Vmac UNDERHOOD 40 Installation Manual
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Vmac UNDERHOOD 40 Installation Manual

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Installation Manual for VMAC
System
V400052
With Advanced Digital Controls
2023 + Ford F - 250 — F - 350 Super Duty
6.8 L Gas
www.vmacair.com

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Summary of Contents for Vmac UNDERHOOD 40

  • Page 1 Installation Manual for VMAC System V400052 With Advanced Digital Controls 2023 + Ford F - 250 — F - 350 Super Duty 6.8 L Gas www.vmacair.com...

  • Page 3: Table Of Contents

    Accessory Products from VMAC ........
  • Page 4 Copyright © 2024 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 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.

  • 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 https://www.vmacair.com/support/find-a-dealer...
  • 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 (alternate location) WHASP 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 Figure 7 — Remove intake tube ☐ Disconnect the fan clutch harness. ☐ Remove the fan clutch stator arm (Figure 8). Stator arm Figure 8 — Remove fan clutch stator arm VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 15 Remove the Primary alternator and fasteners (Figure 9). ☐ Remove the idler from the alternator bracket (Figure 9). ☐ Remove the idler from the VMAC supplied bracket (Figure 9). ☐ Remove the alternator bracket (Figure 9). ☐ Dual alternator only: Remove the stud from the bracket as it will be reused (Figure 10).

  • Page 16: Installing The Main Bracket And Compressor

    Using (×3) of the OEM fasteners, and the supplied bolt and washer, install the VMAC main bracket (Figure 12). 3/8 in washer M10×1.5×100 (×3) OEM fasteners Figure 12 — Install main bracket VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 17 (Figure 14). Figure 14 — Install alternator ☐ Using the OEM fasteners, install the primary alternator onto the main bracket (Figure 14). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 18 (Figure 15). Figure 15 — Isolate secondary alternator harness ☐ Install the OEM, and supplied idlers (Figure 16). OEM idler VMAC idler Figure 16 — Install idlers VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 19 ☐ 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 17). Figure 17 — Apply heat wrap ☐...
  • Page 20 Rotate the boot on the primary alternator cable 180°. ☐ Reconnect the primary alternator cable and wiring clip. ☐ Install and tension the VMAC FEAD belt (Figure 19). Figure 19 — VMAC FEAD belt routing ☐ Reinstall fan clutch stator arm.
  • Page 21 Mount the air filter assembly onto the compressor (Figure 22). Figure 22 — Install air filter assembly ☐ If necessary, trim the air filter hose to prevent it from touching the degauss bottle or hose. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 22: Installing The Waste Heat Air Separator Package (Whasp) Tank

    WHASP Tank and bulkhead fittings. Hose lengths can be found on page 23 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 23 18 1/8 in 15 3/8 in 4 1/2 in 5/16 in or M8 mounting holes Figure 23 — Minimum WHASP Tank mounting clearances VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 24 (Figure 25). Front of vehicle Provide a minimum of 6 in of clearance for air flow Figure 25 — WHASP ventilation VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 25: 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 26: 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 26 — Push-to-connect fittings VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 27 Route the 3/4 in hose toward the firewall and up, over the engine to the passenger side of the vehicle (Figure 28). 3/8 in hose and 1/4 in PTFE tube Figure 28 — Route hoses VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 28 ☐ Route the hose bundle down between the frame and the fender liner, toward the rear of the vehicle (Figure 30). Figure 30 — Route hoses VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 29 Figure 32 — Route hoses ☐ Using the supplied cable ties, secure the 3/8 in hose and PTFE tube to the 3/4 in hose (Figure 32). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 30 ☐ Secure all hoses, tubes, and wires with P-clips and/or cable ties. Use of an air receiver tank (minimum 6 USG) is required with this application. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 31: 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 32: Electrical Schematic

    Electrical Schematic Figure 35 — Electrical schematic VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 33: 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 34 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 35 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 36: Electronics And Control Component Installation

    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. Do not use any bolt as a ground location as the increased resistance could cause system brown-out when the high current fan kicks on.
  • Page 37 OEM wire Barrel Small cap Cap fully removed from tap for illustrative purposes only Figure 36 — Posi-Tap wire connector VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 38 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 39 Remove the kick panel beside the hood release lever. ☐ Locate the black C264 connector (Figure 37) Hood release lever C264 connector Figure 37 — Locate C264 connector VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 40 Route the harnesses along the OEM wiring harness, around the degas bottle, and over to the compressor. ☐ Connect the TEMPERATURE SENSOR T1 harness to the matching connector on the compressor. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 41 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 42: 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 43: 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 44: 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 45 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. ☐ Locate a conspicuous area in the engine bay (where the tag will be easily noticed) to install the System ID tag.

  • Page 46: 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 47: 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 48: 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 49 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 50 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 51 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 52: 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 53 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 53.

  • Page 54: 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 47).

  • Page 55: 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 56: Errors And Error Codes

    • High power radio frequency interference. • Clutch wire unplugged or No current on damaged. xx08 CLUTCH OPEN compressor clutch/ • Harness damaged. solenoid. • Bad clutch ground. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 57 • The two pressure sensor harnesses are reversed. • Blowdown system is Scavenge blowdown xx1E SCAVENGE PRESS pressure fault. damaged. • Blowdown valve blocked. • Scavenge line blocked. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 58 • The Controller is getting xxC1 MCU TEMP (above 83 °C / 181 °F), or too hot or too cold. too low (below -38 °C / -36 °F). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 59 DTC error: Battery damaged, unplugged, or xxEB DTC: BATT V HI/LO voltage too low or too partially connected. high. • Vehicle battery voltage too high or too low. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 60 Harness connecting DTC to xxEC DTC: NO VCAN communication with Controller is damaged. Controller. DTC error: wrong DTC xxED DTC: WRONG FW Wrong DTC for application firmware version. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 61: 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 62 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 63 Display Harness Extension Part number: 3530861 This display harness extension provides an additional 10 ft of cable which allows for greater flexibility in locating the display Panel. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 64 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 65 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 66: 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 68 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...

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V400052

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