Vmac Underhood 70 User manual

www.vmacair.comwww.vmacair.com
Installation Manual for VMAC
System
V900135
2019+Chevrolet 4500 – 6500 Chassis Cab
2019+International CV515 Chassis Cab
6.6 L Duramax Diesel
UNDERHOODUNDERHOODUNDERHOOD
UNDERHOOD
707070
70
TMTMTM
TM
AIR COMPRESSORS

VMAC - Vehicle Mounted Air Compressors
VMAC Technical Support: 888-241-2289
VMAC Knowledge Base: www.kb.vmacair.com
1
Table of Contents
Safety .........................................................................3
Warranty ......................................................................4
General Information ...........................................................6
System Identification, Warranty Registration and Warning Labels ..............8
Preparing for Installation......................................................10
Installing the Crank Pulley and Oil Cooler ..................................... 13
Installing the Air Oil Separator Tank (AOST) ................................... 19
Installing the Main Bracket and Compressor...................................22
Hose Requirements .......................................................... 30
Connecting the Hoses ....................................................... 31
Adding Oil to the System .....................................................36
Installing the Control Components ............................................37
Air Receiver Tank ............................................................ 45
Recommended Accessories .................................................. 46
Completing the Installation ...................................................47
Testing the Installation....................................................... 48
Performance Testing and System Adjustments ................................ 51
Digital Throttle Control Operation and Adjustments...........................52
Accessory Products from VMAC ............................................. 54
Warranty Registration ....................................................... 60

VMAC - Vehicle Mounted Air Compressors
VMAC Technical Support: 888-241-2289
VMAC Knowledge Base: www.kb.vmacair.com
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Document: 1930390
Changes and Revisions
Revision Revision Details Revised by
Checked by
Implemented
Eng. Tech. Qual.
Mech. Elec.
B ECN: 19-100 Add digital throttle information MSP N/A ASE MSP AWM 25 Sept 2019
C ECN: 20-066 Update stud torque value MSP MRH N/A MSP N/A 11 Mar 2020
Additional Application Information
• 2019+Chevrolet 4500 – 6500 Chassis Cab equipped with 6.6 L Duramax
Diesel.
• 2019+International CV515 Chassis Cab equipped with 6.6 L Duramax Diesel.
• Note that this VMAC system may be equipped with either a digital or analog
throttle control.
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.
Loctite®, Loctite®242 and Loctite®567 are registered trademarks of Henkel AG &
Company KGaA.
Eaton Aeroquip® is a registered trademark of EATON AEROQUIP INC.
Chevrolete® and Duramax® are registered trademarks of General Motors Company
LLC.
International® is a registered trademark of NAVISTAR INTERNATIONAL
CORPORATION.

VMAC - Vehicle Mounted Air Compressors
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VMAC Knowledge Base: www.kb.vmacair.com
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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

VMAC - Vehicle Mounted Air Compressors
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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]
[phone]
VMAC - Vehicle Mounted Air Compressors
1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3
LIFETIME
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WARRANTY
Warranty

VMAC - Vehicle Mounted Air Compressors
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VMAC Knowledge Base: www.kb.vmacair.com
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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 (CSR) 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

VMAC - Vehicle Mounted Air Compressors
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VMAC Knowledge Base: www.kb.vmacair.com
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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.

VMAC - Vehicle Mounted Air Compressors
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Special Tools Required
• None.
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

VMAC - Vehicle Mounted Air Compressors
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VMAC Knowledge Base: www.kb.vmacair.com
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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
System Identification, Warranty
Registration and Warning Labels

VMAC - Vehicle Mounted Air Compressors
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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 decal

VMAC - Vehicle Mounted Air Compressors
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Ensure the VMAC Warranty Registration has been completed and
the System Identification Plate and Operating Instruction Label are
installed prior to proceeding (Please see page 8 for details).
Preparing for Installation
To improve access while installing the system, park the vehicle with
the wheels turned all of the way to the driver side.
☐ Disconnect the negative terminal from the batteries.
☐ Drain the coolant into a clean container and set it aside for use later.
Figure 4 — Remove lower radiator ‘Hard line”
Remove
“hard line”
Radiator
(for reference only
Ensure the hose is not damaged when removing the shrink cuffs.
Cut shrink
cuff
☐ Separate the lower radiator hose from the hard line; retain the lower radiator
hose and discard the hard line (Figure 4).
☐ Remove the lower radiator “hard line” (metal tube); retain all of the OEM clamps
(Figure 4).
Lower radiator
hose

VMAC - Vehicle Mounted Air Compressors
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☐ Using a grease pen, mark a line approximately 1/4 in past the curve on the 5/8
in OEM hose where it met the hard line. Cut the radiator hose in the marked
location, ensuring the cut is square to the hose section (Figure 5).
☐ Lay the curved section of the lower radiator hose flat on a bench.
☐ From the engine side of the hose, measure 1 in towards the center of the hose
and mark it with a grease pen (Figure 6).
Figure 5 — Modify 5/8 in hose
Figure 6 — Modify lower radiator hose
Cut hose
Radiator side
1 in

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☐ Cut the radiator hose in the marked location, ensuring the cut is square to the
hose section; discard the 1 in section of hose (Figure 6 on page 11).
☐ Cut 1 in from the front edge of each of the OEM lower radiator braces (Figure 7).
Figure 7 — Modify lower radiator support braces
Cut 1 in from
braces
☐ Remove the tension from the fan drive belt.
☐ Remove and discard the front OEM pulley but retain the (×3) OEM crank pulley
fasteners (Figure 8).
Figure 8 — Remove front OEM pulley

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☐ Using the (×3) OEM crank pulley fasteners, install the VMAC crank pulley
(Figure 9).
☐ Tension the fan drive belt.
☐ Install the supplied coupler with spigot using the supplied gear clamp (Figure 10).
Figure 9 — Install VMAC crank pulley
Figure 10 — Install coupler
Installing the Crank Pulley and Oil Cooler
Install coupler

VMAC - Vehicle Mounted Air Compressors
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☐ Using the OEM spring clamp, connect the modified 5/8 in hose to the spigot on
the coupler (Figure 11).
☐ Using one of the supplied gear clamps, install the modified lower radiator hose
onto the coupler (install the hose with the unmodified end of the hose toward
the coupler) (Figure 12).
Figure 11 — Install 5/8 in hose
Figure 12 — Install modified hose
Modified
end

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☐ Using one of the supplied gear clamps, install the supplied 2 in radiator hose
onto the radiator (Figure 13).
☐ Using the clamp retained earlier, install the oil cooler onto the lower radiator
hose (Figure 14).
Figure 13 — Install radiator hose
Figure 14 — Install oil cooler
Install supplied
radiator hose

VMAC - Vehicle Mounted Air Compressors
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☐ Using one of the supplied gear clamps, connect the modified lower radiator
hose to the oil cooler (Figure 15).
☐ Using the supplied M6 fasteners and lock nuts, secure the oil cooler to the
modified radiator brace (Figure 16).
Figure 15 — Install oil cooler
Figure 16 — Install oil cooler

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☐ Remove the coolant drain back hose running between the degas bottle and the
hard line, retain the spring clamps (Figure 17).
☐ Using a grease pen, mark a line approximately 3 in past the curve on the 5/8 in
OEM coolant drain back hose. Cut the hose in the marked location, ensuring the
cut is square to the hose section (Figure 18).
Figure 17 — Remove coolant drain back hose
Figure 18 — Modify coolant drain back hose
Coolant drain
back “hard line”
3 in
To “hard line”
Remove coolant
drain back hose
The coolant drain back “hard line” can either be removed and
discarded or left in place (provided it remains securely attached to
the engine).

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☐ Using the retained spring clamp, install the modified coolant drain back hose
onto the degas bottle (Figure 19).
☐ Using the remaining spring clamp, install the hose barb onto the modified
coolant drain back hose (Figure 20).
Figure 19 — Install coolant drain back hose
Figure 20 — Install hose barb
☐ Using one of the supplied gear clamps, connect the supplied heater hose to the
hose barb on the coolant drain back hose.
☐ Route the hose down toward the VMAC oil cooler, securing it as necessary with
rubber coated P-clips or cable ties.
☐ Using one of the supplied gear clamps, connect the heater hose to the barb on
the oil cooler.
☐ Fill the coolant system with the coolant that was retained earlier.