Vmac V400041 Installation Manual
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Vmac V400041 Installation Manual

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Installation Manual for VMAC
System
V400041
2023 + Ford F - 250 – F - 600 Super Duty
7.3 L Gas
www.vmacair.com

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Summary of Contents for Vmac V400041

  • Page 1 Installation Manual for VMAC System V400041 2023 + Ford F - 250 – F - 600 Super Duty 7.3 L Gas www.vmacair.com...

  • Page 3: Table Of Contents

    Accessory Products from VMAC ........48...
  • Page 4 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...

  • Page 5: Safety

    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.

  • Page 6: 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 7 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. VMAC will provide direction for repair or replacement of the failed components.

  • Page 8: General Information

    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.
  • Page 9 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.

  • Page 10: Preparing For Installation

    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.
  • Page 11 Figure 2 — Remove intake tube ☐ Disconnect the fan clutch harness. ☐ Remove the fan clutch stator arm (Figure 3). Stator arm Figure 3 — Remove fan clutch stator arm VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 12 ☐ Remove the idler from the alternator bracket (Figure 4). ☐ Remove the alternator bracket (Figure 4). ☐ Remove the idler from the VMAC supplied bracket. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 13: Installing The Main Bracket And Compressor

    (Figure 6). Figure 6 — Install alternator ☐ Using the OEM fasteners, install the primary alternator onto the main bracket (Figure 6). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 14 (Figure 7). Figure 7 — Isolate secondary alternator harness ☐ Install the OEM, and supplied idlers (Figure 8). OEM idler VMAC idler Figure 8 — Install idlers VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 15 Figure 9 — Mount compressor ☐ Remove the spark plug wire (nearest the VMAC main bracket) from the ignition solenoid and, using the 3/4 in heat wrap, wrap the wire as close to the end of the boot as possible (Figure 10).
  • Page 16 ☐ Install and tension the VMAC FEAD belt (Figure 11). Figure 11 — VMAC FEAD belt routing ☐ Reinstall fan clutch stator arm. ☐ Reconnect the fan clutch harness. ☐ Route the clutch ground wire under the air intake spigot and to the back of the compressor.
  • Page 17 Figure 13 — Mount pressure switch ☐ Mount the air filter assembly onto the compressor (Figure 14, Figure 15 on page 16). Figure 14 — Install air filter assembly VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 18 Figure 15 — Pressure switch and air filter assembly VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 19: Installing The Waste Heat Air Separator Package (Whasp) Tank

    WHASP Tank and bulkhead fittings. Hose lengths can be found on page 20 or in the IPL. If the WHASP Tank or bulkhead fitting location requires longer hoses, contact a local VMAC dealer. See page 6 for ordering information .
  • Page 20 18 1/8 in 15 3/8 in 4 1/2 in 5/16 in or M8 mounting holes Figure 16 — Minimum WHASP Tank mounting clearances VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 21 (Figure 18). Front of vehicle Provide a minimum of 6 in of clearance for air flow Figure 18 — WHASP ventilation VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 22: Hose Requirements

    • 1/4 in (PTFE Tube) × 24 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.

  • Page 23: Connecting The Hoses

    Slide the collet out once the tube is fully inserted proper tubing cutters as side cutters will deform the tube. O-ring Figure 19 — Push-to-connect fittings VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 24 Route the 3/4 in hose toward the firewall and up, over the engine to the passenger side of the vehicle (Figure 21). 3/8 in hose and 1/4 in PTFE tube Figure 21 — Route hoses VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 25 ☐ Route the hose bundle down between the frame and the fender liner, toward the rear of the vehicle (Figure 23). Figure 23 — Route hoses VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 26 Figure 25 — Route hoses ☐ Using the supplied cable ties, secure the 3/8 in hose and PTFE tube to the 3/4 in hose (Figure 25). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 27 Use of an air receiver tank (minimum 6 USG) is required with this application. Follow the instructions on page 39 of this manual to prevent damage to the system. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 28: Adding Oil To The System

    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.

  • Page 29: Installing The Control System

    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. •...
  • Page 30 Tying into OEM connectors Some OEM connectors may have locking tabs that must be disengaged prior to inserting a crimped connector. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 31 Control Components Overview Compressor Control module Throttle control WHASP Tank Interface panel Figure 29 — 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 32 Control Module (Figure 30) The control module serves as the primary input/output interface between the vehicle and the various VMAC components (compressor, throttle control, WHASP Tank, interface panel, etc.). Power, 12 V Clutch, throttle WHASP Compressor (switched), and control, and...
  • Page 33 Figure 32 — VMAC digital throttle control Mechanical Pressure Switch (Figure 33) The mechanical pressure switch is mounted on the side of the WHASP Tank and limits the maximum pressure to a safe amount by disengaging the clutch once system pressure is achieved.
  • Page 34 Figure 34 — Electrical schematic VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 35 Remove the kick panel beside the hood release lever. ☐ Locate the black C264 connector (Figure 35). Hood release lever C264 connector Figure 35 — Locate C264 connector VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 36 Ensure the fuse holder is installed as close to the power source as possible. ☐ Connect the other end of the fuse holder to the positive battery terminal. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 37 ☐ Install the interface panel in a suitable location (Figure 37). 3.50 in 2.50 in 2.69 in 3.79 in Figure 37 — Interface panel mounting dimensions VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 38 ☐ Ensure all wires and harnesses are protected with loom and routed away from sharp, hot, or moving components and away from high traffic areas. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 39: Completing The Installation

    Completing the Installation ☐ Check all VMAC and OEM wiring to ensure it will not contact any hot, sharp or moving components and will not interfere with the operation of the vehicle. Secure all wiring with rubber coated P-clips, cable ties and loom as required.
  • Page 40 Figure 40 — Operating Instruction label ☐ Install the VMAC belt routing diagram in a suitable location under the hood. 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 warranty, parts and repairs.

  • Page 41: Air Receiver Tank

    This is normal operation. 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 42: 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 48 for a list of products available for purchase through VMAC.

  • Page 43: Testing The Installation

    If the vehicle fails the test, ensure the wiring to all of the connections are correct and secure. If additional assistance is required, contact your local VMAC dealer or call VMAC Technical Support 1-888-241-2289 or 250-740-3200. Safety Test Ensure the following has been completed: ☐...
  • Page 44 Add oil as necessary to bring the level to the “FULL” line in the sight glass and check for leaks. ☐ Install the VMAC Air Test Tool (P/N: A700052) with the 40 cfm (5/32 in) orifice installed and the ball valve closed. ☐...
  • Page 45 Repeat the steps marked with asterisks for all transmission selector positions, returning the gear selector to “PARK” and cycling the compressor “OFF”, then “ON” after each gear is tested. The VMAC System should not run, and the engine speed should not increase, unless the vehicle is in “PARK”. ☐...
  • Page 46 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). The WHASP Tank cooling fan is thermostatically controlled, and may start or stop without warning.

  • Page 47: Performance Testing And System Adjustments

    Adjustments 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 44).

  • Page 48: 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...
  • Page 49 The cfm produced by the system is directly related to engine speed; this system delivers 30 cfm at 2,900 rpm. Maximum VMAC rpm can be adjusted between 2,000 rpm and 2,900 rpm (in 50 rpm increments) via the ““ or “” buttons in the “MAX RPM” column.

  • Page 50: 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 51 Air receiver tanks are used for lowering compressor duty cycle and removing water from compressed air; recommended for optimum operation of all VMAC Gas Driven, Diesel Driven, Hydraulic, and UNDERHOOD40 air compressors. Manufactured to FMVSS 121 standard; includes fittings, 170 psi pressure relief valve, and tank drain.
  • Page 52 Interface 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 53 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 54: 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 56 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...

This manual is also suitable for:

Underhood 40

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