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Vmac UNDERHOOD 40 Installation Manual

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Installation Manual for VMAC
System
V400044
With Advanced Digital Controls
2023 + Ford Transit
3.5 L Gas PFDI Duratec
www.vmacair.com

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Summary of Contents for Vmac UNDERHOOD 40

  • Page 1 Installation Manual for VMAC System V400044 With Advanced Digital Controls 2023 + Ford Transit 3.5 L Gas PFDI Duratec www.vmacair.com...

  • Page 3: Table Of Contents

    Accessory Products from VMAC ........66...
  • 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

    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.
  • Page 7 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 8: General Information

    VMAC dealer or sourced locally. Refer to this Knowledge Base article for compatible hoses: EXT-ALL-010-Required-VMAC-Hoses.pdf 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: Component Identification And Overview

    (e.g. inside the cab, service body or cabinet). Control Components Overview Compressor Display Controller Display Box WHASP (alternate location) Tank Figure 1 — 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 11 Control Module (Controller) (Figure 2) The control module serves as the primary input/output interface between the vehicle and the various VMAC components (compressor, DTC, WHASP Tank, Display Box, etc.). Figure 2 — Control module Display Box (Figure 3) The display box serves as the operator’s control panel and contains the “ENTER”...
  • Page 12 The system pressure sensor is mounted on the side of the WHASP tank and measures the system pressure. The clutch will disengage once system pressure is achieved. Pressure sensor Figure 5 — WHASP Tank pressure sensor VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 13: 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 14 Leave the seatbelt connected to the seat and lift the seat off of its mount; place the seat on the floor outside of the driver side of the van. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 15 Disconnect the negative battery cable(s) from the battery terminal stud (Figure 10). Remove negative battery cable Figure 10 — Battery cables ☐ Remove the center console or step guard. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 16 OEM 6 rib belt from the crank pulley. Tuck the belt out the way (Figure 12). Tensioner bolt Figure 12 — Remove 6 rib belt VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 17 Remove the bolt and Christmas tree fastener from the driver side cable tray and set them aside for later (Figure 14). Remove bolt and Christmas tree fastener Figure 14 — Remove cable tray VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 18 Figure 15 — Remove cable tray ☐ Remove and discard the timing cover bolts (Figure 16). Remove bolts Figure 16 — Remove timing cover bolts VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 19 Leaving the A/C lines connected, remove the A/C compressor and secure it up and out of the way (Figure 17). Remove A/C compressor Figure 17 — Remove A/C compressor VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 20: Main Bracket And Compressor Installation

    Reinstall the A/C compressor onto the engine. ☐ Using the (×2) supplied M8×1.25×50 mm bolts, install the 4 rib belt tensioner onto the VMAC main bracket (Figure 19). Figure 19 — Install tensioner VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289...
  • Page 21 (in the orientation shown) onto the main bracket (Figure 21). Attach pressure sensor assembly to rear compressor bolt Figure 21 — Mount compressor VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 22 ☐ Install and tension the supplied 4 rib VMAC compressor belt, ensuring that it is centered on the compressor clutch (Figure 22). Figure 22 — Route VMAC belt ☐ Reinstall and tension the OEM 6 rib belt (Figure 23). Figure 23 — 6 rib belt routing...

  • Page 23: Waste Heat Air Separator Package (Whasp) Tank Installation

    WHASP Tank and bulkhead fittings. Hose lengths can be found on page 27 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 24 18 1/8 in 15 3/8 in 4 1/2 in 5/16 in or M8 mounting holes Figure 24 — Minimum WHASP Tank mounting clearances VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 25 (Figure 26). Front of vehicle Provide a minimum of 6 in of clearance for air flow Figure 26 — WHASP ventilation VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 26: Bulkhead Fittings Installation

    26 of this manual. Figure 27 — Bulkhead fittings (A700224 Remote Muffler accessory shown) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 27 This kit includes hoses of an adequate length to connect to the location specified in this manual. If installing in an alternate location: • Contact a VMAC dealer to order hose extensions. • If sourcing custom length hoses locally, Refer to this Knowledge Base article for compatible hoses: EXT-ALL-010-Required-VMAC- Hoses.pdf.
  • Page 28 Apply Loctite 567 (thread sealant) when installing the 1/4 in push-to-connect fittings in the bulkhead fittings (Figure 29, Figure 30). Figure 29 — Interior View Figure 30 — Exterior View VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 29: Hose Requirements

    • 1/4 in (PTFE Tube) × 108 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 30: Hose Installation

    Slide the collet out once proper tubing cutters as side cutters the tube is fully inserted will deform the tube. O-ring Figure 31 — Push-to-connect fittings VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 31 Apply Loctite 567 (thread sealing) compound to the supplied fitting and install it into the blowdown solenoid (Figure 33). Install fitting Figure 33 — Install fitting VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 32 ☐ Route the 1/4 in PTFE tube to the bulkhead fitting, ensuring the tube will not kink or be damaged from incidental damage from other operations. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 33 Connect the discharge fitting (#8 male JIC) to the customer’s air system (hose not supplied). ☐ Secure all hoses, tubes, and wires with P-clips and/or cable ties. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 34 Direct the hose toward the rear of the vehicle, between the engine and the crossmember (Figure 38). Figure 38 — Install 3/4 in hose VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 35 2 supplied P-clips and 5/16 in × 3/4 in sheet metal screws in the existing holes on the frame (Figure 40). P-clips Figure 40 — Hose routing along inside of driver side frame VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 36 Use cable ties, rubber coated P-clips, and suitable hose protection as required. If the vehicle is 4WD, ensure the hoses are protected from the front driveshaft. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 37: 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 38: Electrical Schematic

    Electrical Schematic Figure 44 — Electrical schematic VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 39: Harness Reference

    Batt “+” (Ring terminal) Colour Function Notes Connect to battery “+“ terminal. — VMAC System 12 V power Power supply for VMAC system. Protected with 20 A inline fuse. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 40 Green Ground — 12 V power output from Switched power from Controller. Yellow Controller (Activate 12 V when compressor clutch is Compressor) engaged, 0 V otherwise. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 41 Colour Function Notes Green Ground — 12 V power output from 12 V when blowdown solenoid is Yellow Controller (activate engaged, 0 V otherwise. blowdown solenoid). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 42: Electronics And Control Component Installation

    Component Installation Best Practices • Ensure the system ground is connected to the VMAC recommended ground locations whenever possible. These locations are designed to be used as a ground point and can handle high currents while providing a low resistance connection.
  • Page 43 OEM wire Barrel Small cap Cap fully removed from tap for illustrative purposes only Figure 45 — Posi-Tap wire connector VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 44 If lengths greater than this are required, consult VMAC Technical Support prior to installation. VMAC’s UNDERHOOD 40 Air Compressor systems require up to 20 A at 12 V dc (nominal) to operate. A 20 A inline fuse is included on the red power supply line.
  • Page 45 Figure 46 — Install display box ☐ Remove the battery and battery box (Figure 47). Remove battery and battery box Figure 47 — Remove battery box VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 46 Remove the light switch panel to the left of the steering wheel (disconnect the (×2) harnesses. ☐ Remove the plastic subframe (Figure 49). Remove frame Figure 49 — Remove dash sub frame VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 47 Using the DTC as a template, drill (×4) holes in the fuse box cover. ☐ Using cable ties, mount the DTC to the fuse box cover (Figure 51). Figure 51 — Mount DTC ☐ Reinstall the fuse box cover. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 48 *If pin 6 is already populated: Splice the violet wire (“KEY SW PWR”) into the existing wire populating pin 6 (Figure 52). 10 pin connector Figure 52 — Connect key switch power VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 49 *The grey wire from the DTC to the wire at pin 9 (CAN L). ☐ *The blue wire from the DTC to the wire at pin 10 (CAN H). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 50 Follow the hose routing path under the engine oil pan, and over the front subframe crossmember, towards the passenger side of the vehicle (see Figure 39 on page 33). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 51 Plug the “BLOWDOWN SOL” harness into the solenoid on the WHASP tank. ☐ Coil any excess harness and secure it safely out of the way. ☐ Using cable ties and/or rubber coated P-clips, secure the harnesses. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 52: Telematics Integration (Optional)

    The supplied VMAC display box contains the 120 Ω termination resistor and has CAN packet acknowledgment. • If the supplied VMAC display box is not used the following are required: 120 Ω termination resistor across CAN signal lines. Ǜ CAN packet acknowledgement.

  • Page 53: Remote Start Integration (Optional)

    Remote Start Integration (Optional) The “system on” command is registered after 3 seconds. VMAC recommends programing 3rd party controls or relay actuation for 4 seconds to allow sufficient time for the command to register. A remote start/stop option is available on a signal line provided in the upfitter harness.

  • Page 54: Installing The Air Filter And Power Steering Reservoir

    The VMAC air filter fastener pack is shared with other UNDERHOOD kits. Please discard the parts that are not used. ☐ Mount the VMAC air filter assembly to the supplied bracket using the supplied M6 nylon lock nuts (Figure 57). Figure 57 — Air filter and bracket (A/C compressor removed for clarity) ☐...

  • Page 55: Completing The Installation

    Using the supplied bracket and fasteners, secure the passenger side of the lower engine cable run tray to the engine oil pan (Figure 60). Secure cable tray Figure 60 — Secure cable tray VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 56 Reinstall the center console. ☐ 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 57 Figure 63 — Operating Instruction decal The System Identification Plate must be attached to the vehicle at the time of installation. This plate provides information that allows VMAC to assist the operator with parts and repairs, and specific technical information. ☐...

  • Page 58: 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 59: Recommended Accessories

    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 VMAC system’s air discharge. Pressure Regulator and/or Lubricator or FRL The compressor can produce air pressures up to approximately 150 psi (1035 kPa).

  • Page 60: Testing The Installation

    The display should indicate “Park” only when the gear selector is in park. Note: Neutral is vehicle dependent and could display either “Park” or “Not in Park”. The VMAC system is safe to operate provided the vehicle is not in gear. ☐...
  • Page 61 Ensure all of the compressor outlets are closed. ☐ Ensure the parking brake is engaged and the transmission is in “PARK”. ☐ Start the engine. ☐ Allow the vehicle to reach operating temperature. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 62 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 63 Once the engine is turned off and the system has cooled:* ☐ *Check all components, connections and fasteners. ☐ *Check the compressor oil level. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 64: Basic Operation

    • Press and release the “ENTER” button to make a selection. • Press and hold the ”ENTER”/Power button for 3 seconds to power the VMAC system on. The power indicator on the display should change from “OFF to “ON”. Ǜ...
  • Page 65 Once the above conditions are confirmed, the compressor clutch will engage and the system will start building air. • Engine speed will elevate to “maxRPM” (this is defined by the VMAC system specific to the vehicle application). See “System Adjustment, Optimization, and Basic Parameters” on page 65.

  • Page 66: Performance Testing

    Performance Testing 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 68).

  • Page 67: System Adjustment, Optimization, And Basic Parameters

    VMAC rpm. ☐ With the VMAC system running and in “STANDBY”, mode, navigate to “Sys Parameters”. ☐ Adjust “Max RPM” to the desired value.

  • Page 68: 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 69 90° 3/8 in hose fitting P/N: 4900117. 3/8 in hose fitting for Oil Return Hose. 90° 3/4 in hose fitting P/N: 4900043. 3/8 in hose fitting for Compressor Discharge Hose. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 70 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 71 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 72 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 73 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 74: 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 76 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:

V400044V400039

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