VR70G UNDERHOOD
AI
RCOMPRESSOR
OWNERSMANUAL
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UNDERHOOD ‘G’ User’s Manual
1.0
ACCESSORY PRODUCTS FROM VMAC ............................. 3
2.0
GENERAL INFORMATION ..................................................... 4
2.1
2.2
2.3
2.4
2.5
2.6
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5.0
5.1
5.2
6.0
6.1
6.2
6.3
6.4
6.5
6.6
ORDERING PARTS .................................................................. 4
IMPORTANT SAFETY NOTICE ................................................... 4
SAFETY MESSAGES ................................................................ 5
SAFETY PRECAUTIONS ........................................................... 6
INSTALLATION INSTRUCTIONS .................................................. 9
SYSTEM SPECIFICATIONS...................................................... 10
OPERATING PRINCIPLES ................................................... 11
OIL SEPARATION AND COOLING ............................................. 11
FILTRATION .......................................................................... 11
BELT ALIGNMENT AND TENSIONING ....................................... 12
PRESSURE REGULATION AND ENGINE SPEED CONTROL ......... 12
SAFETY DEVICES.................................................................. 13
LINE PROTECTION ................................................................ 13
SPECIAL INSTALLATION NOTES .............................................. 14
SYSTEM OPERATION .......................................................... 15
CONTROL SYSTEM FEATURES ............................................... 15
CONTROL SYSTEM OPERATION ............................................. 16
DISPLAY BOX MESSAGES...................................................... 21
AUTOMATIC SHUTDOWN AND RESTART .................................. 27
CHECKING MESSAGES AND ERRORS ..................................... 28
ADJUSTABLE SYSTEM PARAMETERS ...................................... 32
OPERATING INSTRUCTIONS ................................................... 34
COLD CLIMATE OPERATION................................................... 36
ADDING OIL TO THE SYSTEM ................................................. 37
ADJUSTING THE SYSTEM .................................................. 39
ADJUSTING THE OPERATING PRESSURE ................................ 40
ELECTRONIC THROTTLE CONTROL ADJUSTMENT ................... 40
ROUTINE MAINTENANCE ................................................... 42
MAINTENANCE SCHEDULE ..................................................... 43
INSPECT THE DRIVE BELT ..................................................... 44
REPLACING THE AIR FILTER .................................................. 45
REPLACING THE OIL FILTER .................................................. 46
CHANGING COMPRESSOR OIL ............................................... 48
CHANGING THE COALESCING FILTER ..................................... 50
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622 Local: 1-250-740-3200
Fax: 1-250-740-3201
1
7.0
PROBLEM DIAGNOSTICS / TROUBLESHOOTING .......... 53
8.0
VMAC WARRANTY .............................................................. 59
Owner Manual - Document #1930193
Underhood Systems with Intelligent Digital Controls
Changes and Revisions
Version
Revision Details
Revised by /date
Checked by
Reviewed by
/date
/date
Implemented
A
Initial Release
SAR 20 Feb 2012
MH 30 Mar 2012
MH 30 Mar 2012
12 Apr 2012
B
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.
Copyright 2012
The contents of this manual may not be reproduced in any form,
without the express written permission of VMAC.
Printed in Canada
1333 Kipp Road, Nanaimo, BC V9X 1R3
1-800-738-8622
2
VMAC – Vehicle Mounted Air Compressors
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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
DE-ICING
HEATER
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 Orings. 200 hour and 400 hour service interval kits
are available
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Fax: 1-250-740-3201
3
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 to 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.
4
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2.3 Safety Messages
!
This symbol is used to call your attention to instructions
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 additional
instructions involving fire hazards.
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5
2.4 Safety Precautions
Read this information before operating the 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 from failure to follow these instructions.
Observe the following general safety rules (continues on next page):
Pay attention to operations; do not leave the vehicle
unattended.
Follow safe work practices and wear the appropriate safety
equipment when operating air-powered equipment,
particularly eye and hearing protection.
Follow all safety precautions for underhood mechanical
work.
Follow safety procedures for the type of work being
completed.
6
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!
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 can 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.
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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 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.
8
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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.
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9
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:
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:
200 PSI / 1379 KPA relief valve in air/oil tank
temperature safety sensor in compressor
rapid blow-down valve to discharge system pressure on
shutdown (10-15 seconds)
drive disable circuit (DDC)(Park/Neutral/Interlock)
park brake engaged/disengaged sensor
hood sensor to disable system when hood ajar
LED beacon warning when engine is capable of
automatically restarting
Buzzer warning before engine automatically restarts
Lubrication: VMAC certified synthetic oil
Filters:
paper-type replaceable air filter
spin-on type high pressure oil filter
coalescing separator element
10
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3.0 Operating Principles
This system uses a flooded-lobe, rotary screw compressor. The oilfilled 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
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.
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11
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 allow 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:
instant response to air flow demands
reduction of standby noise
reduction of cooling system load
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.
12
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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
hood 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.
!
A fuse protects the system. If the fuse blows
continuously, there is an electrical problem that will not
be solved by a higher fuse rating. Exceeding the rating
can cause component damage.
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:
Always ensure that the hoses are secure, do not allow the
hoses to dangle under the vehicle
Always ensure that the hoses do not get pinched in steering
or suspension components
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Make sure to keep the hoses away from hot surfaces, such
as turbocharger housings or exhaust system components
Hoses should not be bent tightly around sharp metal edges
Ensure that hoses are kept away from fan blades or belts
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 damage 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
VR Air/Oil Separator
Tank (AOST)
Install the line as high as
possible, NOT in the
bottom of the auxiliary tank
Figure 1 – Integrated minimum pressure check valve
14
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4.0 System Operation
4.1 Control System Features
 Starting the control system with the Display box or Remote ON
wire
 Stopping the control system with the Display box or Remote ON
wire
 Automatic engine shutdown if no air-use is detected
 Automatic engine restart when air-use is detected.
 Multiple adjustable system parameters for delays, pressures and
restart options
 Monitoring the compressor temperature probe connection range
 Monitoring air pressure for over-pressure or sensor error
 Monitoring clutch connection and current range
 Monitoring engine RPM for under-speed, over-speed, running
when not expected, and engine-restart failure
 Monitoring low battery voltage
 Optional battery-low engine restart
 Error and warning message logging (data-logging)
 Operator compressor servicing reminders (200 and 400 hours)
 Buzzer module to warn before engine restart
 LED beacon module to identify when the unit is able to restart
 Hour meter
 Optional Accessory – In-cab low-temperature engine restart
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15
4.2 Control System Operation
- ON/ENTER Button Pushed
- Remote enable wire to GND
STARTING/
CRANKING
Clear entered_engine_off_flag
Start blowdown_stopping_dealy
SYSTEM
READY
STOPPING
ON/ENTER
Button Pushed
(all arrows to
STOPPING)
BLOW-DOWN
DELAY
Blowdown_from_standby_timer reached
Blowdown_from_stopping_timer reached
RUNNING
Restarted from Low
Battery & no top-up
Set entered_engine_off_flag
Start blowdown_from_standby_timer
Low battery restart enabled and below lower threshold for 30s
Low Cab Temp restart enabled and below lower threshold for 30s
Air use detected or
Air pressure below PRESSURE_RESTART_PSI set-point
Engine running
{System restarted due to low battery}
& {Battery voltage not above upper
threshold for variable delay mins}
OR
{System restarted due to low cab temp}
& {Cab temp not above upper
threshold for variable delay mins}
Restarted from Low Cab temp & topped-up
(Start Standby Delay)
STANDBY delay reached
(minimum 1 min)
STANDBY
ON/ENTER Button Pushed or
DISABLE_AUTO_RESTART_DELAY
reached
Figure 2 - Control System Flow Diagram
16
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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:
 Pressing ON/ENTER from the Display Box
 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.
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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 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.
18
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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 detected, 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
(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.
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System State: STOPPING
When the control system is running and the ON/ENTER button on
the Display Box is pressed, the control system will enter the
STOPPING state.
It is important the ON/ENTER button be used to shut down
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.
20
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4.3 Display Box Messages
ERRORS
Er ror De tected
No Errors
Detected
Erro rs Cleare d?
SYSTEM
CHECK
Press NEXT/BACK
for 5 seconds
SETUP /
DIAGNOSTIC
MENU
SYSTEM
READY
USER
SETUP
ON request
SERVICING
Menu Sele ction
SYSTEM
RUNNING
VIEW LOGGED
ERRORS
VIEW LOGGED
MESSAGES
VIEW LOGGED
SERVICES
Figure 3 - Display Box Flow Diagram
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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
& off, the display will enter the ERRORS menu.
If no 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 & 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.
22
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4.3.3
System Running Menu
If any messages are present, the WARNING LED will
flash on & 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 initiate 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.
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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, also see sections 4.2 Control System Operation &
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:
To scroll through the menu screens press BACK and NEXT.
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
Press ENTER to see the parameter screens
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
24
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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 with 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 3PSI/sec) is ‘less sensitive’ to change to call a restart.
A large Auxiliary tank may require a ‘more sensitive’ rate
change in order to restart (ie. -2PSI/sec).
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 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.
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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.
Pressing ENTER on this screen will display CANCEL
Pressing NEXT will show CONFIRM RESET? Pressing BACK
will display CANCEL again
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.
Pressing EXIT, NEXT or ENTER will bring the user to USER
SETUP SCREEN
Pressing BACK will bring the user to the first user defined
parameter (SYSTEM PRESSURE)
26
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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.
The system may not restart due to system parameter
configuration. For details, see sections 4.2 Control
System Operation and 4.6 Adjustable System
Parameters.
When an error is detected, the controls will automatically shut down
the system. It will also show and log the error that caused the issue.
2013MY and newer RAM trucks using Hard-wired
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.
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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.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
n
hhhh.m
ee
dd mm yy
28
To show that a stored error is being displayed.
Error number 0 to 9.
th
Hour-Meter’s value at time of error to 1/10 of an hour.
Error code describing the type of error.
Error date.
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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.
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ERROR MESSAGE TABLE
Error
Code
1
2
3
4
5
6
7
8
9
Error Message Displayed
Cause
CLUTCH
FAILED - OPEN
CLUTCH
FAILED – SHORT
CLUTCH CURRENT
TOO LOW
CLUTCH CURRENT
TOO HIGH
COMP TEMP SENSOR
FAILED – OPEN
COMP TEMP SENSOR
FAILED – SHORT
COMP TOO COLD
xx.x F/xx.x C
COMP TOO HOT
xx.x F/xx.x C
Clutch is unplugged or wire to control box has
been cut. (<1.0A)
Clutch has shorted or wire to control box is
shorted. (>10.0A)
CAB TEMP SENSOR
FAILED – OPEN
34
CAB TEMP SENSOR
FAILED – SHORT
AIR PRESS SIGNAL
VOLTAGE LOW
AIR PRESS SIGNAL
VOLTAGE HIGH
AIR PRESS SENSOR
TOO HIGH
AIR PRESSURE
xxx.x PSI
PARK BRAKE
NOT ENABLED
ENGINE RPM
TOO LOW TO START
ENGINE RPM
DURING OFF STATE
ENGINE RPM
NOT DETECTED
35
ENGINE CRANK
TIME OUT
10
12
13
14
14
22
26
27
41
-
30
CLOSE HOOD
TO START
DISPLAY CANBUS
CONN ERROR
End of Errors
OK to Retry?
Under-current reading on clutch. (1.0-2.0A)
Over-current reading on clutch. (5.0-10.0A)
Temperature sensor on the compressor is
unplugged or wire to control box has been cut.
Temperature sensor on the compressor is
shorted.
Compressor is too cold to start. The
temperature is displayed. (<-40 C)
Compressor is too hot to start. The
temperature is displayed. (>130 C)
Accessory temperature sensor in the cab is
unplugged, enabled but not installed, or wire
to control box has been cut.
Accessory temperature sensor in the cab is
shorted.
Low voltage reading on the air pressure
transducer. (signal <0.5V)
Over voltage reading on the air pressure
transducer. (signal >4.6V)
Air pressure is higher than expected.
(>180PSI)
If the previous error is present, the air
pressure is displayed.
Park brake needs to be engaged.
Engine RPM is too low to start system.
Engine RPM detected during an OFF state.
Engine RPM is not detected. Wire may be cut.
The engine did not start during the crank
cycle.
The truck’s hood is open. It must be closed
when the unit is run.
A CAN bus error between the Display box and
Control box.
End of errors screen. Pressing ENTER will try
to restart the system.
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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
Error
Code
32
-
54
BATTERY VOLTAGE
TOO LOW
200HR/6MTH SERV
DUE IN xx HOURS
COMPRESSOR SERV
200HR/6MTH
-
400HR/12MTH SER
DUE IN xx HOURS
55
COMPRESSOR SERV
400HR/12MTH
62
63
4.5.5
Cause
Message Displayed
LOW BATT
RESTART
CAB TEMP
RESTART
The battery voltage is too low.
This warning will show up 10 hours before the
200 hour service interval.
The system is due for a service. This warning
will show after every 200 hours of running the
compressor.
Clearing the compressor service reminder is
required through the Diagnostic menu.
This warning will show up 10 hours before the
400 hour service interval.
The system is due for a service. This warning
will show after every 400 hours of running the
compressor.
Clearing the compressor service reminder is
required through the Diagnostic menu.
The truck failed to start when requested to due
to a low battery voltage condition.
The truck failed to start when requested to due
to the cab temperature getting too cold.
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.
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4.6 Adjustable System Parameters
SYSTEM PARAMETER TABLE
Setting
Standby Delay
Description
Delay time to standby
Restart Pressure
PSI
Operating System
Pressure
PSI below system
pressure to allow inlet to
open and build pressure
Air rate set-point for
pressure-based restart
Air pressure set-point for
pressure-based restart
Disable Auto
Restart Delay
Timer for disabling
automatic engine restart
System Pressure
Top-up Pressure
High Air Use Rate
Low Battery
Restart
Batt Lower Thrs
Batt Upper Thrs
Low Batt Restart
Delay
Cab Temp
Restart
Controls if system will
restart when battery
voltage gets too low
Restart point for battery
voltage
Fully-charged set point
for battery voltage
Time delay before going
back to STANDBY after
battery fully charged
Controls if system will
restart when cab
temperature drops too
low – Accessory kit
required
Cab Lower Thrs
Restart cab temperature
Cab Upper Thrs
Fully warmed cab
temperature
Low Cab Restart
Delay
Time delay before going
back to STANDBY after
warming cab
32
Adjustment
1, 2, 5, 10, 15, 30
minutes, Never
80 to 175PSI @
5PSI increments
1 to 10PSI @ 1PSI
increments
0 to -30PSI @
0.5PSI increments
80 to 175PSI @
5PSI increments
Always, 30 min,
60 min, 90 min, 120
min, Never
Enable/Disable
10.0 to 14.0V in
0.1V steps
10.0 to 15.0V in
0.1V steps
Default
10 min
150PSI
5PSI
-3.0PSI/sec
120PSI
30 min
Enabled
12.1V
12.8V
2, 5, 10, 15, 20, 30
min
2 min
Enable/Disable
Disabled
-10 C to +20 C
in 0.1 C steps
+10 C to +30 C
in 0.1 C steps
2, 5, 10, 15, 20,
30 min
10.0 C
20.0 C
5 min
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To modify a system parameter (such as Standby Delay):
1. Turn the key ignition ON. Do not start the compressor
system.
2. Press and hold the NEXT and BACK buttons on the display
box for 5 seconds to enter Setup/Diagnostics Menu.
3. When display box shows USER SETUP, press ON/ENTER
4. Use NEXT and BACK to scroll to STANDBY DELAY.
5. Press ON/ENTER.
6. Use NEXT and BACK to change Standby Delay parameter
value.
7. Press ON/ENTER to select value, or EXIT to cancel change.
8. Verify STANDBY DELAY screen shows desired parameter
value.
9. Press EXIT to return to USER SETUP.
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
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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 15º in slope as
this may affect lubrication and air/oil separation.
15 Deg
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 (if open).
4. Close all compressor air system outlets.
5. Activate the compressor using the ON/ENTER button on the
display box.
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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.
!
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.
4.7.3
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.
5. (If desired) Turn off the vehicle (and power to electronics) by
using the vehicle key switch.
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 and the clutch to
burn out.
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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.
36
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4.9 Adding Oil to the System
1. Remove the fill plug (remote oil fill if equipped), from the inlet
control valve.
!
The oil is clear and the level may be difficult to see in the
sight glass. Have someone watch the level as you add
oil.
Oil Fill Plug
Figure 6 – Compressor (exact appearance
varies by application)
2. Pour oil into the oil 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.
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UP
MAX
ADD
Sight Glass
Window
Drain Plug
VR70
Figure 7 – Oil filter end of the Separator tank
!
38
You must use VMAC certified and approved synthetic
compressor oil. Failure to use this oil will result in
damage to the compressor and may void your warranty.
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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 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.
Ensure the correct orifice for the VR70 system is used.
For 70 CFM application, (VR 70), use a .190 ORIFICE,
(part #3200224).
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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.
Figure 8 - VR Throttle Controller Adjustment Screws
6. Close the air valve slowly to allow the system pressure to rise.
40
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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 should start to rampup 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
1500
Idle Down pressure adjustment
1100
Idle Down Pressure
(
(
Full Pressure
)
175 psi / 1307 kPa maximum
Factory setting, typical 150 psi / 1034 kPa
)
Factory setting, typically 140 psi / 965.3 kPa
Recommend 10 psi / 68.985 kPa below full pressure
Regulator adjustment
500
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.
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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.
!
Impact damage and premature bearing failure may
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.
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.
!
42
Never run the compressor, drive the vehicle or even
allow the vehicle to sit parked without the
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
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 #A700019 (VR70)
400 hours or 1 year:
Replace the air filter, oil filter, coalescing element and
change oil
Use service kit #A700020 (VR70)
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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.
44
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Toll Free: 1-800-738-8622 Local: 1-250-740-3200
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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.
2. Remove the filter cover retaining nut, the filter cover and the filter
element.
3. 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 filter and cover are replaced.
4. 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.
5. Remove the cloth or masking and install a new air filter. Make
sure that the filter fits over the machined step on the housing.
6. Replace the cover and secure it with the cover bolt. Do not overtighten the bolt.
!
Never attempt to clean the filter element with
compressed air. Replace the filter element.
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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 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.
46
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622 Local: 1-250-740-3200
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!
You must use the supplied compressor oil in this
system. Failure to use this special oil may result in
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.
!
Do not overfill the system. Overfilling the system with oil
can flood the sight glass window and make the system
appear empty.
11. Install the fill plug in the inlet control 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.
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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. If you 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 supplied 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.
48
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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.
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49
6.6 Changing the Coalescing Filter
If the system has just been operated, shut off the engine and wait 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.
3. Install and tighten the plug.
4. If you 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
Spring
Safety valve
Thimble screen
O-ring
Rear cap seal
Coalescing filter
Coalescing filter spring
Figure 10 - VR70 Coalescing Filter
50
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!
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.
8. Remove and discard the O-ring seal and the rear cap seal.
9. Wipe out the inside of the tank
10. Remove the thimble screen and spring and clean the discharge
cap.
If you use solvents for cleaning, 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.
!
You must use the supplied compressor oil in this
system. Failure to use this special oil will result in
damage to the compressor and may void your warranty.
18. Turn the compressor clutch clockwise to speed the fill process.
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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 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.
52
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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 equipment
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
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53
SYMPTOM
Compressor does
not run
POSSIBLE CAUSE
Oil temperature too
high.
Oil level is too low.
Drive belt is broken.
No power to the clutch.
Bad clutch ground.
Open clutch stator
windings.
Engine does not
restart from Standby
state
Disable Auto Restart
Delay parameter
setting
Bad START relay
(if equipped)
54
CORRECTIVE ACTION
Turn compressor off, allow to cool
for 30 minutes, retry.
Park on level ground, check level
at sight glass, add as necessary.
Install new compressor belt. Check
alignment of pulleys. Replace
automatic tensioner.
Check for 12 V at the clutch, check
fuse, check for broken wires or
failed switch.
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.
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.
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.
Replace system’s START relay
located on control box mount
bracket.
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SYMPTOM
Frequent overtemperature
shutdowns.
Excessive air
pressure
Engine stalls when
compressor is
activated.
POSSIBLE CAUSE
CORRECTIVE ACTION
Low oil level.
Check oil on level ground, add as
required.
Restriction in the
compressor oil hoses.
Compressor oil filter
plugged.
Heat exchanger not
functioning or is fouled
with deposits.
Engine cooling system
failure (high engine
temperature).
Engine fan clutch
slipping.
High ambient
temperatures.
Oil temperature probe
failure.
System needs service
Check for kinked or pinched oil
hoses.
Replace oil filter.
System Pressure
parameter set too
high.
System return line
blocked or frozen
Electrical inlet solenoid
stuck closed.
Reduce System Pressure in User
Setup Menu.
System is under
pressure.
Allow sufficient time for blow-down.
Blow-down valve not
working.
RPM setting too low or
throttle not set
correctly.
Throttle control not
connected properly at
foot pedal
Replace blow-down valve.
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Remove and clean or replace heat
exchanger.
Correct engine cooling problems.
Replace fan clutch.
Reduce duty cycle.
Replace if defective.
Perform recommended service
Clear or replace the line.
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.
Re-adjust RPM and throttle
settings for optimum operation.
Check for proper connections.
55
SYMPTOM
Belt squeals when
compressor switch is
activated.
Frequent relief valve
operation.
POSSIBLE CAUSE
CORRECTIVE ACTION
System is under
pressure.
Allow sufficient time for blow-down.
Blow-down valve not
working or muffler is
plugged.
Improper belt tension.
Belt is glazed.
Replace blow-down valve or clean
muffler.
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.
Remove the pressure control line
and clear any obstructions. (Blow
out.)
Replace relief valve.
Pressure control line
plugged or frozen.
Relief valve defective.
Check belt tensioner.
Replace belt.
Power fuse blows.
Short to ground in the
control circuit.
Incorrect fuse.
Incorrect wiring.
Locate and correct short or replace
control panel.
Install correct OEM fuse.
Repair wiring according to wiring
diagram.
Low air pressure.
Air flow is too high.
System Pressure
parameter set too low.
Throttle control set too
low.
Electrical inlet solenoid
stuck open.
Reduce consumption.
Increase System Pressure in User
Setup Menu.
Increase maximum RPM settings.
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.
Engine RPM
excessive on initial
startup and during
operation.
56
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.
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SYMPTOM
Objectionable noise
level.
POSSIBLE CAUSE
Excessive gear wear.
Maximum RPM setting
higher than necessary
to meet air demand
requirements.
Engine RPM stays at
base idle when
compressor runs.
CORRECTIVE ACTION
Contact the nearest dealer to
replace compressor/gearbox
assembly. Refer to the dealer.
Reduce maximum RPM settings.
Throttle control not
adjusted properly.
Adjust throttle controls.
Poor electrical
connections.
Throttle control not
functioning.
Pressure sensor
defective or
disconnected.
Test and correct connections.
Throttle controls not
connected properly.
Throttle control not
setup properly.
Pressure sensor
defective or
disconnected.
Check and correct connections.
Engine RPM does
not return to base
idle.
Wiring fault.
Check and correct wiring according
to wiring diagram.
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
Replace HOT 12V relay located on
the control box mount bracket
Replace 3 Amp fuse. If fuse blows
again, check for broken wires and
failed parts to find source of fault.
Engine RPM overrevs when
compressor is
activated.
Throttle not properly
adjusted.
Blown HOT 12V fuse
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Replace throttle control.
Check connections or replace
pressure sensor.
Adjust high idle screw.
Check connections or replace
pressure sensor.
57
SYMPTOM
Excessive oil in the
air.
POSSIBLE CAUSE
CORRECTIVE ACTION
Failed coalescing
separator element.
Clogged scavenge line
screen.
High oil level.
Poor fit between
coalescing filter and
tank – lack of seal at
O-rings.
Vehicle is not within
requirements of 15
degrees of level.
Compressor was
turned off while
running at high speed.
Wing tank – volume
shutting down under
load.
Shutting the engine off
while running at high
speed.
Replace element.
Oil drips from clutch
after shutdown.
Seal leaking.
Contact the nearest dealer to
replace gearbox input shaft seal.
Cannot drive the
vehicle after remotestart operation
RAM truck – remotestart drive interlock
Cycle the key to OFF position then
use as desired.
Oil blows out of
compressor air filter
on compressor
shutdown.
58
Clean or replace parts as required.
Correct oil level.
Replace parts as required.
Level vehicle and check for oil in
the air.
Allow engine RPM to drop before
turning the compressor off.
Clean or replace parts as required.
Allow engine to idle-down before
shutting down the compressor.
Turn off any air tools before
shutting down compressor.
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8.0 VMAC Warranty
1.
GENERAL PROVISIONS AND LIMITATIONS
1.1
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.
1.2
Product Warranty – Underhood Air Compressors applies to
Products(s) manufactured on or after January 1, 2005.
(System ID numbers ending with TA001 or greater).
2.
NO WARRANTY IS MADE WITH RESPECT TO
2.1
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.
2.2
Components or accessories manufactured, warranted and
serviced by others.
2.3
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.
2.4
Consequential damages caused by Product(s) failure.
2.5
Any Product(s) if other than VMAC’s genuine components are
used in the Product(s).
2.6
Normal wear and tear of Product(s).
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59
3.
WARRANTY PERIOD
3.1
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.
3.2
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.
3.3
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.
3.4
Replacement components of Product(s) listed in 3.2, excluding
VMAC factory rebuilt 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.
3.5
VMAC factory rebuilt components shall be warranted for a
period of 6 months from date of shipment from VMAC.
3.6
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.
60
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4.
VMAC OBLIGATIONS
4.1
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.
4.2
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.
5.
BUYER OBLIGATIONS
5.1
Buyer shall notify VMAC of the alleged defect within 10 days
of initial discovery and return the allegedly defective
component(s) within 30 days of initial discovery.
5.2
The Buyer must prepay all costs associated with the warranty
claim and submit receipts and/or invoices to VMAC for
evaluation.
5.3
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.
5.4
Buyer shall maintain and service VMAC Product(s) in
accordance with the VMAC Product(s) Owner’s Manual.
6.
WARRANTY REGISTRATION VALIDATION
6.1
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.
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61
7.
DISCLAIMER AND WARRANTY SERVICE
7.1
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
time or labor provided by unauthorized service personnel are
not provided by this warranty.
7.2
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.
7.3
Warranty claims must be pre-authorized by VMAC, and the
components returned via prepaid freight using the designated
“Returned Merchandise Authorization” number and form.
62
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VMAC Product Warranty Registration
This form must be fully completed and returned to VMAC at the
time of installation. Warranty will be void if this form is not
received by VMAC within 30 days of installation.
VMAC Dealer Information
Company Name: ______________________________________
City: _____________________
State/Prov:______________
Installer Information
Company Name: ______________________________________
City: _____________________
State/Prov:______________
Installation Date: _____/_____/_____
Day
Month
Year
Owner Information
Company Name: ______________________________________
Address: ____________________________________________
City: _____________________
State/Prov:______________
Zip/Postal: ________________
Phone #: (____)____-_____
Vehicle Information
Year: ____________________
Make: _________________
Vehicle Identification Number: ___________________________
Unit #: ___________________
Product Information
System Identification Number: V _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Compressor Serial Number: P_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Throttle Control Serial Number: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
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