Vmac Underhood 40 Installation Manual
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Vmac Underhood 40 Installation Manual

For 2013+ ram 2500-3500 pickup, chassis cab; 2013+ ram 4500-5500 chassis cab
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Installation Manual for VMAC
System
V400006
2013 + RAM 2500 – 3500 Pickup, Chassis Cab
2013 + 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 V400006 2013 + RAM 2500 – 3500 Pickup, Chassis Cab 2013 + 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 If requested, failed parts must be returned to VMAC for evaluation. Dealers may login to the VMAC website to view the "VMAC Labour Time Guide" (under “Agreements”) to see the allowable warranty labour times. Warranty invoices must include the Service Ticket number, VMAC System ID#, hours on the compressor, 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 ☐ 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 14 Remove the throttle body cover (if equipped), the wire harness retainer, and the OEM stud (Figure 8). Remove stud and harness retainer Figure 8 — Throttle body (Throttle body cover not shown) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 15: Installing The Main Bracket And Compressor

    Installing the Main Bracket and Compressor Apply Loctite 242 (blue) to all engine mounted fasteners. ☐ 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.
  • Page 16 ☐ Position the VMAC main bracket onto the driver side of the engine in the location shown (Figure 10). M10 × 1.5 × 30 mm (3×) M8 × 1.25 × 30 mm (2×) Figure 10 — Install main bracket ☐...
  • Page 17 100 mm bolts and torque to specification (Figure 12). M8 × 1.25 × 35 mm M8 × 1.25 × 100 mm Figure 12 — Mounting the compressor VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 18 ☐ 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). OEM fastener Figure 13 — Mounting the compressor...

  • Page 19: 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 20 18 1/8 in 15 3/8 in 4 1/2 in 5/16 in or M8 mounting holes Figure 14 — Minimum WHASP Tank mounting clearances VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 21 (Figure 16). Front of vehicle Provide a minimum of 6 in of clearance for air flow Figure 16 — WHASP ventilation VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 22: 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 23: Connecting The Hoses

    Slide the collet out once proper tubing cutters as side cutters the tube is fully inserted will deform the tube. O-ring Figure 17 — Push-to-connect fittings VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 24 Install the air filter bracket onto the driver side stator bracket, and secure it with the 2 supplied gear clamps (Figure 19). Air filter bracket Stator bracket Supplied gear clamps Figure 19 — Air filter bracket VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 25 Figure 20 — Install air filter Bend the upper radiator hose bracket as necessary to ensure adequate clearance between the radiator hose and the VMAC air filter cover. ☐ Install and tension the VMAC supplied FEAD belt (Figure 21).
  • Page 26 Use of an air receiver tank (minimum 6 USG) is required with this application. Follow the instructions on page 39 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 27: 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 28: Installing The Control System

    Strip the wire at the desired location and solder the VMAC wire into place. Slide the shrink tube up to the soldered joint and seal it. Finally, replace the pin in the connector, taking special care to ensure the pin is fully inserted and the locking tabs are engaged.
  • Page 29 Control Components Overview Compressor Control Module Throttle Control WHASP Tank Interface Panel Figure 26 — 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 30 Control Module (Figure 27) 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 31 “SPEED1” adjusting screw (under side) Figure 29 — VMAC Throttle Controls Mechanical Pressure Switch (Figure 30) 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 32 Figure 31 — Electrical schematic VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 33 Grey cable Grey cable Figure 32 — Wire schematic VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 34 Ensure the fuse holder is installed as close to the power source as possible. ☐ Connect the other end of the fuse holder to the positive battery terminal. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 35 Splice the white wire from the Throttle Control to the brown wire with light blue stripe that is connected to the CKP sensor plug (Figure 34). Brown / Light blue Figure 34 — CKP Sensor (looking into front of connector) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 36 ☐ Splice the blue wire from the Throttle Control to the yellow wire with blue stripe and plug the connector back into the transmission. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 37 PDC housing up out of the bracket (Figure 37). ☐ Pull the housing up and to the passenger side of the truck (Figure 38). Figure 38 — Accessing PDC connectors VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 38 Connector release Figure 39 — Accessing PDC connectors ☐ While holding the release, pull the white lever down (Figure 40). Figure 40 — Accessing PDC connectors VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 39 Splice the orange wire from the Control Module to the pink wire with yellow stripe. ☐ Use 1/4 in wire loom (not supplied) or equivalent protection to cover the wires, and secure the VMAC key switched wire to OEM harness with a cable tie (Figure 43). Figure 43 — Loom wire ☐...
  • Page 40 ☐ Ensure all wires and harnesses are protected with loom and routed away from sharp, hot, or moving components and away from high traffic areas. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 41: 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 42: 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 43: 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 44: 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 45 The second person will actuate the compressor switch and ball valve as necessary ☐ Install the VMAC Air Test Tool (P/N: A700052) with the 40 cfm (5/32 in) orifice installed and the ball valve closed. ☐ With the engine running and the vehicle in “PARK”, release the parking brake.
  • Page 46 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 47: Performance Testing And System Adjustments

    Try turning the engine speed down and observe the performance. When testing the system or adjusting the VMAC Throttle Control, ensure the system does not exceed 2,500 engine rpm. Exceeding this speed will cause erratic system performance and in extreme cases may also cause long term damage to the compressor.
  • Page 48 Control. 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 47).

  • 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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V400006

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