Vmac UNDERHOOD 40 Series Owner's Manual
www.vmacair.com
UNDERHOOD 40 Truck and Van
Series Owner’s Manual
www.vmacair.com
Table of Contents
General Information ...........................................................3
Safety ......................................................................... 4
Safety Precautions ............................................................. 5
Warranty ......................................................................8
System Specifications .........................................................10
Identifying Your System ....................................................... 11
System Components .......................................................... 12
Operating Principles .......................................................... 17
System Operation ............................................................19
General Maintenance Information .............................................22
Maintenance and Repair Safety ...............................................23
Regular Inspection Instructions ...............................................26
200 Hour / 6 Month Service ..................................................31
400 Hour / 1 year Service ................................................... 34
Diagnostics and Trouble Shooting .............................................37
Adjusting the Pressure Switch ............................................... 43
Performance Testing and System Adjustments (Analog Throttle Control) ..... 44
Performance Testing and System Adjustments (Digital Throttle Control) ...... 46
Air Receiver Tank .............................................................49
Recommended Accessories .................................................. 50
Accessory Products from VMAC .............................................. 51
Warranty Registration ....................................................... 56
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1
Document: 1930335
Changes and Revisions
Checked by
Revision Revision Details Revised by
A Initial Release MSP KRM AJH GB AWG 21 Feb 20 18
B ECN: 20- 024 Add digital throttle MSP N/A ASE MSP LPH 22 Ja n 2020
Eng.
Mech. Elec.
Tech . Qu al.
Implemented
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.
Important 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 prior to initiating or proceeding with installation, service, repair or
operation. Current information may clarify the issue. Any person 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 assure 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 any
person to properly adhere to standard safety practices or the procedures set
out in this manual. Safety should be the first consideration when operating, or
performing any service to the equipment. If there are any questions concerning the
procedures in this manual, or more information is required, please contact VMAC
before beginning repairs.
Notice
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
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
2
VMAC - Vehicle Mounted Air Compressors
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General Information
Introduction
This manual provides operating instructions, specifications, adjustment,
maintenance and warranty information for the VMAC UNDERHOOD 40 Truck
and Van Series Air Compressor systems. Read this manual prior to servicing or
operating the compressor system.
Follow all safety precautions when servicing or operating the VMAC system as
moving drive belts, fan blades and other rotating components pose an extreme
hazard.
Proper service and repair 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 the only approved methods of service
and operation.
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 specific installation 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.
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.
Additional Support
Additional resources such as installation manuals, illustrated parts lists, the VMAC
Knowledge Base, air tool consumption guides, etc. are available at
https://www.vmacair.com/support/.
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3
Safety
Safety Messages
This manual contains various warnings, cautions and notices that must be
observed to reduce the risk of personal injury during operation or service, and
the possibility that improper operation or service 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.
4
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Safety Precautions
As the VMAC compressor system is an industrial grade compressor,
it is assumed that the operator has been trained in industry specific
safety practices.
Read this information before operating the compressor for the first time. Follow
the information and procedures in this manual for operation, maintenance and
repair.
Follow all safety precautions for safe operation or service. Moving belts and
rotating components are an extreme hazard. Stay clear of all moving parts when
the system is operating. Only qualified personnel should perform maintenance and
repair on system components and only while the system is properly shut down and
depressurized.
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. Some procedures may require the use of special tools designed for a
specific purpose. Anyone using a replacement part, service procedure or tool must
ensure that neither their safety, nor the safe operation of the equipment will be
compromised by the replacement part, service procedure or tool selected.
Harmful Vapours
Breathing fuel vapours or engine exhaust can expose you to chemicals
known to the State of California to cause cancer and birth defects or
other reproductive harm.
Always start and operate the engine in a well ventilated area.
•
Do not breathe engine exhaust, internal combustion engines
•
produce carbon monoxide, a poisonous odorless gas which can
cause death. Do not start or operate this compressor in an
enclosed area.
If in an enclosed area, vent the exhaust to the outside and ensure
•
there is adequate access to fresh breathable air..
Burn Hazard
The compressor system gets very hot during operation, contact
•
with the components or the oil can cause serious injury. Allow
sufficient time for the system to cool before performing service.
Never allow any part of your body to contact the engine or
•
compressor components.
Do not attempt to service the compressor until it has sufficiently
•
cooled.
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5
Personal Safety
Follow all safe work practices.
•
Do not breathe the compressor air. Vaporized oil is a respiratory
•
hazard.
Service should only be performed by qualified personnel.
•
Always use the appropriate personal protective equipment,
•
particularly eye and hearing protection when operating or servicing
air powered equipment.
Do not leave the vehicle unattended.
•
Fire and Explosion Hazard
Vaporized oil propelled by high pressure air is a potentially
•
explosive mixture.
Fire in the compressor can cause an explosion and flame projection.
•
Should this occur, there is potential for serious injury or death.
Operate the compressor system in a well ventilated area free of
•
flammable vapors, dust, or other combustible materials.
Never place objects against or near the compressor components.
•
Never expose the WHASP Tank or compressor to extreme heat.
•
Serious injury or death may result from an air tank explosion.
•
Never exceed manufacturer’s maximum air pressure rating.
•
Do not repair components, only replace with approved parts.
•
Do not tamper with or disable factory safety equipment.
•
Compressor Air and Oil Hazard
The compressor system is under sufficient pressure that a leak
•
could force the air/oil mixture through the skin directly into the
bloodstream. This could cause serious injury or death.
Ensure the system is completely depressurized before attempting
•
maintenance or repair.
Do not use compressed air to clean off clothing or skin, compressed
•
air can penetrate the skin causing serious injury or death.
Do not service the compressor while it is pressurized or operating.
•
Components and hoses under pressure could separate suddenly,
•
causing serious injury or death. If equipped, the air receiver
tank must be drained before servicing any components in the
compressor system.
Never adjust or attempt to make any repairs to the system while
•
the engine is running.
6
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Moving Parts Hazard
Before performing service, disconnect the negative battery cable.
•
Avoid contact with drive belts and other moving parts while the
•
system is in operation.
General Warnings
Be attentive for unexplained changes in operation and record any
•
changes.
Check the compressor oil level and condition before starting the
•
system. Do not add or change oil while the system is running. Use
only approved oil.
The compressor operates anytime the engine is running.
•
Keep hoses and wiring away from hot, sharp, or moving
•
components.
Use only approved hoses and replacement parts.
•
Do not modify the equipment.
•
Do not operate the air compressor when fatigued or under the
•
influence of alcohol or drugs.
Know how to operate the compressor, read this manual prior to
•
operation.
Inspect equipment before every use.
•
Never bypass or disable any of the safety equipment.
•
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.
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7
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)
O
N
V
N
A
I
R
I
A
A VMAC Lifetime Limited Warranty is offered
on the base air compressor only and only on
UNDERHOOD, Hydraulic Driven, Transmission
Mounted, Gas and Diesel Engine Driven Air
Compressors, Multifunction Power Systems, and
other products as defined by VMAC, provided that
LIFETIME
WARRANTY
T
R
U
S
T
(i) the purchaser fully completes and submits a
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.
T
E
D
E
U
L
A
V
S
E
E
C
R
I
V
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
warranty@vmacair.com
(877) 740- 3202
VMAC - Vehicle Mounted Air Compressors
1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3
8
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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/
1. 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, hours on the
compressor and mileage on the vehicle.
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.
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 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).
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9
System Specifications
Model
• UNDERHOOD 40 Truck/Van Series Air Compressor.
Compressor Type
• Flooded lobe, rotary screw.
Drive System
• Front End Accessory Drive (FEAD).
Control
• Electric on/off 12 V clutch control.
Maximum Air Delivery
• Up to 40 cfm @ 150 psi (dependent upon vehicle installation and engine speed).
Pressure Regulation
• Mechanical pressure switch on the air/oil separation tank signals the
compressor clutch to engage/disengage in response to air demand.
Engine Control
• Single speed throttle control (Maximum rpm adjustable by the end user).
• Elevated engine speed in response to air demand.
Safety Features
• 200 psi (1380 kPa) pressure relief valve in the Waste Heat Air Oil Separation
Package (WHASP) Tank.
• 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.
Lubrication
• VMAC High Performance Compressor Oil.
Filters
• Air filter: Replaceable paper element.
• Oil filter: High pressure spin-on.
• Coalescing filter: High pressure spin-on.
10
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Identifying Your System
The System ID will be requested any time that parts are ordered, when calling for
technical support or submitting a warranty claim.
The system ID is the preferred method of identifying the system as it serves as
a master record of all of the components in the system. The system ID plate is
generally found on the radiator cross member, or in some instances, the inner
fender or firewall (Figure 1).
Figure 1 — System ID location
An alternative method of identifying the system is via the compressor serial
number which is found on a plate attached to the compressor. This is a less
desirable method of identifying the system as it may not link back to the original
system if it has been replaced.
System ID breakdown
The system ID provides specific information about the system such as the model,
revision, production date and the unique identifier (Figure 2).
V400001 A BC 123
Model number
Revision letter
Figure 2 — System ID breakdown
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Unique identifier
Production date code
11
System Components
The UNDERHOOD 40 Air Compressor system consists of the following components:
• Waste Heat Air Separation Package
(WHASP) Tank.
• Compressor.
• Oil return, Air/Oil discharge hoses.
WHASP Tank
Pressure
relief valve
Air outlet
Oil filter
• PTFE oil scavenge tube.
• Control module.
• Interface panel.
• Throttle control.
Coalescing
filter
Blowdown
muffler
Minimum
pressure
check valve
Oil return
fitting
Oil scavenge fitting
(includes check valve)
Oil fill cap
Oil drain
12
Air/oil
inlet
Fan
Pressure
switch
Oil sight glass
Figure 3 — W HA SP Tank
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Compressor
Air filter
Air intake
Clutch
Temperature probe
and harness
Figure 4 — Compressor
(Top inlet version)
Oil scavenge
Air/oil
discharge
Oil return
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. Please contact VMAC for replacement
hoses/tubes or for further information.
Hoses must have an AQP liner.
•
Oil scavenge tubes must be PTFE.
•
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.
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13
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
(switched), and
WHASP fan
Clutch, throttle
control, and
Interface panel
Figure 5 — Control module
WHASP
pressure
switch
Compressor
temperature
sensor
Interface Panel
The interface panel serves as the operator’s control panel and contains the
“ON/OFF” switch, compressor status light, and the compressor hour meter.
Compressor
hour meter
Compressor
status light
“ON/OFF”
switch
Control
module plug
14
Figure 6 — Interface panel
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Throttle Control (Figure 7, Figure 8, Figure 9)
The throttle control responds to signals from the control module and commands the
vehicle’s throttle to increase or decrease engine speed in response to air demand.
The throttle control also allows the operator to configure the vehicle’s engine speed
(when air is demanded) to their needs (maximum cfm, specific tool requirements,
fuel efficiency, or a combination of these factors).
VMAC Digital Throttle Control
Accelerator
pedal
Not used
Figure 7 — VMAC digital throttle control
VMAC Analog Throttle Control
Figure 8 — Analog VMAC throttle
Ford Stationary Elevated Idle Control (SEIC) Compatible Throttle Control
Engine speed
adjusting
knob
OBDII
Not used
Control module,
transmission, park
brake, ground
“SPEED1”
adjusting screw
(under side)
Figure 9 — VMAC throttle control for Ford SIEC systems control
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15
Component Placement Overview
Van Layout
Control
module
WHASP
Pickup layout
Control
module
Tan k
Compressor
Throttle
control
Interface
panel
Figure 10 — General component overview
(Actual installation locations may vary)
Compressor
16
Throttle
control
WHASP
Tan k
Interface
panel
Figure 11 — General component overview
(Actual installation locations may vary)
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