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1. System Testing and Adjustment Tool A700052 39 5 1 Adjusting the Operating Pressure The operating system pressure can only be adjusted by setting adjustment parameters though the Display Box See Section 4 6 Adjustable System Parameters 5 2 Electronic Throttle Control Adjustment 1 Place the automatic transmission in park and fully apply the park brake 2 Allow the vehicle to run until the engine is at operating temperature 3 Operate the air compressor system until the oil is warm 4 Open the ball valve on the test tool and observe the engine tachometer The pressure should be about 100PSI Make sure that there are no restrictions to air flow If the system cannot produce maximum flow from the tank there will be no change in RPM when you turn the adjusting screw 5 Turn the maximum RPM adjustment screw clockwise to increase engine speed and counterclockwise to decrease maximum engine speed Count the turns in case you have to start over IDLE DOWN PRESSURE INCREASE INCREASE Figure 8 VR Throttle Controller Adjustment Screws 6 Close the air valve slowly to allow the system pressure to rise VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 40 7 Once the system pressure is at maximum slowly open the ball valve on the test tool until the pressure is approximately 10 PSI 68 95 KPA below maximum Engine speed s
2. End of Errors OK to Retry End of errors screen Pressing ENTER will try to restart the system 30 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 4 5 4 Warning Messages Listed below are additional messages which may be displayed If a message is present the red WARNING LED will flash on and off These messages appear in both the SYSTEM READY and SYSTEM RUNNING menus WARNING MESSAGE TABLE a Message Displayed cause 32 BATTERY VOLTAGE The battery voltage is too low TOO LOW 200HR 6MTH SERV This warning will show up 10 hours before the fe DUE IN xx HOURS 200 hour service interval The system is due for a service This warning will show after every 200 hours of running the 54 COMPRESSOR SERV compressor 200HR 6MTH Clearing the compressor service reminder is required through the Diagnostic menu p 400HR 12MTH SER This warning will show up 10 hours before the DUE IN xx HOURS 400 hour service interval The system is due for a service This warning will show after every 400 hours of running the COMPRESSOR SERV compressor 55 400HR 12MTH Clearing the compressor service reminder is required through the Diagnostic menu 62 LOW BATT The truck failed to start when requested to due RESTART to a low battery voltage condition 63 CAB TEMP The truck failed to start when requested to due RESTART to the c
3. Contact the nearest dealer to replace compressor gearbox assembly Refer to the dealer Maximum RPM setting higher than necessary to meet air demand requirements Reduce maximum RPM settings Engine RPM stays at base idle when compressor runs Throttle control not adjusted properly Adjust throttle controls Poor electrical connections Test and correct connections Throttle control not functioning Replace throttle control Pressure sensor defective or disconnected Check connections or replace pressure sensor Engine RPM over revs when compressor is activated Throttle controls not connected properly Check and correct connections Throttle control not setup properly Adjust high idle screw Pressure sensor defective or disconnected Check connections or replace pressure sensor Engine RPM does not return to base idle Wiring fault Check and correct wiring according to wiring diagram Throttle not properly adjusted Adjust idle down screw Engine RPM stays at maximum whenever the compressor is running Idle down setting is too high Reset idle down pressure Engine doesn t turn off in Standby state Bad STOP relay if equipped Replace STOP relay located on the control box mount bracket Truck and VR system power off fully instead of entering STANDBY state Bad HOT 12V relay Repla
4. e Pressing ENTER on this screen will display CANCEL e Pressing NEXT will show CONFIRM RESET Pressing BACK will display CANCEL again e Select the desired option and press the ENTER button The END OF USER SETUP screen informs the user there are no more user defined parameters e Pressing EXIT NEXT or ENTER will bring the user to USER SETUP SCREEN e Pressing BACK will bring the user to the first user defined parameter SYSTEM PRESSURE VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 26 4 4 Automatic Shutdown and Restart The system will enter STANDBY mode and shutdown the vehicle s engine if no air use is detected for a preset amount of time It will also enter STANDBY mode if the system was restarted for either low battery or low cab temperature and these have completed their cycle The LED beacon module will illuminate when the system is in STANDBY mode and capable of restarting when air use is detected The system can be restarted by using a large amount of air for a short time air rate or dropping of air pressure below an adjustable value The buzzer module will enable and alert the operator before the engine starts configuration For details see sections 4 2 Control System Operation and 4 6 Adjustable System Parameters The system may not restart due to system parameter When an error is detected the controls will automatically shut down the system I
5. Consequential damages caused by Product s failure Any Product s if other than VMAC s genuine components are used in the Product s Normal wear and tear of Product s VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 59 3 1 3 2 3 3 3 4 3 5 3 6 60 WARRANTY PERIOD The warranty period will commence upon installation of the Product s The returned warranty registration form marks the date of installation If the warranty registration form has not been received by VMAC within 6 months from the date of installation of the Product s then the warranty period will be deemed to commence 30 days from date of shipment from VMAC For the full warranty period to apply installation of Product s must be completed within 36 months from the date of shipment of the Product s from VMAC The following components of Product s are warranted against manufacturer defects in materials and workmanship for a period of 24 months or 2 000 hours of operation whichever expires first Compressor Brackets Air Oil Separator Tank Oil Cooler Control Box and Display Box and Throttle Controller All other components of Product s not listed in 3 2 are warranted against manufacturer defects in materials and workmanship for a period of 12 months or 1 000 hours of operation whichever expires first Replacement components of Product s listed in 3 2 excluding VMAC factory r
6. Pressure control line plugged or frozen Remove the pressure control line and clear any obstructions Blow out Relief valve defective Replace relief valve Power fuse blows Short to ground in the control circuit Locate and correct short or replace control panel Incorrect fuse Install correct OEM fuse Incorrect wiring Repair wiring according to wiring diagram Low air pressure Air flow is too high Reduce consumption System Pressure parameter set too low Increase System Pressure in User Setup Menu Throttle control set too low Increase maximum RPM settings Electrical inlet solenoid stuck open With the system off apply 12V and Ground to the red and black wires of the inlet solenoid It should make an audible click and transition from normally open to close state when powered If behavior not as described replaced electrical inlet solenoid Engine RPM excessive on initial startup and during operation Maximum RPM setting is too high Reduce maximum RPM setting throttle control or reset cable nipple Idle down pressure is too high Reduce idle down setting of the throttle control 56 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Objectionable noise level Excessive gear wear
7. air pressure drops below System Pressure minus Top up Pressure the inlet opens to build pressure Similarly the engine speed will be at VR IDLE RPM when air pressure is at System Pressure If an air tool is used and the air pressure drops below the throttle controller s Idle Down Pressure the engine speed will increase to build pressure If the air pressure stays above System Pressure minus Top up Pressure a timer will start counting down from the STANDBY DELAY value Whereas if air pressure drops below System Pressure minus Top up Pressure the system will reset this timer back to STANDBY DELAY If this timer is able to complete its count down from STANDBY DELAY the system will switch to the STANDBY state While battery voltage is below the adjustable upper threshold the system will remain in the RUNNING state If optional in cab temperature sensor is installed while the temperature is below the adjustable upper threshold the system will remain in the RUNNING state VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 18 System State STANDBY In STANDBY mode the control system will shut down the engine as it has detected no further air use the battery voltage level is in range and if installed the optional in cab temperature is within its range The control system is still operating and able to restart the system with air use if a low battery voltage is dete
8. and the clutch to burn out VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 35 4 7 4 Automatic Engine Shutdown and Restart See Section 4 4 Automatic Shutdown and Restart 4 8 Cold Climate Operation 1 Place the automatic transmission in park and fully apply the park brake 2 Start the vehicle engine and allow it to reach normal operating temperature 3 Allow the vehicle to run for an additional 15 minutes after reaching operating temperature to allow radiant heat transfer throughout the compressor system If the vehicle is to be used consistently in cold climates the use of a De icer kit VMAC part A700031 is recommended 4 Activate the compressor by pressing the ON ENTER button The clutch will engage and engine RPM will rise for a few moments while the compressor system comes up to pressure RPM will settle to the VR Idle RPM System is now in RUNNING mode and is ready for air use VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 36 4 9 Adding Oil to the System 1 Remove the fill plug remote oil fill if equipped from the inlet control valve sight glass Have someone watch the level as you add 1 The oil is clear and the level may be difficult to see in the oil Oil Fill Plug Figure 6 Compressor exact appearance varies by application 2 Pour oil into the oil
9. errors are present the system will go to SYSTEM READY menu 4 3 2 System Ready Menu If any messages are present the WARNING LED will flash on amp off and the messages displayed The unit will run as normal when messages are present If no messages are present both the READY and WARNING LEDs will be off The SYSTEM READY menu will change between the following screens SYSTEM READY VMAC PH 250 740 3200 VMAC WWW VMACAIR COM HOUR METER xxxx x Pressing ON ENTER will initiate the start sequence see section 4 2 Control System Operation Once parameters are in the operating range the SYSTEM RUNNING menu is entered Pressing and holding both the BACK and NEXT buttons for approximately 5 seconds will bring up the SETUP DIAGNOSTIC MENU VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 22 4 3 3 System Running Menu If any messages are present the WARNING LED will flash on amp off the READY LED will remain on and the messages will cycle on the display If no messages are present the display will cycle through the SYSTEM RUNNING AIR PRESSURE COMPRESSOR TEMP ENGINE SPEED TIME TO STANDBY HOUR METER and AIR PRESSURE RATE Pressing the NEXT or BACK buttons in SYSTEM RUNNING menu will take the user to the additional information menus where specific information about the sensors are displayed Pressing the ENTER or EXIT button will init
10. fill hole on the inlet control valve using a funnel It is important not to overfill the system Overfilling the system with oil can flood the sight glass window and make the system appear empty 3 As you add oil turn the compressor clutch clockwise with a ratchet and socket using the hex head cap screw at the center of the compressor clutch 4 Allow five minutes for the oil to drain into the tank then check the sight glass on the tank to ensure that the oil level is correct 5 Install the fill plug and tighten it securely VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 37 Sight Glass Window a Drain Plug VR70 Figure 7 Oil filter end of the Separator tank compressor oil Failure to use this oil will result in t You must use VMAC certified and approved synthetic damage to the compressor and may void your warranty VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 38 5 0 Adjusting the System If insufficient airflow is developed under high demand conditions check engine RPM When the inlet control valve is wide open approximately thirty engine revolutions are required to produce one cubic foot of air flow from the VR70 compressor The Throttle Control is adjusted at the factory to provide good results without adjustment in most typical compressor applications Some applications may
11. require adjustments to provide the necessary airflow and pressure This may also be required if system pressure is changed in the USER SETUP Menu from the factory setting of 150 PSI For detailed instructions on adjusting the electronic throttle controller see section 5 2 Electronic Throttle Control Adjustment Engine RPM adjustments must be made so that the amount of air delivered by the system matches the requirements of the tools or equipment that you will be using Airflow and system pressure are related If airflow demands on the system are low operating pressure will remain high If airflow demands are high operating pressure will reduce By making adjustments to the engine speed while operating a specific tool you will achieve optimum performance If you must set up a system without knowing the demands on the system you can make engine speed adjustments by using an orifice in the outlet to simulate tool use The diagram below shows a system testing and adjustment tool VMAC part A700052 that you can use to simulate different operating situations Install this tester to the tank output fitting before making any changes For 70 CFM application VR 70 use a 190 ORIFICE Q Ensure the correct orifice for the VR70 system is used part 3200224 0 200 PSI pressure gauge K Ball valve pj Tank fitting VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201
12. to the red and black wires of the inlet solenoid It should make an audible click and transition from normally open to close state when powered If behavior not as described replaced electrical inlet solenoid Engine stalls when compressor is activated System is under pressure Allow sufficient time for blow down Blow down valve not working Replace blow down valve RPM setting too low or throttle not set correctly Re adjust RPM and throttle settings for optimum operation Throttle control not connected properly at foot pedal Check for proper connections VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 55 SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Belt squeals when compressor switch is activated System is under pressure Allow sufficient time for blow down Blow down valve not working or muffler is plugged Replace blow down valve or clean muffler Improper belt tension Check belt tensioner Belt is glazed Replace belt Frequent relief valve operation Electrical inlet solenoid stuck closed With the system off apply 12V and Ground to the red and black wires of the inlet solenoid It should make an audible click and transition from normally open to close state when powered If behavior not as described replaced electrical inlet solenoid
13. S ETUP 10 Press EXIT to exit Setup Diagnostics Menu For details and an explanation for adjusting system parameters see section 4 3 6 Setup Diagnostic Menu VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 33 4 7 Operating Instructions 4 7 1 Diesel Particulate Filter Warning DPF When engine driven or PTO driven equipment is run on vehicles with DPF for extended periods of time particulate may build up in the filter All vehicles with a DPF have a warning light or message on the instrument panel or message center Run time until filter build up depends on many variables and is the responsibility of the operator to monitor It is suggested that if equipment is run for extended periods of time over 1 hour without driving the vehicle DPF warning system must be checked after 1 hour and every 15 min thereafter If the DPF warning light or message appears see the vehicle owner s manual for methods of cleaning or regenerating 4 7 2 Starting the Compressor System The vehicle must not be parked on grades exceeding 15 in slope as this may affect lubrication and air oil separation Figure 4 Maximum truck grade when running compressor 1 Place the automatic transmission in park and fully apply the park brake 2 Start and run the vehicle long enough for the engine to stabilize at base idle and reach normal operating temperature 3 Close the hood i
14. UNDERHOOD G User s Manual 1 00 ACCESSORY PRODUCTS FROM VMAC cccsseeeeees 3 2 0 GENERAL INFORMATION Quuuu cccsssssssssesscescssssessesseeseanenes 4 2 1 ORDERING PARTS POAPOA EE AE NA ES AEA STEES 4 2 2 IMPORTANT SAFETY NOTICE uu ccccseeeececceeeseeeeeeeeceeeseeeaneneees 4 2 3 SAFETY MESSAGES basi re e e ste See 5 2 4 SAFETY PRECAUTIONS cesseeiisesseseseeirsnrrsererrrrrreresrrrnrnrrnnesns 6 2 5 INSTALLATION INSTRUCTION 9 2 6 SYSTEM DGPECIEIGATIONS 10 3 0 OPERATING PRINCIPLES 0 cccccscsssssssesseesesssseseeseeeeees 11 3 1 OIL SEPARATION AND COOUNG 11 32A FILTRATION id otf hha ee AAA 11 3 3 BELT ALIGNMENT AND TENSIONING anaes 12 3 4 PRESSURE REGULATION AND ENGINE SPEED CONTROL 12 3 5 SAFETY DEVICES Ee ale eee vee te ee ae 13 3 6 EINE PROTECTION eet ted vel EENEG 13 3 7 SPECIAL INSTALLATIONNOTES 14 4 0 SYSTEM OPERATION cccccssccccesscsccsssssseeseeeeesessseseeseenseas 15 4 1 CONTROL GvSTEMEEATURES 15 4 2 CONTROL SYSTEM OPERATION 16 4 3 DISPLAY BoxyM seuGrEe 21 4 4 AUTOMATIC SHUTDOWN AND RHESTART eee 27 4 5 CHECKING MESSAGES AND EppOpng ee eens 28 4 6 ADJUSTABLE SYSTEM PARAMETERS iiesseseeeeeesereeeerrrrrnnnn 32 4 7 OPERATING INSTRUCTIONS ccceceeeseeceeeeeesseseeeeceseeseeaneneees 34 4 8 COLD CLIMATE OPERATION 36 4 9 ADDING OIL TO THE SYSTEM Qu cececeeeeeeeecceesseeeeeeeeceseeseeaneaeeee 37 5 0 ADJUSTING THE SYSTEM Qu ccctcsscessesseese
15. ab temp Be amp Cab temp not above upper 8 threshold for variable delay mins eo Sa 9j e ST Restarted from Low Cab temp amp topped up ZS EO Start Standby Delay D l Lo SR S e oO SS SE gS ge STANDBY delay reached Ot cm minimum 1 min of nan e ON ENTER Button Pushed or e DISABLE_AUTO_RESTART_DELAY reached STANDBY Figure 2 Control System Flow Diagram VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 4 2 1 Control System Terminology System State SYSTEM READY Compressor system is ready for operation and awaiting a start request A start request can be made by E Pressing ON ENTER from the Display Box LJ Grounding the REMOTE ON wire System State BLOW DOWN DELAY The BLOW DOWN DELAY is implemented by the control system before entering RUNNING mode as a built in safety feature for the system This delay is implemented for 10 or 30 seconds only when the system has come out of STANDBY or STOPPING states respectively i e It is implemented on subsequent restarts from STANDBY or STOPPING states but not implemented when the system starts for the first time VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 System State RUNNING When using an air tool the control system should be in the RUNNING state The inlet remains closed when air pressure is at System Pressure If the
16. ab temperature getting too cold 4 5 5 Checking Messages Stored messages can be checked by following instructions in Section 4 5 2 Viewing Stored Data logged Errors except Step 3 should consist of scrolling to VIEW LOGGED MESSAGES Stores messages can be decoded using the guide in section 4 5 3 Decoding Stored Errors However the first character of line 1 on the Display Box will be M instead of E This is to clarify that Messages are being shown and not Errors VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 31 4 6 Adjustable System Parameters SYSTEM PARAMETER TABLE Setting Description Adjustment Default 1 2 5 10 15 30 A Standby Delay Delay time to standby minutes Never 10 min Operating System 80 to 175PSI System Pressure Pressure 5PSI increments 150PSI PSI below system Top up Pressure pressure to allow inlet to 1 E PSI 5PSI open and build pressure ae Air rate set point for 0 to 30PSI 7 SE pressure based restart 0 5PSI increments 3 0PSl sec Restart Pressure Air pressure set point for 80 to 175PSI 120PS1 PSI pressure based restart 5PSI increments Always 30 min Disable Auto Timer for disabling SE eal a Restart Delay automatic engine restart 60 mn 90 min 120 30min min Never Controls if system will a Battery restart when battery Enable Disable Enabled estart vo
17. age to the system The line from the VMAC tank to the auxiliary air tank must have the supplied check valve and pressure sensor assembly installed to prevent VR tank s blow down from draining the auxiliary tank and to prevent moisture from entering the VMAC tank Do not add a secondary check valve as this will cause issues with the system The line to the auxiliary tank must not be installed in the bottom of the tank but must be installed as high as possible to prevent water from clogging the line Minimum Pressure Check Valve and Pressure Sensor Assembly Auxiliary Tank f M VR Air Oil Separator Tank AOST Iesse pel Install the line as high as possible NOT in the bottom of the auxiliary tank Figure 1 Integrated minimum pressure check valve VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 14 4 0 System Operation 4 1 Control System Features Ed Starting the control system with the Display box or Remote ON wire LJ Stopping the control system with the Display box or Remote ON wire LJ Automatic engine shutdown if no air use is detected LJ Automatic engine restart when air use is detected E Multiple adjustable system parameters for delays pressures and restart options D Monitoring the compressor temperature probe connection range P Monitoring air pressure for over pressure or sensor er
18. also see sections 4 2 Control System Operation amp 4 6 Adjustable System Parameters See section 4 6 Adjustable System Parameters for default parameter values Upon entering this menu the user will see information on how to navigate SETUP DIAGNOSTIC MENU Specifically the following e To scroll through the menu screens press BACK and NEXT e To enter or exit a menu screen press the ENTER or EXIT buttons respectively The user will then see USER SETUP on the display module e Press ENTER to see the parameter screens e To return to SYSTEM READY menu press EXIT Air System Parameters The first user defined parameter is SYSTEM PRESSURE It can be set from 80 to 175PSI with 5 PSI increments The second user defined parameter is STANDBY DELAY which can be set as 1 minute 2 minutes 5 minutes 10 minutes 15 minutes 30 minutes or never This parameter determines how long the control system waits before entering STANDBY mode when the air pressure remains above System Pressure minus Top up Pressure Next is TOP UP PRESSURE a value below system pressure used to keep tank pressure close to System Pressure If pressure goes VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 24 below System Pressure minus Top Up Pressure the inlet will open and will fill to System Pressure The next user defined parameter is HIGH AIR RATE which can be set from 0 5 PSI Sec to 30 PSI Sec wit
19. arameter setting Modify Disable Auto Restart Delay parameter Ensure it isn t at Always or at a value smaller than desired time in STANDBY state before system disables the auto restart feature Bad START relay if equipped Replace system s START relay located on control box mount bracket 54 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Frequent over Low oil level Check oil on level ground add as temperature required shutdowns Restriction in the compressor oil hoses Check for kinked or pinched oil hoses Compressor oil filter plugged Replace oil filter Heat exchanger not functioning or is fouled with deposits Remove and clean or replace heat exchanger Engine cooling system failure high engine Correct engine cooling problems temperature Engine fan clutch Replace fan clutch slipping High ambient Reduce duty cycle temperatures Oil temperature probe failure Replace if defective System needs service Perform recommended service Excessive air pressure System Pressure parameter set too high Reduce System Pressure in User Setup Menu System return line blocked or frozen Clear or replace the line Electrical inlet solenoid stuck closed With the system off apply 12V and Ground
20. ce HOT 12V relay located on the control box mount bracket Blown HOT 12V fuse Replace 3 Amp fuse If fuse blows again check for broken wires and failed parts to find source of fault VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 57 SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Excessive oil in the air Failed coalescing separator element Replace element Clogged scavenge line screen Clean or replace parts as required High oil level Correct oil level Poor fit between coalescing filter and tank lack of seal at O rings Replace parts as required Vehicle is not within requirements of 15 degrees of level Level vehicle and check for oil in the air Compressor was turned off while running at high speed Allow engine RPM to drop before turning the compressor off Wing tank volume shutting down under load Clean or replace parts as required Oil blows out of compressor air filter on compressor shutdown Shutting the engine off while running at high speed Allow engine to idle down before shutting down the compressor Turn off any air tools before shutting down compressor Oil drips from clutch after shutdown Seal leaking Contact the nearest dealer to replace gearbox input shaft seal Cannot drive the vehicle after remote start o
21. cted or a low cab temperature is detected The LED beacon module is enabled to identify that the engine is able to restart When the LED beacon module is illuminated the system berg and engine is able to restart when air use is detected For the system to return to RUNNING mode via STARTING CRANKING mode the operator needs to dump enough air to bring the air pressure below Restart Pressure or dump air at a rate greater than the preset High Air Rate value The Disable Auto Restart Delay setting will prevent the system from going to STARTING CRANKING if the system has spent greater than a preset amount of time in the STANDBY state By default this time is set to 30 minutes This feature can be used to prevent the engine from restarting if left unattended System State STARTING CRANKING The buzzer module will be enabled to identify that the engine is going to restart Then the control system will attempt to start the engine The control system will allow the engine to attempt to start for 20 seconds If the engine starts as expected the system will go to the BLOW DOWN DELAY state However if the engine fails to start the control system will flag a starting error to the Display Box VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 19 System State STOPPING When the control system is running and the ON ENTER button on the Display Box is pressed the control syste
22. d Nanaimo BC V9X 1R3 1 800 738 8622 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 1 0 Accessory Products from VMAC The following accessory products for your VR compressor system are available from VMAC For more information or to order these products call toll free 1 800 738 8622 or local 250 740 3200 In Cab Temperature Sensor Part Number A700185 Monitors cab temperature with UnderHood G systems Eliminator Aftercooler Part Number A800070 Removes up to 80 of moisture from compressed air Quick installation automatic drain and compact design Filter Regulator Lubricator Part Number A700151 Removes lubricants water and dirt from the air stream Adds atomized tool oil to lubricate tools Reduces pressure for longer tool life Hose Reel Part Number A700007 Secure compact retractable hose storage in a sturdy reel Air Receiver Tank Part Number A300010 Thirty five gallon capacity in a compact tank complete with fittings and a gauge De icer Kit Part Number A700031 Insulated rope heater prevents freezing of lines in freezing conditions Service Kits VR70 200 hour Part Number A700019 VR70 400 hour Part Number A700020 Using OEM service products will extend the life of your system Includes oil filters seals and O rings 200 hour and 400 hour service interval kits are available VMAC Vehicle Mounted Air Co
23. d compressor oil in this system Failure to use this special oil may result in damage to the compressor and may void your warranty 6 Turn the compressor clutch clockwise to speed the fill process 7 Allow 5 minutes for the oil to drain into the tank then check the level at the sight glass at the front of the tank Continue adding oil until the level is correct Do not overfill the system Overfilling the system with oil can flood the sight glass window and make the system appear empty 8 Install the fill plug in the inlet control valve and tighten it securely 9 Place the automatic transmission in park and fully apply the park brake 10 Start the engine and allow it to reach operating temperature 11 Press the ON ENTER button on the display box allow the system to pressurize and return to preset base idle speed VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 48 12 Press the ON ENTER button on the display box to shut down the system 13 Allow the system to settle for 5 minutes and then check the oil level through the sight glass The level must be between the minimum and maximum level indicators 14 Check for oil leaks VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 49 6 6 Changing the Coalescing Filter If the system has just been operated shut off the engine and wai
24. e alleged defect within 10 days of initial discovery and return the allegedly defective component s within 30 days of initial discovery The Buyer must prepay all costs associated with the warranty claim and submit receipts and or invoices to VMAC for evaluation If required by VMAC the Buyer must return components claimed under this warranty to a facility designated by VMAC for evaluation to establish a claim under this warranty Buyer shall maintain and service VMAC Product s in accordance with the VMAC Product s Owner s Manual WARRANTY REGISTRATION VALIDATION A warranty registration form is provided to the Buyer with the Product s The form must be fully completed by the Buyer and returned to VMAC upon completion of the installation of the Product s to validate the warranty Warranty registration can also be completed online on the VMAC website at http www vmac ca index php warrantyregistration Warranty claims will not be processed unless VMAC has received a fully completed warranty registration form VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 61 7 1 7 2 7 3 62 DISCLAIMER AND WARRANTY SERVICE Any labor costs claimed in excess of VMAC s set rate and or times are not provided by this warranty If applicable any labor costs in excess of VMAC rate schedules caused by but not limited to location or inaccessibility of the equipment travel ti
25. eaning thoroughly rinse the parts with hot water to remove all solvent residues 11 Clean the thimble screen spring and clean or replace the thimble screen 12 Install a new O ring and rear cap seal 13 Install the wave spring and a new coalescing filter Make sure that the spring is in place as it holds the coalescing filter tight against the rear cap seal The wave spring also prevents electrostatic buildup by grounding the coalescing filter If the spring is not installed an electric arc may occur which could result in an explosion potential tank rupture or fire 14 Install the discharge cap and torque the bolts to specifications 15 Install the lines on the back of the tank 16 Remove the filler plug from the air inlet control valve 17 Pour compressor oil into the oil filler hole on the inlet control valve using a funnel system Failure to use this special oil will result in You must use the supplied compressor oil in this A damage to the compressor and may void your warranty 18 Turn the compressor clutch clockwise to speed the fill process VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 51 19 Allow five minutes for the oil to drain into the tank then check the level at the sight glass at the front of the tank Continue adding oil until the level is correct Do not overfill the system Overfilling the system with oil can flood the sight
26. ebuilt components shall be warranted for the remainder of the original warranty period If the original warranty period has expired replacement components of Product s listed in 3 2 and purchased by Buyer excluding VMAC factory rebuilt components shall be warranted for a period of 12 months or 1 000 hours of operation whichever expires first VMAC factory rebuilt components shall be warranted for a period of 6 months from date of shipment from VMAC Replacement components of Product s listed in 3 3 shall be warranted for the remainder of the original warranty period If the original warranty period has expired replacement components of Product s listed in 3 3 and purchased by Buyer shall be warranted for a period of 12 months or 1 000 hours of operation whichever expires first VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 4 1 4 2 5 1 5 2 5 3 5 4 6 1 VMAC OBLIGATIONS VMAC s obligation is limited to repairing or at VMAC s option replacing during normal business hours at an authorized service facility of VMAC any component which in VMAC s judgment is proven to be defective as warranted VMAC s obligation is limited to Product s proven to be warranted No liability is accepted for any consequential damages injuries or expenses directly or indirectly related to Product s failure BUYER OBLIGATIONS Buyer shall notify VMAC of th
27. f open 4 Close all compressor air system outlets 5 Activate the compressor using the ON ENTER button on the display box VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 34 A ON ENTER button Figure 5 Display Box The clutch will engage and the engine RPM will rise for a few moments while the compressor system comes up to pressure RPM will settle to the VR Idle RPM System is now in RUNNING mode and is ready for air use A 4 7 3 Please note that the control box will not allow system restart for 30 seconds Check the blow down valve for correct operation If the blow down valve has failed 30 seconds will not be adequate time to vent system pressure Stopping the Compressor System 1 Ensure the discharge valve is closed 2 Allow the engine to idle for 1 minute 3 Press the ENTER ON button on the display box 4 Wait until the system has completed shutdown and shows SYSTEM READY on the display screen on If desired Turn off the vehicle and power to electronics by using the vehicle key switch Q A It is important the ON ENTER button be used to shut down the system Once the system has completed its shutdown procedure then the vehicle can be turned off fully Do not use the vehicle key switch to shut off the compressor system Starting the compressor immediately after an improper shutdown will cause the belt to slip
28. glass window and make the system appear empty 20 Install the fill plug in the inlet control valve and tighten it securely 21 Place the automatic transmission in park and fully apply the park brake 22 Start the engine and allow it to reach operating temperature 23 Press the ON ENTER button on the display box allow the system to pressurize and return to preset base idle speed 24 Press the ON ENTER button on the display box to shut down the system 25 Allow the system to settle for five minutes and then check the oil level through the sight glass The level must be between the minimum and maximum level indicators 26 Check for oil leaks VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 52 7 0 Problem Diagnostics Troubleshooting Problem diagnosis should follow sound recognized practice Quick accurate diagnosis of problems should involve the following accurately identify the problem by operating the system yourself determine possible causes for the problem by understanding how the system operates isolate the potential causes by accurate testing using the correct recognized procedures perform proper repairs using the correct procedures and the recommended replacement parts perform proper post repair testing to ensure that the repairs were effective do not use test practices that are potentially harmful to people or the equi
29. h 0 5 PSI Sec increments This is one of two ways for the system to restart from STANDBY High air use is only applicable when the system is in STANDBY it will detect if an air tool is being used and call the control system to restart the engine A more negative value 10PSI sec rather than 3PSl sec is less sensitive to change to call a restart e A large Auxiliary tank may require a more sensitive rate change in order to restart ie 2PSI sec e A small Auxiliary tank may require a less sensitive rate change as there is no air pressure buffer before a restart is triggered ie 5PSI sec The next parameter is RESTART PRESSURE If air pressure has gone below the Restart Pressure value while in STANDBY mode the system and engine are restarted It can be set from 80 to 175PSI with 5 PSI increments The next parameter is DISABLE AUTO RESTART DELAY This parameter allows for disabling the system s ability to restart depending on the time spent in STANDBY mode It can be set to Always 30 min 60 min 90 min 120 min or Never Low Battery Restart Parameters The next parameter is ALLOW LOW BATTERY RESTART This parameter enables or disables the system s ability to restart when low battery voltage is detected The factory default is ENABLED The next parameter is LOW BATTERY RESTART VOLT This parameter determines the voltage at which the system will restart It can be set between 10 0 to 14 0V in 0 1V steps The
30. he compressor for the first time Follow the information and procedures in this manual for operation maintenance and repair Observe the following items to reduce the chance of personal injury or equipment damage Follow all safety precautions for mechanical work Moving fan belts and fan blades 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 Proper service and repair are important to the safety of the service technician and the safe reliable operation of the equipment Always use genuine VMAC replacement parts do not use any substitutes The procedures described in this service manual are effective methods of service and repair Some procedures may require the use of tools specially designed for a specific purpose Anyone using a replacement part service procedure or tool must first determine that neither their safety nor the safe operation of the equipment will be compromised by the replacement part service procedure or tool selected This manual contains various warnings cautions and notices that must be observed to reduce the risk of personal injury during service or repair and the possibility that improper service or repair may damage the equipment or render it unsafe Be aware that it is impossible to warn of all the possible hazardous consequences that might result fr
31. hould start to ramp up at this point 8 Adjust the Idle Down Pressure up or down so that the engine speed just starts to climb at approximately 10 PSI 68 95 KPA below maximum system pressure The adjustment for idle down pressure must be turned clockwise to increase pressure or counterclockwise to reduce pressure 2500 Maximum RPM adjustment 2000 Factory setting typically 1800 RPM 4 1500 lt gt Idle Down pressure adjustment Idle Down Pressure D psi 1307 kPa maximum a en setting typically 140 psi 985 3kPa eee Recammend 16 psi 68 985 kPa below full pressure Regulator adjustment 500 i i 25 50 75 100 125 150 175 200 Figure 9 VR Throttle Controller Pressure vs RPM response 9 Open the ball valve fully with the test tool The system pressure should be about 100PSI VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 41 6 0 Routine Maintenance The compressor system contains no reed valves or other easily fouled fatigue prone components With proper maintenance the need for premature repair or component replacement can be drastically reduced occur in the compressor bearings if the system is not operated on a regular basis due to vibration caused by truck operation Operate the system at least every 30 days for 15 minutes at no load to ensure bearing lubrication and rotation Impact damage and premature bearing fa
32. iate the stopping sequence 4 3 4 Stopping Sequence To stop the system the user can press the ENTER button at any point during operation 4 3 5 Additional Information Menu The additional information menu for the display box allows the user to monitor specific information about the system The parameters displayed are AIR PRESSURE AIR RATE ENGINE SPEED COMPRESSOR TEMPERATURE TIME TO STANDBY and HOUR METER The user can scroll through the screens by pressing the BACK and NEXT buttons Pressing the EXIT button will return the display box to SYSTEM RUNNING menu The display box will return to the SYSTEM RUNNING menu after three minutes of no buttons being pressed by default Pressing the ENTER button will initiate the stopping sequence VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 23 4 3 6 Setup Diagnostic Menu SETUP DIAGNOSTIC MENU can only be reached from the SYSTEM READY menu by holding both the BACK and NEXT buttons for five seconds This menu allows the user to define parameters of system operation User defined parameters include SYSTEM PRESSURE STANDBY DELAY TOP UP PSI HIGH AIR RATE RESTART PRESSURE DISABLE AUTO RESTART DELAY BATTERY RESTART ENABLE LOW BATTERY VOLTAGES LOW CAB TEMPERATURE ENABLE and LOW CAB TEMPERATURE VALUES The User may also reset the unit to factory settings from this menu For more information on these parameters
33. ilure may During the warranty period you must follow the maintenance schedule and use only original genuine VMAC replacement parts to maintain your system and your warranty The most critical aspect of maintenance is proper air filtration and clean oil If any particles enter the compressor through the air inlet they can contaminate roller bearings gears and the rotors in the compressor Contamination will cause severe rapid damage to components allow the vehicle to sit parked without the Never run the compressor drive the vehicle or even A recommended air filter and filter cover installed VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 42 6 1 Maintenance Schedule The following maintenance schedule should be observed to assure good performance and long service life The hours indicated are those displayed on the Display Box Service should be performed at the lesser of the two intervals whichever occurs first For replacement part numbers please check the appropriate Illustrated Parts List for your application or call a dealer near you Always use a VMAC oil filter that is designed to withstand the high pressures not an automotive filter 50 hours Check the drive belt 200 hours or 6 months Replace the air filter oil filter and change oil Use service kit 4700019 VR70 400 hours or 1 year Replace the air filter oil filter coalescing element a
34. in the tank housing Install the short threaded end into the tank Ensure the nipple does not obstruct the cross drilling 5 Check the gasket sealing surface on the front of the tank for contamination old gasket material or damage 6 Apply a thin coating of compressor oil to the filter sealing gasket and fill the filter with VMAC compressor oil 7 Spin the filter onto the threaded nipple until the gasket contacts the sealing surface on the tank then tighten the filter an additional 3 4 to 1 turn to seat the sealing gasket Never over tighten the filter as this may damage the seal or the filter 8 Remove the filler plug from the air inlet control valve and pour VMAC compressor oil into the oil filler hole on the inlet control valve using a funnel VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 46 system Failure to use this special oil may result in 1 You must use the supplied compressor oil in this damage to the compressor and may void your warranty 9 Turn the compressor clutch clockwise to speed the fill process 10 Allow 5 minutes for the oil to drain into the tank then check the level at the sight glass at the front of the tank Continue adding oil until the level is correct can flood the sight glass window and make the system Do not overfill the system Overfilling the system with oil appear empty 11 Install the fill plug in the inlet c
35. llow or stop the flow of air at atmospheric pressure from entering the compression chamber The engine speed controller referred to more commonly as the throttle controller adjusts engine RPM to respond to air consumption demand These control devices provide the following benefits e instant response to air flow demands e reduction of standby noise e reduction of cooling system load e fuel conservation when not using air For information and adjustment please refer to the section 4 6 Adjustable System Parameters An external regulator is recommended for operation at pressures lower than 145 PSI 999 7 KPA VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 12 3 5 Safety Devices A 200 PSI 1379 KPA pressure relief valve exists in the tank to prevent system over pressure The system is also equipped with an automatic rapid blow down system to discharge system pressure on shutdown There is a switch which only permits operation when the mechanical or air park brake is applied Vehicles with automatic transmission are fitted with a Drive Disable Circuit DDC which disables the throttle control and prevents engine speed increase when the vehicle is in gear The compressor is equipped with an oil temperature sensor which stops system operation should the temperature become excessive The control system only permits the system to operate if the vehicle s h
36. ltage gets too low Restart point for battery 10 0 to 14 0V in Batt Lower Thrs voltage 0 1V steps 12 1V Fully charged set point 10 0 to 15 0V in SE for battery voltage 0 1V steps E Time delay before going TEE i baok to STANDBY after 9 10 1 320 39 2min y battery fully charged Controls if system will restart when cab oe Temp temperature drops too Enable Disable Disabled estart low Accessory kit required 2 o o Cab Lower Thrs Restart cab temperature 1 0 C to 20 C 10 0 C in 0 1 C steps Fully warmed cab 10 C to 30 C d Cab Upper Thrs temperature in 0 1 C steps 20 0 C Time delay before going Low Cab Restart pech to STANDBY after 2 gt 10 15 20 5 min Delay 30 min warming cab 32 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 To modify a system parameter such as Standby Delay 1 N Ee D 9 Turn the key ignition ON Do not start the compressor system Press and hold the NEXT and BACK buttons on the display box for 5 seconds to enter Setup Diagnostics Menu When display box shows USER Use NEXT and BACK to scroll to STANDBY DELAY Press ON ENTER SETUP press ON ENTER Use NEXT and BACK to change Standby Delay parameter value Press ON ENTER to select value or EXIT to cancel change Verify STANDBY DELAY screen shows desired parameter value Press EXIT to return to US ER
37. m ee Line 2 D dd M mm Y yy The following tables provide information on decoding these error messages to determine when and what kind of error occurred ERROR DECODING GUIDE E To show that a stored error is being displayed n Error number 0 to 9 hhhh m Hour Meter s value at time of error to 1 10 of an hour ee Error code describing the type of error dd mm yy Error date VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 28 For example E9 0004 7 13 D 20 M 10 Y 12 This screen is saying that error 9 occurred at 4 7h on November 20 2012 and was a code 13 Looking up error code 13 one knows the cause was an over voltage reading on the pressure transducer VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 29 ERROR MESSAGE TABLE Error 7 Code Error Message Displayed Cause 1 CLUTCH Clutch is unplugged or wire to control box has FAILED OPEN been cut lt 1 0A 2 CLUTCH Clutch has shorted or wire to control box is FAILED SHORT shorted gt 10 0A CLUTCH CURRENT 3 TOO LOW Under current reading on clutch 1 0 2 0A 4 A E Over current reading on clutch 5 0 10 0A 5 COMP TEMP SENSOR Temperature sensor on the compressor is FAILED OPEN unplugged or wire
38. m will enter the STOPPING state It is important the ON ENTER button be used to shut down Q the system Once the system has completed shutdown then the vehicle can be turned off fully Do not use the vehicle key switch to turn off the compressor system After the system has completed the stopping sequence the system will revert back to the SYSTEM READY state If the system was started by grounding the REMOTE ON the system will also enter STOPPING by un grounding the REMOTE ON wire VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 20 Fax 1 250 740 3201 4 3 Display Box Messages SYSTEM CHECK Errors Cleared ERRORS No Errors Detected for 5 seconds SYSTEM READY Error Detected ON request SYSTEM RUNNING Press NEXT BACK SETUP DIAGNOSTIC MENU SERVICING VIEW LOGGED ERRORS Menu Selection VIEW LOGGED MESSAGES VIEW LOGGED SERVICES Figure 3 Display Box Flow Diagram VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 21 4 3 1 System Check Menu Ensure the pneumatic equipment is securely connected and turned off During the system check both the WARNING and READY LEDs remain illuminated and SYSTEM CHECK is displayed If any errors are present the WARNING LED will flash on amp off the display will enter the ERRORS menu If no
39. me or labor provided by unauthorized service personnel are not provided by this warranty This warranty is in lieu of all other warranties or obligations express or implied VMAC expressly disclaims all implied warranties of merchantability or fitness for a particular purpose Warranty claims must be pre authorized by VMAC and the components returned via prepaid freight using the designated Returned Merchandise Authorization number and form VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201
40. mpressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 2 0 General Information This manual provides operation instructions specifications adjustment maintenance and warranty information for the VMAC 70G underhood air compressor and VMAC Electronic Throttle Controller 2 1 Ordering Parts To order parts contact your VMAC dealer Your dealer will ask for the VMAC serial number part number a description of the part and the quantity To locate your nearest dealer call 1 800 738 8622 2 2 Important Safety Notice The information contained within 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 and service techniques If a discrepancy is noted in this manual contact VMAC prior to initiating or proceeding with service Current information may clarify the matter Any person with knowledge of such discrepancies who performs any work on the system 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 performance or the operational safety of the equipment VMAC will not be held responsible for any liability injuries loss or damage t
41. n cause serious burns Allow sufficient time for the system to cool before performing service Components and hoses under pressure could separate suddenly fly out and cause serious injury or death If equipped the auxiliary air tank must be drained before servicing any components in the compressor system Observe these rules when operating the compressor Constant vigilance is necessary around high energy equipment Be attentive for unexplained changes in operation parameters and record any changes VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 Do not bypass or disable the oil temperature sensor Do not expose the tank or compressor to extreme heat Do not perform any service until the system has been completely blown down and you have verified that all air has been discharged Do not try to repair or service a pressurized system Maintenance and repair on system components should only be performed by qualified personnel The vehicle must be in park with the park brake or the air spring brake fully applied before starting the compressor and at all times during compressor operation Use a regulator in the output line to precisely control the final air delivery pressure Run the system at idle speed under no load conditions for 1 minute before turning the system off to allow system cooling and lubrication Do not bypass the park brake or DDC connections Do
42. nd change oil Use service kit 4700020 VR70 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 43 6 2 Inspect the Drive Belt Check the drive belt carefully for evidence of glazing missing portions of the ribs or damage to the belt edges and surface If the belt is damaged install a new drive belt Inspect all pulleys and idlers for damage If any component shows cracks chipping impact damage or any other indications of physical damage replace the pulley or idler If the damage indicates possible misalignment check pulley alignment If the pulleys are not properly aligned check all fasteners to ensure that they are properly torqued and that there are no loose components VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 44 6 3 Replacing the Air Filter If the system has been just operated shut off the engine and wait at least 30 seconds for the air pressure to vent before working on the system 1 Clean loose debris from the area around the compressor and the filter cover to prevent contamination entering the compressor Remove the filter cover retaining nut the filter cover and the filter element Immediately cover the air inlet opening by masking with tape or with a clean cloth to prevent contamination Do not use compressed air or perform any other tasks around the compressor until the filte
43. next parameter is LOW BATTERY RESTART LOWER VOLT This parameter determines the upper level for a fully charged system It can be set between 10 0 to 15 0V in 0 1V steps The next parameter is LOW BATT RESTART DELAY This parameter determines the time the system remains in RUNNING once the system has reached its fully charged level It can be set to 2 5 10 15 20 30 min VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 25 In Cab Temperature Restart Parameters Accy Only The next parameter is ALLOW LOW CAB TEMP RESTART This parameter enables or disables the system s ability to restart when the cab temperature is too cold This requires an additional temperature probe accessory to be installed The factory default is DISABLED The next parameter is LOW CAB TEMP RESTART LOWER TEMP This parameter determines the temperature at which the system will restart It can be set between 10 C to 20 C in 0 1 C steps The next parameter is LOW CAB TEMP RESTART UPPER TEMP This parameter determines the upper level for a fully warmed cab It can be set between 10 C to 30 C in 0 1 C steps The next parameter is LOW CAB TEMP RESTART DELAY This parameter determines the time the system remains in RUNNING once the cab has been fully warmed It can be set to 2 5 10 15 20 30 min Factory Reset The next parameter screen in the USER SETUP menu screen is the FACTORY RESET
44. not operate the compressor while driving Do not tamper with the pressure relief valve Do not attempt to repair or modify any component Use caution when replacing system relay if equipped as certain pins are HOT 12V even with the vehicle s key in the off position VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 2 5 Installation Instructions Detailed information provided in a separate publication Installation Manual for VMAC Systems which provides specific information for each different application This information includes torque tables recommendations and other important information for correct installation The information in the installation manual is intended for use by trained professional technicians with the knowledge tools and equipment to do the job properly and safely Installation should not be performed by persons without the appropriate skills Do not attempt to install any of these systems without the appropriate installation manual Ensure that the safety and operational instruction decal is affixed in an obvious location so that vehicle operators can easily see it This vehicle is equipped with a VMAC Air Compressor System VEHICLE MOUNTED AIR COMPRESSORS OPERATING INSTRUCTIONS Daily Pre Start Check 1 Check oil level in tank 2 Check drive belt system 3 Check for leaks Start Up Procedure 1 Ensure air system i
45. o individuals or to equipment as a result of the failure of any person to properly adhere to the procedures set out in this manual or standard safety practices Safety should be your first consideration in performing service operations If you have any questions concerning the procedures set out in this manual or require any more information on details that are not included in this manual please contact VMAC before beginning any work VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 2 3 Safety Messages concerning your 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 alert to the possibility of personal injury or death Be alert your safety is involved While it is impossible to warn about every conceivable hazard let good common sense be your guide This symbol is used to call your attention to instructions on a specific procedure that if not followed may damage or reduce the useful life of the compressor This symbol is used to call your attention to instructions This symbol is used to call your attention to additional instructions involving fire hazards VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 2 4 Safety Precautions Read this information before operating t
46. om failure to follow these instructions Observe the following general safety rules continues on next page e Pay attention to operations do not leave the vehicle unattended e Follow safe work practices and wear the appropriate safety equipment when operating air powered equipment particularly eye and hearing protection e Follow all safety precautions for underhood mechanical work e Follow safety procedures for the type of work being completed VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 Avoid all contact with pressurized air because if it penetrates your skin it can enter your bloodstream and cause serious bodily harm or even death Fire in the compressor can cause an explosion and flame projection Should this occur there is potential for serious injury or death To prevent compressor explosion or fire make sure that the air entering the compressor is free of flammable vapors To prevent compressor explosion or fire make sure that correct servicing procedures and intervals are observed Vaporized oil propelled by high pressure air is an explosive mixture Do not breathe the compressor air vaporized oil is a severe respiratory hazard Avoid contact with drive belts and stay clear of all moving parts when the system is operating The compressor and the compressor system get very hot during operation contact with the components or the oil ca
47. ontrol valve and tighten it securely 12 Place the automatic transmission in park and fully apply the park brake 13 Start the engine and allow it to reach operating temperature 14 Press the ON ENTER button on the display box allow the system to pressurize and return to preset base idle speed 15 Press the ON ENTER button on the display box to shut down the system 16 Allow the system to settle for 5 minutes and then check the oil level through the sight glass The level must be between the minimum and maximum level indicators 17 Check for oil leaks VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 47 6 5 Changing Compressor Oil If the system has just been operated shut off the engine and wait at least 30 seconds for the air pressure to vent before working on the system Also allow sufficient time for the oil to cool 1 Clean the area around the oil drain plug on the front of the air oil tank to prevent contamination 2 Remove the drain plug and drain the oil into a container large enough to hold at least 5 litres 1 32 U S gal for the VR70 3 Install and tighten the plug 4 Ifyou are replacing the oil filter follow filter replacement procedures 5 Remove the filler plug from the air inlet control valve and pour VMAC compressor oil into the oil filler hole on the inlet control valve using a funnel You must use the supplie
48. ood is shut The beacon module illuminates to inform the operator that the system is able to restart when air use is detected The buzzer module sounds before engine restarts continuously there is an electrical problem that will not be solved by a higher fuse rating Exceeding the rating can cause component damage T A fuse protects the system If the fuse blows Do not disable or bypass the over temperature shutdown circuit Failure of the shutdown system could result in equipment damage injury or death 3 6 Line Protection To prevent damage to the lines observe the following e Always ensure that the hoses are secure do not allow the hoses to dangle under the vehicle e Always ensure that the hoses do not get pinched in steering or Suspension components VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 13 e Make sure to keep the hoses away from hot surfaces such as turbocharger housings or exhaust system components e Hoses should not be bent tightly around sharp metal edges e Ensure that hoses are kept away from fan blades or belts e If the hoses are secured in a bundle protect them from abrasion by insulating them from each other using rubber padding or plastic loom 3 7 Special Installation Notes You must use an auxiliary air tank with this system you must observe the following installation procedure Failure to observe this procedure may result in dam
49. peration RAM truck remote start drive interlock Cycle the key to OFF position then use as desired 58 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 8 0 VMAC Warranty 1 1 1 2 1 2 2 2 3 2 4 2 5 2 6 GENERAL PROVISIONS AND LIMITATIONS VMAC Division of Mangonel Investments Corporation hereafter VMAC warrants to each original retail purchaser hereafter Buyer of its new Underhood Air Compressor Systems hereafter Product s from VMAC or its authorized Dealers that such Product s are at the time of delivery to the Buyer free of manufacturer defects in material and workmanship Product Warranty Underhood Air Compressors applies to Products s manufactured on or after January 1 2005 System ID numbers ending with TA001 or greater NO WARRANTY IS MADE WITH RESPECT TO Any Product s which have in VMAC s judgment been subject to negligence accident or improper storage installation application operation or maintenance or have been repaired or altered in such a way that affects the Product s adversely Components or accessories manufactured warranted and serviced by others Damages caused from normal maintenance service and repairs and corrections with minimum action such as adjustments and inspections or replacement of items such as service filters belts seals and service kits
50. pment Electrical testing should be performed according to the processes described in the troubleshooting chart For accurate diagnosis refer to the electrical circuit diagram in the installation manual Always ensure automatic transmissions are in park with the park brake applied before starting the engine or operating the system VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 53 SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Compressor does not run Oil temperature too high Turn compressor off allow to cool for 30 minutes retry Oil level is too low Park on level ground check level at sight glass add as necessary Drive belt is broken Install new compressor belt Check alignment of pulleys Replace automatic tensioner No power to the clutch Check for 12 V at the clutch check fuse check for broken wires or failed switch Bad clutch ground With 12 V applied to the clutch check for voltage between the clutch stator housing and the engine If voltage is present ground the stator Open clutch stator windings With compressor switch off and clutch wire disconnected check resistance between the input wire and ground Resistance less lead resistance should be 2 5 ohms to 3 0 ohms If outside this range replace the stator Engine does not restart from Standby state Disable Auto Restart Delay p
51. r and cover are replaced Clean the inside of the filter cover with a clean dry cloth Do not use flammable solvents to clean the inside of the cover If you do use solvent rinse the inside of the cover thoroughly with fresh water and dry it before installing the cover Remove the cloth or masking and install a new air filter Make sure that the filter fits over the machined step on the housing Replace the cover and secure it with the cover bolt Do not over tighten the bolt A Never attempt to clean the filter element with compressed air Replace the filter element VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 45 6 4 Replacing the Oil Filter If the system has been just operated shut off the engine and wait at least 30 seconds for the air pressure to vent before working on the system Do not attempt to change the oil filter until the oil has cooled Hot oil can cause severe burns 1 Clean the area around the tank and the filter to prevent contamination 2 Remove the drain plug and drain the oil into a container large enough to hold at least 1 32 USG 5 liters for the VR70 3 Install and tighten the plug 4 Remove the filter by turning it counterclockwise Before discarding the filter check to make sure that the threaded nipple did not unscrew with the filter If the nipple is in the filter remove it carefully to avoid thread damage and replace it
52. ral Interlock park brake engaged disengaged sensor hood sensor to disable system when hood ajar LED beacon warning when engine is capable of automatically restarting e Buzzer warning before engine automatically restarts Lubrication VMAC certified synthetic oil Filters e paper type replaceable air filter e spin on type high pressure oil filter e coalescing separator element VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 10 3 0 Operating Principles This system uses a flooded lobe rotary screw compressor The oil filled compressor housing contains two rotors Compression occurs when inlet air at normal atmospheric pressure enters a chamber where it is trapped between the rotating rotor lobes A lubricated pitch line provides sealing As the lobes mesh they reduce the volume of the air compressing it to the desired pressure 3 1 Oil Separation and Cooling The system has a two stage air oil separator The first separation stage consists of baffles which perform mechanical separation The second stage uses an integral serviceable coalescing element A liquid to liquid cooler connected to the engine cooling system cools the oil This maintains the oil temperature in an optimal performance range that increases system durability and reduces the temperature of the compressed air 3 2 Filtration The rotary screw compressor is designed and machined to exacting
53. ror fa Monitoring clutch connection and current range EI Monitoring engine RPM for under speed over speed running when not expected and engine restart failure E Monitoring low battery voltage ES Optional battery low engine restart LJ Error and warning message logging data logging LJ Operator compressor servicing reminders 200 and 400 hours Ki Buzzer module to warn before engine restart LJ LED beacon module to identify when the unit is able to restart LJ Hour meter BW Optional Accessory In cab low temperature engine restart VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 4 2 Low battery restart enabled and below lower threshold for 30s 16 Low Cab Temp restart enabled and below lower threshold for 30s Air use detected or Control System Operation point E_RESTART_PSI set Air pressure below PRESSUR SYSTEM READY ON ENTER Button Pushed Remote enable wire to GND gine_off_flag pping_dealy Start blowdown_sto STARTING CRANKING Clear entered_en Engine running STOPPING ON ENTER Button Pushed all arrows to STOPPING BLOW DOWN DELAY Blowdown_from_standby_timer reached Blowdown_from_stopping_timer reached System restarted due to low battery amp Battery voltage not above upper 5 threshold for variable delay mins OR gt System restarted due to low c
54. s depressurized 2 Ensure all air outlets are CLOSED 3 Place vehicle in Neutral or Park and engage park brake 4 Start engine and bring to operating temperature 5 Turn ON compressor Shutdown Procedure 1 Ensure discharge valve is CLOSED 2 Allow engine to idle for 1 minute 3 Turn OFF compressor 4 Wait for system to depressurize before restarting For Technical Support Parts contact your VMAC Dealer To locate your nearest dealer call 1 800 738 8622 250 740 3200 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 2 6 System Specifications Model Underhood Air Compressor with Intelligent Digital Controls Type rotary screw Drive System Front End Accessory Drive FEAD Control electric on off 12V clutch control Maximum Air Delivery e VR70 70 CFM and 175 PSI 1207 KPA Pressure Regulation electronically controlled solenoid inlet valve modulates flow in response to demand Engine Controls throttle control to modulate between idle and upper limit RPM to maintain air requirements NOTE Some trucks have onboard computers that must be programmed by the OEM dealer to permit operation of the electronic throttle control Safety Features e 200 PSI 1379 KPA relief valve in air oil tank e temperature safety sensor in compressor e rapid blow down valve to discharge system pressure on shutdown 10 15 seconds drive disable circuit DDC Park Neut
55. sssssseeseeeeees 39 5 1 ADJUSTING THE OPERATING PRESSURE oseere 40 5 2 ELECTRONIC THROTTLE CONTROL ADIUSTMENT 40 6 0 ROUTINE MAINTENANCE uuu cescssssessesseescssseseeseeeenes 42 6 1 MAINTENANCE GCHEDULE 43 6 2 INSPECT THE DRIVE BET 44 6 3 REPLACING THE AIR Euren 45 6 4 REPLACING THE OIL FILTER c ccceceeeeeeeeceeeseceeeeeeeeeeeeeeeaeas 46 6 5 CHANGING COMPRESSOR OI 48 6 6 CHANGING THE COALESCING FILTER 00ccccccsseeeeeseeseeeeeeeeees 50 VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 7 0 PROBLEM DIAGNOSTICS TROUBLESHOOTING 53 8 0 VMAC WARRANT c cccecssssssssseeseeesnssnsscseeeseeseneensees 59 Owner Manual Document 1930193 Underhood Systems with Intelligent Digital Controls Changes and Revisions Version Revision Details Revised by date Checked by Reviewed by Implemented date date Initial Release SAR 20 Feb 2012 MH 30 Mar 2012 MH 30 Mar 2012 12 Apr 2012 ECN 13 019 low batt cab temp MP 06 Aug 2013 SM 19 Aug 2013 RF 19 Aug 2013 19 Aug 2013 upgrades ECN 13 067 RAM updates Manuals are subject to change without notice Registered Trademarks All trademarks used in this manual are the property of the respective copyright holder The contents of this manual may not be reproduced in any form Copyright 2012 without the express written permission of VMAC Printed in Canada 1333 Kipp Roa
56. t at least thirty seconds for the air pressure to vent before working on the system Also allow sufficient time for the oil to cool In some applications you may have to remove the tank from the frame and lower the back end to access the back of the tank 1 Clean the front and back of the tank to prevent contamination 2 Remove the drain plug and drain the oil into a container large enough to hold at least 5 litres 1 32 U S gal for the VR70 Install and tighten the plug 4 Ifyou are replacing the oil filter follow filter replacement procedures 5 Disconnect the air outlet line 1 4 inch and 3 16 inch lines from the back of the tank 6 Remove the bolts holding the discharge cap from the back of the tank and remove the cap and small spring 7 Remove the coalescing filter with wave spring attached from inside the tank Discharge cap Safety valve Rear cap seal Coalescing filter Coalescing filter spring Figure 10 VR70 Coalescing Filter VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 50 Check the inside of the tank for any evidence of metal filings or contamination if found flush the tank hoses and cooler Metal filings will damage the compressor Remove and discard the O ring seal and the rear cap seal Wipe out the inside of the tank 10 Remove the thimble screen and spring and clean the discharge cap If you use solvents for cl
57. t will also show and log the error that caused the issue 2013MY and newer RAM trucks using Hard wired berg Remote Start ie V90G126 A safety feature of remote start mode prohibits driving the vehicle If you try to drive the vehicle it will turn off In order to drive the vehicle you must cycle the key off and turn the vehicle back on This takes the vehicle out of remote start mode VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 27 4 5 Checking Messages and Errors 4 5 1 Present Errors If an error is present the control systems WILL NOT start the compressor until the error is cleared When an error is present the display box s WARNING LED will flash on off and the screen will display ERRORS DETECTED followed by the following list of errors The user MUST scroll through ALL the displayed errors by pressing the NEXT button before the unit can re try the start sequence 4 5 2 Viewing Stored Data logged Errors 1 Turn key ignition ON Do not start the compressor system 2 Press the NEXT and BACK buttons on the display box for 5 seconds to enter Diagnostics mode 3 Use NEXT and BACK to scroll to VIEW LOGGED ERRORS Press ON ENTER button to view the errors 4 Use NEXT and BACK to scroll though the errors 4 5 3 Decoding Stored Errors Stored error messages are shown on the two lines of the Display Box in the following format Line 1 En hhhh
58. to control box has been cut 6 COMP TEMP SENSOR Temperature sensor on the compressor is FAILED SHORT shorted 7 COMP TOO COLD Compressor is too cold to start The ZRK OERI temperature is displayed lt 40 C 8 COMP TOO HOT Compressor is too hot to start The xX x F xx x C temperature is displayed gt 130 C Accessory temperature sensor in the cab is 9 SED TEMP SENSOR unplugged enabled but not installed or wire FAILED OPEN to control box has been cut 10 CAB TEMP SENSOR Accessory temperature sensor in the cab is FAILED SHORT shorted 12 AIR PRESS SIGNAL Low voltage reading on the air pressure VOLTAGE LOW transducer signal lt 0 5V 13 AIR PRESS SIGNAL Over voltage reading on the air pressure VOLTAGE HIGH transducer signal gt 4 6V 14 AIR PRESS SENSOR Air pressure is higher than expected TOO HIGH gt 180PSI 14 AIR PRESSURE If the previous error is present the air xXxx x PS pressure is displayed PARK BRAKE 22 NOT ENABLED Park brake needs to be engaged ENGINE RPM 26 TOO LOW TO START Engine RPM is too low to start system ENGINE RPM 27 DURING OFF STATE Engine RPM detected during an OFF state ENGINE RPM R 34 NOT DETECTED Engine RPM is not detected Wire may be cut P ENGINE CRANE pee did not start during the crank TIME OUT Leien 41 CLOSE HOOD The truck s hood is open It must be closed TO START when the unit is run E DISPLAY CANBUS A CAN bus error between the Display box and CONN ERROR Control box
59. tolerances Foreign particles entering the system will drastically damage or shorten the life expectancy of the compressor and will result in damage to bearings gears rotors and the inside of the housing The system is equipped with a replaceable paper element air inlet filter spin on cartridge type high pressure capable oil filter and a scavenge screen filter These system filters enhance performance and extend component life by reducing damage from dust and other debris Proper filter maintenance is the key to long compressor life VMAC Vehicle Mounted Air Compressors Toll Free 1 800 738 8622 Local 1 250 740 3200 Fax 1 250 740 3201 3 3 Belt Alignment and Tensioning This system is equipped with automatic belt tensioning and does not require manual adjustment Always check pulley alignment to ensure proper belt operation All components are designed and machined for precision some variation in mounting holes may still occur 3 4 Pressure Regulation and Engine Speed Control This system uses two means of controlling system air pressure inlet valve control and engine speed control The inlet valve control consists of an electrical solenoid valve and an inlet valve The electrical solenoid valve is normally open but is closed electronically by the control system when the system needs to build pressure This solenoid valve determines whether or not the compressor s pressure is able to act on the inlet valve which moves to a

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