Vmac UNDERHOOD 40 Series User manual

www.vmacair.com
Installation Manual for VMAC
System
V400021
2020+Ford Super Duty F-250 – F-550
6.7 L Diesel

VMAC - Vehicle Mounted Air Compressors
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Table of Contents
Safety .........................................................................3
Warranty ......................................................................4
General Information ...........................................................6
Preparing for Installation ......................................................8
Installing the Main Bracket, Compressor and Belt ............................. 12
Installing the Waste Heat Air Separator Package (WHASP) Tank............. 20
Hose Requirements ...........................................................22
Routing and Connecting the Hoses ...........................................23
Adding Oil to the System .....................................................27
Installing the Control System .................................................28
Completing the Installation .................................................. 35
Air Receiver Tank .............................................................37
Recommended Accessories .................................................. 38
Testing the Installation .......................................................39
Performance Testing and System Adjustments ................................42
Accessory Products from VMAC ............................................. 44
Warranty Registration ....................................................... 48

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Document: 1930430
Changes and Revisions
Revision Revision Details Revised by
Checked by
Implemented
Eng. Tech. Qual.
Mech. Elec.
AInitial Release MSP MCA ASE JWL LPH 31 Mar 2020
B ECN: 20-210 Receiver tank requirement MSP MRH N/A MSP N/A 5 Nov. 2020
Additional Application Information
• Use of an air receiver tank (minimum 6 USG) is required with this application.
• 2020+Ford Super Duty F-250 – F-550 6.7 L Diesel.
• This system is not compatible with dual alternator vehicles.
• The vehicle must be equipped with a secondary cooling system water pump
with integrated mounting ears. See page 8 of this manual to identify. For
water pumps without integrated mounting ears, order VMAC adaptor kit P/N:
A900022.
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.
Loctite®, Loctite®242 and Loctite®567 are registered trademarks of Henkel AG &
Company KGaA.
Nylok® is a registered trademark of Nylok Fastener Corporation.
Eaton Aeroquip® is a registered trademark of EATON AEROQUIP INC.
Ford® and Super Duty® are registered trademarks of Ford Motor Company.
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

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Safety
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.
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.

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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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Preparing for Installation
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.
Apply Loctite 242 (blue) to all fasteners (except nylon lock nuts)
unless otherwise stated.
When dissembling engine components, cover the openings to
prevent debris from entering the system.
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 20 for WHASP tank installation requirements.
☐ Confirm the vehicle is equipped with the compatible secondary cooling system
water pump. If the secondary cooling system water pump does not have
integrated mounting ears VMAC adaptor P/N: A900022 must be ordered (Figure 1).
Mounting
ears
Figure 1 — Identifying compatible secondary cooling system water pump
Water pump with integrated
mounting ears
Water pump without integrated
mounting ears
☐ Disconnect the battery leads and cover the battery terminals to prevent
electrical shorts.
☐ Remove the air filter box cover, air filter, and intake tube (from the air filter
outlet to the turbo inlet on the engine).

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The power steering reservoir cap will leak if the reservoir is not kept
upright.
☐ Remove the (×5) bolts (×3 on the driver side and ×2 on the passenger side) and
the wire clips securing the upper fan shroud and remove it from vehicle.
☐ Unhook the coolant hose from the upper fan shroud.
☐ Slide a sheet of cardboard between the fan and the radiator to protect the
radiator from accidental damage.
☐ Disconnect the fan clutch wire and remove the bolt securing the fan stator arm
to the engine. Retain the bolt as it will be reused later.
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.
☐ Remove the fan and pull it out of the engine bay.
☐ Remove the 4 fan stator nuts. Remove the fan stator by rotating it to clear the
lower lip of the lower fan shroud. It is not necessary to remove the lower fan
shroud.
☐ Remove the OEM Front End Accessory Drive (FEAD) belt.
☐ Cover the turbo inlet and the outlet on the air-box cover to prevent debris
entering the engine.
Optional: The fan shroud can provide extra room while installing the main bracket
and compressor*:
☐ *Drain the secondary radiator into a clean container. Set the coolant aside
for use later.
☐ *Disconnect the hoses from the secondary coolant reservoir (attached to
passenger side of fan shroud), and remove the reservoir from the fan shroud.
☐ Keeping the power steering lines connected, remove the bolt securing the
power steering reservoir to the upper fan shroud. Slide the reservoir up out of
the clip securing it to the upper fan shroud and secure it out of the way with
cable ties.

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☐ Confirm the driver side idler is on the appropriate post (Figure 2, Figure 3).
Figure 2 — OEM idlers
Single alternator
idler post
This VMAC compressor uses the OEM FEAD belt, and is installed
in the optional secondary OEM alternator location. As such, this
compressor system is not compatible with vehicles equipped with
dual OEM alternators.
Figure 3 — Confirm idler location
OEM idler Dual alternator idler post
Single alternator
idler post

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If the vehicle came equipped with smooth idlers, they must be
removed and replaced during the compressor installation with the
ribbed idlers included in this kit.
If installing the VMAC adaptor P/N: A900022 with the steel bracket,
install the idler on the dual alternator idler post (Figure 2, Figure 4).
Figure 4 — A900022 idler location
Dual alternator post
(A900022 only)

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For vehicles equipped with water pumps that do not have integrated
mounting ears, please refer to the instructions in the A900022
VMAC adaptor manual.
☐ Cut the cable ties securing the OEM wiring bundle to the wiring tray. Use a
10 mm socket to remove the wiring tray (Figure 5).
☐ Using cable ties, secure the harness to the cable tray mounting bosses (Figure 6).
Figure 6 — Preparing for main bracket installation
Figure 5 — OEM wiring tray
OEM wiring
tray
Installing the Main Bracket, Compressor
and Belt
Apply Loctite 242 (blue) to all fasteners (except nylon lock nuts)
unless otherwise stated.

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Figure 7 — Preparing for main bracket installation
☐ Loosen the (×2) front passenger side fasteners on the intake manifold (Figure 7).
Figure 8 — Preparing for main bracket installation
☐ Remove the idler beside the power steering pump and set aside for later (Figure 8).
Remove
idler
Loosen (×2)
front manifold
fasteners

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☐ Install the smaller rear bracket onto the main bracket using the (x2) M8 × 1.25 ×
30 mm fasteners (Figure 9).
Figure 9 — Installing the rear bracket
☐ Install the compressor and main bracket assembly onto the engine (Figure 10).
Figure 10 — Mounting the compressor onto the engine
M10 ×1.5 ×90 mm
M10 ×1.5 × 45 mm

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☐ Apply plastic loom or equivalent hose protection (not supplied) to the 1/2 in ×
24 1/2 in and 3/4 in × 215 in discharge hoses, as well as the 3/8 in × 240 in oil
return hose.
☐ Install the 45° fitting from the 1/2 in × 24 1/2 in discharge hose onto the
compressor discharge fitting. Orient the hose in the same direction as the
#6 JIC oil fitting on the side of the compressor and tighten the hose securely
(Figure 12).
Figure 11 — Compressor discharge fitting
☐ The compressor discharge fitting will be oriented towards the oil return fitting,
use a 3/4 in wrench to hold the fitting and a 7/8 in wrench to ensure the locking
nut is tight (Figure 11).
Use 3/4 in
wrench
Use 7/8 in
wrench
Figure 12 — Compressor discharge fitting

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☐ Reinstall the idler removed earlier (Figure 14).
If the vehicle was equipped with smooth idlers in the locations
shown, replace them with the VMAC supplied ribbed idlers
(Figure 14).
Ensure the discharge fitting does not contact the main bracket
and that the hose does not twist or kink while the compressor is
installed
☐ Insert one of the M8 × 1.25 × 100 mm fasteners into the front driver side mount
of the compressor.
Figure 13 — Mount compressor
M8 × 1.25 × 100 mm
Figure 14 — Reinstall the idler
Install ribbed
idlers if not
already equipped
M8 × 1.25 × 35 mm
☐ Install the compressor onto the VMAC main bracket (Figure 13).

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☐ Install the air filter bracket onto the air filter assembly (Figure 15).
Figure 15 — Install the air filter bracket
☐ Install the supplied intake tube (if using A900022 kit, install the intake hose
supplied with that adaptor kit) onto the air filter assembly and the compressor
inlet, and secure with the supplied hose clamps (Figure 16, Figure 17).
Figure 16 — Installing the compressor air filter
(standard main bracket)

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☐ Secure the VMAC air filter bracket in place using the fan shroud mounting stud
(Figure 18).
Fan shroud
mounting stud
Figure 17 — Installing the compressor air filter
(A900022 main bracket)
Figure 18 — Securing the filter assembly
If necessary, trim the compressor side of the hose to provide
adequate clearance to the fan. If modifying the hose, trim as little
as possible to prevent causing a restriction between the hose and
the snout of the intake.