Vmac UNDERHOOD 40 Series User manual

www.vmacair.com
Installation Manual for VMAC
System
V400016
2019+RAM 2500 – 3500 Pickup, Chassis Cab
2019+RAM 4500 – 5500 Chassis Cab
6.7 L Cummins Diesel

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 .................................. 16
Installing the Waste Heat Air Separator Package (WHASP) Tank.............. 19
Hose Requirements ...........................................................22
Connecting the Hoses .......................................................23
Adding Oil to the System .....................................................26
Installing the Control System .................................................27
Air Receiver Tank ............................................................ 38
Recommended Accessories ...................................................39
Completing the Installation .................................................. 40
Testing the Installation ....................................................... 41
Performance Testing......................................................... 44
Digital Throttle Control Operation and Adjustments ......................... 45
Accessory Products from VMAC ..............................................47
Warranty Registration ........................................................52

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Document: 1930384
Changes and Revisions
Revision Revision Details Revised by
Checked by
Implemented
Eng. Tech. Qual.
Mech. Elec.
D ECN: 20-173 Update Park Neutral voltage MSP N/A ASE MSP N/A 1 Sept. 2020
E ECN: 20-210 Receiver tank requirement MSP KRM N/A MSP N/A 14 Jun. 2021
Additional Application Information
• Use of an air receiver tank (minimum 6 USG) is required with this application.
• 2019+ RAM 2500 – 3500 Pickup, Chassis Cab 6.7 L Cummins Diesel.
• 2019+ RAM 4500 – 5500 Chassis Cab 6.7 L Cummins Diesel.
• Vehicles equipped with the “Engine Idle Shut Down Timer“ (sales code: XLC)
should refer to the associated FCA Body Builder Instruction for information on
how to adjust the shut down timer. See page 43 for more information.
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.
RAM® is registered trademark of FCA US LLC.
Cummins® is registered trademark of Cummins Inc.

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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. Failed parts must be held by the dealer for a period of six months, and sent to
VMAC if requested (along with the RMA number) for evaluation, unless otherwise
instructed by VMAC.
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, mileage on the vehicle, 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.
For Standard Warranty (Limited): If the completed warranty
registration form has not been received by VMAC within 6 months
from the date of installation of the Product(s), the warranty period
will be deemed to commence 30 days from the date of shipment
from VMAC.
For Lifetime Warranty (Limited): The completed warranty
registration form must be received by VMAC within 3 months from
the date of purchase or 200 hours of operation of the product(s)
(whichever occurs first).
Failure to follow this procedure 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
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 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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Special Tools Required
• Pneumatic fan wrench (Lisle 43300 or equivalent)
• 6 mm ball end hex driver.
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.
Apply Loctite 242 (blue) or equivalent on all engine mounted fasteners. Torque
values are with Loctite applied unless otherwise specified.
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

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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 19 for WHASP tank installation requirements.
Do not use a test light to probe for power on vehicle circuits, the
increased current draw of the test light may damage components!
☐ Locate the yellow wire with blue stripe going to pin 9 in the transmission range
sensor connector (Figure 5).
Figure 4 — Locate range sensor
Range sensor
Figure 5 — View from front of connector
Pin 9
Identify the “PARK”/”NEUTRAL” Wire.
Aisin AS69RC Transmission (see next page for 68RFE transmission):
☐ Locate the 10 pin connector plugged into the transmission range sensor on the
driver side of the transmission (Figure 4).
RAM’s Vehicle System Interface Module (VSIM) provides an easy
to access upfitter connection for the Park/Neutral and Park Brake
signals. If the vehicle is equipped with VSIM, skip to page 12.

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☐ To verify pin 9 is the “PARK”/”NEUTRAL” wire, turn the ignition key to “RUN” but
do not start the engine.
☐ Using a multimeter, back probe (connector must be plugged in in order to get
a proper reading) the wire to verify that the voltage is between 0 V - 2 V while
the gear selector is in “PARK” or “NEUTRAL”, and approximately 12 V in all other
gears.
☐ Mark the “PARK”/”NEUTRAL” wire for identification later.
☐ Turn the ignition key to “OFF”.
☐ Disconnect the negative terminal from the batteries.
68RFE Transmission:
☐ Locate the 23 pin connector plugged into the transmission range sensor on the
driver side of the transmission (Figure 6).
☐ Locate the yellow wire with blue stripe going to pin 4 in the transmission range
sensor connector (Figure 7)
Figure 6 — Locate range sensor
Range sensor
Figure 7 — View from front of connector
Pin 4
☐ To verify pin 4 is the “PARK”/”NEUTRAL” wire, turn the ignition key to “RUN” but
do not start the engine.
☐ Using a multimeter, back probe (connector must be plugged in in order to get
a proper reading) the wire to verify that the voltage is between 0 V - 2 V while
the gear selector is in “PARK” or “NEUTRAL”, and approximately 12 V in all other
gears.
☐ Mark the “PARK”/”NEUTRAL” wire for identification later.
☐ Turn the ignition key to “OFF”.

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☐ Disconnect both of the batteries.
☐ Remove the radiator cover and intake ducting (Figure 8).
Figure 8 — Remove intake ducting
☐ Cover the intake tube to prevent any contaminants from entering the system.
☐ Remove the aesthetic engine cover (Figure 9).
Figure 9 — Remove aesthetic engine cover

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☐ Remove the fan shroud (Figure 10).
Figure 10 — Remove fan shroud
☐ Remove the fasteners securing the fan stator and shift the fan stator toward the
front of the vehicle (Figure 19).
Figure 11 — Remove fan stator

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Figure 12 — Stator bracket
Remove stator
bracket
☐ 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 re-installation later (Figure 12).
☐ 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 13).
Figure 13 — 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 14).
Figure 14 — Compressor bracket mounting surface
(Some radiator hoses removed for clarity)
Inspect surface
and mounting
holes

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Apply Loctite 242 (blue) to all fasteners.
Installing the Main Bracket
and Compressor
☐ Remove the idler from the VMAC main bracket.
☐ Position the VMAC main bracket onto the driver side of the engine in the
location shown (Figure 15).
Figure 15 — Install main bracket
(×3) M10 × 1.5
× 30 mm
(×2) M8 × 1.25
× 40 mm
☐ Install the (×3) M10 × 1.5 × 30 mm fasteners finger tight into the top of the main
bracket (Figure 15).
☐ Install the (×2) M8 × 1.25 × 40 mm fasteners finger tight into the front of the
main bracket (Figure 15).
☐ Torque the fasteners to specification.
☐ Route the straight fitting of the 3/4 in discharge hose down, through the engine
bay, and toward the rear of the vehicle.

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☐ Loosely install the 45° fitting on the 3/4 in discharge hose to the matching fitting
on the rear of the compressor.
☐ Using the (×4) M8 × 1.25 × 90 mm fasteners (do not apply Loctite), temporarily
mount the compressor and air filter bracket to the VMAC main bracket (Figure 16).
(×4) M8 × 1.25 × 90 mm
Figure 16 — Mounting the compressor
Air filter
bracket
☐ Orient the hose and the fitting to ensure the hose will not come in contact with
the throttle body, engine, or other vehicle components (Figure 17).
Figure 17 — Discharge hose orientation
3/4 in hose
Throttle
body
☐ Remove the compressor from the main bracket and tighten the discharge fitting
on the compressor, ensuring the hose and fittings are kept in position while
tightening.

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☐ Apply Loctite 242 (blue) to the (×4) M8 × 1.25 × 90 mm compressor fasteners
and reinstall the compressor and air filter bracket, torquing the fasteners to
specification.
☐ Reinstall the 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 18).
Figure 18 — Securing the upper radiator tube
OEM fastener