Installation Manual for VMAC System V990002

Installation Manual for VMAC System V990002
Installation Manual for VMAC
System V990002
Ford 2005 - 2006 6.0L Power Stroke Diesel
Odin Foam - Without Dual Alternators
General Information..................................................................... 3
Before You Start ..................................................................... 3
Part 1: Preparing for Installation............................................... 4
1.1 Preparing for Installation................................................. 4
1.2 Modifying the Passenger Battery Tray........................... 7
1.3 Mounting the Vacuum Tank ............................................ 9
1.4 Glow Plug Modules .......................................................... 12
1.5 Relocating the ICP Sensor .............................................. 12
1.6 Installing the Crank Pulley .............................................. 12
Part 2: Installing the Tank and Hoses....................................... 13
2.1 Installing the Brackets ..................................................... 13
2.2 Installing the Tank............................................................ 16
Part 3: Installing the Cooler, Bracket and Compressor.......... 18
3.1 Installing the Oil Cooler ................................................... 18
3.2 Installing the Main Bracket.............................................. 20
3.3 Installing the Compressor ............................................... 23
3.4 Completing the Installation ............................................. 26
3.5 Adding Oil to the System................................................. 31
Part 4: Installing the Control Components .............................. 32
4.1 Installing the Components .............................................. 33
4.2 Connecting the Under-hood Wiring................................ 34
4.3 Connecting the In-cab Wiring ......................................... 35
4.4 Completing and Testing the Installation........................ 39
Part 5: Finishing the Installation ................................................ 41
5.1 Before Starting the Engine Checklist............................. 41
5.2 After Starting the Engine Checklist................................ 41
5.3 Setup, Performance Testing and Adjustments ............. 42
5.4 System Identification and Warnings .............................. 43
5.5 Auxiliary Air Receiver ...................................................... 44
Accessory Products from VMAC ............................................... 45
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1
Document #1930091
Installation Manual for VMAC System V990002
Ford 2005 - 2006 6.0L Power Stroke Diesel
Odin Foam – Without Dual Alternators
Changes and Revisions
Version
00
a
b
c
Revision Details
Original manual
2005 rear tank bracket
2006 revisions
2006 revisions
Revised by/date
IB 18 Apr 2005
IB 07 Jun 2005
IB 09 Sep 2005
IB 04 Oct 2005
Approved
SM 10 May 2005
BC 09 Jun 2005
SM 11 Sep 2005
SC 04 Oct 2005
Implemented
12 May 2005
11 Jun 2005
15 Sep 2005
07 Oct 2005
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 underhood mechanical work. Any
grinding, bending or restructuring operations for correct fit in modified
vehicles must follow standard shop practices.
These instructions are a general guide for installing this system on
standard production trucks and do not contain information for
installation on non-standard trucks. This system may not fit special
order models or those which have had other changes without
additional modifications. If you have difficulty with the installation,
contact VMAC.
The VMAC warranty form is located at the back of this manual. 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.
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.
Copyright 2005
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
2
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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 model years and different
situations that are listed in the manual. Open the package, unpack
the components and identify them.
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
Foot-pounds (ft-lb)
9
18
35
55
80
Newton meter (N•m)
12
24
47
74
108
9/16
110
149
5/8
170
230
¾
280
379
STANDARD GRADE 8 NATIONAL FINE THREAD
Size
3/8
7/16
Foot-pounds (ft-lb)
40
60
Newton meter (N•m)
54
81
1/2
90
122
5/8
180
244
¾
320
434
METRIC CLASS 10.9
Size
Foot-pounds (ft-lb)
Newton meter (N•m)
M12
69
93
M14
104
141
M16
174
236
M8
19
25
M10
41
55
Hose Coding
Different frame designations will affect the tank mounting position. If
you have to move the tank, the lines may be too short. Measure the
hose shortfall and order a Hose Extender Kit. The following table
shows the color code used by VMAC to identify hose diameters.
Hose Diameter
1/4 inch
5/16 inch
1/2 inch
5/8 inch
3/4 inch
1 inch
Colour-Coded Label
Yellow
Orange
Blue
Blue
Green
Green
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Part 1: Preparing for Installation
1.1 Preparing for Installation
Preparation for installation is very important. Missing an item can
cause problems in the installation or even damage to components.
Check off each item as it is completed so that you do not miss any
preparation steps.
□ Drain
the cooling system, remove the upper and lower radiator
hose and disconnect the coolant expansion tank hose from the
top of the radiator.
□ Disconnect the batteries and remove the passenger side battery.
□ Remove
the plastic air deflector from the upper section of the fan
shroud. Keep this part if the vehicle is to be returned to stock
condition.
□ Remove
the two screws securing the upper section of the fan
shroud to the radiator. There are two options for removing the
fan shroud (you can remove the air cleaner to make this easier):
a. Carefully pry the shroud upward to release the rubber seal
from the groove in the stator. Push the top corner of the
shroud back to clear the upper hose spigot and pull the
shroud out. Be careful not to crack the shroud.
b. Locate the molded lines on the fan shroud, one on each side
about 6 inches (15cm) down from the top (Figure 1.1). Use a
suitable tool to cut the fan shroud between these lines
(Figure 1.1). Do not cut the rubber seal. Remove the upper
shroud section along with the rubber seal, then remove the
lower fan shroud section.
□ Disconnect
the fan clutch wiring harness from the fan stator and
the fan clutch wiring plug connector. Remove the fan.
□ Remove
the rear fan stator (large plastic section with cooling fins
behind the fan) and store it for future use if the vehicle is to be
returned to stock condition.
4
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Upper shroud
Rubber seal
Cut along molded line
Lower shroud
Figure 1.1
□ Remove
the four bolts from the water pump pulley and replace
them with the supplied low profile head bolts.
□ Remove the OEM serpentine belt.
□ Remove the OEM belt tensioner assembly.
□ Remove
the intercooler tube on the passenger side and keep the
2-1/2 inch OEM clamps. Discard the intercooler tube, the
connecting hose from the intercooler and the two larger T-bolt
clamps.
Cover the turbo outlet and the intercooler inlet to
protect the system.
□ Disconnect
and remove the glow plug relay module with the
mounting bracket. Detach the module from the mounting bracket,
discard the bracket but keep the nuts.
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□ Unscrew
the engine oil fill tube. Plug the oil filler opening to
protect the engine.
□ On
automatic transmission models, remove the transmission
dipstick from the passenger side valve cover and install the
supplied bracket (using the OEM nut) with the spacer facing
down and away from the valve cover. Attach the transmission
dipstick to the lower spacer of the bracket using the supplied
fasteners.
□ Remove
the wiring harness retainers from the studs at the front
of the valve cover. Cut the tape back far enough so that you can
reroute the harness behind the transmission dipstick tube and
over the valve cover. Most of the wiring and the glow plug
connectors should be behind and below the alternator.
□ Cut
off the upper threaded section of the two front valve cover
bolt (just below the alternator) flush with the hex nut.
□ Remove
the steel heater return pipe with rubber O-ring. Save the
O-ring and the M6 bolt. Disconnect the steel pipe from the heater
hose and discard the pipe.
Figure 1.2
6
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□ Install
the OEM O-ring onto the replacement heater hose barb
connector and install it into the front of the engine where the
heater hose pipe was removed (Figure 1.2). Cut a short piece of
3/4 inch hose from the supplied 8 inch piece, fit it onto the hose
barb and secure it with a clamp.
□ Insert
the long end of the supplied replacement steel heater pipe
into the short 3/4" heater hose and position the short end with
the tab along the alternator, pointing toward the firewall.
□ Ifhood.
equipped, remove the sound proofing from the underside of the
□ Remove
the plastic clips holding the flexible mud deflectors to
the top and bottom of the radiator cross-member.
□ For
easier installation of the cooler, remove the bolts from the
small power steering cooler in front of the radiator cross-member
and leave it loose in position. You can also remove the radiator
hold-downs and raise the radiator for better access.
□ Some
trucks may have a crossbeam behind the air dam and
under the radiator while others may have a crossbeam that also
retains the tow-hooks. This can be removed to provide easier oil
cooler installation.
1.2 Modifying the Passenger Battery Tray
□ Remove the passenger side battery tray.
□ Turn
the battery tray over and cut off the fender bracket along
the bottom crease of the battery tray (Figure 1.3).
□ Install
the supplied battery bracket to the inner side of the
passenger fender using the two OEM M8 bolts (Figure 1.4).
□ Install
the passenger side battery tray reversed 180 degrees and
fasten it in place with 5/16 x 1 inch bolts with 3/8 inch flat
washers and 5/16 inch lock washers and nuts. The battery tray
hold-down clamp should face to the rear of the vehicle and the
tray should be on a slight angle. Slide the tray as far forward as
possible.
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You may have to trim off some of the plastic web on the
windshield washer bottle to clear the edge of the battery
tray.
Figure 1.3
Battery bracket
Figure 1.4
8
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□ Drill
an 11/32 inch diameter hole through the OEM support
bracket using an existing hole in the battery tray as a guide.
Install a 5/16 x 1 inch bolt with 3/8 inch flat washer and 5/16 inch
lock washer and nut. Tighten all fasteners.
1.3 Mounting the Vacuum Tank
If the truck does not have air conditioning, you must
still relocate the vacuum tank on the plastic fender liner
to clear the compressor but will not have to replace the
short hose or use the mount bracket.
□ Remove
the vacuum tank from the passenger side fender and
save the nuts for reinstallation.
□ Disconnect
the hoses from the vacuum tank and discard the
short hose from the vacuum pump to the vacuum tank.
□ Remove
the three bolts mounting the air conditioning
receiver/dryer from the heater housing.
If necessary, remove the fender liner for better access.
□ Carefully
bend the forward facing top larger air conditioning line
out towards the inner fender until parallel to the fender. Twist on
the vertical section while supporting the receiver/dryer canister
and push inwards. This can be accomplished using a long pry
bar protected where it rests between the two vertical sections of
the lines (Figure 1.5).
□ Bend
the other line by pulling upward and forward on the
receiver/dryer canister to provide adequate clearance.
□ Remove and discard the plastic shroud from the receiver/dryer.
□ Remove
the bolt and clamping components from the supplied
heavy duty clamp and slide the clamp up onto the receiver drier
with the open side towards the front of the vehicle, above the
electrical connection.
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Position the cannister in front of the wiring plug
Second bend
pull up on the
bottom of the
cannister toward
the front
Support first
bend by pushing
here
First bend
Place the clamp above the electrical
connector facing forward
Figure 1.5
□ Install
the clamping bolt in the clamp and through the vacuum
tank bracket. Leave the clamp loose enough so that you can
adjust the position (Figure 1.5).
□ Remove
the front bolt holding the vacuum pump bracket to the
passenger side fender. Place the supplied vacuum tank bracket
in position over the OEM vacuum pump bracket and install the
OEM bolt.
□ Mount
the vacuum tank bracket using the original OEM M6 nuts
with the hose connections at the bottom, angled at approximately
45 degrees (Figure 1.6). If required, bend up OEM vacuum pump
and OEM vacuum pump bracket approximately 20 degrees to
clear the air conditioning condenser (Figure 1.7).
□ Install
the supplied 1/8 inch rubber hose between the vacuum
pump and the vacuum tank and connect the other hoses.
10
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Figure 1.6
Figure 1.7
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1.4 Glow Plug Modules
□ Mount
the glow plug module to the supplied bracket using the
two OEM M6 nuts so that the module will face toward the center
of the engine when the bracket is installed.
□ Install
the assembly on the passenger side engine valve cover
studs beside the engine oil fill-tube using OEM nuts.
□ Wrap
any loose OEM wires with tape and connect the glow plug
relays. Make sure that the wire harness is secured behind the
alternator where it will not touch the compressor or turbocharger.
□ Install the oil fill tube.
1.5 Relocating the ICP Sensor
On trucks after 2004.5, the ICP sensor is located on the passenger
side valve cover.
□ Remove
the ICP sensor. Make sure that the sealing O-ring
gasket is on the sensor.
□ Thread the sensor into the supplied banjo fitting and tighten.
□ Install
the banjo fitting into the valve cover. Make sure that the
copper sealing gaskets are in good condition and are in place.
Point the ICP sensor toward the rear of the truck and torque the
banjo fitting to 15 ft-lbs.
1.6 Installing the Crank Pulley
□ Clean
the face of the OEM pulley, install the VR pulley, align the
bolt holes and ensure that the pulley is sitting flush. Apply
Loctite, install three M10 x 70 mm bolts and flat washers and
torque to specification.
12
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Part 2: Installing the Tank and
Hoses
2.1 Installing the Brackets
For 2005-2006 F450 and F550 model trucks see the
special installation instructions for the rear tank mount.
□ Remove
the bolts, washers and nuts from the tank clamps and
the P-clips from the stand-off brackets.
□ Lay
the tank brackets on a flat surface with the wide flanges
away from each other (Figure 2.1). The front and rear brackets
are different and are stamped “Front” and “Rear”.
P-clip and
stand-off
bracket
Upper frame clip
Spacer (not used on wide frames)
Inner tank clamp
5/16” x 1/2”
Lower frame clip
Figure 2.1
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□ Insert
the cable straps through the upper frame clips and place
one cable on each tank bracket with the cables in the grooves.
□ Place
one inner tank clamp onto the front tank bracket. Place
one stand-off bracket under the top front hole.
□ Apply
Loctite to the 5/16 x 1/2 inch hex head bolts (with flat
washers) and attach the inner clamp to the front tank bracket
(the top front bolt also mounts the stand-off bracket). Tighten all
the bolts.
2.1.1 All Trucks Except 2005 - 2006 F450 and F550
□ Place
the inner tank clamp on the rear tank bracket with the
stand-off bracket under the top rear hole. Apply Loctite and
attach the clamp to the bracket using 5/16 x 1/2 inch hex head
bolts. Tighten all the bolts.
□ Clean
the area on the frame between the two cab mounts on the
passenger side and place the front bracket on the frame in front
of the transmission cross-member and as far forward on the
frame as possible. Place the upper frame clip on the frame rail
and make sure the frame seats in the groove.
□ Wrap
the cable under the frame, insert the lower frame clip and
make sure the frame is seated in the clip. Install a spacer (if
necessary) a washer and a nut. Tighten the nut securely (do not
over-tighten) and install a second nut as a lock.
□ Place
the rear bracket behind the transmission cross-member
and as far back as possible. Attach in the same manner as the
front bracket.
The tank brackets must be positioned far enough apart
to provide good support for the tank, but must not be
positioned in any location where the tank will not be
level when installed.
14
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2.1.2 2005 – 2006 F450 and F550
□ Place
spacers on the rear tank bracket as shown in Figure 2.2;
1/2 inch spacers on the top and bottom front holes, 5/8 inch
spacer on the top rear hole and a 3/4 inch spacer on the bottom
rear hole.
□ Place
the inner tank clamp on the spacers with the stand-off
bracket under the top rear hole.
□ Apply
Loctite and install 5/16 x 1 inch bolts with washers through
the two front holes, 1/2 inch spacers and into the bracket.
□ Apply
Loctite and install a 5/16 x 1-1/4 inch bolt with washer
through the top rear hole, stand-off bracket, 5/8” spacer and into
the bracket.
□ Apply
Loctite and install a 5/16 x 1-1/4 inch bolt with washer
through the bottom rear hole, 3/4 inch spacer and into the
bracket. Tighten all the bolts.
5/8” spacer
Rear tank bracket
Stand-off bracket
5/16” x 1-1/4”
3/4” spacer
1/2” spacers
Inner tank clamp
5/16” x 1”
Figure 2.2
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□ Clean
the area on the frame between the two cab mounts on the
passenger side and place the front bracket on the frame as
shown in Figure 2.3. Place the upper frame clip on the frame rail
and make sure the frame seats in the groove.
□ Wrap
the cable under the frame, insert the lower frame clip and
make sure the frame is seated in the clip. Install a spacer (if
necessary) a washer and a nut. Tighten the nut securely (do not
over-tighten) and install a second nut as a lock.
□ Place
the rear bracket on the frame as shown in Figure 2.3 and
attach in the same manner as the front bracket.
Tops will be about
1/4” closer together
7.5”
4”
Figure 2.3
2.2 Installing the Tank
□ Install
the front outer tank clamp with both bolts and washers and
leave the bolts very loose.
□ Lift the tank and slide it into the front clamp.
□ Install the rear outer tank clamp.
□ Position
the tank for sufficient clearance at both ends and rotate
the tank until the arrow molded into the rear of the tank is
pointing upward. Tighten the clamp bolts.
16
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□ Thread
the fittings of the 1/4 and 5/16 inch steel tubes into the
matching fittings on the rear of the tank with the flexible hose end
to the front of the truck. (Figure 2.4).
□ Install
the P-clips on the two steel lines and fasten them to the
stand off brackets. Adjust the tubes in the P-clips as necessary
and tighten the fittings and P-clip bolts.
Figure 2.4
□ Connect
the straight end of the longest 5/8 inch hose to the
matching fitting on the front of the tank. Route this hose along
the frame rail, over and inside the cab mounting bracket and
around the steering idler arm to the front of the vehicle. Do not
tighten the fitting.
□ Connect
the straight end of the 1-1/4 inch hose to the matching
fitting on the front of the tank. Route this hose outside the cab
mount, up behind the mud guard and fender liner towards the
rear of the engine and along the passenger side valve cover. Do
not tighten the fitting.
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17
Part 3: Installing the Cooler,
Bracket and Compressor
3.1 Installing the Oil Cooler
□ Insert
M10 x 90 mm bolts into the top of the two mount brackets
(Figure 3.1) and place them over the cross-member that runs
under the radiator, outboard of each power steering mounting
bracket.
M10 x 90 mm bolts
with washers
Mount brackets
Spacers
Figure 3.1
□ Place
the cooler in position with the threaded fittings facing to the
rear of the vehicle (Figure 3.2) and thread the top bolts into the
top outermost holes on the cooler mount. Leave the bolts loose
enough so that you can move the cooler on the cross-member.
□ Insert
bolts into the lower holes and install the spacers. Thread
them into the outermost lower holes on the cooler mount.
18
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To engine
r
diato
To ra
Coolant
bypass
hose
connection
Cross-member
1/2” hose to compressor
1/2” hose from tank
Figure 3.2
□ Loosen
the clamp on the hoses attached to the cooler. Connect
the hose to the lower radiator spigot, adjust for best fit and
tighten the clamps.
On some models, the hose will interfere with the
steering linkage. If necessary, cut some material off the
radiator end of the hose to move the hose forward and
away from the steering linkage.
□ Install
the OEM lower hose between the engine spigot and the
cooler and secure it with clamps.
□ Connect
one end of the longest supplied heater hose to the
spigot on the side of the cooler and secure it with a clamp. Route
the hose up to the engine.
□ Connect
the 90 degree end of the 5/8 inch hose from the VR
tank to the passenger side fitting on the cooler. Do not tighten
the fitting.
□ Connect
the 90 degree end of the short 5/8 inch hose to the
cooler and route it up the passenger side of the engine
compartment. Do not tighten the fitting.
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□ Adjust
the cooler as required to provide a good fit with all hoses
and tighten the mounting bolts.
3.2 Installing the Main Bracket
Due to vehicle assembly variations, the rear right corner
of the main bracket may interfere with the right hand
rocker cover. Make sure that there is clearance between
the bracket and rocker cover before tightening down the
bracket. If necessary, grind a small amount of material
off the bracket where the interference exists until
adequate clearance is achieved.
□ Remove
the idlers, idler mount bracket and tensioner from the
main bracket.
□ Mount
the main bracket to the right-hand side of the engine
using three M10 x 55mm flange lock bolts (with Loctite) in the
two upper holes and one in the lower outer-most hole. Check to
make sure that the bracket is not interfering with any OEM parts.
□ Carefully
bend the air conditioning lines as necessary to provide
clearance for the bracket and compressor. You may have to
adjust line position again once the compressor is installed.
!
Do not twist, break or damage the air conditioning lines.
Make sure that the connections at the receiver/drier are
not damaged or cracked while repositioning the lines.
□ Route
the A/C compressor wiring harness behind the bracket.
Make sure it is not pinched by the bracket.
□ Install
the M10 x 35mm flange head bolt into the lower innermost attachment point (Figure 3.3) and torque to specifications.
□ Install the OEM belt tensioner.
□ Install the OEM 8-rib belt (Figure 3.4).
□ Install
the idler mount bracket to the main bracket using three
M8 x 25 mm socket head bolts and install the idler (Figure 3.5).
20
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□ Install the VR tensioner assembly to the main bracket.
M10 × 55mm
M10 × 35mm
Figure 3.3
Figure 3.4
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Smooth idler
Spacer
1/2 × 1-1/4 inch
Tensioner
M10 × 80mm
M8 × 25mm
Idler mount bracket
Tensioner
pin locates
here
Ribbed Idler
Spacer
1/2 × 1-1/4 inch
Figure 3.5
□ Install
the remote idler brace assembly and 8-grooved idler
(Figure 3.6) to the machined location on the coolant return
section of the coolant manifold just above the fan pulley using al
an M10 x 110 mm bolt with spacer and a supplied bolt. Tighten
to specifications
□ Install
the remote mounted 8-groove idler with the supplied stub
and spacer to the machined stub on the front coolant manifold
casting on the front of the engine, slightly down and to the driver
side of the fan pulley, using an M10 x 110 mm bolt (Figure 3.7).
Tighten to specifications
22
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Remote idler brace
Supplied locating bolt
Idler pulley
Spacer
M10 x 110 mm bolt
Figure 3.6
Idler stub
Idler pulley
Spacer
M10 x 110 mm bolt
Figure 3.7
3.3 Installing the Compressor
□ Place
the compressor in position on the main bracket. Check the
air conditioning lines to make sure they do not touch the
compressor and adjust as necessary to provide about one inch
clearance between the compressor and the air conditioning lines.
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□ Route
the straight end of the short 5/8 inch hose from the oil
cooler up the front of the passenger side of the engine, clear of
moving components and tie it to the passenger side post on the
VR bracket supporting the idler mounting bracket.
□ Connect
the 5/8 inch hose onto the elbow fitting on the
compressor and tighten the connection.
□ Connect
the 45 degree swivel fitting of the 1-1/4 inch hose to the
fitting on the back of the compressor. Route the hose along the
valve cover. Angle the 45 degree connector inwards to allow
clearance for all OEM components. Tighten the connection using
two wrenches to prevent hose twist.
Make sure that no part of this hose is higher than the
center of the compressor, as oil trapped in the line can
flood the compressor and cause damage on startup.
□ Remove
the inlet control valve from the compressor. Immediately
cover the opening to protect the compressor.
□ Install
two M8 x 110 mm socket head bolts through the
passenger side compressor mounting holes and thread them into
the main bracket.
□ Remove
the two OEM mounting bolts from the passenger side of
the alternator. Place the supplied brace on the alternator and
thread the alternator bolts back into place but leave them loose
(Figure 3.8).
□ Install
the small diameter spacer under the front hole of the
support brace and insert an M8 x 140 mm bolt through the brace,
the spacer the front driver side compressor mount hole and
thread it into the main bracket.
□ Install
the large diameter spacer under the rear hole of the
support brace and install an M10 x 50 mm bolt through the
bracket and spacer. Thread it into the compressor housing.
□ Tighten
the three bolts holding the compressor to the bracket to
specifications.
24
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Compressor
Alternator
Figure 3.8
□ Align
the tab on the steel heater tube with the small hole in the
brace bracket and insert the 1/4 inch NC bolt.
□ Install
the inlet control valve and tighten the bolts to
specifications.
□ Tighten
the OEM alternator bolts and the remaining VR bolt to
specifications.
□ Route
the 5/16 and 1/4 inch hoses from the tank above the front
cab body mount, up inside the wheel well and inner fender
towards the rear of the engine valve cover around the outside of
the oil fill tube. Connect them to the matching fittings on the inlet
control valve on the compressor.
The 5/16 inch line can be routed to the connection at the
inlet control valve from the rear of the compressor, but
if this routing may result in hose damage, rotate the
fitting on the inlet control valve until it faces the front of
the compressor, then route the line around the front of
the inlet valve.
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25
□ Loop
the flexible hose from the compressor air filter to the inlet
control valve and secure it with a clamp. Make sure that the hose
is clear of the turbocharger.
3.4 Completing the Installation
□ Cut
a 2 inch length of 3/4 inch heater hose then push it onto the
plastic tee and the steel heater tube. Connect the OEM heater
hose to the tee (Figure 3.9).
OEM hose
Tee fitting
Long hose to cooler
Short hose
Figure 3.9
□ Route
the long heater hose from the oil cooler up to the top of
the engine and connect it to the Tee fitting. Clamp the
connection. Make sure that the hose is properly secured so that
it does not contact any hot or moving parts and will clear the
OEM belt.
□ Install the compressor drive belt (Figure 3.10).
□ Install the fan spacer washer, then install the engine fan.
□ Ifpositioning
you removed the fan shroud in one piece, place it in the lower
holes and install the top bolts.
□ If you cut the shroud at the marked lines:
• place the lower half in position and locate it in the lower
positioning holes
• install the upper half of the fan shroud and slip the shroud
rubber seal onto the lower half of the shroud as it is being
lowered
• attach the top shroud to the radiator using the original OEM
bolts install the four supplied self tapping screws into the
holes on each side of the shroud where it was cut
26
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Figure 3.10
□ Remove
the front driver’s side air intake bolt and install the fan
wiring harness bracket over the adjacent stud (Figure 3.11).
Install the air intake bolt through the fan wiring harness bracket
and the supplied nut onto the OEM stud. Tighten all fasteners.
□ Reposition
the wiring harness to provide more wire length and
insert the fan wiring harness moulded connector into the bracket
and tie strap in position using two ties. Make sure that the fan
wiring is well clear of the fan and other moving components.
!
Adequate clearance between the fan and plastic
harness is important as the fan will flex forward during
operation.
□ Connect
the upper radiator hose and the coolant expansion tank
hose to the radiator and secure them with clamps.
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27
Fasten with bolt on air intake
Fan wire harness
fits in this holder
Fit over stud on front of intake
Figure 3.11
3.4.1 Installing the Intercooler Tube
□ Remove
the driver’s side alternator mounting bolt and install the
supplied intercooler tube securing bracket under the bolt.
□ Make
sure that the elbow, the intercooler tube, the clamps and
the turbocharger connections are clean and dry. Any oil on the
components will cause the fittings to come apart.
If the intercooler tube connections are not installed and
tightened correctly, they will blow off during operation.
□ Prior
to installing the VMAC supplied intercooler tube and OEM
blue silicon elbow on the engine, fit the elbow to the VMAC tube
and make sure that the internal rib of the elbow fits properly into
the groove on the intercooler tube. Mark the position on the
intercooler tube. Also mark the location of the internal rib on the
outside of the elbow so you can accurately position the clamp.
□ Remove
the staples holding the clamp on the turbocharger end
of the elbow. Install the intercooler tube and adjust the elbow for
best fit. Mark this position on the elbow, intercooler tube and
turbocharger. Also mark the new position for the clamp.
If necessary, cut about 1 inch from the end of the
coolant hose on the manifold from the coolant tank
(directly under the intercooler tube) to allow more
clearance for the intercooler tube.
28
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□ Position
the clamps so that the center of the clamp is directly
over the internal rib. The OEM blue silicon elbow has a white line
on one end to indicate clamp position. Note the location of this
line in reference to the bead
□ Fasten
both clamps to the elbow using staples or small poprivets (Figure 3.12). This will ensure that the elbow will not slip
out from under the clamps during high turbo pressures.
If you use staples:
1. Use the existing holes in the OEM clamp or drill small
holes through the clamp to match the width of a standard
1/2 inch staple. Drill three locations around the clamp.
2. Insert the staples into the clamp and press them through
the blue silicon elbow using needle-nose pliers. If you
have difficulty pushing the staples through, make a pilot
hole using a small sharp object, such as a nail or pick.
3. Securely crimp the staple on the inside of the elbow so
that it begins to embed in the material of the duct
If you use pop-rivets:
1. Drill two holes in the clamp and elbow opposite the Tbolt.
2. Remove the nut and spring; open the clamp to permit
access for a pop-rivet tool.
3. Insert the pop-rivets from the inside and fasten them in
place. The pop-rivet head should embed slightly in the
material of the duct.
□ Install
the supplied 90 degree 3-1/4 inch silicon rubber elbow to
the passenger side intercooler connection and position it
vertically. Loosely install the T-bolt clamps.
□ Tighten
the nut on the clamps until all of the coils on the spring
are in contact, then torque the nut to 12 N.m (106 in-lbs). Check
torque again when the clamp and duct are hot.
□ Fitandtheattach
supplied rubber covered clip around the intercooler tube
it to the bracket using the supplied bolt and nut.
Adjust the bracket as necessary to get a good fit.
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□ Install
all other OEM parts removed during preparation that were
not discarded for VR installation. Install the plastic Power Stroke
emblem. You may have to trim the passenger side on the Power
Stroke emblem to prevent it from pushing the intercooler tube up
against the hood.
Install staples or
pop-rivets
Seat the rib in the
groove
Mark the position
of the elbow end
on the tube
Place the center of
the clamp directly over
the rib
Figure 3.12
□ Close
the hood slowly and make sure that the intercooler tube
does not hit. If you are not sure, use a block of putty on the
intercooler tube to check the clearance.
□ Tighten all hose fittings.
□ Remove
the oil filter from the tank and discard the cardboard. Fill
the filter with VR compressor oil, lubricate the gasket and install
the filter, tightening an additional three-quarter to one turn after
the gasket contacts the base.
30
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□ Check
all components for clearance from hot or moving parts.
Check hose routing for clearance. Check all hose clamps and
fittings.
□ Secure
all hoses with tie straps to prevent abrasion and damage.
Protect hoses from damage by using nylon loom.
3.5 Adding Oil to the System
!
You must use the VMAC supplied and approved
compressor oil in this system. Failure to use this
special oil will result in damage to the compressor and
will void your warranty.
□ Remove
the fill plug from the air inlet control valve and pour oil
into the oil fill hole on the inlet control valve using a funnel.
□ Turn
the compressor clutch clockwise with a ratchet and a 1/2
inch socket using the hex head bolt at the centre of the
compressor clutch during the fill process.
□ Allow
5 minutes for the oil to drain into the tank, then check the
level at the sight glass at the front of the tank. Continue adding
oil until the level is correct.
□ Install the fill plug in the inlet control valve and tighten it securely.
!
Do not overfill the system. Overfilling the system with
oil can flood the sight glass window and make the
system appear empty.
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31
16GA WHT
CLUTCH
16GA WHT
4 PIN
CONNECTOR
(GREEN)
TEMPERATURE
PROBE
BLUNT CUT
SEIC WIRES BY
PARK BRAKE
TACH-OUT
THROTTLE
CONTROL
PTO-RPM - ORG/YEL
PTO-VREF - ORG/RED
PTO-RTN - ORG/BLK
PTO - ORANGE
OEM CLEAN
TACH-OUT
CIRCUIT 76 (LT GRN/WHT)
CLEAN TACH-OUT
(CTO)
CCT # 76
BLACK
BROWN
GREEN
RED
NO CONNECTION
TAPE UP END
PARK
BRAKE
BLACK
GREEN WITH
RED STRIPE
BLACK
LEGEND
JOIN IF NOT USED
YELLOW
YELLOW
WHITE
BLACK
GREEN
RED
RED
PUMP & ROLL
R SP
STATIONARY
COMPRESSOR
MODE
1.877.634.6223
PUMP
AND ROLL
MODULE
BLACK
BROWN
RED
WIRE
LABEL
PUMP AND ROLL SWITCH
WHITE
XXXX
XXXX
XXXX
REMOTE
SWITCH
CUT OFF CONNECTOR
AND SPLICE TO
RED 12V WIRE
RED
WHITE
WHITE
GREEN
CONTROL PANEL
WHITE
OEM KEY
SWITCHED
12 VOLTS (WHT/LT BLU)
CIRCUIT 294
FIREWALL BULKHEAD
COMPRESSOR
FIREWALL BULKHEAD
IGNITION
SWITCHED
12 VOLTS
INLET VALVE
OVE
32
EE D
WHITE
INTERFACE
CONNECTOR
RED
GREEN
BLUE
CHASSIS
GROUND
CONTROL
GREY
PURPLE
RED
SPEED 2
TO ODIN
HI/LOW SW
GREEN
WHITE
RED
BLACK
SPEED 1
TO ODIN
HI/LOW SW
FIND RED WIRE IN
"COMPRESSOR MODE"
SWITCH (CHECK FOR 0V
IN "STATIONARY" MODE)
OFF
ON
HIGH IDLE
NO
CONNECTIONS
KEY-SWITCHED
12V
THROTTLE
PARK BRAKE
SWITCH/DDC
ODIN
HI/LOW
SWITCH
YELLOW
CLUTCH
LOW
HI
COMPRESSOR
SPEED
5-PRONG RELAY
(BOSCH TYPE)
5-PRONG RELAY
(BOSCH TYPE)
Part 4: Installing the Control
Components
REMOTE
SWITCH
GROUND
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4.1 Installing the Components
□ Remove
the driver-side plastic door frame base panel and the
plastic molding ahead of the base panel.
□ Mount
the control box using the supplied sheet metal screws
(Figure 4.1).
□ Route
the wire harness under the floor covering, along the inside
of the door where it will be covered by the trim piece and up
under the dash. Place the floor covering back into position and
replace the inside left kick panel.
Keep wires away from the park brake mechanism.
Route wires clear of the steering column and pedals so
they do not contact moving parts.
Driver’s Seat
Control box
Cut a notch for the wire
in the door trim
Figure 4.1
□ Cut
a notch in the edge of the trim piece through the saw-tooth
section just inside the edge of the trim so that the wire is not cut
when the trim is installed. Replace the door trim piece.
□ Remove the trim panel from under the dash.
□ Tie-wrap
the throttle control box to the dash support bracket to
the right of the steering column, behind the diagnostic connector
(Figure 4.2) with the adjusting screws facing out.
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33
□ Coil
and secure the grey harness from the throttle control (black,
red, white and green wires with spade connectors) out of the
way. These connections are not used.
Throttle pedal
connector
Diagnostic
connector
Tie-wrap to this bracket
Figure 4.2
□ Tie-wrap the pump-and-roll module to a support under the dash.
□ Coil
and secure the white wire labeled “tach-out throttle control”
out of the way. This connection is not used.
□ Mount
two relays, the compressor mode, high idle and
compressor speed switches in an accessible location (not
supplied).
4.2 Connecting the Under-hood Wiring
□ Make
a slit or cut a small cross in a harness boot or other firewall
plug and pass the small gray harness with the green connector
and the white wire from the pump-and-roll module with a bullet
connector from the cab into the engine compartment.
□ Route
the wires along the engine and firewall to the compressor
and connect them to the matching connectors on the
compressor. Cover the wires with plastic loom and secure them
to OEM harnesses and other objects with nylon ties (Figure 4.3).
34
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!
Avoid the turbo and other hot or moving parts.
Secure wires with ties
Firewall
Firewall
Keep wires
away from
Turbo
Coolant
Reservoir
Turb
o
air d
ucti
n
g
Figure 4.3
4.3 Connecting the In-cab Wiring
□ Connect
the blue wire with the ring connector to the black wire
from the compressor mode switch.
□ Attach
the green “ground” wire from the pump-and-roll module
and the blue wire from the compressor mode switch to the
dashboard ground point above the diagnostic connector (Figure
4.4).
□ Connect the two white interface connectors together.
□ Connect
the red “ignition switched 12V” wire from the pump and
roll module and the yellow wire from the throttle control box to
the OEM white wire with a light blue stripe (CCT #294) under the
dash above the OEM diagnostic connector (Figure 4.4).
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35
g
rin
ee
St
Dash
m
lu
co
n
White wire with a
light blue stripe
OEM ground
OEM diagnostic connector
Figure 4.4
□ Connect
the white, brown, black, red and green wires from the
pump-and-roll module to the compressor mode switch as shown
in Figure 4.5.
WHITE
BLACK
RED
BLUE
PUMP AND ROLL SWITCH
COMPRESSOR
MODE
STATIONARY
GREEN
OVE
EE D
R SP
WHITE
RED
PUMP & ROLL
BLACK
1.877.634.6223
BROWN
PUMP
AND ROLL
MODULE
Figure 4.5
36
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□ Solder
and seal the white “OEM Clean Tach out” wire from the
pump and roll module to the light green wire with a white stripe
(CTO – Ford CCT #76) in the bundle of blunt cut wires near the
park brake (Figure 4.6).
Yellow wire with a white stripe
Wire bundle
HOOD
Figure 4.6
□ Ifwitha remote
switch is not used, join the two yellow wires together
the butt connector.
□ Ifpolea remote
switch is used, connect the yellow wires to a singlesingle-throw (SPST) switch capable of carrying 10 Amps at
12 Volts.
□ Solder
and seal the black wire from the pump-and-roll module to
the green with red stripe wire at the park brake (Figure 4.7).
On some trucks the park brake switch is located on the
back of the park brake assembly.
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37
□ Connect
the wire harness from the throttle control to the SEIC
blunt cut wires by the park brake as follows:
Throttle Control Wire
Red
Green
Brown
Black
SEIC Wire
PTO – Orange
PTO-RTN – Orange/Black
PTO-VREF – Brown
PTO-RPM - Black
Green wire with a red stripe
Figure 4.7
□ Connect
the high idle switch, compressor speed switch and two
five-prong Bosch-type relays (not supplied) as shown in Figure
4.8.
38
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HIGH IDLE
ON
Key-switched
12 Volts
COMPRESSOR
SPEED
OFF
HI
LOW
Red speed 1 wire
Purple speed 2 wire
Red “Odin Hi/Low Switch
wire from pump-and-roll module
5-PRONG RELAY
(BOSCH TYPE)
FIND RED WIRE IN
"COMPRESSOR MODE"
SWITCH (CHECK FOR 0V
IN "STATIONARY" MODE)
From throttle
control box
Figure 4.8
4.4 Completing and Testing the Installation
□ Check
all wiring to ensure that it will not contact any hot or
moving components and will not interfere with the operation of
the truck. Secure all wiring with nylon ties and loom as required.
□ Install and connect the batteries.
4.4.1 Safety Test
□ Place
the truck in a safe operating position and block the wheels.
Ensure that there are no people around the truck before
beginning the test.
□ SitPark,in the
driver’s position with the automatic transmission in
manual transmission in neutral and the park brake fully
engaged.
□ Turn
the control box off, and the Compressor Mode switch to
“stationary”.
□ Start
the truck engine and wait for the idle to stabilize. Engine
temperature should be in the normal operating range.
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39
□ Test
the operation of the safety system by quickly turning the
compressor on and then off. The engine should start to idle up
and the compressor clutch should engage.
□ Firmly
apply the service brake pedal and hold it down. Release
the park brake and momentarily activate the compressor as
before. The engine should not idle up.
□ Apply
the park brake and shift the automatic transmission into
reverse with your foot on the service brake pedal. Momentarily
activate the compressor as before; the engine should not idle up.
□ Shift the transmission back into Park and turn off the control box.
□ Temporarily disconnect the clutch wire.
□ Turn
the Compressor Mode switch to “pump & roll” and turn on
the compressor. The engine should not idle up.
□ Using
the accelerator pedal, slowly increase engine speed to
about 2700-2800 RPM and watch the Compressor Mode overspeed lamp. When the over-speed cutout is engaged, the red
lamp will be on.
□ Reduce
engine speed back to idle and put the Compressor
Mode switch into “stationary” mode. Wait 30 seconds, and
switch back to “pump & roll” mode. The red lamp should be off
and remain off until the engine is over revved again.
□ Turn
off the compressor, shut down the engine and reconnect
the clutch wire.
!
40
If the truck fails the test, check the wiring to make sure
that all the connections are correct and secure. If you
require additional assistance, contact your local VMAC
dealer. Call 1-800-738-8622 or 250-740-3200.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
Part 5: Finishing the Installation
5.1 Before Starting the Engine Checklist
Make sure that the following have been completed:
□ Check the coolant.
□ Check the compressor oil level.
□ Do
a final inspection to make sure that everything has been
completed and tightened.
□ Perform a final belt alignment check.
□ Check all wiring for security and protection.
5.2 After Starting the Engine Checklist
!
Place the truck in a safe operating position and block
the wheels. Ensure that there are no people around the
truck before beginning the test.
Make sure that the following have been completed:
□ Operate
the system with an air tool for at least 1/2 hour (1 hour
preferred).
□ Road test the truck for approximately 14 miles (20 km)
□ Watch
the underhood operation to make sure that belts rotate
properly and nothing is rubbing or contacting hot parts.
□ Check
all components once the engine is turned off and the
system has cooled
□ Check
the coolant after the engine reaches operating
temperature.
□ Check
the compressor oil level after the engine has been shut
down and the oil level has had time to stabilize.
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41
5.3 Setup, Performance Testing and Adjustments
This system has been adjusted at the factory for general operation. If
your tests indicate that adjustment is necessary, refer to the owner’s
manual for specific instructions on how to adjust the system.
You can test the system operation using the tools that will be
operated by the system or you can test operations sing an orifice in
the outlet to simulate tool use (Figure 5.1).
Figure 5.1
1. Install the test tool in the tank outlet fitting.
2. Make sure that the ball valve is closed.
3. Place the manual transmission in neutral or the automatic
transmission in park and fully apply the park brake.
4. Allow the vehicle to run until the engine is at operating
temperature.
5. Operate the air compressor system 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 about 1,800 2,200 RPM.
8. Close the air valve slowly to allow the system pressure to rise.
9. Once the 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 start to ramp-up when air pressure
drops to approximately 140 PSI.
42
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
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5.4 System Identification and Warnings
The System Identification Number Plate must be attached to the
vehicle at the time of installation (Figure 5.2). This plate provides
information which allows VMAC to assist in customer inquiries and
the ordering of parts. Mark and drill two 7/64 inch holes, then secure
the plate with self-tapping screws.
tem
Sys
b
um
ID n
late
er p
Left Front
Figure 5.2
As part of the installation process, ensure that the safety and
operational instruction decal is affixed in an obvious location so that
it can be seen by vehicle operators (Figure 5.3).
This Vehicle is Equipped with a VMAC Air Compressor System
OPERATING INSTRUCTIONS
Daily Pre-Start Check
Start Up Procedure
Shutdown Procedure
1. Check Oil Level in Tank
2. Check Drive Belt
3. Check for Leaks
1. Ensure Compressor is OFF
2. Ensure discharge valve is
CLOSED
3. Ensure air system is discharged
4. Place vehicle in Neutral or
Park and engage vehicle
safety features - park brake
5. Start engine and bring up to
operating temperature
6. Turn ON compressor
1. Allow engine to idle for 1 minute
2. Turn OFF compressor
3. Wait for system to discharge
for 1 minute before restarting
For Technical Support/Parts contact your VMAC Dealer
To locate your nearest dealer call 1-800-738-8622 (250-740-3200)
! WARNING
Always allow system pressure to discharge before restarting
Figure 5.3
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43
5.5 Auxiliary Air Receiver
!
If you intend to use an auxiliary air receiver with this
system you must observe the following installation
procedure to prevent damage to the system.
The line from the VMAC tank to the auxiliary air receiver must have a
one-way check valve installed (part #3600078) to prevent blow back
from the auxiliary tank to stop moisture from entering the VMAC tank
(Figure 5.4).
The line to the auxiliary tank must not be installed in the bottom of
the tank, but must be installed as high as possible to prevent water
from entering the line.
One-way check valve
VR Tank
Auxiliary Tank
Install the line as high as
possible, NOT on the
bottom of the auxiliary tank
Figure 5.4
44
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
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Accessory Products from VMAC
The following accessory products for your VR compressor system
are available from VMAC. For more information or to order these
products, call 1-800-738-8622.
Eliminator Aftercooler
Removes up to 80% of moisture from
compressed air. Quick installation,
automatic drain and compact design
Filter Regulator Lubricator
Removes lubricants, water and dirt
from the air stream. Adds atomized
tool oil to lubricate tools. Reduces
pressure for longer tool life.
Auxiliary Tank Valve
Equalizes pressure between storage
tanks and the VR tank. Built-in check
valve. No electrical connections or
adjustments required.
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Fax: 1-250-740-3201
45
Hose Reel
Secure, compact, retractable hose
storage in a sturdy reel.
Air Receiver Tank
Thirty-five gallon capacity in a
compact tank, complete with fittings
and a gauge.
De-icer Kit
Insulated rope heater prevents
freezing of lines and regulator.
System Testing Tool
Simulates tool use to provide for
accurate system adjustments. Orifice
fittings included for both VR70 and
VR140 systems.
VR Service Kits
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
46
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
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