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Vmac UNDERHOOD 40 Series Owner's Manual

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UNDERHOOD 40 Truck and Van
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Summary of Contents for Vmac UNDERHOOD 40 Series

  • Page 1 UNDERHOOD 40 Truck and Van Series Owner’s Manual www.vmacair.com www.vmacair.com...

  • Page 3: Table Of Contents

    Accessory Products from VMAC ........
  • Page 4 Copyright © 2020 VMAC Global Technology Inc. All Rights Reserved. These materials are provided by VMAC for informational purposes only, without representation or warranty of any kind, and VMAC shall not be liable for errors or omissions with respect to the materials. The only warranties for VMAC...

  • Page 5: General Information

    Ordering Parts To order parts, contact a VMAC dealer. The dealer will ask for the VMAC System ID (see page 11), part number, description and quantity. Locate the nearest dealer online at www.vmacair.com/dealer-locator or call 1-877-912-6605.

  • Page 6: Safety

    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 VMAC Knowledge Base: kb.vmacair.com...

  • Page 7: Safety Precautions

    Proper service and operation are important to the safety of the operator and the safe, reliable operation of the equipment. Always use genuine VMAC replacement parts. The procedures described in this manual are effective methods of service and repair.
  • Page 8 • Never adjust or attempt to make any repairs to the system while the engine is running. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 9 Never adjust or attempt to make any repairs to the compressor system while the engine is running or the air system pressurized. Components and hoses under pressure could fail and cause serious injury or death. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 10: Warranty

    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.
  • Page 11 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.

  • Page 12: System Specifications

    • Thermal monitoring and electronic control. • Rapid blowdown valve to relieve system pressure on shutdown. Use only genuine VMAC replacement parts to maintain the system. Genuine VMAC replacement parts are designed to work with the high pressure and heat generated by the compressor. Substituting genuine VMAC replacement parts may void the warranty and could cause equipment damage, injury, or death.

  • Page 13: Identifying Your System

    (Figure 2). V400001 A BC 123 Model number Unique identifier Production date code Revision letter Figure 2 — System ID breakdown VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 14: System Components

    Oil filter Air/oil inlet Oil scavenge fitting (includes check valve) Oil fill cap Pressure switch Oil sight glass Oil drain Figure 3 — WHASP Tank VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 15 (Top inlet version) Hoses / Tubes The hoses used in VMAC compressor systems have an AQP inner liner that is compatible with VMAC compressor oil. The PTFE tube used in VMAC systems is rated for the high temperatures VMAC compressors generate. Use of hoses or tubes other than those supplied or recommended by VMAC may cause compressor damage and may void your warranty.
  • Page 16 Control Module The control module serves as the primary input/output interface between the vehicle and the various VMAC components (compressor, throttle control, WHASP Tank, Control Interface, etc.). Power, 12 V Clutch, throttle WHASP Compressor (switched), and control, and pressure temperature...
  • Page 17 Figure 8 — Analog VMAC throttle Ford Stationary Elevated Idle Control (SEIC) Compatible Throttle Control Engine speed adjusting knob Figure 9 — VMAC throttle control for Ford SIEC systems control VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 18 (Actual installation locations may vary) Pickup layout Control Compressor module Throttle control WHASP Tank Interface panel Figure 11 — General component overview (Actual installation locations may vary) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 19: Operating Principles

    Operating Principles Air Compression At the heart of VMAC’s UNDERHOOD 40 Air Compressor systems is a flooded lobe, rotary screw compressor. Compression occurs when filtered air, at normal atmospheric pressure, enters the chamber where it is trapped between meshing rotor lobes. Cooled oil is injected into the compressor housing during compression to seal the rotor lobes for maximum compression efficiency.
  • Page 20 2 grooves showing on either side of the belt). Pressure Regulation and Engine Speed Control When shut down, the VMAC system “blows down” or discharges all air stored in the WHASP Tank. When the system is started, the mechanical pressure switch in the...

  • Page 21: System Operation

    To prevent FEAD belt slip and compressor clutch damage, do not attempt to restart the compressor before the system has fully blown down. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 22 In order to activate the system again, re-engage the appropriate lockout and cycle the VMAC “OFF” then “ON” via the control box. 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”...
  • Page 23 Once the WHASP Tank has completed the blowdown cycle, turn the compressor system on and the system should operate normally. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 24: General Maintenance Information

    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 in the absence of a torque value provided by the OEM.

  • Page 25: Maintenance And Repair Safety

    Use only genuine VMAC replacement parts to maintain the system. Genuine VMAC replacement parts are designed to work with the high pressure and heat generated by the compressor. Substituting genuine VMAC replacement parts may void the warranty and could cause equipment damage, injury, or death.
  • Page 26 The following maintenance schedule must be observed to maintain both the “Standard” and “Lifetime” VMAC warranties and to assure proper performance and long service life of the system. In the event of a warranty claim, VMAC may request service records.
  • Page 27 Wire Schematic Figure 14 — Electrical schematic VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 28: Regular Inspection Instructions

    Wear appropriate Personal Protective Equipment and follow all industry standard safety practices. 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.
  • Page 29 Listen for the pressurized air to blowdown through the muffler on the WHASP Tank. Blowdown should be completed in approximately 20 seconds. ☐ If the muffler is showing signs of blockage, contact a local VMAC dealer for a replacement. A replacement blowdown muffler is included with the VMAC 400 hour service kit.
  • Page 30 ☐ If the pressure relief valve is showing loss of functionality, contact a local VMAC dealer for a replacement. A replacement pressure relief valve is included with the VMAC 400 hour service kit.
  • Page 31 If the pulleys are not properly aligned, check all fasteners to ensure that they are properly torqued and that there are no loose or worn components. For instructions on replacing the drive belt, refer to the specific VMAC installation manual for the system in question.
  • Page 32 Replace the air filter cover and secure it with the cover nut. Do not over tighten the nut. ☐ If removed for service, reinstall the filter onto the filter bracket. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 33: 200 Hour / 6 Month Service

    Inspect the Viton® O-ring on the oil drain plug for damage, hardness or defects and replace if necessary. ☐ Install and tighten the oil drain plug. ☐ Remove the oil filter (Figure 19). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 34 3/4 to 1 turn to seat the gasket. ☐ Remove the filler cap on the WHASP Tank. Fill the WHASP Tank with VMAC compressor oil until is reaches the “MAX” mark. The air compressor system holds approximately 4 L (1 USG) of oil (Figure 21).
  • Page 35 Once the system has sat for 5 minutes, check the oil level through the sight glass and add oil as necessary. ☐ Verify there are no oil leaks. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 36: 400 Hour / 1 Year Service

    Inspect the Viton O-ring on the oil drain plug for damage, hardness or defects and replace if necessary. ☐ Install and tighten the oil drain plug. ☐ Remove the oil filter (Figure 22). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 37 3/4 to 1 turn to seat the gasket. ☐ Remove the filler cap on the WHASP Tank. Fill the WHASP Tank with VMAC compressor oil until is reaches the “MAX” mark. The air compressor system holds approximately 4 L (1 USG) of oil (Figure 24).
  • Page 38 Once the system has sat for 5 minutes, check the oil level through the sight glass and add oil as necessary. ☐ Verify there are no oil leaks. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 39: Diagnostics And Trouble Shooting

    Performing proper post repair testing to ensure that the repairs were effective. • Electrical testing should be performed according to the processes described in the troubleshooting charts and in conjunction with any documentation provided by VMAC. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 40 Compressor has shut Compressor down due to compressor Refer to related symptom Temperature Probe over temperature (145 °C on next page. Hot. / 293 °F). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 41 The normal operating too low or too high range for the DTC is • between 9.8 V and 16 V. Faulty or damaged DTC. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 42 See accessories on regulator installed. System pressure higher than page 51. tool requires. Aftermarket pressure Adjust pressure regulator to regulator set too high. desired pressure. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 43 SEIC restart delay (Ford only). blowdown, restart compressor. • Test system blowdown function. See page 27. Pressure switch detects • system is already pressurized. Pressure switch faulty. Replace pressure switch. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 44 Intake valve failure. necessary. Symptom Possible Cause Corrective Action Oil drips from clutch after Contact VMAC dealer to Input shaft leaking. shut down. replace input shaft seal. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 45: Adjusting The Pressure Switch

    “cut-out” pressure must be set below the lowest rated pressure of any components in the system. In applications that require pressures below 150 psi, VMAC recommends leaving the maximum pressure set at 150 psi and installing a regulator downstream to regulate pressure to the desired amount.

  • Page 46: Performance Testing And System Adjustments (Analog Throttle Control)

    Try reducing the engine speed and observe the performance. When testing the system or adjusting the VMAC throttle control, ensure the system does not exceed 3,000 engine rpm. Exceeding this speed will cause erratic system performance and in extreme cases may also cause long term damage to the compressor.
  • Page 47 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 40 cfm (5/32 in) orifice in the outlet to simulate tool use (Figure 28).

  • Page 48: Performance Testing And System Adjustments (Digital Throttle Control)

    The DTC is located under the dashboard panel near the steering wheel. Maximum VMAC rpm can be adjusted via the “MAX RPM” ““ or “” buttons (in 50 rpm increments). After pressing one of the buttons, the throttle will temporarily jump up to the new maximum rpm.
  • Page 49 Open the ball valve slowly, until the system maintains approximately 85 psi. ☐ Allow the system to run for 3 minutes while the VMAC digital throttle calibrates itself. During this time, engine speed may gradually increase until achieving the maximum VMAC rpm.
  • Page 50 Compressor Performance Testing (Digital Throttle) 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 40 cfm (5/32 in) orifice in the outlet to simulate tool use (Figure 30).

  • Page 51: Air Receiver Tank

    Prior to performing any service work on the system, discharge any stored air in the air receiver tank. The VMAC WHASP Tank has a built-in check valve. Use of an additional check valve is not required and may cause erratic performance.

  • Page 52: Recommended Accessories

    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 51 for a list of products available for purchase through VMAC.

  • Page 53: Accessory Products From Vmac

    Compressor Service Kits 200 Hour or 6 Month Service Kit - Part number: A700263 Includes 4 L VMAC high performance compressor oil, oil filter, air filter, and next service due decal. 400 Hour or 1-Year Service Kit - Part number: A700264...
  • Page 54 Recommended for optimum operation of VMAC Hydraulic Air Compressors, VMAC Diesel Driven Air Compressors, UNDERHOOD 40, UNDERHOOD 70 and 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.
  • Page 55 Harness Extension Part number: A700265 This interface harness extension provides an additional 10 ft of cable which allows for greater flexibility in locating the interface panel. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 56 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 57 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 58: Warranty Registration

    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.
  • Page 60 Manufactured by ® 888-241-2289 tech@vmacair.com 877-740-3202 warranty@vmacair.com www.vmacair.com www.kb.vmacair.com 1333 Kipp Road, Nanaimo, B.C., V9X 1R3 Canada...

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