1 1/4 in 2 3/4 in

1/2 in

5/8 in

3/4 in

Figure 24 — Fan shroud modification

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Grind the shaded portion of the rib (Figure 25, Figure 26).
1 1/4 in 3/4 in
Figure 25 — Fan shroud modification

Figure 26 — Fan shroud modification (rib modified)

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Remove the shaded portion of clip nut mount (Figure 27, Figure 28).
3/4 in Figure 27 — Fan shroud modification

Figure 28 — Fan shroud modification (after all upper coolant hose modifications)

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VMAC Tensioner Clearance
Remove the shaded portion of the shroud to provide clearance for the VMAC
tensioner (Figure 29, Figure 30, Figure 31).

Figure 29 — Fan shroud modification 1 3/4 in

1 1/8 in

5/8 in

Figure 30 — Fan shroud modification

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Figure 31 — Fan shroud modification (after modification)

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Installing the Crank Pulley and Main Bracket
Apply Loctite 242 (blue) to all fasteners (except nylon lock nuts) unless otherwise stated.
Main bracket installation
Ensure the alternator slide bushing is flush with the inside face of the alternator
mount (Figure 32).

Ensure bushing is flush with this face
Figure 32 — Reset alternator slide bushing
If required, adjust the bushing position using the OEM fastener and a shim
block.

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Grind the shaded area of the terminal post shroud flush to the base (Figure 33).
Grind shaded area

Figure 33 — Modify alternator post isolator
Using the (×3) OEM fasteners, and the supplied bolt and washer, install the
main bracket (Figure 34).

(×1) OEM fasteners

(×2) OEM fasteners

M10×1.5×100 mm

3/8 in washer

Figure 34 — Install main bracket

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Install the alternator using (×1) OEM fastener and (×1) supplied fastener
(Figure 35).
M10×1.5×35 mm
OEM fastener Figure 35 — Install alternator
Install the OEM idler onto the VMAC main bracket (Figure 36).

Install OEM idler

Figure 36 — Install OEM idler

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Install and tension the single alternator OEM FEAD belt (see note on page 8)
(Figure 37).

Figure 37 — OEM FEAD belt routing
Installing the crank pulley
Remove and discard the OEM crank pulley bolt. Inspect the face of the OEM pulley and remove any ruste, clearcoat, or surface
burrs to ensure there is a clean mating surface for the VMAC crank pulley.
Place the VMAC crank pulley in position over the OEM pulley. Ensure that it fits
flat against the OEM pulley.
Liquid Loctite 242 must be used to achieve correct torque on the crankshaft bolt as it functions as a thread lubricant, as well as a locking compound. Solid or Stick Loctite cannot be used.
Completely coat the threads with Loctite 242 (blue) and install the supplied
VMAC crankshaft bolt washer, and spacer finger tight (Figure 38).

Completely coat threads with Loctite 242
Figure 38 — VMAC crank pulley bolt

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Rotate the VMAC crank pulley counterclockwise until the lugs on the back
of the pulley are tight against the OEM pulley spokes and tighten the bolt sufficiently to hold the pulley in position Figure 39).

Figure 39 — Engage VMAC crank pulley lugs on OEM pulley
Ensure the VMAC crank pulley does not move off of the OEM pulley face before tightening the pulley bolt. Ensure the pulley is rotated tight against the pulley lugs. Do not use an impact tool to tighten the pulley bolt.
Torque the VMAC crank pulley bolt as per Ford specifications. The Ford specifications as of 1 January 2020: 1) Torque to 66 ft·lbs (89 N·m). 2) Loosen 360°. 3) Torque to 129 ft·lbs (175 N·m). 4) Turn an additional 150°. *Angle can be measured with Lisle 28100 Torque Angle Meter.

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Connecting the Alternator
The instructions related to completing the alternator installation (including electrical connections) are vehicle configuration specific.
Single Alternator / Single Battery Vehicles
Remove the rubber OEM terminal lug boot and set it aside. Install the supplied bracket and terminal post onto the main bracket (Figure 40).

Figure 40 — Install terminal post
Secure the supplied boot, OEM cable, and jumper cable onto the terminal post
as shown (note the orientation of the harness terminals) (Figure 41).

OEM harness

VMAC harness

Figure 41 — Install alternator harness

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Close the terminal boot cover (Figure 42).

Figure 42 — Install OEM alternator boot
Using the supplied extension kit, extend the length of the alternator sensor harness (see page 57 for “best practices” when using in-line butt splice connections).
Cut the alternator sensor wire a few inches from the end of the 2-pin
alternator connector.
*Using the supplied butt connectors, splice the extension wire to the
alternator harness sensor wire.
Wrap the harnesses in the supplied heat wrap. Cut the heat wrap as required for the harness breakout connections. Using the suppled P-clips and fasteners, secure the heat wrapped bundle to
VMAC main bracket, in front of the terminal post (Figure 43).

Figure 43 — Secure positive battery harness (dual battery harness shown)
Slide the OEM electrical boot over the alternator side of the supplied jumper
cable and, using the OEM fastener, connect it to the alternator.
Connect the supplied 3 pin jumper harness to the alternator.
Single Alternator / Dual Battery Vehicles
Follow the above instructions but use the P-clips from the Dual Battery Adaptor
kit (P/N: A900023) to accommodate the larger diameter harness.

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Dual Alternator / Dual Battery Vehicles Dual Alternator / Dual Battery vehicles will use the components included in the Dual Battery Adaptor Kit (P/N: A900023) for this section. The terminal post and associated fasteners used in single alternator applications can be discarded as it is not required.
Using the supplied heat shrink tubing, cover the upper alternator ring terminal
(Figure 44).
Figure 44 — Isolate secondary alternator harness
Using a cable tie, secure the ring terminal to the harness to protect it from
shorting.
Using the (×2) sheets of supplied heat wrap (overlapping the sheets as
necessary to accommodate the larger circumference of the dual alternator harness), wrap the harness in the supplied heat wrap and secure the cables ties and P-clips (Figure 45).
To alternator

Figure 45 — Secure positive battery harness
Connect the harness and cable to the alternator.

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Installing the VMAC FEAD Bracket and Compressor
Remove the tensioner and idlers from the VMAC FEAD bracket. Using the supplied fasteners, install the FEAD bracket onto the VMAC main
bracket (Figure 46).
Figure 46 — Install VMAC idler bracket
Lower the fan shroud into the engine bay approximately half way. Install the idlers and tensioner onto the VMAC FEAD bracket (Figure 47).

Figure 47 — Install VMAC idler bracket

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Install the fan spacer onto the fan driver. Remove the fan blades from the fan clutch. Raise the fan shroud enough to allow the fan clutch to be slid into the engine
bay.
Install the fan clutch onto the fan spacer. Install the fan harness spacer (Figure 48).

Figure 48 — Install fan harness spacer
Connect the fan harness. Re-attach the fan blades to the fan clutch. Using the OEM fasteners, secure the fan shroud. Re-attach the harness that runs below the shroud. Reinstall the lower fan shroud.
Installing the compressor
Remove the inlet valve from the compressor and cover the opening to prevent
debris entering the compressor.

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Position the compressor on the mounting bracket and secure it using the (×4)
supplied bolts; torque the compressor bolts to specification (Figure 49).

Figure 49 — Install Compressor
The inlet valve is secured with bolts of varying lengths. Install the longer bolts nearest to the air filter. Installing the bolts in the wrong location will damage the compressor housing when tightened.
Remove the protective covering and reinstall the Viton O-ring and inlet onto the
compressor. Torque to specification (Figure 50).

Longer bolts

Shorter bolts

Figure 50 — Install the inlet

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Install and tension the VMAC drive belt (Figure 51).

Figure 51 — VMAC belt routing

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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 (except nylon lock nuts) unless otherwise stated.
Installing the AOST
Prior to proceeding with the AOST installation, review this chapter, as well as the UNDERHOOD 150 AOST Relocation Kit (P/N: A700250) accessory instructions (included with this kit), to determine the AOST mounting location. Note that the A700250 accessory is not compatible with pickup trucks or chassis cab applications equipped with a midship fuel tank. The AOST will either mount in the “mid ship” location (A700250) or to the passenger side frame rail behind the transmission crossmember (Figure 52).

Front of vehicle
38

Figure 52 — AOST installed
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The top bolt on the forward tank mount will need to be installed from the inside of the frame (Figure 53).

Install the tank mounting brackets on the frame (Figure 53):
· The front tank mount bracket mounts between the transmission crossmember and the control arm mount.
· The rear tank mount bracket mounts just before the bend in the frame.

(×4) 3/8 in flange lock nuts

(×4) 3/8 in washers

(×4) 3/8 in × 1 1/2 in bolts

(×8) 5/16 in bolts

(×4) 3/8 in × 6 in bolts

Spacer bar

Tank mount (bracket with offset
to the front)

(×4) 3/8 in lock washers

(×4) 3/8 in nuts

Front of vehicle

Figure 53 — Installing the AOST (For clarity, the rear AOST mounting hardware is not shown)
Mount the inner portion of the tank mounting bracket clamp onto the tank
mounts (Figure 53).
Using a floor jack, raise the AOST up to the mounting bracket clamps and
install the front and rear tank outer clamps (Figure 53).
Leave the tank clamps finger tight so the tank can be shifted forward or back
when installing the hoses.

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Rotate the tank so that the directional arrow on the rear of the tank is pointing
upwards (Figure 54).

Figure 54 — Securing the AOST (Rear view)
AOST orientation is critical. The arrow must be pointing up to prevent compressor failure due to oil starvation, or oil in the discharge air.

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Hose Requirements
Only attempt to shorten the supplied hose if there is access to the appropriate equipment. Do not cut and splice the hose 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:
· 1/2 in × 60 in. · 1/2 in × 86 in. · 1 in × 72 in. · 1/4 in (PTFE Tube): Shipped with the A700250 AOST Relocation Kit. Cut to
length as required.
· 3/16 in (PTFE Tube): Shipped with the A700250 AOST Relocation Kit. Cut to
length as required.
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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Routing and 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 55 — Push-to-connect fittings

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Hose Routing for Frame Rail Mounted AOST
Connect the straight fitting on the 1 in discharge hose to the matching fitting
on the compressor, leave the fitting somewhat loose to allow the hose to be adjusted.
Route the 1 in discharge hose to the firewall, then toward the passenger side of
the vehicle (Figure 56). Route hose
Figure 56 — Route discharge hose
Route the 1 in discharge hose down between the frame and the fender liner,
and toward the AOST (Figure 57).

Figure 57 — Install hose routing bracket

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Remove the ground cap nut securing the ground strap on the passenger side of
the firewall (Figure 58).
M6 locknut
Figure 58 — Install hose routing bracket
Using the supplied M6 locknut and the ground cap nut, install the hose routing
bracket onto the firewall (Figure 58).
Using the supplied P-clip and fasteners, secure the discharge hose to the
firewall (Figure 59).

Figure 59 — Routing the hoses

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Secure the hose away from the sharp edge of the body mount using the
supplied P-clip, bracket, bolt, nut and snubbing washer (Figure 60). Bracket

Figure 60 — Routing the hoses
Due to vehicle frame variations, the square hole (Figure 61) may not be present.
On applications without the square hole, route the hose along the top of the frame to the AOST. If routing along the top of the frame, skip to page 50.
Connect the 45° fitting to the matching fitting on the AOST. Using tape, secure the cap plugs in place on the longer 1/2 in oil hose. From the straight fitting on the longer hose, measure 8 in and mark the
location.
From the straight fitting on the longer hose, measure 45 1/2 in and mark the
location.
Apply the supplied spiral wrap loom to the hose, centering the loom sections on
the locations marked in the previous steps.
Connect the 90° fitting on the longer hose to the matching fitting on the driver
side of the oil cooler.
Route the hose from the oil cooler, between the frame cross member and the
body coloured radiator support and over to the passenger side frame rail.

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Route the hose into the frame via the square located near the AC compressor
(Figure 61).

Route hose into frame
Figure 61 — Route oil hose
Route the oil hose out of the frame via the round access hole under the cab
mount near the front of the AOST.
Remove the cap plug from the oil hose and connect it to the matching 45°
fitting on the AOST.
Verify that the spiral wrap loom is positioned to properly protect the hose
where it enters and exits the frame.
Turn to page 50 for the remainder of the hose installation instructions.

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Hose Routing for “Mid Ship” Mounted AOST
The following steps may not be compatible with all chassis configurations, or optional equipment but can serve as a general guideline for installing the UNDERHOOD 150 AOST Relocation Kit (P/N: A700250).
Refer to the cautions at the beginning of this chapter for “best practices”.
Rotate the 45° discharge fitting on the compressor to the 10 o’clock position,
facing the driver side.
Connect the straight fitting on the 1 in discharge hose to the matching fitting
on the compressor, leave the fitting somewhat loose to allow the hose to be adjusted.
Route the hose to the driver side of the steering shaft and down between the
frame and fender liner (Figure 62).

Figure 62 — Routing the hoses

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Route the hose between the frame and control arm, bringing it to the inside of
the frame (Figure 63).
Front of vehicle
Figure 63 — Routing the hoses
Route the hose between the transmission and frame, and connect it to the
AOST, leaving the connection loose (Figure 64).

Figure 64 — Routing the hoses

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Using the supplied P-clip, clip nut, and bolt, secure the hose to the frame where
it passes between the frame and the control arm (Figure 65). Control arm
Figure 65 — Routing the hoses
Secure the supplied bracket to the crossmember brace using the supplied
fasteners (the snubbing washer and bolt can be inserted into the crossmember via the gap in the bottom of the crossmember) (Figure 66).

Figure 66 — Routing the hoses
Connect the 90° fitting on the longer 1/2 in hose to the matching fitting on the
driver side of the oil cooler.
Route the 1/2 in hose along the top of the frame to where the discharge hose
passes to the inside of the frame rail (Figure 65).
Continue routing the 1/2 in hose to the AOST, following the same path as the
discharge hose, and connect it to the matching fitting on the AOST.

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All AOST mount locations
Connect the 90° fitting on the shorter 1/2 in hose to the matching fitting on the
passenger side of the oil cooler.
Route the hose up to the compressor and connect it to the matching fitting on
the side of the compressor.
Apply the supplied loom to the 1/4 in and 3/16 in PTFE tubes. Connect the PTFE tubes to their respective fittings on the inlet. Route the 1/4 in and 3/16 in PTFE tubes along the 1 in discharge hose, securing
the PTFE tubes to the 1 in hose using cable ties.
Trim the PTFE tubes as necessary and connect them to their respective fittings
on the rear of the AOST.
Adjust the hoses and/or the AOST to minimize sharp bends, or contact with
any hot, sharp or moving parts. Tighten all of the fittings, the tank mounts and straps.
Bundle the hoses together and secure them with cable ties. Move the steering between the left and right lock positions to confirm
adequate clearance.

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Modifying and Installing the Degas Bottle
Vehicles equipped with dual batteries will modify and use the degas bottle included in the Dual Battery Adaptor kit (P/N: A900023). The degas bottle shown in this chapter is the single battery degas however, the installation instructions are identical.
Cut the indexing feature of the degas bottle flush with the foot (Figure 67).

Remove indexing feature
Figure 67 — Modify degas bottle
Rotate the large hose connected to the power steering reservoir 90°
counterclockwise (Figure 68).

Rotate hose 90°

Figure 68 — Modify degas bottle

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Single Battery Vehicles
Using the supplied fasteners, mount the power steering relocation bracket, and
the degas relocation bracket, to the degas bottle (Figure 69, Figure 70).
(×2) M8 nut

M8×1.25×30 mm bolt

M8×1.25×25 mm flat head bolt

Figure 69 — Power steering relocation bracket

M8×1.25×25 mm flat head bolt

M8 nut

Figure 70 — Degas bottle relocation bracket

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Dual Battery Vehicles
Using the supplied fasteners, mount the degas bottle to the degas relocation
bracket, and the battery post relocation bracket (Figure 71).
(×2) M8 nut

M8×1.25×25 mm flat head bolt

M8×1.25×30 mm bolt

Figure 71 — Power steering / battery post relocation brackets
Using the supplied fasteners, mount the degas bottle relocation bracket to the
degas bottle (Figure 72).

M8×1.25×25 mm flat head bolt

M8 nut

Figure 72 — Degas bottle relocation bracket

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All Vehicle Configurations
Using (×3) OEM battery box fasteners, and (×1) supplied flange nut, install the
degas bottle assembly into the engine bay (Figure 73, Figure 74).

Figure 73 — Power steering / battery post relocation brackets (dual battery degas bracket shown)

Figure 74 — Degas bottle relocation bracket (dual battery degas bracket shown)

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Insert the power steering reservoir into the slot on the reservoir relocation
bracket. Adjust the large power steering hose (that was re-clocked earlier) as necessary to prevent kinking or stress (Figure 75).

Figure 75 — Mount power steering reservoir
Using the supplied fasteners, secure the power steering reservoir to the bracket
(Figure 75).
Specific instruction for remounting the components to the degas bottle are not possible due to the differences between vehicle models and the various brake systems and degas bottles.
Reconnect the coolant tubes, and re-attach the various components to the
degas bottle. Where the harnesses or components cannot be mounted to the degas bottle in their original position, secure them using cable ties.
Using loom and cable ties (not supplied), ensure that any hoses or components
are protected from abrasion.
Dual battery vehicles: Prior to proceeding, refer to the Dual Battery Adaptor (P/N: A900023) kit for instructions on mounting the second battery and connecting the battery cables.
Install the upper coolant hose quick connect, retained earlier, onto the upper
radiator spigot.

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Install the supplied bent tube into the upper coolant hose as shown, and orient
it toward the upper radiator spigot (Figure 76).

Figure 76 — Connect upper radiator hose
Using the supplied gear clamp, install the short side of the supplied 90° hose
onto the quick connect and connect the other side to the bent tube (Figure 76).
Using the OEM fastener, secure the upper coolant bracket to the fan shroud
(Figure 76).
Using the supplied P-clip and fasteners, secure the upper coolant hose to the
bracket. Ensure the hose is secured away from the clutch (Figure 76).
As the coolant system pressurizes, the upper hose assembly may move up to 3/4 in, ensure it is adequately secured to prevent it from contacting moving components, and protected from abrasion.

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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.
Posi-Tap Connectors

Figure 77 — Posi-Tap wire connector

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· Slide the OEM (live) wire into the slot on the large cap as far as it will go. · Thread the tap (barrel with pin) over the slotted cap, ensuring the pin is
centered on the wire. Firmly tighten the tap.
· Strip approximately 3/8 in from the end of wire. · Unscrew the small cap. · Twist the wires together and insert the wire into the cap. · Deflect the wires to one side. · Insert the cap into the tap, ensuring the wires enter one side of the metal core. · Ensuring the wire does not slip out of the cap, push and turn until the threads
catch and firmly tighten the cap.
· Ensure all of the connections are firmly tightened by hand (overtightening will
cause the threads to strip).
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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Digital Throttle Control Wire Schematic

Figure 78 — Digital throttle control

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Control Box
Remove the plastic trim panel from the doorsill and the kick panel on the driver
side.
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.
Digital Throttle Control (DTC)
Using cable ties, secure the throttle control under the dashboard, next to the
OBD II port. Ensure it is away from moving parts and positioned so that the buttons and LED lights are accessible.
Connecting the Wiring
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.
Connect the interface harness to the matching connector from the control box. Replace the doorsill trim and the kick panel. Attach the (×2) green wires with ring connectors, running from the control box,
and the DTC to a good ground under the dashboard.
Remove the kick panel beside the hood release lever. Locate the black C264 connector (Figure 79).

Hood release lever

C264 connector

Figure 79 — Locate C264 connector

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Splice the blue wire running from the DTC to the wire at pin 19 (green wire with
blue stripe at the time of writing) of the C264 connector (Figure 80).

Figure 80 — C264 connector (male)
Splice the grey wire running from the DTC to the wire at pin 20 (white wire with
green stripe at the time of writing) of the C264 connector (Figure 80).
Remove the glove box compartment to gain access to the wire run behind it. Shorten the darker blue wire running from the throttle control and apply
insulation (e.g. shrink tube, electrical tape, etc.) to safely terminate the wire.
The SEIC blunt cut harness is located in the passenger side footwell. It may be necessary remove the black module behind the kick panel to gain access to the SEIC wire bundle.
Route the following wires to the SEIC interface located behind the kick panel in the passenger side footwell (there is a wire run behind the glove compartment):
Black wire from the white 4-pin connector. Red wire from the white 4-pin connector. Splice the blunt cut red wire (from 4-pin connector) to the brown wire with blue
strip on the SEIC pigtail harness (CBA07: key switched 12 V).
Splice the black wire to the grey wire with brown stripe (CET22: Park status).
Route the following wires into the engine compartment via a grommet in the firewall:
Grey cable with the green plug connector from the control box. Grey cable with the black connector from the throttle controller. *White wire with a bullet connector from the interface cable. Cover all of the engine compartment wires with plastic loom.
Compressor connections
Route the (×2) grey cables and the white wire over to the compressor. Connect the grey cable with the green plug connector to the corresponding
connector coming from the rear of the compressor.
Connect the grey cable with the black connector to the matching connector on
the pressure transducer at the compressor.
Connect the white wire with the bullet connector to the matching connector at
the compressor clutch.

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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 cap from the oil-fill port located on the Inlet valve (Figure 81).
Oil fill cap

Figure 81 — Oil fill location
Add the (×2) 4 L (1 USG) jugs of oil to the system. Rotate the compressor clutch by hand while adding oil to speed the process. Do
not use power tools to rotate the clutch.
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 from the 1 L (1 qt) bottle until the level is correct. Replace the oil fill cap and tighten.

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Completing the Installation
Reinstall the air intake tube and resonator assembly Reinstall the radiator cross member cover. Connect the upper degas hose to the radiator and VMAC degas tank (trim
hoses as necessary).
Reinstall the lower bumper air dam (if removed). Optional: Install the vacuum cooling system filler and follow the manufacturer’s
instructions to fill and bleed the system.
Ensure the radiator drain spigot is closed. Fill the degas bottle to the “MAX FILL” line. Install the degas bottle cap until it contacts the hard stop. Reinstall the air intake tube and resonator assembly 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. Ensure all wiring, hoses and tubes are secured with cable ties and protected with loom as required.
Cover all VMAC under-hood wiring with high heat plastic loom (if not done
previously). Secure the harness with cable ties as needed to avoid hot, sharp or moving components.
Pull any excess wiring back into the cab and tie it up and out of the way under
the dash with cable ties.
Reconnect the battery terminal(s).
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 82).

Figure 82 — System Identification Plate

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To alert any technicians that may service the vehicle, affix the servicing
caution/contact label in the engine compartment near the hood latch in a visible location (Figure 83).
Figure 83 — Advisory label
Install the belt routing label in the engine compartment near the hood latch in
a visible location (Figure 84).
Figure 84 — Belt routing label (actual belt routing label may differ)
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 85).

Figure 85 — Operating Instruction label

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Remote Operation (Optional)
The VMAC compressor can be started, and shut down remotely using the remote start/stop wires. The remote wires are tucked into the heat shrink tubing at the base of the control box (Figure 86).

Remote start / stop wires

Figure 86 — Remote start / stop wires
Installation
Connect the red wire (ON) to a switch that will apply a momentary ground
when activated.
Connect the black wire (OFF) to a switch that will apply a momentary ground
when activated.
Starting the Compressor via Remote Start
· Place the vehicle transmission in “PARK” and fully apply the parking brake. · Start the engine and allow the vehicle to reach operating temperature. · Ensure the oil level in the AOST is above the “ADD” line (this should be checked
while parked on level ground).
· Ensure the vehicle hood is closed. · Ensure all compressor air valves/tools are closed. · Turn on the compressor using the remote momentary “ON” switch.
Shutting Down the Compressor via Remote Shutdown
· Close all open air valves/tools and allow the system to build to full pressure
(factory default: 150 psi).
· Allow the engine speed to reduce to VMAC base idle for at least 10 seconds. · Turn the compressor off using the remote momentary “OFF” switch.

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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 75 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 (1207 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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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 87).
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 87 — Air receiver tank

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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 verify that it is illuminated. If there is no display, there
is no power to the control box.
Press the “ON” button. The green LED on the control box, as well as the “STATUS”, “PRK BRAKE”, and “PRNDL”, LED’s on the DTC should illuminate.
Shift the vehicle into “NEUTRAL”.
The green LED on the control box should flash and the display will flash
“OUT OF PARK”.
The “PRNDL”, LED on the DTC will turn off.
Disengage the park brake.
*The “PRK BRAKE” LED on the DTC will turn off. Shift the vehicle back into “PARK”, reengage the park brake, and press the “OFF”
button on the control box, followed by the “ON” button. The green LED on the control box, and the interlock LED’s on the DTC 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 150 cfm (0.250 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”. Disconnect the clutch wire at the bullet connector near clutch (required for
calibration).
Secure the clutch wire away from the belt line. Start the engine.

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After Starting the Engine Checklist.
Check for any leaks, confirm belt alignment, and ensure the belts are rotating
properly.
Close and latch the hood. Allow the vehicle to reach operating temperature.
Coolant System Purge Instructions
Regardless of whether a vacuum cooling system filler is used or not, the following procedure must be performed.

1. Turn the climate control system off. 2) Start the engine and increase the engine speed to 3,500 rpm and hold it there
   for 30 seconds. 3) Turn the engine off for and wait for 1 minute to purge any large air pockets
   from the cooling system.
   To prevent injury, ensure the engine is shut off, the engine and coolant have cooled to a safe temperate, and the pressure has dissipated prior to loosening the degas bottle cap.
2. Check the engine coolant level in the degas bottle. If necessary, fill to the:
   o If the engine is warm, ensure the level is to the “MAX FILL” line on degas bottle.
   o If the engine is cold, ensure the level is to the MIN FILL LEVEL line on degas bottle.
3. Start the engine and let it idle until the cooling fan cycles on at least once. 6) Increase the engine speed to 3,500 rpm and hold it there for 30 seconds. 7) Allow the engine to idle for 30 seconds.
   To prevent injury, ensure the engine is shut off, the engine and coolant have cooled to a safe temperate, and the pressure has dissipated prior to loosening the degas bottle cap.
4. Turn the engine off for 1 minute. 9) Repeat steps 6 through 8 a total of 10 times to remove any remaining air
   trapped in the system. 10) Check the engine coolant level in the degas bottle. If necessary, fill to the
   “MAX FILL” line on degas bottle. 11) Install the degas bottle cap until it contacts the hard stop.
   DTC Calibration
   Press the “ON” button on the control box. The green LED on the control box
   will turn on. The DTC will turn on with the “STATUS”, “PRK BRAKE”, and “PRNDL”, LEDs illuminated. If not, ensure that the vehicle is in Park with the Park Brake applied.

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Press and hold “” and “” buttons in the “RAMP UP PRESSURE” column for
several seconds until all of the LEDs turn on. Then release the buttons (this indicates the DTC is in “Idle Adjust Mode”)
The engine RPM will stay at VMAC base idle (approximately 1,000 rpm)
regardless of the pressure level returned by the system pressure sensor.
Allow the DTC to calibrate for 3 minutes. During this time the “STATUS” LED will
occasionally flash indicating that the DTC is calibrating. The engine speed will eventually settle at VMAC base idle (approximately 1,000 rpm).
After 3 minutes. Press the “OFF” button on the control box. Shut down the vehicle. Connect the white clutch wire.
Continue Safety Test
Close and latch the hood. Start the vehicle. Allow the vehicle to run for a minimum of 30 seconds. Press the “ON” button on the control box. When the VMAC system is first engaged, the engine speed should increase to
approximately 2,350 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 1,000 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 “MAX” 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. Release the park brake. Open the ball valve to drain the air from the system. The engine speed should not increase. Re-engage the park brake. Press the “OFF” button on the control box.

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Press the “ON” button on the control box. Allow the engine speed to stabilize after re-engaging the compressor.
With the brake pedal firmly depressed, shift the vehicle into “REVERSE”.
The engine speed should reduce to OEM base idle (Approximately 650 rpm). The green LED on the control box will go out indicating the system has shut
down.
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
remains at OEM base and the system shuts off when the vehicle is shifted out of “PARK”.
The VMAC digital throttle is equipped with an auto calibration and engine learning routine that will assist with maintaining accurate and stable engine speeds. No user input is required unless the DTC is replaced or reset.
Operators may however notice that while the system is at full system pressure and the vehicle is at base VMAC idle, the vehicle engine speed may drop by a few hundred rpm and then return to normal VMAC base idle as the VMAC digital throttle control auto calibrates. This is normal and should only occur once each time the system is being operated.
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 compressor operation to ensure that the belt alignment is good
and 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 150 cfm (0.250 in) orifice in the outlet to simulate tool use (Figure 88).

JIC Adapters

Orifice

Ball valve

Install orifice here
Figure 88 — 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 150 cfm (0.250) 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:
Engine speed should increase to approximately 2,400 rpm. Close the air valve slowly to allow the system pressure to rise. Once 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 when the pressure drops to approximately 140 psi.

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Digital Throttle Control Operation and
Adjustments
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 89 — Throttle control
If the park brake is released, or the vehicle is placed in gear, the “STATUS” LED and the corresponding lockout 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.
MAX RPM
The cfm produced by the system is directly related to engine speed; this system delivers 92 cfm at 2,400 rpm, and 102 cfm at 2,850 rpm.
Maximum VMAC rpm can be adjusted between 1,500 rpm and 2,850 rpm (in 50 rpm increments) via the “” or “” buttons in the “MAX RPM” column.
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.

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“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 DTC will need to be recalibrated.
DTC Calibration
Disconnect the white clutch wire Press the “ON” button on the control box. The green LED on the control box
will turn on. The throttle control will turn on with the PRNDL, PRK BRAKE, and STATUS LEDs illuminated. If not, ensure that the vehicle is in Park with the Park Brake applied.
Press and hold “” and “” buttons in the “RAMP UP PRESSURE” column for
several seconds until all of the LEDs turn on. Then release the buttons (this indicates the DTC is in “Idle Adjust Mode”)
The engine RPM will stay at VMAC base idle (approximately 1,000 rpm)
regardless of the pressure level returned by the system pressure sensor.
Allow the DTC to calibrate for 3 minutes. During this time the “STATUS” LED will
occasionally flash indicating that the DTC is calibrating. The engine speed will eventually settle at VMAC base idle (approximately 1,000 rpm).
After 3 minutes. Press the “OFF” button on the control box. Shut down the vehicle. Connect the white clutch wire.
For more information on the digital throttle, including error codes, see the related article the VMAC Knowledge Base: https://kb.vmacair.com/help/vmac- digital-throttle-control

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Accessory Products from VMAC
Compressor Service Kits
200 Hour or 6 Month Service Kit Part number: A700059 Includes 9 L VMAC high performance compressor oil, oil filter, air filter, and next service due decal. 400 Hour or 1-Year Service Kit Part number: A700060 Includes 9 L VMAC high performance compressor oil, oil filter, air filter, coalescing filter, pressure relief valve, muffler, and next service due decal.
Air Aftercooler — 185 cfm
Part number: A800185 (includes A700221 FRL) Improves tool performance and extends the life of air tools; removes up to 80% of water from compressed air; includes automatic water drain and A700221 Filter, Regulator, Lubricator).
· Max air flow: 185 cfm / 200 psi. · Port size: 1 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) — 185 cfm
Part number: A700221 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 185 cfm / 200 psi. · Port size: 1 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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Notes

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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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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: V 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

®

888-241-2289

tech@vmacair.com

877-740-3202

warranty@vmacair.com

www.vmacair.com

kb.vmacair.com

1333 Kipp Road, Nanaimo, B.C., V9X 1R3 Canada

References

• VMAC Knowledge Base
• Find A Dealer - VMAC
• Find A Dealer - VMAC

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