Installation Manual for VMAC System
Installation Manual for VMAC
System
V910020
2017+ Ford Super Duty F-250 – F-550
6.7 L Diesel
Installation Manual for VMAC
System V910020
2017+ Ford Super Duty F-250 – F-550
Safety ................................................................................................. 3
Warranty............................................................................................. 4
General Information .......................................................................... 5
System Identification, Warranty and Warnings .............................. 7
Preparing for Installation.................................................................. 9
Relocating the ABS Hydraulic Control Unit (HCU) ........................ 14
Modifying the Hoses, Installing the Cooler .................................... 17
Modifying and Installing the Passenger Side Battery Tray,
Air Intake and VMAC Degas Bottle .................................................. 24
Modifying the Fan Shroud and Fan Stator ...................................... 30
Installing the Main Bracket, Idler Bracket and Compressor ......... 34
Installing the Air Oil Separator Tank (AOST) and Hoses .............. 40
Relocating the batteries ................................................................... 44
Modifying and Installing Charge Air Cooler and Washer Bottle. .. 58
Installing the Charge Air Cooler (CAC) and Hoses ........................ 61
Installing the Control Components ................................................. 68
Completing and Testing the Installation ......................................... 72
Setup, Performance Testing and Adjustments .............................. 79
Air Receiver Tank .............................................................................. 81
Accessory Products ......................................................................... 82
Warranty Registration ....................................................................... 83
Document: 1930305
Changes and Revisions
Revision
Revision Details
Revised
by
Checked by
Eng.
Mech.
Elec.
Tech.
Qual.
Implemented
B
ECN 17-004 Confirmation Update
KRM
DSA
N/A
GB
AMG
C
ECN 17-023 2nd confirmation update
MSP
KRM
AJH
RB
AMG
10 Feb 2017
D
ECN 17-033 Battery rel. / cooler update
MSP
KRM
N/A
GB
AMG
10 April 2017
17 JAN 2017
Additional Application Information
•
2017+ Ford Super Duty F-250 – F-550, 6.7 L Diesel
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 to, or endorsement of said
companies.
Loctite® and Loctite® 242 are registered trademarks of Henkel AG &
Company KGaA.
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 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 vehicles must follow
standard shop practices.
Notice
Copyright © 2017 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. You may
print or copy for your personal use any whole page or pages in this
document. 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
2
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Safety
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 installation, service or
repair. 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, consequential damages,
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 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 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. As 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 or other equipment.
This symbol is used to call your attention to additional instructions or
special emphasis on a specific procedure.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
3
Warranty
Standard Product Warranty
For complete warranty information, including both our standard Product
Warranty and Limited Lifetime Warranty 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.
Limited Lifetime Warranty
Effective 1 October 2015 - The Compressor Assembly (excluding Inlet and
Clutch, where applicable) is warranted against manufacturer defects in
materials and workmanship for the lifetime of the Compressor
Assembly. Restrictions apply – refer to VMAC Warranty Policy and VMAC
Limited Lifetime Warranty for full details.
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 4 ways warranty forms can be submitted to VMAC:
Online
www.vmacair.com/warranty/
Email
tech@vmacair.com
Fax
(250) 740-3201
Mail
VMAC - Vehicle Mounted Air Compressors
1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3
4
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
General Information
Optional Equipment Compatibility
Whilst 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 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.
Special Tools Required
•
•
Pneumatic fan wrench removal set (such as Lisle® 43300) or a manual
fan pulley holder (such as KD Tool® KD3900)
Pulley removal tool kit (such as a Lilse 39000, Jet H3565 or
Performance Tool 389708 or equivalent).
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 your VMAC dealer. Your dealer will ask for the VMAC
serial number, part number, description and quantity. To locate your nearest
dealer, call 1-877-912-6605 or online at www.vmacair.com.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
5
Torque Specifications
All fasteners must be torqued to specifications. Use manufacturers’ torque
values for OEM fasteners. Apply Loctite 242 (blue) 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
Foot-pounds (ft•lb)
9
18
35
55
80
110
170
Newton meter (N•m)
12
24
47
74
108
149
230
STANDARD GRADE 8 NATIONAL FINE THREAD
Size
3/8
7/16
1/2
5/8
Foot-pounds (ft•lb)
40
60
90
180
Newton meter (N•m)
54
81
122
244
Size
Foot-pounds (ft•lb)
Newton meter (N•m)
METRIC CLASS 10.9
M6
M8
M10
4.5
19
41
6
25
55
M12
69
93
M14
104
141
3/4
280
379
3/4
320
434
M16
174
236
Table 1 – Torque Table
6
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
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
steps.


Check through the illustrated parts list to ensure that all components are
present and they are in the correct quantity. If any components are
missing, have the system ID ready and call VMAC technical 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/warranty/
This warranty form must be completed and returned 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 with parts and repairs.

Mark and drill 2 x 7/64 in holes in the top of the cross member in front of
the hood support. Secure the plate with supplied self- tapping screws
(Figure 1).
Figure 1 - System Identification Plate

To alert any technicians or emergency responders that may service the
vehicle or respond to an accident, thoroughly clean the radiator cross
member and affix the battery relocation warning label in a conspicuous
location (Figure 2).
Figure 2 – Battery relocation warning label
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
7

As part of the installation process, ensure the operating instruction label
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 3).

To alert any technicians that may service the vehicle, affix the warning
label in the engine compartment near the hood latch in a visible location.
Thoroughly clean the selected area before affixing the label (Figure 4).
Figure 3 - Operating Instruction Label
Figure 4 - Warning Label
8
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Preparing for Installation
Do not use a test light to probe for power on vehicle circuits,
the increased current draw of the test light may damage
components.
Ensure the VMAC Warranty Registration has been filled out.
Install the System Identification Number Plate and operating
instruction label. (Please see page 6 for details).
VMAC provides material to relocate the vehicle batteries from
the engine bay to the driver side frame rail. Depending on the
application, the end user may wish to relocate the batteries to
an alternate location (Please see page 44 before continuing).












Locate the blunt-cut OEM SEIC wire harness, on the passenger side in
the foot well. Find the transmission park signal, (Grey wire with Brown
stripe).
Use a multi-meter to verify the transmission park signal. Turn the key to
the “IGN2” position but do not start the truck (on vehicles equipped with
a “START” button, depress the button but to not apply the service brake)
to supply power to the dash display. The resistance to ground should
read close to 0 Ω in “PARK” and open circuit in all other gears. If this is
correct, put the vehicle in “PARK” and turn the ignition “OFF”.
Mark the transmission park signal wire for connection later in the
“Installing the Control Components” section.
Disconnect and remove both batteries.
Remove the lower bumper/air dam to improve access.
Remove the top radiator cross member cover.
Remove the 8 bolts securing the grille and pull gently to remove the
grille from the vehicle.
Remove the driver side headlight. The headlight is mounted with 4 bolts,
1 bolt is hidden behind the rubber trim between the fender and the
bumper.
Drain the primary and secondary radiators into separate, clean
containers. Set the coolant aside for use later.
Remove the intake air box and cover the engine-side port to prevent
debris entering the engine.
Remove the ground strap running between the battery and the inner
fender to improve access.
Remove the passenger side battery tray, intake snorkel, and lower duct
assembly.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
9











Remove the secondary coolant reservoir.
Remove the upper radiator hose and cover the ports to prevent debris
accessing the engine or coolant system.
Disconnect the ‘hot’ side ducting from both the turbo and the Charge Air
Cooler (CAC) and set the ducting aside for modification.
Cover the turbo and CAC ports to prevent debris entering the engine.
Disconnect the rest of the CAC connections and cover the openings to
prevent debris entering the engine air intake or coolant systems.
Remove the CAC.
Remove the driver side battery tray and degas bottle assembly. This will
not be reused but can be retained should the vehicle be reverted to
stock.
Mark the washer fluid pump wire harness for modification in a later
chapter.
Remove the front 3 inner fender liner bolts and pull the fender liner out of
the way to access the fasteners securing the washer fluid reservoir.
Disconnect and remove the washer fluid reservoir and battery tray
support bracket.
Thoroughly clean the surface around the M12 threaded hole on the front
driver side of the engine block, directly below the valve cover (Figure 5).
Clean surface
Figure 5 – Installing the negative battery cable
10
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201

Using the M12 x 1.75 x 25 bolt, attach the 1/0 AWG VMAC negative
battery relocation cable to the engine block (Figure 6).
Figure 6 – Installing the negative battery cable

Route the cable along the engine, crossing to the outside of the frame
just after the forward body mount. Installation will continue later in the
manual (Figure 7).
Figure 7 – Routing the negative battery



Reinstall the inner fender liner bolts.
Remove the inner fender clip nut from the driver side battery tray support
bracket and set aside for later.
Drain the washer fluid into a clean receptacle and retain for use later.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
11



The washer fluid reservoir and battery tray support bracket will not be
reused but can be retained should the vehicle be reverted to stock.
Keeping the power steering lines connected, remove the power steering
reservoir from the driver side of the fan shroud.
Temporarily tie the power steering reservoir up and out of the way of the
shroud.
The power steering reservoir cap will leak if the reservoir is not
kept upright.


Remove the upper radiator shroud.
Disconnect the radiator fan harness and remove and discard the OEM
bolt (Figure 8).
Discard OEM
fastener
Figure 8 – Disconnect fan harness




Remove the fan and harness assembly using a pneumatic fan wrench
(such as Lisle 43300).
Remove the fan shroud stator.
Remove the OEM FEAD belt.
Remove the primary alternator (Figure 9).
Remove
shroud post
Note location and
remove OEM Idler
Figure 9 – OEM alternator and power steering bracket
12
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Do not remove the power steering fluid lines from the power
steering pump.

On vehicles equipped with adaptive power steering, removing
the power steering pump pulley will improve access to the
fasteners.
Unbolt the power steering pump and secure it out of the way (Figure 9).
For vehicles equipped with the optional “Adaptive Power
Steering” power steering pump, relocate the upper rear
bushing to the upper forward mount position (Figure 10).
Adaptive power
steering bushing
(OEM location)
Adaptive power
steering bushing
(VMAC location)
Figure 10 – Adaptive power steering pump




Take note of the location of the OEM idler on the power steering pump /
primary alternator bracket.
Remove the OEM idler from the bracket (Figure 9).
Remove the fan shroud stator post from the OEM bracket (Figure 9).
Remove the OEM alternator / power steering pump bracket from the
engine. This will not be reused but may be retained.
Remove the 4 rubber bushings from the main bracket bolt
holes and set aside for later.

Remove the primary drain-back hose running between the engine and
the OEM degas bottle (Figure 11).
Figure 11 – Remove the primary drain-back hose
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
13
Relocating the ABS Hydraulic Control
Unit (HCU)
Depending on the application, the following steps may not be
necessary. If the HCU is mounted towards the firewall
(Figure 15), proceed to the next chapter. If the HCU bracket is
mounted using the holes shown in Figure 12, follow the steps
in this chapter.
Failure to follow these instructions may result in brake
system contamination, component damage and/or death.
It may be necessary to rotate the brake lines that connect the
master cylinder to the ABS HCU module to avoid kinking the
flexible rubber hoses as the HCU is shifted to its new
position. The following process will help to avoid air from
entering the brake system as brake fluid is forced out of the
system.
Do not pump the brakes at any time while the brake lines are
loose as air may be drawn into the system.
Have an assistant gently depress the service brake as the
brake line is loosened, rotated into a relaxed position and
then quickly re-tightened. Adjust one brake line at a time. If
there is a significant amount of brake fluid escaping from the
fitting, the pedal is being pressed too hard and/or the fitting
has been loosened too much.
Do not allow the brake master cylinder to run dry during
these steps. The master cylinder may be damaged if operated
without fluid.
Use only clean brake fluid from an unopened container that
meets Ford specifications.
If there is any concern that air may have entered the brake
system, consult a local Ford dealer or licensed repair facility
for vehicle specific HCU brake bleeding instructions.
14
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201

Remove the bolt and 2 nuts securing the HCU and lift it clear of the
shock tower (Figure 12).

Apply Loctite 242 (blue) to the supplied flat head fastener and install the
supplied HCU relocation bracket (Figure 13).
Figure 12 – Relocating the HCU
HCU relocation
bracket
Figure 13 – Relocating the HCU
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
15

Gently shift the HCU towards the firewall taking care not to bend or kink
the brake lines. Align the bracket with the second set of mounting holes
(Figure 14).

Reinstall the bolt and 2 nuts (Figure 15).
Figure 14 – Relocating the HCU
Figure 15 – Relocating the HCU
16
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Modifying the Hoses, Installing the
Cooler
Apply Loctite 242 (blue) to all engine mounted fasteners.

Place a bucket under the lower radiator hose and slit the hose in the
center to drain the remainder of the fluid. (Figure 16).
To engine
To radiator
4 in – 6 in 4 in – 6 in
Figure 16 – Lower radiator hose




Uncouple the lower radiator hose assembly at the engine and radiator
and remove the assembly from the engine bay (Figure 16).
From the center, measure and cut approximately 4 in - 6 in to the
radiator side of the hose. Do the same on the engine side of the hose.
Set these pieces aside for later (Figure 16).
Roll the OEM anti-abrasion mesh up towards the radiator side quick
connect as this will be retained on the hose.
From the OEM quick connector cuff on the radiator side of the hose,
measure 4 1/2 in along the outside radius towards the center of the hose
and mark with a grease pen (Figure 17).
To radiator
4 1/2 in
Figure 17 – Lower radiator hose modification
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
17

From the OEM quick connector cuff on the engine side of the hose,
measure 6 in along the outside radius towards the center of the hose
and mark with a grease pen (Figure 18).
To engine
6 in
Figure 18 – Lower radiator hose modification



18
Cut the hose in the 2 marked locations.
Install the modified radiator side of the lower radiator hose onto the
radiator.
Install the modified engine side of the lower radiator hose onto the
engine.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201

Remove the anti-abrasion sleeve from the center section of the lower
radiator hose and slide it over the radiator side coolant tube; securing it
in place with cable ties (Figure 19).
Figure 19 – Radiator side anti-abrasion sleeve


(System removed from vehicle for clarity)
Cut a straight 6 in section of the discarded lower radiator hose and slit
lengthwise.
Wrap the 6 in section around the straight section of the driver side
coolant tube and secure with cable ties. This will be used as an antiabrasion sleeve on the driver side coolant tube. (Figure 20).
6 in coolant hose
“abrasion sleeve”
Figure 20 – Engine side anti-abrasion sleeve
(System removed from vehicle for clarity)
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
19



Remove the studs securing the vehicle transmission cooler in place and
discard.
Route the engine side coolant tube (P/N: 1720719) up between the
crossmember and the radiator support and insert it into the modified
engine hose (Figure 21).
Route the radiator side coolant tube (P/N: 1720718) up between the
crossmember and the radiator support and insert it into the modified
engine hose. The end with the sharpest bend goes toward the radiator
(Figure 21).
If necessary, gently deflect the transmission cooler lines aside
to create sufficient clearance for the coolant tube
Modified
radiator side
OEM hose
Modified
engine side
OEM hose
The tightest
bend goes
toward the
radiator
Coolant tube
P/N: 1720718
Coolant tube
P/N: 1720719
Coolant elbow
P/N: 1710878
Coolant elbow
P/N: 1700658
Figure 21 – VMAC cooler assembly

Reinstall the transmission cooler using the supplied spacers and
fasteners (Figure 22).
Figure 22 – Relocate the transmission cooler
20
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Installing the Cooler
 Position the cooler in the center of the black front crossmember, below
the body coloured radiator support, and slide the cooler mount bracket
over the crossmember. Bolt in place using the supplied fasteners
(Figure 23).
Figure 23 – VMAC cooler installation



Install the longer elbow to the radiator side of the cooler and the shorter
elbow to the engine side.
Attach the coolant tubes to the elbows.
Disconnect the small flexible hose secured to the cable run tray on the
front of the engine, above the steering linkage, from the metal coolant
tube. Retain the OEM spring clamp (Figure 24).
Retain clamp
Front of
vehicle
Disconnect
flexible hose
Cable run tray
(For reference)
Figure 24 – Disconnect the heater return hose
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
21

Insert the supplied aluminum plug into the flexible hose section and
secure using the OEM spring clamp (Figure 25).
Plug
Flexible hose
OEM spring
clamp
Front of
vehicle
Figure 25 – Plug the flexible hose

Connect one end of the supplied hose to the metal coolant tube. Ensure
the hose is seated against the bead in the OEM hard line and secure
using a hose clamp (Figure 26).
OEM hard
hose
Front of
vehicle
VMAC supplied
flexible hose
OEM flexible
hose
(plugged)
Figure 26 – Install VMAC hose


22
Secure the plugged OEM flexible hose to the metal coolant tube using a
cable tie.
Route the supplied hose forward, following the path of the larger coolant
tubes past the frame crossmember and over the cooler towards the
passenger side of the vehicle.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201

Connect the hose to the small spigot on the passenger side of the cooler
using a hose clamp (Figure 27).
Front of
vehicle
Figure 27 – Connect hose to VMAC cooler



Ensure the hose is not kinked and is secured away from any hot, sharp
or moving components.
Adjust all connections to confirm that all joints are engaged securely and
there are no twists, kinks or pinching.
Secure all the connections with the supplied hose clamps.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
23
Modifying and Installing the
Passenger Side Battery Tray, Air
Intake and VMAC Degas Bottle
Modifying the Passenger Side Battery Tray
 Remove the snorkel and lower duct assembly from the battery tray
(Figure 28).
Remove snorkel
Remove lower
duct
Figure 28 – Preparing the battery tray

Remove the battery hold down U-bolt. This will not be reused
(Figure 29).
Remove battery
hold down U-bolt
Figure 29 – Preparing the battery tray
24
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201



Mark a cut line from the engine side battery tray mount, down to the
base of the battery tray (Figure 30 and Figure 31).
Continue the cut line along the base of the of the battery tray (Figure 30
and Figure 31).
Mark a vertical cut line along the forward side of the engine face of the
battery tray (Figure 30 and Figure 31).
Figure 30 – Modifying the battery tray
Figure 31 – Modifying the battery tray



Cut the tray along the marked lines. Deburr any rough edges.
Re-assemble the snorkel and lower duct assembly onto the battery tray.
Reinstall the modified battery tray assembly into the vehicle.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
25

Install the VMAC degas bottle and battery post relocation bracket into
the modified battery tray (Figure 32).
VMAC fasteners
Figure 32 – Installing the degas bottle bracket

Install and secure the VMAC degas bottle to the bracket. (Figure 33).
Leave loose until after
negative terminal is
connected, then tighten
Figure 33 – Installing the degas bottle
26
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Passenger Side Battery Relocation
 Mount the battery relocation cables onto the VMAC battery posts.
 Install the OEM negative battery terminal using the supplied post and
fastener. (Figure 34).
Battery cable extension
Figure 34 – Installing the negative battery terminal

Reinstall the ground strap to the inner fender.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
27
Primary coolant drain-back hose
 Lay the primary coolant drain-back hose on a bench with the spigot

facing up.
From the OEM quick connect, measure 5 3/4 in and cut the hose square
(Figure 35).
5 3/4 in
Figure 35 – Primary drain-back hose modification



Install a hose barb and the supplied 45 in length of hose and secure with
hose clamps.
Install the remaining hose barb and the supplied 90° section of hose.
Orient the 90° section of hose back toward the OEM quick connect
(Figure 36).
Figure 36 – Modified primary drain-back hose



28
Tighten all of the hose clamps.
Connect the modified primary drain-back hose to the relocated degas
bottle.
Reinstall the intake air box.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201

Route the hose down, under the engine and up to the original engine
inlet. The A/C lines may need to be deflected slightly to facilitate routing
(Figure 37).
Install primary
drain-back
Figure 37 – Installing the primary drain-back
Secure the primary drain-back hose to the transmission cooler lines
using the supplied P-clips and bolt (Figure 38).
Figure 38 – Secure the primary drain-back hose
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
29
Modifying the Fan Shroud and Fan
Stator

Cut a relief for the VMAC crank pulley between the 2 lower stator
mounts (Figure 39).
Grind flush to
stator support vane
Grind flush to
stator vane
4
1
See detail
view below
3/4 in
1/2 in
3 1/2 in
Figure 39 – Stator modifications



30
From the bottom left stator mount, count 4 vanes in a clockwise direction
and mark the left side of the vanes with a grease pen. (Figure 39).
Mark the left side of the upper left stator mount’s vane.
Remove the material between the marked lines (Figure 39).
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201

From the OEM notch on the top right of the stator, count clockwise 6
vanes and mark the outer edge, tracing the profile of the cowl
(Figure 40).

Using a die grinder or similar tool, cut the hard plastic lip flush with the
cowl of the stator (Figure 40).
Cut a rectangle out of the soft rubber section on the back of the fan
shroud (Figure 41).
Figure 40 – Stator modifications

1/2 in
8 in
Figure 41 – Fan shroud modification
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
31

Due to variances with trucks it may be necessary to remove
more material from the fan shroud. After the truck is
assembled inspect the area to ensure there is enough
clearance.
Remove the power steering mounting boss and cut out the shaded area
(Figure 42 and Figure 43).
See detail
view below for
dimensions
Follow the edge
of the molded
bracket
Figure 42 – Fan shroud modification

Use the VMAC power steering bracket as a template to locate and mark
the location of the top hole (Figure 43).
1 3/4 in
1 3/8 in
1 1/4 in
Drill OEM
shroud here
Bolt VMAC
bracket here
Figure 43 – Fan shroud modification

32
Drill the marked location using a 1/4 in drill bit.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Install the supplied steering reservoir bracket to the shroud using 2 of
the supplied fasteners. Place the 2 supplied fender washers on the
radiator side of the fan shroud and secure with the supplied nylon lock
nuts (Figure 44).
Figure 44 – Installing the power steering fluid reservoir
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
33
Installing the Main Bracket, Idler
Bracket and Compressor
Apply Loctite 242 (blue) to all engine mounted fasteners.
Main bracket installation
 Ensure the alternator slide bushing is flush with the inside face of the
alternator mount (Figure 45).
Ensure bushing is
flush with this face
Figure 45 – Reset alternator slide bushing

34
Remove the upper bolt securing the OEM cable tray to the primary water
pump in preparation for VMAC bracket installation
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201

Place the alternator on its back on a bench with the pulley facing up.
Align the VMAC main bracket over the top of the alternator, with the
mating surface facing down. Lower the bracket over the alternator
(Figure 46)

Pull the alternator up and rotate it counter clockwise until the alternator
mount holes are aligned with the VMAC bracket (Figure 47).
Figure 46 – Mounting the alternator
Figure 47 – Mounting the alternator
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
35








Install the alternator using the OEM alternator bolts
Install the retained rubber bushings onto the 4 OEM fasteners and
mount the bracket onto the engine. The VMAC bracket uses the same
mount location as the OEM bracket.
Reconnect the primary alternator wiring.
Install the power steering pump onto the VMAC main bracket using the 3
OEM bolts.
Reinstall OEM cable tray bolt
Protect the battery cables in the cable tray using a piece of the scrap
radiator hose retained from earlier in the installation and secure with a
cable tie.
Reinstall the power steering pump pulley if removed.
Install the OEM idler onto the VMAC main bracket in the location noted
when the idler was removed (Figure 48).
Dual alt. idler
location
Single alt. idler
location
Figure 48 – Installing the OEM idler

Install the stator mount onto the VMAC main bracket (Figure 49).
Stator mount
Figure 49 – Installing the stator mount
36
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201

Install and tension the OEM belt (Figure 50 or Figure 51).
Figure 50 – OEM single alternator belt routing
Figure 51 – OEM dual alternator belt routing
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
37
Installing the compressor
 Remove the inlet valve from the compressor and cover the opening to
prevent debris entering the compressor.
Due to the weight of the compressor, VMAC recommends
having an assistant hold the compressor in place while the
bolts are threaded.

Position the compressor on the mounting bracket and secure with the 4
supplied bolts (note the location of the shorter bolt). Torque the
compressor bolts to specification.
The inlet valve is secured with bolts of 2 different lengths.
Install the longer bolts nearest to the air filter. Installing the
bolts in the wrong location will damage the compressor
housing when tightened.
Shorter bolts
Longer bolts
M8 x 110 SHCS
M8 x 100 SHCS
(Shortest bolt)
M8 x 110 SHCS
Figure 52 – Inlet installation

38
Remove the protective covering and reinstall the Viton O-ring and inlet
onto the compressor. Torque the inlet bolts to specification.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Installing the Crank Pulley
 Remove the 4 OEM crank pulley bolts and discard.
 Install the modified fan stator.
 Install the VMAC crank pulley using the supplied fasteners.
 Torque the crank pulley bolts to 22 ft•lb (Additional torque instructions


below)*.
Remove the tensioner and idlers from the FEAD bracket.
Install the FEAD bracket onto the VMAC main bracket (Figure 53).
Figure 53 – Installing the FEAD bracket



Reinstall the idlers and tensioner and torque to specification.
*Tighten all 4 crank pulley bolts an additional 90°.
Install and tension the VMAC drive belt (Figure 54).
Figure 54 – VMAC belt routing
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
39
Installing the Air Oil Separator Tank
(AOST) and Hoses
Depending on other installed equipment, it may be necessary
to move the AOST 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 the warranty.
Please contact VMAC for replacement hoses and further
information.
When installing the AOST tank mounts, ensure the harness
running along the top of the frame is not pinched.
The AOST will mount to the passenger side frame rail behind the
suspension radius arm mount (Figure 55).
Front of vehicle
Figure 55 –AOST installed
40
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201





The front tank mount bracket assembly consists of the offset
bracket, a spacer and the strap that goes on the inside of the
frame.
Apply Loctite 242 (blue) to the fasteners and install the tank mounting
brackets on the frame (Figure 56).
o The front tank mount bracket mounts to the rear of the transmission
cross member.
o The rear tank mount bracket mounts to the rear of the cab mount.
Install the front and rear tank straps onto the frame mount brackets
(Figure 56).
Install the tank onto mounts by loosening the tank clamps and sliding the
tank in from the rear.
Leave the tank clamps finger tight so the tank can be shifted forward or
back when installing the hoses.
Adjust and the rotate tank within the clamps until the arrow on the front
of the AOST is pointing up and the oil drain is at the 6 o’clock position.
(4x) 3/8 in flange
lock nuts
(4x) 3/8 in washers
(4x) 3/8 in x 6 in bolts
(4x) 3/8 in x
1 1/2 in bolts
(8x) 5/16
in bolts
Spacer bar
(4x) 3/8 in nuts Offset bracket
(4x) 3/8 lock washers
Front of vehicle
Figure 56 – Installing the AOST
(Rear mount not shown for clarity)
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
41
Installing the hoses
When routing hoses, ensure cap-plugs are installed so that
contaminants do not enter the line. Take care when routing
hoses as a hose failure can damage the compressor and/or
cause injury.
All hoses, tubes and wires that are rerouted or shifted
during installation must be secure so they do not contact
sharp edges, hot or moving parts. Use rubber coated P-clips
wherever possible. Follow the routing suggestions in this
manual and cover all hoses with plastic loom.


Connect the 45° fitting to the compressor discharge port.
Route the discharge hose from the compressor down and in between
the engine and steering column (Figure 57).
If necessary, gently deflect the brake lines away from the discharge
hose to provide adequate clearance.
Firewall
Steering
column
Discharge hose
Compressor
Figure 57 – Routing the hoses
42
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201


Route the hose along the transmission bell housing (Figure 58).
Secure the hose onto the bell housing fasteners with the 3 supplied Pclips. The P-clips should be mounted toward the rear of the vehicle.

The hose will gradually bend 90° to connect to the fitting on the front of
the AOST.
Apply the split loom to the PTFE tubes.
Route the PTFE tubes along the main discharge hose and connect them
to the AOST.
Secure the PTFE tubes to the main discharge hose as necessary with
cable ties.
Connect the 90° fitting on the longest 1/2 in hose to the driver side fitting
of the cooler and route it along the frame to the AOST.
Secure the hose to the suspension bump stop using the supplied cable
ties.
Connect the 90° fitting on the shorter 1/2 in hose to the passenger side
of the cooler and run it up to the oil return fitting on the compressor.
Adjust the hoses and/or the AOST to minimize sharp bends, contact with
any hot, sharp or moving parts, then tighten all fittings and the tank
mounts and straps.
Bundle the hoses together and secure with cable ties.
Move the steering between the left and right lock positions to confirm
adequate clearance.
Figure 58 – Routing the hoses









VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
43
Relocating the batteries
Apply Loctite 242 (blue) to all frame mounted fasteners.
VMAC’s universal battery relocation bracket is designed to
accommodate a multitude of frame variations as the rounded
spacers allow for a variety of mounting locations. Due to the
universal nature of the bracket, it will protrude slightly from
the side of the vehicle. Final battery location and whether to
use the supplied relocation bracket is up to the upfitter or end
user.
Batteries installed using VMAC relocation
hardware
Figure 59 – Both batteries (side view)
Figure 60 – Rear battery (top view)
44
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Mounting the front battery box
 Insert (1x) M10 x 1.5 x 150 bolt into the bottom of the rear battery box
mount, this will be inaccessible once the battery box is attached (Figure
61).
Insert M10 x 1.5 x 150
bolt
Figure 61 – Installing the front battery box

Attach the battery box finger tight to the front battery mounting brackets
(Figure 62).
Figure 62 – Installing the front battery box
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
45

Raise the battery box and straps into position. The battery box mounts
straddle the radius arm mount on the driver side of the frame. Remove
any barbed cable ties as needed to allow the OEM wiring harness to
pass over the top of the battery box cover (Figure 63).
Rear bracket:
P/N: 1200978
M10 x 1.5 x 150
Front bracket:
P/N: 1200977
(2x) M10 x 1.5 x 130
Figure 63 – Installing the front battery box
Ensure the battery mounts and fasteners will not crimp or
pinch any wire harness or brake lines that run along the top of
the frame rail. Run the fasteners below any harness / brake
lines.


46
Install the backing straps and tighten the assembly to the frame to
prevent the bracket from shifting.
Torque the mounting fasteners to specification.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201

Remove the top rear fastener from the mounting bracket (Figure 64).
Figure 64 – Installing the front battery box

Loosen the 2 forward fasteners and the lower rear fastener securing the
battery box to the mounting brackets and lift the battery box up and to
the rear of the vehicle to remove it from the bracket (Figure 65).
Figure 65 – Installing the front battery box
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
47
Mounting the rear battery box
 Dependent on the vehicle model and frame configuration, there may be
a cable run tray attached to the middle body mount (Figure 66).
Cable run tray
Figure 66 – Preparing to install the rear battery box

If equipped, remove the cable run tray from the body mount. It should be
secured with “Christmas tree” fasteners and cable ties (Figure 67).
Figure 67 – Preparing to install the rear battery box
48
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201

Remove the “ears” from the cable run tray as indicated. (Figure 68).
Cut away the “ears”
Figure 68 – Modifying the cable run tray

Insert the (3x) M10 x 1.5 x 30 bolts through the battery mount brackets
into the battery mount joiner bracket and torque to specification
(Figure 69).
Figure 69 – Installing the rear battery box
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
49


Thread the nuts onto the bolts until they are just started.
Thread the fourth bolt into the battery mount joiner bracket until the bolt
face is flush with the battery mount joiner bracket (Figure 70).
Figure 70 – Installing the rear battery box
50
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201

Raise the battery box and straps into position. The rear battery box
mount straddles the park brake cable standoff bracket or the body mount
(dependent upon the vehicle model / frame) (Figure 71 / Figure 72).
Figure 71 – Installing the rear battery box
Figure 72 – Installing the rear battery box


Install the backing straps and tighten the assembly to the frame to
prevent the bracket from shifting.
Torque the mounting fasteners to specification.


The rear battery box mounting location may vary dependent
on vehicle configuration and the location of body mounts,
cross members, etc. VMAC recommends keeping the battery
as far forward as possible to keep the battery cables as short
as possible.
Reinstall the cable run tray on the body mount.
Reattach the cable to the cable run tray with cable ties.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
51

Ensure the battery mounts and fasteners will not crimp or
pinch any wire harness or brake lines that run along the top of
the frame rail. Run the fasteners below any harness / brake
lines.
Support the crossmember guard and remove the 2 OEM fasteners
underneath the forward park brake cable standoff (Figure 73).
Remove OEM
fasteners
Figure 73 – Installing the master battery disconnect assembly

Install the master battery disconnect assembly using the OEM fasteners
(Figure 74).
Figure 74 – Installing the master battery disconnect assembly
52
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201

Place the batteries in the battery boxes and install the hold down
clamps.
Ensure the ring terminals on the battery cables are adequately
insulated to prevent an electrical short.

Wrap the ring terminal end of the (2x) 2 AWG positive battery cables
with tape to prevent electrical shorts (Figure 75).
Wrapped to prevent
electrical shorts
Figure 75 – Installing the batteries

Apply dielectric grease to the battery terminals and connect the battery
cables to the battery (Figure 76).
Figure 76 – Installing the batteries
Battery cable legend
Front battery
Rear battery
Long 2 AWG negative cable
Long 2 AWG positive cable
Short 2 AWG positive cable
Short 2 AWG negative cable
Table 2 – Battery cable legend
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
53

Attach the lids to the battery boxes.
The battery boxes and batteries are heavy. Use caution when
lifting into position or lowering. Assistance is recommended
to prevent personal injury or damage to the batteries.


Raise the forward battery box and mount it onto the brackets.
Install the top rear fastener and tighten the other box mount fasteners
(Figure 77).
Figure 77 – Mounting the front battery box



Install the safety cables onto the brackets.
Raise the rear battery box and mount it onto the bracket.
Torque the top rear fastener to specification then install the nut
(Figure 78).
Figure 78 – Mounting the rear battery box
54
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201

Tighten the remaining battery box mount fasteners (Figure 79).

Install the safety cables onto the brackets.
Figure 79 – Mounting the rear battery box
When connecting the positive battery cable to the starter /
solenoid, avoid overtightening the nut as this can damage the
starter / solenoid.

Connect one end of the 1/0 AWG positive battery cable to the vehicle’s
starter / solenoid post using the OEM nut (Figure 80).
Connect
positive cable
Figure 80 – Connecting the battery cable to the starter
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
55

Route the positive battery cable along the transmission bell housing
following the same path as the VMAC hoses (Figure 81).
Figure 81 – Routing the positive battery cable

Continue routing the cable over the frame and to the rear of the forward
body mount where it will join up with the main grounding cable and
continue toward the main battery disconnect. Secure the battery cable
as necessary with P-clips and / or cable ties (Figure 82).
Positive battery cable
Negative battery cable
Figure 82 – Routing the positive battery cable
56
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201


Apply dielectric grease to the VMAC main battery disconnect terminals.
Connect the 1/0 AWG positive battery cable to the positive post on the
main battery disconnect and secure it in place with the flange nut
(Figure 83).
Figure 83 – Connecting the main positive battery cable

Install the supplied carriage bolt into the main battery disconnect.
Connect the 1/0 AWG negative battery cable to the negative post on the
top of the main battery disconnect and secure it in place with the nut and
washer. (Figure 84).
Figure 84 – Connecting the main negative battery cable

The remainder of the battery connections will be performed later in the
installation.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
57
Modifying and Installing Charge Air
Cooler Bracket and Washer Bottle.
Apply Loctite 242 (blue) to all engine mounted fasteners.






Install the fan spacer onto the fan driver.
Install the fan.
Install the fan stator using the VMAC stator spacer, washer and bolt.
Connect the fan harness.
Install the upper fan shroud.
Install the power steering reservoir into the bracket. Ensure the power
steering reservoir is not being pulled or stressed by the hoses. Secure
the reservoir in place with the supplied fasteners (Figure 85).

Mount the CAC support bracket to the driver side grille support and
framework where the OEM washer bottle bracket was mounted
(Figure 86).
Figure 85 – Installing the power steering reservoir
Reuse the
OEM fasteners
Figure 86 – Installing the CAC support bracket assembly
58
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201

Ensure the battery clamps and cables are routed below the
plane of the bracket so they do not interfere with the CAC hose
connections.
Mount the washer reservoir bracket to the CAC relocation bracket
(Figure 87).
Figure 87 – CAC and washer bottle relocation brackets

Mount the washer bottle reservoir onto the washer reservoir and CAC
relocation bracket assembly (Figure 88).
Figure 88 – Mounting the washer bottle
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
59

Attach the CAC relocation and washer bottle bracket assembly to the
CAC support bracket installed in the vehicle and to the inner fender
(Figure 89).




Route the OEM battery cables under the brake lines at the HCU.
Install the OEM battery clamps onto the VMAC battery posts.
Mount the battery relocation cables onto the VMAC battery posts.
Route the driver side VMAC battery cable extensions along the inner
fender.
Join the driver side battery cable extensions to the passenger side
battery cable extensions and follow the same routing between the frame
and the body mount.
Connect the OEM windshield washer hoses to the VMAC washer
reservoir.
Cut the OEM windshield washer pump motor harness at the plug.
Connect the VMAC windshield washer harness to the OEM windshield
washer harness with the butt connectors:
OEM black wire with green stripe to VMAC back wire.
OEM blue wire with white stripe to VMAC blue wire.
Figure 89 – Installing the CAC relocation bracket assembly






The OEM low washer fluid harness will not be reconnected.

60
Connect the VMAC windshield washer harness to the washer pump
motor.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Installing the Charge Air Cooler
(CAC) and Hoses


Lay the CAC on a bench with the ports facing up.
Lay the OEM hose clamp over the “cold” port on the CAC with the
assembly clips facing down (Figure 90).

Install one of the supplied 2 1/2 in silicone hoses onto the “cold” port and
tighten the hose clamp. The silicone hoses will be a tight fit on the spigot
(Figure 91).
Figure 90 – Installing the CAC
Figure 91 – Installing the CAC
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
61

Install the CAC onto the VMAC CAC relocation bracket (Figure 92).

Secure the CAC to the CAC relocation bracket. Install the fastener
nearest the firewall first using a VMAC supplied fastener. Reuse the
OEM fastener in the upper mount location (Figure 93).
Figure 92 – Installing the CAC
Reuse the
OEM fastener
Install this
fastener first
Figure 93 – Installing the CAC
62
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
CAC Cold Ducting
 Remove the protective covering from the intake port.
 Remove the quick connect fitting from the OEM hose and reinstall it on
the vehicle. Save the hose clamp for reuse (Figure 94).
Figure 94 – Installing the CAC hoses


Insert the silicone reducer into the supplied 3 in flex hose.
Install the 3 in flex hose and reducer assembly onto the OEM quick
connect and secure with the OEM hose clamp (Figure 95).
Figure 95 – Installing the CAC hoses
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
63

Install the VMAC supplied “cold” CAC tube and secure with VMAC
supplied hose clamps (Figure 96).
OEM clamp
VMAC clamp
OEM clamp
VMAC clamp
Figure 96 – Installing the CAC hoses
CAC Hot Ducting
 Install the supplied 2 1/2 in silicone hose onto the VMAC supplied “hot”
CAC tube and secure with a VMAC supplied hose clamp. Ensure the
tube is inserted 1 1/2 in into the silicone hose (Figure 97).
3 in
1 1/2 in
Figure 97 – Installing the CAC hoses
64
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201


Separate the engine side coupler from the OEM steel duct.
Install the VMAC “hot” CAC tube into the OEM silicone hose on the
engine side OEM “hot” CAC quick connect and secure with the OEM
hose clamp. Ensure the internal bead on the silicone coupler engages
the bead on the VMAC tube (Figure 98).
OEM clamp
VMAC clamp
Figure 98 – Installing the CAC hoses

Install the OEM “hot” CAC tube into the VMAC silicone hose. Ensure the
silicone hose has equal coverage of both components
(Figure 99).
Note the
orientation
of the gear
clamps
Figure 99 – Installing the CAC hoses

Remove the protective covering from the turbo port.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
65

After ensuring the wire bail on the OEM quick connect is in the locking
position, install the assembly onto the turbo port. The wire locking bail
should be heard to click into place as it secures the quick connect onto
the turbo port (Figure 100).

Install the OEM CAC tube onto the CAC. Rotate the CAC tube as
necessary to ensure there is adequate clearance between the tube and
the compressor inlet and fittings (Figure 101).
Figure 100 – Installing the CAC hoses
Figure 101 – Installing the CAC hoses
66
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
CAC Coolant hose
 Measure and mark 3 in from the outside radius of the OEM hose on the
CAC coolant Tee and cut the hose (Figure 102).
Cut “B”
OEM CAC side
Cut “A”
3 in
Figure 102 – CAC hose modification (cut only along dashed lines)






Install the 90° hose barb in cut location “A” and secure with a hose
clamp.
Install the supplied 11 in heater hose onto the 90° hose barb and secure
with a hose clamp.
Install the straight hose barb into the hose extension and connect it to
the OEM hose that runs along the top of the radiator, routing it under the
upper radiator hose location.
Connect cut “B” of the Tee to the CAC and secure with a hose clamp.
Secure the hose to the OEM power steering reservoir clip nut using the
OEM fastener and the supplied P-clip.
Remove the protective cover from the engine spigot and reinstall the
upper radiator hose (Figure 103).
Cut “B”
Secure with
P-clip
Cut “A”
Figure 103 – Installing the CAC hoses
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
67
Installing the Control Components
Figure 104 – Wire diagram
68
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Installing the control components
VMAC suggests not cutting OEM wires whenever practical.
The preferred method is to remove the pin from the connector
using an appropriate tool and slide the shrink tube onto the
wire. 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 (Figure 105).
If this is not practical, cut the OEM wire and solder and seal
using shrink tube.
Figure 105 - Splice onto OEM wire
Keep wires away from the park brake mechanism. Route wires
clear of the steering column and pedals so they do not contact
moving parts. Before drilling holes, ensure there are no OEM
wires, hoses, or components in the way.
Ensure all wires are protected and routed so they do not
contact hot, sharp or moving components.



Remove the plastic trim panel from the doorsill and the kick panel on the
driver side.
Install the control box in a convenient location in the cab, positioned so
the wire harness will reach the compressor. The preferred location is
between the driver side seat and the door.
If using the preferred control box location, route the cables from the
control box along the doorsill, under the trim panel, behind the kick panel
and up under the dash.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
69



If routing the cables along the doorsill, a notch may need to be cut into
the sill where the cable enters from the control box.
Remove the dashboard panel below the steering wheel.
Locate the throttle control under the dash away from moving parts and
positioned so the idle down pressure (IDP) and maximum rpm adjusting
screws are accessible (Figure 106).
Throttle control
Figure 106 – Installing the throttle control
Connecting the “in cab” wiring
 Unplug the OEM cable from the accelerator pedal and plug it into the



matching connector from the throttle control box. Plug the cable from the
throttle control into the matching connector on the accelerator pedal.
Connect the red wire from the throttle controller to the interface cable
clutch wire connector.
Connect the green wires from the interface connector and the throttle
control to the OEM ground located on the dashboard support.
Remove the glove box compartment to gain access to the wire run
behind it (Figure 107).
Route cable
toward SEIC
bundle
Figure 107 – SEIC pass through
70
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201






Run the wires from the throttle control to the SEIC behind the glove box
and secure with cable ties.
Unplug the SEIC pigtail from the SEIC interface plug.
Connect the red wire with butt connector from the interface connector to
the green wire with orange stripe (CBP22).
Solder and seal the black wire from the interface connector to the white
wire with violet stripe (CMC25).
Solder and seal the white wire from the throttle control to the blue wire
(CE913).
Solder and seal the blue wire from the throttle control to the grey wire
with brown stripe (CET22).
Connecting the underhood wiring
 Cut a slit in the firewall plug on the driver side, under the firewall







insulation and feed the following wires into the engine compartment:
• grey cable with the green plug connector from the control box
• grey cable with the black connector from the throttle controller
• white wire with a bullet connector from the interface cable
Connect the grey cable with the green plug connector to the
corresponding connector coming from the rear of the compressor.
Connect the grey cable with the black connector to the matching
connector on the pressure transducer at the compressor.
Connect the white wire with the bullet connector to the matching
connector on the compressor clutch.
Pull all excess wiring back into the cab.
Cover all VMAC underhood wiring with high heat plastic loom. Secure
the harness with cable ties as needed to avoid hot, sharp or moving
components.
Replace the dashboard panel and glove box (as well as any other
panels that may have been removed during the installation).
Remove the plastic trim panel from the doorsill and the kick panel on the
driver side.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
71
Completing and Testing the
Installation




Reinstall the driver side headlight.
Reinstall the grille.
Reinstall the radiator cross member cover.
Reinstall the secondary coolant reservoir.
Modifying the Degas Hose Network
There are 2 Tee fittings in the degas hose network that will be
reused. One of the Tee’s has a built-in orifice which dictates
its orientation; this Tee is labeled (Figure 108).
Tee with orifice
Figure 108 – Degas Tee orientation



Remove the OEM hose clamps from the 2 Tee’s and discard.
Disconnect the short hose running between the 2 Tee’s.
Rotate the passenger side (unlabelled) Tee 90° counter clockwise and
reinstall it onto the 2 hoses. Secure the hoses with the supplied hose
clamps (Figure 109 and Figure 110).
Figure 109 – Modifying the degas hose network
72
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Figure 110 – Modifying the degas hose network

Remove the hose connected to the Tee labeled “RAD” and connect it to
the vacant spigot on the unlabeled Tee (Figure 111).
Figure 111 – Modifying the degas hose network
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
73

Cut the hose coming out of the radiator where it starts to curve across
the radiator (Figure 112).
Remove this section
of hose
Figure 112 – Modifying the degas hose network

Connect the spigot labeled “RAD” to the short radiator hose and the
spigot labeled “ENG” to the hose running to the engine (Figure 113).
Figure 113 – Modifying the degas hose network
74
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201

Using the hose that previously ran to the OEM degas location, connect
the degas bottle to the spigot marked “DGAS” (Figure 114).




Secure all of the connections with hose clamps.
Reinstall the lower bumper air dam.
Fill both coolant reservoirs with the coolant saved earlier.
Confirm that all OEM hoses and wires that were shifted during install are
secured away from any hot, sharp or moving parts.
Confirm that all VMAC hoses and wires are secured as necessary with
cables ties and/or rubber P-clips to prevent contact with any hot, sharp,
or moving parts.
Remove the protective tape from the ring terminal on the front battery’s
positive cable and insert it into the red cable connection boot
(Figure 115).
Figure 114 – Modified degas hose network


Figure 115 – Connecting the positive battery cables
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
75

Remove the protective tape from the ring terminal on the rear battery’s
positive cable and insert it into the red cable connection boot
(Figure 116).

With the ring terminals aligned in the center of the boot, slide the cables
and boot onto the positive terminal on the main battery disconnect and
secure it with the nylon lock nut (Figure 117).
Figure 116 – Connecting the positive battery cables
Figure 117 – Connecting the positive battery cables


76
Close the boot cover to protect against debris and weather.
Connect the negative battery cables to the negative terminal on the top
of the main battery disconnect and secure it with the nylon lock nut.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Testing the installation
 Place the automatic transmission in “PARK” and apply the park brake.





Turn the ignition “ON” but do not start the engine.
Check the control box to see if it is illuminated. If it is not illuminated,
there is no power to the control box.
Press the “ON” button. The green light should come on and the
compressor clutch will engage, this should be audible.
Release the park brake. The green light should flash and the
compressor clutch should disengage and flash “PARK BRAKE”. Apply
the park brake again and press the “ON” button. The light should come
on and the clutch should engage.
Press the “OFF” button.
Turn the ignition “OFF”.
The engine must be running to complete the final step in the
safety test. This will be done after the pre-start checks have
been completed.
If the truck fails the test, check the wiring to ensure that all
the connections are correct and secure. If additional
assistance is required, contact VMAC technical support at 1888-241-2289 or 250-740-3200.
Before Starting the Engine Checklist
Ensure the following has been completed:
 Check the coolant.
 Check the compressor oil level at the tank sight glass.
 Perform a final inspection to ensure that everything has been completed
and secured.
 Perform a final belt alignment check.
 Check all wiring for security and protection.
 Ensure all compressor outlet valves are closed.
 Ensure the parking brake is engaged and the transmission is in “PARK”.
 Start the engine.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
77
After Starting the Engine Checklist
Place the truck in a safe operating position and adequately
block the wheels. Ensure there are no people around the
truck before beginning the test.













78
Check for any leaks, confirm belt alignment and ensure the belts are
rotating properly.
Close and latch the hood.
Allow the engine to reach normal operating temperature.
Press the “ON” button on the display box to start the compressor.
The engine speed should increase to between 1,800 rpm and 2,200 rpm
and then drop down to VMAC base idle (approximately 1,000 rpm).
With the system running, check for any leaks.
Release the park brake.
• The display box should read “PARK BRAKE”, the compressor clutch
should disengage and engine speed should reduce to OEM idle.
Re-engage the park brake and start the compressor.
Allow engine speed to stabilize after re-engaging the compressor.
With the brake pedal firmly depressed, shift the truck into “REVERSE”.
Engine speed should reduce to OEM base idle (Approximately 650 rpm).
Return the gear selector to “PARK” and repeat this test in all gear
selector positions. Ensure that engine speed does not increase unless
the selector is in “PARK”.
Confirm all air valves are closed and the system has no air leaks.
Turn on the vehicle’s air conditioning (if equipped).
• Turn the steering wheel from lock to lock.
• Listen for any belt squeal.
• Confirm the discharge hose has adequate clearance from the front
wheels.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Setup, Performance Testing and
Adjustments
This system requires minimal adjustment. The maximum system pressure is
adjusted via the regulator on the inlet valve, and the output is adjusted with
the throttle control. Refer to the owner’s manual for specific instructions on
how to adjust the system.
Test the system operation using the tools that will be operated by the
system. Alternatively, the system can be tested using a 1/4 in orifice in the
outlet to simulate tool use (Figure 118).
Figure 118 - VMAC Air Test Tool (A700052)
1.
Install the test tool at the system outlet. If using the VMAC test tool, the
appropriate orifice size is 1/4 in.
2.
Ensure the ball valve is closed.
3.
Place the transmission in “PARK” and fully apply the park brake.
4.
Allow the engine to run until it is at operating temperature.
5.
Turn on the air compressor system and allow it to operate until the oil is
warm.
6.
Observe the pressure gauge. Pressure should be approximately 150 psi.
7.
Open the ball valve on the test tool and observe the engine tachometer.
Engine speed should increase to approximately 2,000 rpm – 2,500 rpm.
8.
Close the air valve slowly to allow the system pressure to rise.
9.
Once system pressure is at maximum, slowly open the ball valve on the
test tool until the pressure on the gauge begins to drop. Engine speed
should ramp when the pressure drops to approximately 140 psi.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
79
Final Testing
Ensure the following has been completed:
 Operate the system with an air tool (or the VMAC Air Test Tool) for at
least 1/2 hour (1 hour preferred).
 Road test the truck for approximately 20 km (14 miles).
 Watch the underhood operation to ensure the belts rotate properly,
pulleys rotate smoothly and nothing is rubbing or contacting hot parts.
 Check all components, connections and fasteners once the engine is
turned off and the system has cooled.
 Check the coolant level after the engine has been operated.
 Check the compressor oil level after the engine has been shut down and
the oil level has had time to stabilize.
80
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Air Receiver Tank
Pressure in the air receiver tank will not be relieved when the
compressor system blows down. This is normal operation.
Prior to performing any service work on the system, relieve
the pressure in the air receiver tank.
If an air receiver tank will be used with this system, the
following installation procedure must be used to prevent
damage to the system.
An air receiver tank provides a buffer as it gives the compressor time to react
by increasing the engine speed and producing air before the tool stalls. It
also has the advantage of lowering the duty cycle of the compressor system.
The VMAC compressor system will automatically depressurize when it is
shut-down, therefore the line from the VMAC Air/Oil Separator Tank (AOST)
to the air receiver tank must have a 1-way check valve installed. This
prevents blow back and moisture from the receiver tank entering the AOST
(Figure 119).
The line to the receiver tank must be installed as high as
possible to prevent water from entering the line.
1-way check
valve
Install the line as
high as possible
Figure 119 – Air Receiver Tank
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
81
Accessory Products
These accessory products for your underhood compressor system are
available from VMAC. For more information or to order these products, call
1-800-738-8622 or email sales@vmacair.com.
Eliminator Aftercooler
Part Number A800185
Removes up to 80% of moisture from compressed
air. Quick installation, automatic drain and compact
design
Filter Regulator Lubricator
Part Number A700221
Removes lubricants, water and dirt from the air
stream. Adds atomized tool oil to lubricate tools.
Reduces pressure for longer tool life. (1 in fittings)
Hose Reel
Part Number A700007
Secure, compact, retractable hose storage in a
sturdy reel.
Air Receiver Tank
Part Number A300010
35 gallon capacity in a compact tank, complete with
fittings and a gauge.
De-icer Kit
Part Number A700031
Insulated rope heater prevents freezing of lines and
regulator.
Service Kits
VR150 200 hour Part Number A700059
VR150 400 hour Part Number A700060
Using OEM service products will extend the life of
your system. Includes oil, filters, seals and O-rings.
200 hour and 400 hour service interval kits are
available
82
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
Warranty Registration
This form must be fully completed and returned to VMAC at the
time of installation. Warranty may be void if this form is not
received by VMAC within 30 days of installation.
VMAC’s Warranty policy and registration can be viewed online
at: www.vmacair.com/warranty
VMAC Dealer Information
Company Name: __________________________________________
City: _____________________
State / Province:_______________
Installer Information
Company Name: _____________________________________
City: _____________________
State / Province:______________
Installation Date: _____/_____/_____
Day
Month
Year
Owner Information
Company Name: __________________________________________
Address: ________________________________________________
City: _____________________
State / Province:_______________
Zip/Postal: ________________
Phone #: (____) ____ - _____
Email Address: ___________________________________________
Vehicle Information
Year: ____________________
Make: _________________
Vehicle Identification Number: ___________________________
Unit #: ___________________
Product Information
System Identification Number:
V____________
Compressor Serial Number: P_ _ _ _ _ _ _ _ _ _ _ _
Throttle Control Serial Number: _ _ _ _ _ _ _ _ _ _ _ _
AOST Serial Number:
____________
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
83
This page intentionally left blank
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising