Vmac V300002 Installation guide

Installation Manual for VMAC

System V300002

2014 - 2015 Ram Promaster

3.6 L Gas

www.vmacair.com

TM

COMPACT. POWERFUL.

VMAC – Vehicle Mounted Air Compressors 
Toll Free: 1-888-241-2289 
Fax: 1-250-740-3201  
1 
Installation Manual for VMAC 
System V300002 
2014 - 2015 Ram Promaster 
3.6L Gas 
General Information .......................................................................... 3 
Before You Start ................................................................................. 3 
Torque Specifications ......................................................................... 3 
Special Tools Required ....................................................................... 3 
Hose Information ................................................................................. 3 
Important Safety Notice .................................................................... 4 
Safety Messages ................................................................................ 4 
Ordering Parts ..................................................................................... 5 
Warranty Registration ......................................................................... 5 
Part 1: System Identification, Warranty and Warnings ................. 6 
Part 2: Preparing for Installation ..................................................... 8 
2.1  Preparing for Installation .......................................................... 8 
Part 3: Installing the Compressor ................................................... 13 
3.1  Installing the Main Bracket and Compressor ........................... 13 
Part 4: Installing the Bulkhead Fittings .......................................... 21 
Part 5: Installing the Tank and Hoses ............................................. 24 
5.1  Locating the WHASP Tank ...................................................... 24 
5.2  Connecting the Hoses .............................................................. 27 
5.3  Remote Muffler Installation ...................................................... 30 
Part 6: Adding Oil to the System ..................................................... 35 
Part 7: Recommended Accessory Installation ............................... 36 
Part 8: Auxiliary Air Receiver ........................................................... 37 
Part 9: Installing the Control Components ..................................... 38 
9.1  Installing the Control Components ........................................... 39 
9.2  Connecting the Control Panel, Tank & Clutch .......................... 41 
9.3  Installing the Relay Harness .................................................... 43 
9.4  Connecting the Throttle Control ............................................... 44 
Part 10: Testing the Installation ....................................................... 47 
10.1 Final Testing ......................................................................... 49 
Part 11: Setup, Performance Testing and Adjustments ................ 50 
11.1 Throttle Control Adjustment .................................................. 51 
Part 12: Accessory Products ........................................................... 52 
Part 13: Warranty Registration ........................................................ 54 
 

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

2

Installation Manual for VMAC System V300002

2014-2015 Ram Promaster

3.6L Gas

Document 1930249

Changes and Revisions

Important Information

The information in this manual is intended for certified VMAC installers

who have been trained in installation procedures and for people with

mechanical trade certification who have the tools and equipment to

properly and safely perform the installation. Do not attempt this installation

if you do not have the appropriate mechanical training, knowledge and

experience.

Follow all safety precautions for mechanical work. Any grinding, bending

or restructuring operations for correct fit in modified trucks must follow

standard shop practices.

Notice

Manuals are subject to change without notice.

Registered Trademarks

All trademarks mentioned in this manual are the property of their

respective owners. Their use by VMAC is for identification of the

manufacturers’ products only and does not imply any affiliation or

endorsement by said companies.

Loctite®, Loctite® 242 and are registered trademarks of Henkel AG &

Company KGaA.

Nylok® is a registered trademark of Nylok Fastener Corporation.

All trademarks used in this manual are the property of the respective copyright holder.

The contents of this manual may not be reproduced in any form without the express

written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3.

Printed in Canada

Revisio

n

Revision Details

Revised

by

Checked by

Implemented

Eng.

Tech.

Qual.

Mech.

Elec.

B

ECN 16-063

MSP

AJP

N/A

GB

TK

30 Jun 2016

C

ECN 16-140 Park interlock update

MSP

N/A

AJH

GB

AMG

24 Nov. 2016

D

ECN: 17-094 Improved safety testing

MSP

N/A

AJH

GB

AMG

28 June 2017

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General Information

Before You Start

Read this manual before attempting installation so that you can

familiarize yourself with the components and how they fit on the vehicle.

Identify variations for different engine models and different situations that

are listed in the manual. Open the package, unpack the components and

identify them.

Torque Specifications

All fasteners must be torqued to specifications. Use manufacturers

torque values for OEM fasteners. Apply Loctite 242® or equivalent on

all engine-mounted fasteners. Torque values are with Loctite applied

unless otherwise specified.

STANDARD GRADE 8 NATIONAL COARSE THREAD

Size

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

Foot-pounds (ft-

lb)

9

18

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

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

M8

M10

M12

M14

M16

Foot-pounds (ft-lb)

19

41

69

104

174

Newton meter (N•m)

25

55

93

141

236

Special Tools Required

• 6mm ball nose socket driver 3” long

• 1/8” drill bit

• VMAC test tool (A700052)

• Push-lock fitting insert tool (New Line FT1268 or LOT-116, or

equivalent), if building new hoses with push-lock fittings.

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 our 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.

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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 and service techniques. If a discrepancy is noted in this

manual, contact VMAC prior to initiating or proceeding with service.

Current information may clarify the issue. Any person with knowledge of

such discrepancies who performs 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 assure that

their safety and that of others is not being compromised and that there will

be no adverse effects on performance or the operational safety of the

equipment.

VMAC will not be held responsible for any liability, injuries, loss or damage

to individuals or to equipment as a result of the failure of any person to

properly adhere to the procedures set out in this manual or standard

safety practices. Safety should be your first consideration in performing

service operations. If you have any questions concerning the procedures

in this manual or require any more information on details that are not

included in this manual, please contact VMAC before beginning repairs.

Safety Messages

This manual contains various warnings, cautions and notices that must be

observed to reduce the risk of personal injury during service or repair and

the possibility that improper service or repair may damage the equipment

or render it unsafe.

This symbol is used to call your attention to instructions

concerning your 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 alert to the possibility of personal

injury or death. Be alert; your safety is involved. While it is

impossible to warn about every conceivable hazard, let good

common sense be your guide.

This symbol is used to call your attention to instructions on a

specific procedure that if not followed may damage or reduce

the useful life of the compressor.

This symbol is used to call your attention to additional

instructions or special emphasis on a specific procedure.

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Ordering Parts

To order parts, contact your VMAC dealer. Your dealer will ask for the

VMAC serial number, part number, description and quantity. To locate

your nearest dealer, call 1-800-738-8622 or online at www.vmacair.com

Warranty Registration

The VMAC warranty form is located at the back of this manual. This

warranty form must be completed and sent to VMAC at the time of

installation for any subsequent warranty claim to be considered valid.

There are four ways warranty forms can be submitted to VMAC:

Online

http://vmacair.com/support/warranty/

Email

[email protected]

Fax

(250) 740-3202

Mail

VMAC - Vehicle Mounted Air Compressors

1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

6

Part 1: System Identification,

Warranty and Warnings

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 you do not miss

any preparation steps.

□ Check through the illustrated parts list, ensure that no components

are missing, and that they are in the correct quantity. If any

components are missing, have the system ID ready and call VMAC

tech support at (888) 241-2289.

□ Complete the warranty form. The VMAC warranty form is located at

the back of this manual, as well as online at:

http://vmacair.com/support/warranty/

This warranty form must be completed and mailed or faxed to VMAC

at the time of installation for any subsequent warranty claim to be

considered valid.

The System Identification Number Plate must be attached

to the vehicle at the time of installation. This plate

provides information that allows VMAC to assist in parts

and repairs.

□ Mark and drill two 7/64-inch holes in an appropriate location, close

to the compressor. Secure the plate with supplied self- tapping

screws (Figure 1.1).

Figure 1.1 – System Identification Plate

□ Install the VMAC belt routing diagram in a suitable location under

the hood.

□ As part of the installation process, ensure that the safety and

operational instruction decal is affixed in an obvious location so that

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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 1.2).

Figure 1.2 - 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. Thoroughly clean the selected area

before affixing the label (Figure 1.3).

Figure 1.3 - Warning Label

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Part 2: Preparing for Installation

2.1 Preparing for Installation

□ Remove the panel located by the driver’s feet for access to the

battery.

□ Disconnect battery leads and cover terminals to prevent electrical

shorts.

□ Remove the splash plate located under the van on the passenger

side, this will allow access to the engine belt line.

□ Loosen the three bolts on the power steering pump pulley.

□ Remove the OEM belt from the engine.

□ Siphon as much power steering fluid out of the reservoir as possible,

this will assist when draining the fluid in the following steps.

□ Loosen the banjo bolt holding the high pressure power steering line

onto the pump until fluid begins to drain.

□ Drain the power steering fluid.

Ensure all power steering components are kept clean and

free of debris.

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□ Completely remove the banjo bolt from the power steering pump.

□ Install the banjo fitting adaptor to the power steering pump using the

factory banjo bolt. Note the direction of the tab on the adaptor fitting

(Figure 2.1).

Figure 2.1 – Banjo fitting adapter

□ Remove the power steering pump from the bracket and move it out

of the way.

□ Remove the power steering pump bracket from the engine.

Front of pump

Tab

OEM

Banjo

Bolt

Crush washers

Cut-out facing

rear of pump

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□ Remove the heat shields located on top of the steering ram and the

one along the side of the battery box (Figure 2.2).

Figure 2.2 – Heat Shield

□ Disconnect the O2 sensor from the wiring harness and move the

connectors out of the way.

□ Using the palm of your hand push up on the hard line running along

the top of the mounting holes of the OEM power steering bracket.

This line should be bent upwards by approximately 0.5” in order to

clear the fitting on the compressor (Figure 2.3).

Figure 2.3 – Hard Line

Heat Shield

Hard line

Push

up

OEM Power Steering Mount

Holes

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□ Install the compressor cradle bracket onto the engine using two M8

x 30mm flat head bolts, one M10 X 75mm socket head bolt and the

supplied M10 spacer (shorter spacer). It may help to loosely install

one of the long M8 bolts into the lower mount hole, this will help the

bracket align properly for the next few steps. After tightening the

bolts, remove the temporary M8 bolt (Figure 2.4).

Figure 2.4 – Compressor Bracket

□ Install the back idler, 10mm fender washer and M10x30mm bolt to

the idler post on the bracket (Figure 2.5).

Figure 2.5 – Back Idler

M8x30

FHCS

Spacer

M10x75

Temp M8

bolt here

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□ Connect the straight end of the 3/8 x 94” hose to the #6 fitting on the

side of the compressor (Figure 2.6).

□ Connect the straight end of the 1/2 x 12” section of hose to the #8

fitting on the back of the compressor (Figure 2.6).

Once the compressor has been moved into position the oil

return hose cannot be tightened. Make sure the hoses are

tight to the fitting before proceeding to the next step.

Figure 2.6 – Compressor Hoses

□ The straight end of the 1/2 x 12” hose will connect to the supplied #8

to #12 Male JIC adaptor fitting, and to the straight end of the 3/4 x

83” hose (Figure 2.7).

Figure 2.7 – #8 to #12 Male JIC adaptor

3/8 x 94” Oil

Return Line

1/2 x 12”

Discharge

line

ORB nut

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Part 3: Installing the Compressor

3.1 Installing the Main Bracket and

Compressor

□ Apply blue Loctite® to the two supplied M8 x 35 socket head bolts

and install the compressor to the bracket assembly on the engine

using the bottom two fastener locations (Figure 3.1).

Figure 3.1 – Installing the Compressor

□ Orientate the discharge hose so that it clears the exhaust system

and tighten the ORB Nut and hose fitting.

M8x35

Compressor

bolts

ORB Nut

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□ Install the power steering half of the aluminum cast bracket. Use the

four supplied fasteners and the supplied spacer (tall spacer). (Figure

3.2).

The power steering pump bracket uses the locating

features of the bottom bracket for orientation. Ensure that

the top bracket is fully seated as the fasteners are being

tightened.

Figure 3.2 – Power Steering Bracket

Tall Spacer

1/2" hose fits in groove

M8x130

M8x150

mm

M8x150

M8x90mm

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□ \Install the power steering pump onto the VMAC power steering cast

bracket using the OEM bolts and spacers (Figure 3.3).

Figure 3.3 – Power Steering Pump

The OEM spacers go behind the bracket.

OEM

Spacers

OEM bolts

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□ Install the power steering hose, banjo bolt, and crush washers into

the banjo fitting adapter (Figure 3.4).

Figure 3.4 – Connecting the Power Steering Hose

□ Re-install the power steering pulley using the three OEM fasteners.

Note the orientation of the pulley, there is an offset in the hub.

Tighten to finger tight only, the installation of the belt will help stop

the pulley from rotating when tightening the bolts.

VMAC Banjo Bolt

Banjo washers

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□ Install the supplied belt in the following configuration (Figure 3.5).

Figure 3.5 – Belt Routing

□ Tighten the three bolts holding the power steering pump pulley to

the pump body.

□ Fill the power steering fluid and check for leaks.

□ Install the relocation bracket to the hard line located on top of the

steering ram. Ensure that the hose is held away from the power

steering pump pulley (Figure 3.6).

Figure 3.6 – Relocation Bracket

IDLER

A/C

ALT

IDLE

R

IDLER

COMP

P/S PUMP

CRANK

W/P

TENSIONER

OEM Bracket

P/S

Pump

Relocation

Bracket

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□ Use the small adaptor brackets for the P-clamps, this will eliminate

the need to fully remove the bolts (Figure 3.7).

□ Install the compressor intake tube using the supplied hose clamps,

fasteners along with adaptor brackets. Make sure the hose does not

rub on any parts of the engine. Use the engine mounted fasteners

for these clamps (Figure 3.8).

Figure 3.7 – P-clip Adaptor Brackets

Figure 3.8 – Engine mounted fasteners

Slide this end

under engine

mounted bolts

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Vmac V300002 Installation guide

Vmac V300002 Installation guide

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