Vmac UNDERHOOD 40 Series User manual

www.vmacair.com
Installation Manual for VMAC
System
V400012
2017+Ford Super Duty F-250 – F-350
6.2 L Gas

VMAC - Vehicle Mounted Air Compressors
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Table of Contents
Safety .........................................................................3
Warranty ......................................................................4
General Information ...........................................................6
System Identification, Warranty Registration and Warning Labels..............8
Preparing for Installation .....................................................10
Installing the Main Bracket
and Compressor .............................................................. 17
Installing the Waste Heat Air Separator Package (WHASP) Tank..............22
Hose Requirements ...........................................................25
Connecting the Hoses ........................................................26
Adding Oil to the System .....................................................29
Installing the Control System ................................................ 30
Air Receiver Tank .............................................................37
Recommended Accessories .................................................. 38
Completing the Installation ...................................................39
Testing the Installation ....................................................... 41
Performance Testing and System Adjustments ............................... 44
Accessory Products from VMAC ............................................. 46
Warranty Registration ........................................................52

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Additional Application Information
• Use of an air receiver tank (minimum 6 USG) is required with this application.
• 2017+Ford Super Duty F-250 – F-350 6.2 L Gas.
Important Information
The information in this manual is intended for certified VMAC installers who
have been trained in installation and service procedures and/or for anyone with
mechanical trade certification who has the tools and equipment to properly and
safely perform the installation or service. Do not attempt installation or service
without the appropriate mechanical training, knowledge and experience.
Follow all safety precautions. Any fabrication for correct fit in modified vehicles
must follow industry standard “best practices”.
Notice
Copyright © 2020 VMAC Global Technology Inc. All Rights Reserved. These
materials are provided by VMAC for informational purposes only, without
representation or warranty of any kind, and VMAC shall not be liable for errors
or omissions with respect to the materials. The only warranties for VMAC
products and services are those set forth in the express warranty statements
accompanying such products and services, if any, and nothing herein shall be
construed as constituting an additional warranty. Printing or copying of any page
in this document in whole or in part is only permitted for personal use. All other
use, copying or reproduction in both print and electronic form of any part of this
document without the written consent of VMAC is prohibited. The information
contained herein may be changed without prior notice.
Printed in Canada
Registered Trademarks
All trademarks mentioned in this manual are the property of their respective
owners. VMAC’s use of manufacturers’ trademarks in this manual is for
identification of the products only and does not imply any affiliation to, or
endorsement of said companies.
Lisle® is a registered trademark of the Lisle Corporation.
Loctite®, Loctite®242 and Loctite®567 are registered trademarks of Henkel AG &
Company KGaA.
Eaton Aeroquip® is a registered trademark of EATON AEROQUIP INC.
Ford® and Super Duty® are registered trademarks of Ford Motor Company.
Document: 1930346
Changes and Revisions
Revision Revision Details Revised by
Checked by
Implemented
Eng. Tech. Qual.
Mech. Elec.
C ECN 19-157 Cap model year MSP N/A N/A MSP N/A 5 Nov 2019
D ECN 19-206 Valve cover mod MSP BJG N/A MSP LPH 3 Dec 2019
E ECN: 20-210 Receiver tank requirement MSP MRH N/A MSP N/A 4 Nov. 2020

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Important Safety Notice
The information contained in this manual is based on sound engineering principles,
research, extensive field experience and technical information. Information
is constantly changing with the addition of new models, assemblies, service
techniques and running OEM changes. If a discrepancy is found in this manual,
contact VMAC Technical Support prior to initiating or proceeding with installation,
service or repair. Current information may clarify the issue. Anyone with knowledge
of such discrepancies, who proceeds to perform service and repair, assumes all
risks.
Only proven service procedures are recommended. Anyone who departs from the
specific instructions provided in this manual must first ensure that their safety and
that of others is not being compromised, and that there will be no adverse effects
on the operational safety or performance of the equipment.
VMAC will not be held responsible for any liability, consequential damages, injuries,
loss or damage to individuals or to equipment as a result of the failure of anyone
to properly adhere to the procedures set out in this manual or standard safety
practices.
Safety should be the first consideration when performing any service operations.
If there are any questions concerning the procedures in this manual, or more
information is required, please contact VMAC Technical Support prior to beginning
work.
Safety Messages
This manual contains various warnings, cautions and notices that must be
observed to reduce the risk of personal injury during installation, service or repair
and the possibility that improper installation, service or repair may damage the
equipment or render it unsafe.
This symbol is used to call attention to instructions concerning
personal safety. Watch for this symbol; it points out important
safety precautions, it means, “Attention, become alert! Your
personal safety is involved”. Read the message that follows and
be aware of the possibility of personal injury or death. As it is
impossible to warn of every conceivable hazard, common sense and
industry standard safety practices must be observed.
This symbol is used to call attention to instructions on a specific
procedure that if not followed may damage or reduce the useful life
of the compressor or other equipment.
This symbol is used to call attention to additional instructions or
special emphasis on a specific procedure.
Safety

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VMAC Standard Warranty (Limited)
For complete warranty information, including both VMAC Standard
Warranty (Limited) and VMAC Lifetime Warranty (Limited)
requirements, please refer to our current published warranty located
at: www.vmacair.com/warranty
If you do not have access to a computer, please contact us and we
will be happy to send you our warranty.
VMAC’s warranty is subject to change without notice.
VMAC Lifetime Warranty (Limited)
A VMAC Lifetime Limited Warranty is offered
on the base air compressor only and only on
UNDERHOOD, Hydraulic Driven, Transmission
Mounted, Gas and Diesel Engine Driven Air
Compressors, Multifunction Power Systems, and
other products as defined by VMAC, provided that
(i) the purchaser fully completes and submits a
warranty registration form within 3 months of purchase, or 200 hours of operation,
whichever occurs first; (ii) services are completed in accordance with the Owner’s
Manual; (iii) proof of purchase of applicable service kits are made available to
VMAC upon request.
The VMAC Lifetime Warranty is applicable to new products shipped on or after
1 October, 2015.
Warranty Registration
The VMAC warranty registration form is located near the back of this manual. This
warranty registration form must be completed and sent to VMAC at the time of
installation for any subsequent warranty claim to be considered valid.
There are 4 ways the warranty can be registered with VMAC:
www.vmacair.com/warranty
[e-mail]
(877 ) 740-3202
VMAC - Vehicle Mounted Air Compressors
1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3
LIFETIME
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WARRANTY
Warranty

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VMAC warranty work must be pre-authorized by VMAC. Claims are
processed via our dealer network. If you are not a VMAC dealer,
please select one to work with via our Dealer Locator:
https://www.vmacair.com/dealer-locator/
1. Communicate with VMAC Technical Support at 1-888-241-2289 or
[e-mail] to help diagnose/troubleshoot the problem prior to repair.
VMAC technical support will require the VMAC System ID, hours on the
compressor and mileage on the vehicle.
2. VMAC will provide direction for repair or replacement of the failed components.
3. If requested, failed parts must be returned to VMAC for evaluation.
4. Dealers may login to the VMAC website to view the "VMAC Labour Time Guide"
(under “Agreements”) to see the allowable warranty labour times.
5. Warranty invoices must include the Service Ticket number, VMAC System ID#,
hours on the compressor, and a detailed description of the work performed.
6. VMAC Warranty does not cover consequential damages, overtime charges,
mileage, travel time, towing/recovery, cleaning or shop supplies.
7. Dealers submit warranty claims on behalf of the Vehicle Owner/End User
affected by the defective part(s). The dealer ensures that all warranty credits
are refunded back to the Vehicle Owner/End User who made the initial warranty
claim.
In order to qualify for Lifetime Warranty (Limited), the completed
warranty registration form must be received by VMAC within 3
months of the buyer receiving the Product(s), or 200 hours of
operation, whichever occurs first.
If the completed warranty registration form has not been received
by VMAC within 3 months of the buyer receiving the Product(s),
or 200 hours of operation, the warranty period will be deemed to
commence 30 days from the date of shipment from VMAC.
Failure to follow the warranty claim process may result in denial of
the warranty claim.
VMAC Product Warranty Policies & Warranty Registration can be found on the
VMAC website (see previous page for URL).
VMAC Warranty Claim Process

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General Information
Optional Equipment Compatibility
While VMAC strives to design systems compatible with optional OEM equipment
(such as running boards), it is impractical to develop systems that accommodate
every OEM and aftermarket option or add-on. Whenever possible, VMAC
endeavors to advise of compatibility issues in the “Additional Application
Information” section of the manual. Even when specific optional equipment is
determined by VMAC to be incompatible, it does not preclude the vehicle upfitter
or end user from modifying the optional equipment to make it compatible with
the installed VMAC system. VMAC does not warranty or accept responsibility or
liability for the fitment, function or safety of any products modified in any way not
expressly outlined in the installation manual.
Before Starting
Note and label all parts that are removed from the vehicle as many
of the OEM parts will be reused during the installation of the VMAC
system.
Read this manual prior to beginning the installation to ensure familiarity with the
components and how they will fit on the vehicle. Identify any variations from the
application list such as vehicle model, engines, or optional equipment (e.g., dual
alternator, active steering assist, etc.).
Open the package, unpack the components and identify them using the Illustrated
Parts List (IPL) included in the Fastener Pack.
Hose Information
Depending on other installed equipment, it might be necessary to move the air/oil
separation tank from its intended location. The hoses used in VMAC compressor
systems have a specific inner liner that is compatible with VMAC compressor oil.
Use of hoses other than those supplied or recommended by VMAC may cause
compressor damage and may void your warranty. Please contact VMAC for
replacement hoses and further information.
Ordering Parts
To order parts, contact a VMAC dealer. The dealer will ask for the VMAC serial
number, part number, description and quantity. Locate the nearest dealer online at
www.vmacair.com/dealer-locator or call 1-877-912-6605.

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Table 1 — Torque Table
Standard Grade 8 National Coarse Thread
Size (in) 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4
Foot pounds (ft•lb) 918 35 55 80 110 170 280
Newton meter (N•m) 12 24 47 74 108 149 230 379
Standard Grade 8 National Fine Thread
Size (in) 3/8 7/16 1/2 5/8 3/4
Foot pounds (ft•lb) 40 60 90 180 320
Newton meter (N•m) 54 81 122 244 434
Metric Class 10.9
Size (mm) M6 M8 M10 M12 M14 M16
Foot pounds (ft•lb) 4.5 19 41 69 104 174
Newton meter (N•m) 625 55 93 141 236
Special Tools Required
• Pneumatic fan wrench removal set (such as Lisle® 43300) or a manual fan
pulley holder (such as KD Tool® KD3900).
Torque Specifications
All fasteners must be torqued to specifications. Use manufacturers’ torque values
for OEM fasteners.
The torque values supplied in Table 1 are intended for VMAC supplied components,
or for use as a guide in the absence of a torque value provided by an OEM.
Torque values are with Loctite applied unless otherwise specified.
Apply Loctite 242 (blue) to all fasteners (except nylon lock nuts)
unless otherwise stated.

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Preparation for installation is very important. Missing a step
or an item can cause problems in the installation or damage to
components.
☑
Check off each item as it is completed so that no steps are
missed.
☐ Review the contents of the system using the illustrated parts list to ensure all
components are present and in the correct quantity. If any components are
missing, have the system ID ready and call VMAC Technical Support at
[phone].
The VMAC warranty form must be completed and returned to VMAC
at the time of installation for any subsequent warranty claim to be
considered valid.
☐ Complete the warranty form. The VMAC warranty form is located at the back
of this manual, as well as online at: www.vmacair.com/warranty
The System Identification Plate must be attached to the vehicle at
the time of installation. This plate provides information that allows
VMAC to assist with parts and repairs.
☐ Locate a conspicuous area in the engine bay (where the tag will be easily
noticed) to install the System ID tag.
☐ Mark and drill (×2) 7/64 in holes and secure the plate with the supplied self-
tapping screws (Figure 1).
Figure 1 — System Identification Plate
☐ Install the VMAC belt routing diagram in a suitable location under the hood.
System Identification, Warranty
Registration and Warning Labels

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☐ As part of the installation process, ensure that the safety and operational
instruction decal is affixed in an obvious location so that it can be seen by
vehicle operators. A good spot for this is usually on the inside of the door or on
the panel underneath the steering wheel (Figure 2).
Figure 2 — Operating Instruction label
☐ To alert any technicians that may service the vehicle, affix the servicing
caution/contact decal in a conspicuous area in the engine bay (where the decal
will be easily noticed) (Figure 3).
Figure 3 — Advisory label

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Preparing for Installation
Due to the variety of possible WHASP tank installation locations,
VMAC does not include bulkhead fittings or hoses to run between
any bulkhead and the WHASP tank. VMAC recommends determining
where the WHASP tank will be located early in the installation so
that appropriate hose lengths and bulkhead fittings can be ordered.
Refer to page 22 for WHASP tank installation requirements.
Optional: Raise front of vehicle and support on jack stands.
This system is designed to work with both dual and single radiator
vehicles.
☐ Disconnect the battery(ies).
☐ Remove the lifting eye (if equipped) (Figure 4).
If lifting the vehicle, ensure it is supported safely with appropriately
rated jack stands.
Figure 4 — Remove lifting eye
Remove
lifting eye
☐ Drain the coolant into a clean container and set it aside for use later.

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☐ Remove the air intake and cover the ports to prevent debris entering the engine
(Figure 5).
Figure 5 — Remove air intake
☐ Remove the top radiator cross member cover.
☐ Remove the upper radiator hose.
☐ Disconnect the fan clutch wire and remove the bolt securing the fan stator arm
to the engine.
☐ Remove the fan and pull it out of the engine bay.
For ease of fan removal and installation, it is recommended that a
pneumatic fan wrench removal set (such as Lisle 43300) or a manual
fan pulley holder (such as KD3900) is used.
☐ Keeping the power steering lines connected, remove the power steering
reservoir from the fan shroud.
☐ Temporarily tie the power steering reservoir up and out of the way of the
shroud.
Ensure the power steering reservoir is kept upright to prevent it
from leaking.
☐ Remove the fan shroud.
☐ Remove the Front End Accessory Drive (FEAD) belt and discard it.

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☐ Remove the driver side idler and set it aside for use later (Figure 6)
Figure 6 — Remove driver side idler
Remove idler
☐ Remove the thermostat housing and set it aside for use later. Leave the rubber
seal and thermostat in place (Figure 7).
Figure 7 — Remove thermostat housing

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☐ Assemble the VMAC thermostat spacer, O-ring, thermostat housing, and the
supplied M6 fasteners (Figure 8).
☐ Apply Loctite 242 (blue) to the M6 fasteners and rotate the thermostat housing
assembly into place. Torque the fasteners to specification (Figure 8).
☐ Disconnect the harness from the Radio Interference Suppressor (RIS) and
remove it from the mounting stud on the driver side timing cover (Figure 9).
Figure 9 — Remove RIS
Figure 8 — Install thermostat spacer and housing
M6 ×1.0 ×
60 mm (2×)
OEM thermostat
housing VMAC O-ring
Thermostat
VMAC thermostat
spacer

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☐ Remove the corners of the RIS mount (Figure 10).
Figure 10 — Modify RIS mount
☐ Remove and discard the RIS stud (Figure 11).
☐ Remove and discard the indicated fasteners (Figure 12).
Figure 11 — Remove RIS stud
Remove and
discard stud
Figure 12 — Remove and discard fasteners
Remove and discard
fasteners

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☐ Remove and discard the indicated cable retainers (Figure 13).
Figure 13 — Remove cable retainers
Remove and
discard cable
retainers
Alternate view of
fastener shown in
Figure 12
☐ Using a die grinder or pneumatic cut off wheel, remove the wire harness
mounting tab on the driver side valve cover (Figure 14).
Figure 14 — Disconnect sensor

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VMAC recommends wrapping the sensor harness, as well as the
harness running along the front of the valve cover, with protective
loom (not supplied) to prevent abrasion as they will be routed under,
or around the back of the VMAC compressor bracket.
☐ Shift the harness running along the front of the valve cover toward the firewall
as it will route between the compressor bracket and the valve cover.
☐ Disconnect the sensor in the valve cover (Figure 15).
Figure 15 — Disconnect sensor
Loom harnesses

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Apply Loctite 242 (blue) to all engine mounted fasteners.
Installing the Main Bracket
and Compressor
While this compressor system was designed to accommodate dual
battery vehicles, the battery harnesses may need to be rerouted to
prevent conflict with VMAC components.
Ensure any wires shifted during the installation are routed to avoid
hot, sharp, or moving components and are sufficiently protected
from abrasion.
Figure 16 — Install main bracket
☐ Remove the idlers from the main bracket.
☐ To install the main bracket, slide the bracket over the cable retainer boss on the
driver side of the valve cover, then rotate the bracket into place over top of the
valve cover.
☐ Feed the valve cover sensor connector and harness under the bracket and
toward the front of the engine.
☐ Secure the bracket using the (3×) M8 × 1.25 × 50 mm fasteners; leave the
fasteners quite loose to ease the next step (Figure 16).

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☐ Install the spacer between the engine block and the main bracket and secure it
with the supplied M16 fastener, do not torque it (Figure 17).
Ensure the harnesses are not pinched between the engine block and
the main bracket.
☐ Grab the wire harnesses going to the valve cover sensor on both sides of
the VMAC main bracket and confirm they are not pinched between the main
bracket and the engine.
☐ Torque the (3×) M8 fasteners to specification.
☐ Torque the M16 fastener to specification.
☐ Reconnect the sensor removed from the valve cover.
☐ Install the driver side OEM idler (Figure 18).
Figure 18 — Install OEM idler
Figure 17 — Install main bracket spacer
Install spacer