Vmac UNDERHOOD 40 Series User manual

www.vmacair.com
Installation Manual for VMAC
System
V400006
2013+RAM 2500 – 3500 Pickup, Chassis Cab
2013+RAM 4500 – 5500 Chassis Cab
6.7 L Cummins Diesel

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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 .................................. 13
Installing the Waste Heat Air Separator Package (WHASP) Tank.............. 17
Hose Requirements .......................................................... 20
Connecting the Hoses ....................................................... 21
Adding Oil to the System .....................................................25
Installing the Control System .................................................26
Air Receiver Tank .............................................................39
Recommended Accessories .................................................. 40
Completing the Installation ................................................... 41
Testing the Installation .......................................................42
Performance Testing and System Adjustments ............................... 45
Accessory Products from VMAC ..............................................47
Warranty Registration ........................................................52

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Document: 1930338
Changes and Revisions
Revision Revision Details Revised by
Checked by
Implemented
Eng. Tech. Qual.
Mech. Elec.
AInitial Release MSP KRM AJH GB AWG 14 Feb 2018
B ECN: 20-210 Receiver tank requirement MSP MRH N/A MSP N/A 2 Nov. 2020
Additional Application Information
• Use of an air receiver tank (minimum 6 USG) is required with this application.
• 2013+ RAM 2503.0 – 3500 Pickup, Chassis Cab 6.7 L Cummins Diesel.
• 2013+ RAM 4500 – 5500 Chassis Cab 6.7 L Cummins Diesel.
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.
Torx® is a registered trademark of Acument Intellectual Properties, LLC
Nylok® is a registered trademark of Nylok Fastener Corporation.
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.
RAM® is registered trademark of FCA US LLC.
Cummins® is registered trademark of Cummins Inc.
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”.

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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
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 (Lisle 43300 or equivalent) or a manual fan pulley
holder (such as KD3900).
• 6 mm hex ball end extended socket.
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.
☐ Mark and drill 2 × 7/64 in holes in the top of the cross member in front of the
hood support. 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 label in the engine compartment near the hood latch in a
visible location (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 17 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 both of the batteries.
☐ Remove the aesthetic engine covers (if equipped).
☐ Remove the top 2 bolts from the fan shroud and insert a protective sheet of
cardboard between the radiator and the fan.
☐ Remove the 4 nuts securing the fan stator to the engine mounted support
brackets (2 are located at the top, 2 are located near the harmonic balancer).
☐ Disconnect the clutch fan harness connector and the stator brace (Figure 4).
If lifting the vehicle, ensure it is supported safely with appropriately
rated jack stands.
Figure 4 — Radiator fan harness connector
Disconnect

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☐ Remove the fan and stator shroud as one unit and set them aside.
☐ Remove the Front End Accessory Drive (FEAD) belt and retain it in the vehicle.
In the unlikely event of a compressor failure, the VMAC belt can be removed
and the OEM belt can be reinstalled to operate the vehicle.
☐ Remove the upper driver side stator bracket. Set the bracket and hardware
aside for reinstallation later (Figure 5).
Figure 5 — Stator bracket
Remove stator
bracket
☐ Remove the engine mounted portion of the upper radiator hose support
bracket. Discard the M10 mounting bolt and the lower part of the bracket but
retain the M6 bolt for later in the installation (Figure 6).
Figure 6 — Radiator hose support bracket
(Upper hose removed for clarity)
Discard M10 bolt
and lower bracket
Retain M6
bolt

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☐ Ensure the mounting surface and (3×) M10 threaded holes are clean and free of
debris (Figure 7).
Figure 7 — Compressor bracket mounting surface
(Some radiator hoses removed for clarity)
Inspect surface
and mounting
holes
☐ Remove the throttle body cover (if equipped), the wire harness retainer, and the
OEM stud (Figure 8).
Figure 8 — Throttle body
(Throttle body cover not shown)
Remove stud and
harness retainer

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Apply Loctite 242 (blue) to all engine mounted fasteners.
Installing the Main Bracket
and Compressor
☐ Remove the idler from the VMAC main bracket.
☐ Install the 2 supplied dowels into the main bracket (Figure 9).
Figure 9 — Installing the dowels
Ensure the dowels are properly seated in the main bracket prior to
mounting the compressor.

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☐ Position the VMAC main bracket onto the driver side of the engine in the
location shown (Figure 10).
Figure 10 — Install main bracket
M10 ×1.5 ×
30 mm (3×)
M8 ×1.25 ×
30 mm (2×)
☐ Install the (3×) M10 × 1.5 × 30 mm bolts finger tight into the top of the main
bracket (Figure 10).
☐ Install the (2×) M8 × 1.25 × 30 mm bolts finger tight into the front of the main
bracket (Figure 10).
☐ Torque the (3×) M10 bolts to 41 ft•lb (55 N•m).
☐ Torque the (2×) M8 bolts to 19 ft•lb (25 N•m).

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Apply Loctite 242 (blue) to the compressor mounting fasteners.
☐ Secure the compressor using the M8 × 1.25 × 35 mm and the (2×) M8 × 1.25 ×
100 mm bolts and torque to specification (Figure 12).
☐ Mount the compressor onto the main bracket (Figure 11).
Figure 11 — Mounting the compressor
M8 ×1.25 ×
35 mm
M8 ×1.25 ×
100 mm
Figure 12 — Mounting the compressor

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☐ Reinstall the washer and idler onto the VMAC main bracket and torque to
41 ft•lb.
☐ Install the radiator tube bracket onto the VMAC main bracket using the OEM
M6 fastener retained earlier (Figure 13).
Figure 13 — Mounting the compressor
OEM fastener

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WHASP Tank location guidelines
When determining a mounting location for the WHASP Tank, ensure
the following conditions are met:
• Adequate supply of fresh air and venting for the cooling fan.
• Minimum of 12 in of clearance at the front of the cooling fan.
• Minimum of 6 in clearance at the rear of the unit.
• Hose connections and wiring are accessible.
• Mounted on a level surface.
• Impact protection.
• The oil level sight glass is easily accessible.
• The oil fill and drain ports are accessible for servicing.
• Minimize the hose lengths to maximize performance.
Mounting the WHASP Tank
Refer to (Figure 14) for mounting dimensions.
Special consideration must be made to ensure the WHASP Tank will be protected
from damage and to ensure that it has adequate ventilation.
In some cases, it may be necessary to fabricate a mounting bracket to position the
tank in an appropriate location.
Secure the WHASP Tank by bolting the mounting feet to the installation surface,
use M8 or 5/16 in fasteners (not supplied).
Mounting in an Enclosure or Body
Mounting the WHASP Tank in an enclosure will limit access to cooling air or restrict
the escape of hot air from around the unit and will have an adverse effect on
cooling.
Ensure adequate ventilation is provided for the cooling system to function properly.
It is not possible to make absolute recommendations regarding ventilation because
of the widely differing configurations that are possible. Duty cycle, ambient
temperature and enclosure shape are some of the important variables that need
to be taken into account when determining the suitability of enclosure mounting.
Cool air ducted to the cooler and installing an exhaust fan to remove hot air is
recommended.
Confirm the hose lengths included in this kit when determining the
location of the WHASP Tank and bulkhead fittings. Hose lengths
can be found in the Illustrated Parts List (IPL). If the WHASP Tank
or bulkhead fitting location requires longer hoses, contact a local
VMAC dealer. See page 6 for ordering information .
Installing the Waste Heat Air Separator
Package (WHASP) Tank

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Figure 14 — Minimum WHASP Tank mounting clearances
20 1/14 in
18 1/8 in
Maintain adequate
clearance for servicing
15 3/8 in
4 1/2 in
5/16 in
or M8
mounting
holes
12 in Fan out
20 7/16 in