VMAC V900146 Underhood70 Air Compressors Owner’s Manual
- June 15, 2024
- VMAC
Table of Contents
V900146 Underhood70 Air Compressors
70 UNDERHOOD TM AIR COMPRESSORS
Specifications
-
Product: VMAC System
-
Model: V900146
-
Compatible Vehicles: 2019+ Ram 3500 Pickup (high output engine)
and 5500 Chassis Cab 6.7 L Cummins Diesel -
Website: www.vmacair.com
Installation Manual for VMAC System
This manual provides detailed instructions for installing the
VMAC System on the compatible vehicles mentioned above.
Table of Contents
- VMAC – Vehicle Mounted Air Compressors
- VMAC Technical Support: 888-241-2289
- VMAC Knowledge Base: kb.vmacair.com
- Document: 1930377 Changes and Revisions
Additional Application Information
The VMAC System is also compatible with the 5500 Chassis Cab
with 6.7 L Cummins Diesel. For more information, refer to the VMAC
Knowledge Base article EXT-VR-001.
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 purposes only and does not imply
any affiliation or endorsement by said companies.
Safety
Important Safety Notice
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
equipment as a result of the failure 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 if 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.
Safety Symbol 1: 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.
Safety Symbol 2: 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.
Safety Symbol 3: This symbol is used to call
attention to additional instructions or special emphasis on a
specific procedure.
Warranty
VMAC offers a Standard Warranty (Limited) for their products.
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
FAQ
-
1. How do I contact VMAC Technical Support?
You can reach VMAC Technical Support by calling
888-241-2289.
-
1. Where can I find more information about VMAC products?
You can find more information about VMAC products in the VMAC
Knowledge Base at kb.vmacair.com
70 UNDERHOOD TM AIR COMPRESSORS
Installation Manual for VMAC System
V900146
2019+ Ram 3500 Pickup (high output engine) and 5500 Chassis Cab 6.7 L Cummins
Diesel
www.vmacair.com
Table of Contents
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warranty . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 4 General Information. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 System
Identification, Warranty Registration and Warning Labels . . . . 8 Preparing
for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 10 Installing the Main Bracket and Compressor . . . .
. . . . . . . . . . . . . . . . . . . . 19 Installing the Oil Cooler . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installing the Air Oil Separator Tank (AOST) . . . . . . . . . . . . . . . . .
. . . . . . 35 Hose Requirements . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 41 Connecting the Hoses . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 42 Adding Oil to the System . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 47 Installing the Control Components .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Air Receiver
Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 55 Recommended Accessories . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . 56 Completing the
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 57 Testing the Installation . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 58 Performance Testing and
System Adjustments. . . . . . . . . . . . . . . . . . . . . . 61 Digital
Throttle Control Operation and Adjustments . . . . . . . . . . . . . . . . 62
Accessory Products from VMAC. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 64 Warranty Registration. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
VMAC – Vehicle Mounted Air Compressors
VMAC Technical Support: 888-241-2289
1
VMAC Knowledge Base: kb.vmacair.com
Document: 1930377 Changes and Revisions
Revision
Revision Details
M
ECN: 23-203 Update AOST mounting instructions.
Revised by MSP
Checked by Eng.
Tech. Qual. Mech. Elec. MRH N/A MSP LPH
Implemented 26 Sept. 2023
Additional Application Information
· 2019+ Ram 3500 Pickup (high output engine only, engine sales code ETM) |
5500 Chassis Cab with 6.7 L Cummins Diesel.
· 2019+ Ram 2500 Pickup | 3500 Pickup (standard output, engine sales code
ETL) | or 3500 4500 Chassis Cab applications require system: V900144.
· Vehicles equipped with dual alternators will need to be converted to single
alternator. See VMAC Knowledge Base article EXT-VR-001.
· 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.
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 © 2021 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
VMAC – Vehicle Mounted Air Compressors
2
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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.
VMAC – Vehicle Mounted Air Compressors
VMAC Technical Support: 888-241-2289
3
VMAC Knowledge Base: kb.vmacair.com
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:
www.vmacair.com/warranty
[email protected]
877-740-3202 VMAC – Vehicle Mounted Air
Compressors 1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3
VMAC – Vehicle Mounted Air Compressors
4
VMAC Technical Support: 888-241-2289
VMAC Knowledge Base: kb.vmacair.com
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/
- 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.
- VMAC will provide direction for repair or replacement of the failed components.
- If requested, failed parts must be returned to VMAC for evaluation. 4)
Dealers may login to the VMAC website to view the “VMAC Labour Time
Guide” (under “Agreements”) to see the allowable warranty labour times. 5) Warranty invoices must include the Service Ticket number, VMAC System ID#,
hours on the compressor, and a detailed description of the work performed. 6) VMAC Warranty does not cover consequential damages, overtime charges,
mileage, travel time, towing/recovery, cleaning or shop supplies. 7) Dealers submit warranty claims on behalf of the Vehicle Owner/End User
affected by the defective part(s). The dealer ensures that all warranty credits are refunded back to the Vehicle Owner/End User who made the initial warranty claim.
In order to qualify for Lifetime Warranty (Limited), the completed warranty registration form must be received by VMAC within 3 months of the buyer receiving the Product(s), or 200 hours of operation, whichever occurs first. If the completed warranty registration form has not been received by VMAC within 3 months of the buyer receiving the Product(s), or 200 hours of operation, the “Standard” warranty period will be deemed to commence 30 days from the date of shipment from VMAC. Failure to follow the warranty claim process may result in denial of the warranty claim.
VMAC Product Warranty Policies & Warranty Registration can be found on the VMAC website (see previous page for URL).
VMAC – Vehicle Mounted Air Compressors
VMAC Technical Support: 888-241-2289
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VMAC Knowledge Base: kb.vmacair.com
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.
VMAC – Vehicle Mounted Air Compressors
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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.
Mark and drill (×2) 7/64 in holes in the top of the cross member in front of
the
hood support. Secure the plate with the supplied self-tapping screws (Figure
1).
Figure 1 — System Identification Plate
VMAC – Vehicle Mounted Air Compressors
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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 label in the engine compartment near the hood latch in a
visible location (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).
Apply Loctite 242 (blue) to all fasteners.
Vehicles equipped with RAM’s Vehicle System Interface Module (VSIM), skip, to
page 12.
Identify the “PARK”/”NEUTRAL” Wire.
Aisin AS69RC Transmission:
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
Do not use a test light to probe for power on vehicle circuits, the increased
current draw of the test light may damage components!
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To verify pin 9 is the “PARK”/”NEUTRAL” wire, turn the ignition key to “RUN”
but
do not start the engine.
Using a multimeter, back probe (connector must be plugged in in order to get
a proper reading) the wire to verify that 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”. Disconnect the negative terminal from the batteries.
68RFE Transmission:
Locate the 23 pin connector plugged into the transmission range sensor on the
driver side of the transmission (Figure 6).
Range sensor
Figure 6 — Locate range sensor
Locate the yellow wire with blue stripe going to pin 4 in the transmission
range
sensor connector (Figure 7)
Pin 4
Figure 7 — View from front of connector
To verify pin 4 is the “PARK”/”NEUTRAL” wire, turn the ignition key to “RUN”
but
do not start the engine.
Using a multimeter, back probe (connector must be plugged in in order to get
a proper reading) the wire to verify that 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
radiator cover and intake ducting (Figure 8).
Figure 8 — Remove intake ducting
Disconnect the harnesses and remove the air box assembly (Figure 9).
Figure 9 — Remove air box
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Cover the intake tube to prevent any contaminants from entering the system. Remove the aesthetic engine cover (Figure 10).
Figure 10 — Remove aesthetic engine cover
Remove the fan shroud (Figure 11).
Figure 11 — Remove fan shroud
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Remove the fan stator (Figure 12).
Figure 12 — Remove fan stator
Disconnect the fan clutch wire. Insert a sheet of cardboard between the fan
and the radiator.
Ensure the fan is stored vertically to prevent premature failure.
Remove the fan. Drain the coolant into a clean container and set it aside for
use later. Remove the lower radiator hose and set it aside for use later.
Remove the upper radiator hose and set it aside for use later. Remove the
upper radiator hose support bracket from the cylinder head. Retain
the upper portion of the bracket as it will be used later (Figure 13).
Retain
Discard
Figure 13 — Remove upper radiator hose bracket
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Remove any clear coat from the support bracket mounting surface. Clean the
support bracket and the tapped holes on the cylinder head (in front
of the throttle body intake tube).
Remove the plastic EGR wiring harness clip from the stud on the front of the
OEM intake tube (Figure 14).
Figure 14 — Invert EGR harness clip
Mark the throttle body shield at the bottom of the flange nut (Figure 15).
Figure 15 — Remove throttle body shield
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Remove the throttle body shield (Figure 16).
Figure 16 — Remove throttle body shield
Remove the area marked on the throttle body tab in the previous step (Figure
17).
Remove the hatched area of the tab
Figure 17 — Modify throttle body shield
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Disconnect the electrical harness and the intercooler hose, and remove the
throttle body (Figure 18).
Figure 18 — Remove throttle body
Cover the intercooler hose to prevent debris from entering the system. Remove
any old gasket material from the throttle body and the OEM intake tube.
Ensuring the directional arrow is facing toward the front of the vehicle,
install the
throttle body adapter and one of the supplied gaskets onto the OEM intake tube
(Figure 19).
Arrow on adapter
Front of vehicle Figure 19 — Install throttle body adapter
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Install the remaining gasket, and the throttle body (in the new orientation),
onto
the throttle body adapter (Figure 20).
Front of vehicle
Figure 20 — Install throttle body.
Connect the throttle body harness, ensuring there is adequate slack in the
wires.
If there is not adequate slack in the throttle body wires, unwrap the harness
where the wires branch off, relieve the tension, and re-wrap the harness.
Install the modified throttle body shield. Re-install the EGR wiring harness
clip onto the stud. With the FEAD (Front End Accessory Drive) belt still
tensioned, loosen the OEM
crank pulley bolts.
Remove the tension from the FEAD belt. Remove and discard the OEM crank pulley
bolts. Discard the crank pulley locking plate (if equipped).
Retain any shims that may be installed behind the OEM crank pulley.
Remove the OEM crank pulley. Scrape the clear coat from the inside front face
of the crank pulley hub.
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Installing the Main Bracket and Compressor
Apply Loctite 242 (blue) to all fasteners.
Re-using any OEM shims removed during disassembly, mount the OEM crank
pulley, aligning it with the locating pin.
Route the OEM FEAD belt but do not tension the belt (Figure 21).
OEM belt routing with A/C
OEM belt routing without A/C
Figure 21 — OEM FEAD belt routing
Place the VMAC crank pulley in position over the OEM pulley ensuring it is
aligned with the locating pin and fits flat against the OEM pulley.
Install the (×4) supplied crank pulley bolts and washers, and torque them to
69 ft·lb (Figure 22).
Locating pin
Figure 22 — Install VMAC crank pulley
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Loosen the (×2) fasteners securing the fan stator brace. The “captive” lower
fastener will be used to secure the VMAC main bracket later in the
installation (Figure 23).
Captive fastener
Figure 23 — Remove fan stator
Discard the fan stator brace. Position the VMAC main bracket, along with the
radiator hose bracket, and
insert the (×2) M10 fasteners; leave the fasteners finger tight (Figure 24).
Figure 24 — Install VMAC main bracket
VMAC – Vehicle Mounted Air Compressors
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Insert the (×2) M8 fasteners and washers through the timing gear cover into
the
main bracket, leave the fasteners finger tight (Figure 25).
Figure 25 — Install VMAC main bracket
Thread the OEM fan stator brace fasteners into the main bracket (Figure 26).
Captive fastener
Figure 26 — Install VMAC main bracket
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Torque all of the main bracket fasteners to specification. Tension the OEM
FEAD belt. Install the supplied tensioner onto the main bracket (Figure 27).
M10 × 1.5 × 60
Figure 27 — Install VMAC main bracket
Install the idler bracket onto the main bracket (Figure 28).
M8 × 1.25 × 60
Figure 28 — Install VMAC main bracket
VMAC – Vehicle Mounted Air Compressors
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Install the idlers onto the idler bracket (Figure 29).
Smooth idler
Ribbed idler
Figure 29 — Install VMAC main bracket A 6 mm ball end hex driver will be
required to access some of the fasteners.
Install the 3/4 in discharge hose onto the compressor (it will be difficult to
install after the compressor is mounted).
Install the compressor onto the main bracket, routing the discharge hose under
the air intake/EGR tube (Figure 30).
Figure 30 — Install compressor
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Install and tension the VMAC drive belt (Figure 31).
Figure 31 — Route the VMAC drive belt
Apply the split loom to the PTFE tubes. Rotate the 3/16 in push-to-connect
fitting clockwise to align with the 1/4 in
push-to-connect fitting
Install the 3/16 in and 1/4 in PTFE tubes in their respective fittings on the
inlet. Route the PTFE tubes across the front of the engine, parallel to the
OEM wiring,
and under the thermostat housing spigot. Ensure the tubes do not contact the
EGR valve (Figure 32).
Figure 32 — Route PTFE tubes
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Secure the PTFE tubes to the OEM wiring bundle. From the thermostat housing
spigot, route the PTFE tubes down, behind the
alternator (Figure 33).
Figure 33 — Route PTFE tubes
Cut the upper driver side stator mounting boss flush with the indent (Figure
34).
Figure 34 — Modify fan stator
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Install the fan. Connect the fan clutch harness and secure it using the OEM
“tree” style
fastener or a cable tie.
Remove the protective cardboard. Install the fan stator onto the (×3) OEM fan
stator brackets. Loosen the (×2) top clutch bolts on the VMAC compressor and
slide them, along
with the clutch wire retainer, forward (Figure 35).
Figure 35 — Install fan stator brace
Install the supplied fan stator brace onto the front of the compressor and
torque the fasteners (Figure 36).
Figure 36 — Install fan stator brace
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Using the fan stator brace as a guide, drill a hole in the fan stator. Secure
the fan stator brace using the supplied M6 fastener (installed from the
fan side of the brace), 1/4 in washer and lock nut (Figure 37). Lock nut
Stator brace 1/4 in washer
M6 × 1 × 16
Figure 37 — Install fan stator brace
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Installing the Oil Cooler
Apply Loctite 242 (blue) to all fasteners.
Lay the lower radiator hose flat on a bench. From the radiator side of the
hose, measure 2 1/2 in towards the center of the
hose and mark it with a grease pen (Figure 38).
2 1/2 in
Engine side
90° 90°
3 1/2 in
Figure 38 — Modify lower radiator hose
From the grease mark, measure 3 1/2 in along the outside radius towards the
center of the hose and mark with a grease pen (Figure 38).
Cut the radiator hose in the two marked locations, ensuring that the cuts are
square to the hose section; keep only the center (3 1/2 in) section of hose.
Install the 3 1/2 in modified hose onto the short oil cooler spigot using one
of the supplied hose camps. Leave the hose clamp loose to allow adjustment
(Figure 39).
Figure 39 — Install modified hose
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Fit the other hose clamp onto the modified hose, leaving it loose. Remove the
OEM fastener securing the radiator brace and set it aside (Figure 40).
Radiator (for reference only)
Radiator brace
Remove OEM fastener
Passenger side body mount (for reference only)
Figure 40 — Remove OEM fastener
Install the radiator brace and oil cooler bracket using the OEM fastener
retained from the previous step; leave the fastener finger tight (Figure 41).
Radiator brace
Figure 41 — Install cooler bracket
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Install the bottom fastener onto the backing strap, leaving the nut finger
tight
(Figure 42).
Install fastener in orientation shown
Figure 42 — Install backing strap
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 43).
Shift hoses upward
Figure 43 — Deflect hoses
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Install the supplied flex hose onto the engine spigot (Figure 44).
Install flex hose
Figure 44 — Install flex hose
Mount the cooler onto the cooler bracket, fitting the hoses loosely onto the
cooler spigots (Figure 45).
Figure 45 — Mount cooler
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Install the top cooler bracket fastener finger tight (Figure 46).
Install top fastener
Figure 46 — Install top fastener
Install the (×2) bottom cooler fasteners (Figure 47).
Install fasteners
Figure 47 — Install bottom cooler fasteners
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.
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Remove and discard the plug from the passenger side of the cylinder head
(Figure 48).
Remove coolant vent plug
Figure 48 — Coolant vent plug
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 49).
Figure 49 — Install pipe nipple
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Apply Loctite 567 (thread sealant) to the hose barb and install it onto the
tee
fitting (Figure 50). Hose barb
Figure 50 — Install hose barb
Connect the supplied 10 mm ID coolant hose to the hose barb and secure it
using the supplied gear clamp (Figure 51).
Figure 51 — 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 52).
Front of vehicle
Figure 52 — AOST installed
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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 37 (Figure 53).
Figure 53 — Standard Duty Chassis For “heavy duty” chassis, turn to page 39 (Figure 54).
Figure 54 — 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 55).
Snubbing washer
Front of vehicle
Through frame spacer
M10 × 1.5 × 30 fastener
M10 × 1.5 × 30 fastener
Figure 55 — 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 56).
(×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 56 — Installing the AOST
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Remove the tank clamp pinch bolts (Figure 57).
(×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 57 — 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 57):
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 58).
(×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 58 — 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 59).
(×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 59 — Installing the AOST
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Remove the tank clamp pinch bolts (Figure 60).
(×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 60 — 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 60):
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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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. Dependant
upon 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 × 81 in. · 1/2 in × 53 in. · 1/2 in × 68 in. · 1/4 in (PTFE tube) ×
125 in. · 3/16 in (PTFE tube) × 124 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 61 — Push-to-connect fittings
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Route the 3/4 in hose (connected to the compressor earlier) down and toward
the transmission bellhousing.
Using the OEM bellhousing fastener, install the driver side discharge hose
support bracket (Figure 62).
Figure 62 — Route discharge hose
Route the 3/4 in hose through the rubber coated P-clip and secure it to the
support bracket using the supplied fastener and nut (Figure 63).
Figure 63 — Route discharge hose
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Using the OEM transmission support fastener, install the passenger side
discharge hose support bracket (Figure 64).
Figure 64 — Route discharge hose
Route the 3/4 in hose under the transmission cooler lines, through the rubber
coated P-clip, and secure it to the support bracket using the supplied
fastener and nut (Figure 65).
Figure 65 — Route discharge hose
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A 45° #12 JIC fitting has been included in the kit and can be installed onto
the AOST as necessary to aid in routing the discharge hose.
Route the 3/4 in discharge hose between the frame, and the radius arm, and
connect it to the fitting on the AOST (Figure 66). Transmission cooler lines
Figure 66 — Route discharge hose
Connect the straight fitting on the shorter 1/2 in hose to the matching
fitting
on the compressor.
Route the 1/2 in hose under the engine toward the oil cooler (Figure 67).
Compressor
Figure 67 — Route oil return hose
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Connect the 90° fitting to the driver side fitting of the oil cooler (Figure 68).
To compressor
From AOST
Figure 68 — Install hoses
Connect the straight fitting on the longer 1/2 in hose to the corresponding
fitting on the air oil separator tank.
Run the hose along top of frame, up along wheel well, and forward to the
cooler.
Connect the 90° fitting to the passenger side fitting of the oil cooler
(Figure 68).
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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 fitting from the inlet (mounted on the top of the compressor
(Figure 69).
Oil fill fitting
Figure 69 — Oil fill location
Using a funnel, fill the system 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 fitting 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 70 — Analog throttle control
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Digital Throttle Control Wire Schematic
Figure 71 — 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.
Throttle Control
Using cable ties, secure the throttle control under the dashboard, away from
moving parts and positioned so that the adjusting screws, or the buttons and
LED lights, are accessible.
Route the following wires into the engine compartment via a grommet in the
firewall:
White wire from the 4 pin connector (clutch wire). 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). 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 (×2) grey wires and the white wire over to the compressor. Connect
the gray wire with the green 4 pin connector to the matching
connector at the compressor.
Connect the gray wire with the black 3 pin connector to the matching
connector at the compressor.
Connect the white wire with the bullet connector to the compressor clutch.
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.
Attach the (×2) green wires with ring connectors to a good ground under the
dash.
Connect the interface harness to the matching connector from the Control Box.
Replace the doorsill trim and the kick panel.
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.
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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 72).
Unplug CKP Sensor harness
Figure 72 — 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 73).
Pin 3 Brown / light
blue wire
Pin 1
Figure 73 — 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 74).
Figure 74 — 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 74).
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 75).
Figure 75 — 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 76).
Figure 76 — 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. Digital throttle control only: Cut the loop
of grey wire from the black module on
the DTC main harness (Figure 77).
Cut loop
Figure 77 — Disable pull up harness
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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 78).
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 78 — 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 64 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.
Ensure all wiring, hoses and tubes are secured with cable ties and protected
with 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. Cut 1 in from
the radiator side of the top radiator hose to improve the clearance
for the VMAC air filter.
Install the top radiator hose onto the support bracket using the supplied
fastener (Figure 79).
Figure 79 — Install radiator hose support bracket
Reinstall the fan shroud. Reinstall the radiator cover and intake ducting.
Reinstall the air box, ensuring the electrical connectors are reconnected.
Replace all engine bay covers removed during installation. Using the open port
on the tee (installed into the cylinder head earlier) as an
air bleed, fill the coolant system at the reservoir tank. Once coolant is seen
coming out at the tee, install the supplied plug and finish filling the system
normally.
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 and the compressor
clutch will engage, this should be audible.
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 light on the control box should flash and
the
display will flash “PARK BRAKE”. Apply the park brake again and press the “ON”
button. The green light 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, confirm belt alignment, and ensure the belts are rotating
properly.
Close and latch the hood.
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Allow the vehicle to reach operating temperature. Turn on the compressor.
Analog Throttle Control
When the VMAC system is first engaged, the engine speed should increase
to between 1,800 rpm and 2,200 rpm and then drop down to VMAC base idle
(approximately 1,000 rpm) once system pressure is reached.
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. Release the park brake.
· The control box should read “PARK BRAKE”, the compressor clutch should
disengage and engine speed should reduce to OEM idle.
Re-engage the park brake and start the compressor. Allow engine speed to
stabilize after re-engaging the compressor.
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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. 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”.
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 “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
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 70 cfm (0.190 in)
orifice in the outlet to simulate tool use (Figure 80).
JIC Adapters
Orifice
Ball valve
Install orifice here
Figure 80 — 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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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 81 — 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.
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: A700019 Includes 5 L VMAC high
performance compressor oil, oil filter, air filter, and next service due
decal. 400 Hour or 1-Year Service Kit Part number: A700020 Includes 5 L VMAC
high performance compressor oil, oil filter, air filter, coalescing filter,
pressure relief valve, muffler, and next service due decal.
Air Aftercooler — 70 cfm
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 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 Green Series Air Compressors, 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 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 Green Series Air Compressors, 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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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
®
www.vmacair.com
kb.vmacair.com
1333 Kipp Road, Nanaimo, B.C., V9X 1R3 Canada