Vmac Underhood 40 Installation Manual
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Vmac Underhood 40 Installation Manual

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

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Summary of Contents for Vmac Underhood 40

  • Page 1 Installation Manual for VMAC System V400016 2019 + RAM 2500 – 3500 Pickup, Chassis Cab 2019 + RAM 4500 – 5500 Chassis Cab 6.7 L Cummins Diesel www.vmacair.com...

  • Page 3: Table Of Contents

    Accessory Products from VMAC ........
  • Page 4 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...

  • Page 5: Safety

    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.

  • Page 6: Warranty

    (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.
  • Page 7 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.

  • Page 8: General Information

    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.
  • Page 9 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.

  • Page 10: System Identification, Warranty Registration And Warning Labels

    ☐ 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.
  • Page 11 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 VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 12: Preparing For Installation

    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.
  • Page 13 “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”. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 14 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 VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 15 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 VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 16 ☐ 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.
  • Page 17 Ensure the mounting surface and (×3) M10 threaded holes are clean and free of debris (Figure 14). Inspect surface and mounting holes Figure 14 — Compressor bracket mounting surface (Some radiator hoses removed for clarity) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 18: Installing The Main Bracket And Compressor

    Apply Loctite 242 (blue) to all fasteners. ☐ 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). (×3) M10 × 1.5 × 30 mm (×2) M8 ×...
  • Page 19 ☐ 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). Air filter bracket (×4) M8 × 1.25 × 90 mm Figure 16 —...
  • Page 20 ☐ 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).

  • Page 21: Installing The Waste Heat Air Separator Package (Whasp) Tank

    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 . VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289...
  • Page 22 18 1/8 in 15 3/8 in 4 1/2 in 5/16 in or M8 mounting holes Figure 19 — Minimum WHASP Tank mounting clearances VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 23 (Figure 21). Front of vehicle Provide a minimum of 6 in of clearance for air flow Figure 21 — WHASP ventilation VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 24: Hose Requirements

    • 1/4 in (PTFE Tube) × 180 in. If longer hoses are required: To order parts, contact a VMAC dealer. The dealer will ask for the VMAC serial number, part number, description and quantity. See page 6 for ordering information.

  • Page 25: Connecting The Hoses

    Cut the tube squarely, using only proper tubing cutters as side cutters the tube is fully inserted will deform the tube. O-ring Figure 22 — Push-to-connect fittings VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 26 ☐ Reinstall the fan stator bracket onto the driver side of the engine. Bend the upper radiator hose bracket as necessary to ensure adequate clearance between the radiator hose and the VMAC air filter cover. ☐ Install the intake hose onto the compressor inlet and the spigot on the bottom of the air filter housing.
  • Page 27 Use of an air receiver tank (minimum 6 USG) is required with this application. Follow the instructions on page 45 of this manual to prevent damage to the system. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 28: Adding Oil To The System

    Adding Oil to the System The VMAC supplied and approved compressor oil must be used in this system. Failure to use this special oil will result in damage to the compressor and will void warranty. Do not overfill the system. Overfilling the system with oil can flood the sight glass window and make the system appear empty.

  • Page 29: Installing The Control System

    Do not use a test light to probe for power on vehicle circuits, the increased current draw of the test light may damage components. • VMAC recommends using only sealed crimp and solder butt connectors for all electrical connections. •...
  • Page 30 Control Components Overview Compressor Control module Throttle control WHASP Tank Interface panel Figure 27 — General component overview (Actual installation locations may vary) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 31 Control Module (Figure 28) The control module serves as the primary input/output interface between the vehicle and the various VMAC components (compressor, throttle control, WHASP Tank, Control Interface, etc.). Power, 12 V Clutch, throttle WHASP Compressor (switched), and control, and...
  • Page 32 Figure 30 — VMAC Digital throttle control Mechanical Pressure Switch (Figure 31) The mechanical pressure switch is mounted on the side of the WHASP Tank and limits the maximum pressure to a safe amount by disengaging the clutch once system pressure is achieved.
  • Page 33 Figure 32 — Electrical schematic 1 VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 34 Figure 33 — Electrical schematic 2 VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 35 Black wire from the white interface connector: Pin 11 in the • brown 16 cavity connector (dark green wire with white stripe). Blue wire from the VMAC throttle control: Pin 7 in the grey 24 • cavity connector (yellow wire with dark blue stripe).
  • Page 36 ☐ Connect the green connector on the grey cable to the matching connector on the compressor. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 37 There are 2 extra ring terminals included with the pressure switch harness; if desired, cut the harness to length and crimp the spare ring connectors to it. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 38 Remove the PDC housing from the bracket by simultaneously squeezing the (×4) latches and pulling the PDC housing up out of the bracket (Figure 38). Figure 38 — Remove PDC VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 39 (pin 7 / connector C5, or pin 9 / connector C7). ☐ Use 1/4 in wire loom (not supplied) or equivalent protection to cover the wires, and secure the VMAC key switched wire to the OEM harness with a cable tie. ☐ Reinstall the PDC into its holder.

  • Page 40: Air Receiver Tank

    This is normal operation. Prior to performing any service work on the system, discharge any stored air in the air receiver tank. The VMAC WHASP Tank has a built-in check valve. Use of an additional check valve is not required and may cause erratic performance.

  • Page 41: Recommended Accessories

    Recommended Accessories While the compressor system will function without the following accessories, VMAC strongly recommends their use for optimal performance. See the “Accessory Product” section of this manual on page 47 for a list of products available for purchase through VMAC.

  • Page 42: Completing The Installation

    Completing the Installation ☐ Check all VMAC and OEM wiring to ensure that it will not contact any hot, sharp or moving components and will not interfere with the operation of the vehicle. Secure all wiring with rubber coated P-clips, cable ties and loom as required.

  • Page 43: Testing The Installation

    If the vehicle fails the test, ensure the wiring to all of the connections are correct and secure. If additional assistance is required, contact your local VMAC dealer or call VMAC Technical Support 1-888-241-2289 or 250-740-3200. Safety Test Ensure the following has been completed: ☐...
  • Page 44 Add oil as necessary to bring the level to the “FULL” line in the sight glass and check for leaks. ☐ Install the VMAC Air Test Tool (P/N: A700052) with the 40 cfm (5/32 in) orifice installed and the ball valve closed. ☐...
  • Page 45 Ensure the following has been completed: ☐ Operate the system with an air tool (or the VMAC Air Test Tool with the appropriate orifice installed) for at least 1/2 hour (1 hour preferred). The WHASP Tank cooling fan is thermostatically controlled, and may start or stop without warning.

  • Page 46: Performance Testing

    System operation can be tested using the tools that will be operated by the system or by using the VMAC Test Tool (A700052) with the 40 cfm (5/32 in) orifice in the outlet to simulate tool use (Figure 40).

  • Page 47: Digital Throttle Control Operation And Adjustments

    The throttle control is configured at the factory for optimum performance at maximum cfm. In applications where maximum cfm is not required, or noise is a concern, the throttle control can be adjusted to reduce the maximum VMAC rpm. Safety features...
  • Page 48 The cfm produced by the system is directly related to engine speed; this system delivers 40 cfm at 2,300 rpm. Maximum VMAC rpm can be adjusted between 1,000 rpm and 2,400 rpm (in 50 rpm increments) via the ““ or “” buttons in the “MAX RPM” column.

  • Page 49: Accessory Products From Vmac

    Compressor Service Kits 200 Hour or 6 Month Service Kit - Part number: A700263 Includes 4 L VMAC high performance compressor oil, oil filter, air filter, and next service due decal. 400 Hour or 1-Year Service Kit - Part number: A700264...
  • Page 50 Air receiver tanks are used for lowering compressor duty cycle and removing water from compressed air; recommended for optimum operation of all VMAC Gas Driven, Diesel Driven, Hydraulic, and UNDERHOOD40 air compressors. Manufactured to FMVSS 121 standard; includes fittings, 160 psi pressure relief valve, and tank drain.
  • Page 51 Interface Harness Extension Part number: A700265 This interface harness extension provides an additional 10 ft of cable which allows for greater flexibility in locating the interface panel. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 52 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 53 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 54: Warranty Registration

    Warranty Registration This form must be fully completed and returned to VMAC at the time the vehicle is put into service. Warranty may be void if this form is not received by VMAC within 3 months of receiving the vehicle, or 200 hours of operation, whichever occurs first.
  • Page 56 Manufactured by ® 888-241-2289 tech@vmacair.com 877-740-3202 warranty@vmacair.com www.vmacair.com kb.vmacair.com 1333 Kipp Road, Nanaimo, B.C., V9X 1R3 Canada...

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V400016

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