V900122 Manual
Installation Manual for VMAC
System
VR70 V900122
2017+ Ford Super Duty F-250 – F-350
6.2 L Gas V8
Installation Manual for VMAC
System V900122
2017+ Ford Super Duty F-250 – F-350
6.2 L Gas V8
Safety ................................................................................................. 3
Warranty............................................................................................. 4
General Information .......................................................................... 5
System Identification, Warranty and Warnings .............................. 6
Preparing for Installation.................................................................. 8
Relocating the ABS Hydraulic Control Unit (HCU) ........................ 12
Installing the Main Bracket and Compressor ................................. 15
Modifying the Hoses, Installing the Degas Bottle and Cooler ...... 22
Installing the Air Oil Separator Tank (AOST) and Hoses .............. 27
Installing the Control Components ................................................. 34
Completing and Testing the Installation ......................................... 38
Setup, Performance Testing and Adjustments .............................. 41
Air Receiver Tank .............................................................................. 43
Accessory Products ......................................................................... 44
Warranty Registration ....................................................................... 45
VMAC – Vehicle Mounted Air Compressors
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1
Document: 1930297
Changes and Revisions
Revision
Revision Details
Revised
by
Checked by
Eng.
Mech.
Elec.
Tech.
Qual.
Implemented
A
Initial Release
MSP
CJH
AJH
DSB
AMG
30 May 2017
B
ECN: 17-131 Water pump update
MSP
CAM
AJH
GB
AMG
10 Aug 2017
Additional Application Information
•
•
V900122: 2017+ Ford Super Duty F-250 – F-350, 6.2 L Gas V8
Single battery application only. Dual battery vehicles will require
accessory A900016
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®, Loctite® 242 and are registered trademarks of Henkel AG &
Company KGaA.
Ford® is registered trademark 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
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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.
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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
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General Information
Before You Start
Read this manual before attempting installation so that you can familiarize
yourself with the components and how they fit on the vehicle. Identify
variations for different engine models and different situations that are listed in
the manual. Open the package, unpack the components and identify them.
Torque Specifications
All fasteners must be torqued to specifications. Use manufacturers’ torque
values for OEM fasteners. Apply Loctite 242 (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
METRIC CLASS 10.9
M6
M8
M10
4.5
19
41
6
25
55
Size
Foot-pounds (ft-lb)
Newton meter (N•m)
M12
69
93
M14
104
141
3/4
280
379
3/4
320
434
M16
174
236
Table 1 – Torque Table
Special Tools Required
•
Pneumatic fan wrench removal set (such as Lisle® 43300) or a manual
fan pulley holder (such as KD Tool® KD3900)
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.
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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 that 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

As part of the installation process, ensure that the caution decal
regarding the heavy-duty water pump is affixed in an obvious location so
that it can be seen by maintenance personnel (Figure 2).
Figure 2 – Heavy-duty water pump Label
6
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
As part of the installation process, ensure that 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).
Figure 3 - Operating Instruction Label

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 4 - Warning Label
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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 that you have filled out the VMAC Warranty
Registration. Install the System Identification Number Plate
and operating instruction label. (Please see page 6 for details).






Locate the blunt-cut OEM SEIC wire harness, on the passenger side in
the foot well. You will need to find the transmission park signal, (grey
with brown stripe wire).
Use a multi-meter to verify the transmission park signal. Turn the key to
the IGN2 position, (do not start the truck), so as to supply power to the
dash display. The resistance to ground should read close to 0-ohms in
park and open circuit in all other gears. If this is correct, put the vehicle
in park and turn the key to the off position.
Mark transmission park signal wire for connection later in installing
control components section.
Disconnect the battery (or both batteries if equipped with dual batteries).
Drain the coolant into a clean container and set aside for use later.
Remove the power steering reservoir from the driver side of the fan
shroud. Keep the power steering lines connected. Temporarily tie the
reservoir up and out of the way of the shroud.
The power steering reservoir cap will leak if the reservoir is not
kept upright.


8
Remove the upper radiator hose and set aside as this will be modified in
a later chapter.
Remove the degas bottle. On vehicles equipped with dual batteries,
remove the battery from the battery tray / degas bottle assembly. Retain
the OEM bolts as they will be reused.
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Single battery degas bottle modification:
Vehicles equipped with dual batteries will have an integrated
degas bottle and battery tray which requires a different
mounting bracket and different modification instructions.
Please contact VMAC to order A900016.
Very carefully remove the indexing material for the quick
connect coupling. Removing too much material could weaken
the degas bottle and cause premature failure.

Carefully remove the material shaded in red to allow the hose to mount
in the required orientation (Figure 5).
Figure 5 – Single battery degas bottle modification






Swing the lower shroud forward and tape in place.
Disconnect the fan stator plug.
Remove the fan using a pneumatic fan wrench (such as Lisle 43300).
Remove the fan harness bracket (13 mm nut on stud with bracket).
Remove the entire fan shroud for easiest access.
With the accessory belt tensioned, loosen the 4 water pump pulley bolts.
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This VMAC compressor system includes a heavy-duty water
pump, with an integrated fan spacer, which replaces the OEM
water pump (Figure 6).
Heavy-duty
water pump
OEM water
pump
Figure 6 – Heavy Duty / OEM water pump comparison





Remove the accessory drive belt.
Remove the 4 water pump pulley bolts and retain for reuse (Figure 7).
Remove the water pump pulley and set aside for reuse.
Remove the 4 water pump bolts and the water pump.
Inspect and clean the sealing surfaces.
Prior to seating the water pump in the engine, ensure the bolt
holes are aligned as the water pump cannot be rotated once
seated in the engine cavity. Rotating the water pump once it is
installed in the engine may damage the O-ring and cause the
water pump to leak.
Figure 7 – Replace coolant pump
10
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



Lubricate the new water pump O-ring with clean engine coolant and
install the new pump.
Apply Loctite 242 (blue) to the 4 water pump bolts and install the
supplied heavy-duty water pump.
Tighten the water pump bolts in 2 stages using a criss-cross pattern:
1. Tighten all bolts finger tight.
2. Torque bolts to 18 ft•lb.
Remove the idler (Figure 8).
Figure 8 – Remove OEM idler

Relocate the Radio Interference Suppressor (RIS) to the bolt directly
above the idler (Figure 9).
OEM RIS
location
Relocated RIS
position
Figure 9 – RIF relocation





Install the water pump pulley and 4 bolts hand tight.
Reinstall the idler leaving the bolt hand tight.
Install and tension the accessory drive belt.
Torque the 4 water pump pulley bolts to 18 ft•lb.
Remove and discard the idler bolt, leaving the belt tensioned and the
idler on the post.
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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
13), proceed to the next chapter. If the HCU bracket is
mounted using the holes shown in Figure 10, 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 avoid air entering
the brake system as brake fluid will be forced out of the
system rather than air permitted to enter the system.
Do not pump the brakes at any time while the brake lines are
loose or 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 retightened. Adjust 1 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 as 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.
12
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
Remove the bolt and 2 nuts securing the HCU and lift it clear of the
shock tower (Figure 10).
Figure 10 – Relocating the HCU

Apply Loctite 242 (blue) to the supplied pan head fastener and install the
supplied HCU relocation bracket (Figure 11).
HCU relocation
bracket
Figure 11 – Relocating the HCU
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
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 12).
Figure 12 – Relocating the HCU

Reinstall the bolt and 2 nuts (Figure 13).
Figure 13 – Relocating the HCU
14
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Installing the Main Bracket and
Compressor
When modifying the valve cover, it is important to remove only
the webs indicated and not cut past the face shown in Figure
14. Cutting into the main valve cover body may compromise
the O-ring sealing the valve cover to the cylinder head

Remove the webbed area on both the upper and lower sides of the
driver side valve cover the using a die grinder or pneumatic cut off wheel
(Figure 14).
Remove shaded area
Shaded area removed
Before webs removed
After webs removed
Figure 14 – Modifying the Valve Cover

Remove the wire harness mounting tabs on the driver side valve cover
as shown using a die grinder or pneumatic cut off wheel (Figure 15).
Tab removed
Remove mounting tab
Figure 15 – Modifying the Valve Cover
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
Install the fan spacer bracket onto the alternator bracket and route the
extension harness along the front of the valve cover (Figure 16).
Install fan
spacer bracket
Figure 16 – Fan spacer bracket
16
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Main bracket installation
Apply Loctite 242 (blue) to all engine mounted fasteners.
When fitting the main bracket, it is important that the bracket
sits flush on all mounting surfaces. Ensure the bracket is not
contacting the valve cover when installed. If necessary, trim
the valve cover until proper fitment is obtained.

Remove the bolt directly beneath the driver side valve cover, as well as
the stud that the RIS was originally secured to (Figure 17).
Figure 17 – Installing the main bracket

Relocate the OEM wire hold down clip from the front of the bracket to
the firewall side of the bracket using the provided barbed cable tie
(Figure 18).
Relocate wire hold
down clip to the
rear of mount
Figure 18 – Relocate the wire hold down clip
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Failure to follow the procedure below may cause excessive
stress to the bracket and fasteners which could lead to
failure.





Remove the captive bolt from the VMAC supplied tensioner and discard.
The bolt may be pressed out or lightly hammered. Place the tensioner
on the VMAC bracket
Position the bracket securely against the engine and install the tensioner
and all 5 bolts finger tight.
Confirm that the bracket is positioned correctly, is tight to the against the
engine and that no wires are pinched.
Grab the fan extension wire harness on both sides of the VMAC main
bracket and confirm it is not pinched in the main bracket.
Torque the (2) M16 bolts to specification followed by the (3) M8 bolts
(Figure 19).
M8 x 120 bolt
5/16 in washers
5/8 in washers
M8 x 100 bolt
M8 x 120 bolt
M16 Bolts
Figure 19 – Installing the main bracket
18
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
Install the idlers and tensioner pivot post onto the bracket and torque to
specification (Figure 20).
Tensioner
pivot post
M10 bolts
10 mm fender
washer
Figure 20 – Installing the idlers

Install the tensioner plate on the OEM tensioner (Figure 21).
Figure 21 – Installing the tensioner plate
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Installing the Compressor
 Remove the inlet valve from the compressor and cover the opening to

prevent debris entering the compressor.(Figure 22)
Position the compressor on the mounting bracket and secure with the 4
supplied bolts. Torque 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.
Longer bolts
Shorter bolts
Figure 22 – Inlet installation

20
Remove the protective covering and reinstall the Viton O-ring and inlet
onto the compressor. Torque to specification.
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Installing the Crank Pulley and Drive Belts
 Remove the center bolt from the OEM crankshaft pulley and discard.



Lightly oil the threads of the M14 x 110 bolt.
Install the VMAC crank pulley using the supplied M14 x 110 bolt and
9/16 in washer. Once the bolt is finger tight, rotate the VMAC crank
pulley counter-clockwise until the 3 lugs are against the web of the OEM
crank pulley
Using a strap wrench (or similar tool) to prevent the engine from turning
over, torque the bolt to 129 ft•lb then an addition 90°.
Install the VMAC drive belt (Figure 23).
After the fan is installed, the tensioner can be rotated using a
pry bar against the idler’s tensioner pivot post (Figure 23).
Figure 23 – VMAC belt routing
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Modifying the Hoses, Installing the
Degas Bottle and Cooler

Using the OEM bolts retained earlier and the supplied nuts, install the 2
supplied brackets onto the modified degas bottle (Figure 24).
Figure 24 – Mounting the degas bottle

Align the base with the OEM mounting location and reinstall the degas
bottle assembly into the engine bay using the supplied bolts (Figure 25).
Figure 25 – Installing the degas bottle
22
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Installing the cooler and hoses
Do not damage the diverter valve or the hoses as they will be
reused.

Uncouple the lower radiator hose assembly at the engine, remote oil
cooler, radiator and degas bottle and remove the assembly from the
engine bay.

Position the cooler in the center of the black front crossmember, below
the body coloured radiator support with the oil ports facing down
(Figure 26).
Front of vehicle
Fender washer
Lock washer
Figure 26 – Installing the cooler


Apply Loctite 242 (blue) and insert the bolts and washers as shown. The
larger bolts are used in the bottom of the cooler (Figure 26).
Carefully cut the 4 molded plastic cuffs clamping the lower radiator
hoses to the oil cooler diverter valve and the OEM quick connects. After
removing the cuffs, separate the hoses from the fittings (Figure 27).
To degas
Cut cuff
From radiator
To engine
Cut cuff
Diverter
valve
Cut cuff
Cut cuff
Figure 27 – OEM coolant hose modifications
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




With the radiator side quick connect removed, measure and cut 1/2 in of
radiator hose and reinsert the quick connect using the supplied hose
clamp (cut “A”) (Figure 28).
With the diverter side quick connect removed, measure 10 in along the
outside radius and cut the hose (cut “B”) (Figure 28).
Measure 6 1/2 in from the newly cut “A” along the outside radius towards
the center of the hose to remove the center which can be discarded.
Move the quick connect removed from the diverter end quick connect to
cut location “C”, and loosely install the supplied hose clamp (Figure 28).
Insert the OEM diverter with the spigots facing towards the rear of the
vehicle.
6 1/2 in C
A
1/2 in
Discard
Modified hose
Retain
Move to
cut “C”
location
B 10 in
Figure 28 – Radiator hose modification


Remove the hose running between the oil cooler diverter and the degas
bottle “T” and discard (Figure 29).
Disconnect the degas hose from the “T” connector. Retain the hose and
clamp (Figure 29).
Disconnect
degas hose
Discard
Figure 29 – Remove and discard the OEM degas hose
24
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

Connect the supplied driver side radiator hoses and tubes between the
cooler and degas bottle “T” and secure with the supplied hose clamps.
Trim hoses as necessary to prevent the hose from kinking (Figure 30).
Cut the oil cooler hoses 8 in from the diverter cuffs and extend them with
the provided 3/4 in hoses and barbed fittings. When pushing the oil
cooler hoses onto the 3/4 in hose barb do not push on the entire way, 1
in of hose barb should be left showing in the centre of the barb. Ensure
the hose routing is clear of the crank pulley and secure with hose clamps
(Figure 30).
Apply the mesh loom to the hoses where they pass between
the cross member and the radiator support.
24 in hoses
P/N: 1700177
Modified
radiator hose
Barbed
connectors Degas
bottle ”T”
Diverter valve
Section retained
from modified
radiator hose
P/N: 1710875
Tube connectors
P/N: 1700874
P/N: 1700638
Connect long
section to cooler
Figure 30 – Cooler assembly


Cut the quick connect cuff on the upper radiator hose, remove the cuff of
the quick connect. Remove 1/2 in of the hose on the radiator side.
Using the supplied hose clamp, reinstall the OEM quick connect on the
upper radiator hose.
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Modifying the Degas Hose
 Measure 6 1/2 in from the start of the radius and cut the hose; retaining
the quick connect end. Rotate the hose 180° on the quick connect
(Figure 31).
Discard
6 1/2 in
Figure 31 – Degas hose modification



Insert the supplied hose barb into the modified degas quick connect and
hose and secure with a hose clamp. Rotate the quick connect 90° from
its original position and reattach to the degas bottle with the hose
curving towards the fender (Figure 32).
Route the modified degas hose towards the fender and down to the
degas bottle “T”. Secure the hose to the degas bottle “T” with a supplied
hose clamp.
Secure the hose to the degas base bracket with the supplied P-clips
(Figure 32).
Driver side fender
Secure hose
with P-clips
Figure 32 – Installing the modified degas hose
26
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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, care must be used to
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 33).
Front of vehicle
Figure 33 – AOST installed
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Apply Loctite 242 (blue) to the (2) 3/8 in x 6 in bolts and install the front
tank and rear backing strap between the radius arm mount and the
transmission crossmember. Leave the bolts finger tight to allow minor
adjustment (Figure 33)
Apply Loctite 242 (blue) to the (2) 3/8 in x 6 in bolts and install the rear
tank mount and backing strap approximately 10 in ahead of the rear cab
mount. Leave the bolts finger tight to allow minor adjustment (Figure 33).
Remove the tank clamp pinch bolts.
Install the tank clamps over front of tank and slide towards center of the
tank.
Install the tank onto the tank mounts (Figure 34).
o Adjust the tank in the straps to bring the rear of the tank close to
(but not touching) the rear cab mount .
o Apply Loctite 242 (blue) to the 2 x 3 in x 1/4 in pinch bolt and install
them into the mounting clamp.
The top bolt on the forward tank mount will need to be installed
from the inside of the frame.
Front of vehicle
(2) tank clamp
lock nut
(4) 3/8 in x 6 in bolts
(4) 5/16 in x
1/2 in bolt
(4) 3/8 in nut
(8) 3/8 in washer
(2) Pinch bolt
Figure 34 – Installing the AOST
(Front tank clamp not shown for clarity)
28
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Installing the hoses
When routing hoses, ensure cap-plugs are installed so that
contaminants do not get into the line. Take care when
routing hoses as a hose failure can damage the compressor
and cause injury.
All hoses, tubes and wires that are installed, rerouted or
shifted during installation must be secure so that they do
not contact hot, sharp or moving components. Use rubber
coated P-clips wherever possible. Follow the routing
suggestions in this manual and cover all hoses with plastic
loom.
Lubricate the tube and firmly push it into the fitting so that the
tube fully seats in the fitting. Slide the collet out, away from
the body of the fitting to lock the tubing in place. Ensure the
tube does not have any ‘play’ to prevent the O-ring from
wearing.
Cut the tube square. Do not use side
cutters as they will deform the tube
Slide the collet out once
the tube is fully inserted
Figure 35 – Push-to-connect fittings
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Connect the straight fitting to the compressor discharge port.
Route the discharge hose from the compressor down and in between
the engine and steering column (Figure 36).
Firewall
Discharge hose
Steering column
Compressor

Figure 36 – Routing the hoses
Install the P-clip bracket (P/N: 120943) and supplied P-clip on the driver
side frame rail. Route the discharge hose away from the exhaust and
above the driveshaft (Figure 37).
P-clip bracket
Figure 37 – Routing the hoses
30
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

Install the bellhousing P-clip bracket (P/N: 1200939) and P-clips on the
transmission bell housing. The P-clips should be mounted to the
transmission side of the bracket.
Route the hose across the underside of the truck through the P-clips
(Figure 38).
P-clip bracket
Figure 38 – Routing the hoses

Install the frame mount P-clip bracket (P/N: 1200937) and P-clip into the
slot in the frame above the radius arm and route the hose to the outside
of the frame (Figure 39).
P-clip bracket
Bump stop
Figure 39 – Routing the hoses
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32
The hose will gradually bend 90° to connect to the fitting on the front of
the AOST.
The PTFE lines will route back to the firewall, over the engine and down
towards the wheel well to meet with the discharge hose. Use cable ties
to attach it to the discharge hose and pass it between the frame and the
radius arm.
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
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.
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Adding oil to the system
The VMAC supplied and approved compressor oil must be
used in this system. Failure to use this special oil will result in
damage to the compressor and will void warranty.
Do not overfill the system. Overfilling the system with oil can
flood the sight glass window and make the system appear
empty.

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 in socket using the hex head
bolt at the centre of the compressor clutch during the fill process
(Figure 40).
Oil fill plug
Figure 40 – Adding oil to the system
Do not use power tools to rotate the clutch.


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.
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33
34
Connect to SEIC Blue wire CE913
Connect to SEIC Grey wire with Brown stripe CET22
Connect to SEIC White wire with Purple stripe CMC25
Connect to SEIC Green wire with Orange stripe CBP22
Installing the Control Components
Figure 41 – Wire diagram
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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 42).
If this is not practical, cut the OEM wire and solder and seal
using shrink tube.
Figure 42 - 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 that there are no
OEM wires, hoses, or components in the way.
Ensure all wires are protected and routed so that they do not
contact hot, sharp or moving components.
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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
that the wire harness will reach the compressor. The preferred location
is between the driver’s 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.
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

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.
Cable tie the throttle control under the dash away from moving parts and
positioned so that the idle down pressure (IDP) and maximum rpm
adjusting screws are accessible (Figure 43).
Throttle control
Figure 43 – 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 matching red wire
from the display box.
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 44).
Route cable toward
SEIC bundle
Figure 44 – SEIC pass through
36
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
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 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 under-hood wiring
 Cut a slit in the firewall plug on the driver side, under the firewall

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
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 at the compressor clutch.
Pull all excess wiring back into the cab.
Cover all VMAC under-hood 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).
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Completing and Testing the
Installation
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38
Confirm that the 3/4 cooler lines running from the diverter valve are
oriented toward the firewall and are secured away from the crank pulley
and any hot, sharp or moving components.
Install the fan and shroud as one unit.
Install the upper radiator hose. Rotate the hose on the quick connect to
minimize twists or kinks and tighten the hose clamp.
Fill the cooling system with the coolant saved earlier.
Reinstall the power steering fluid reservoir onto the fan shroud. Top up
the fluid as necessary.
Cover all VMAC under-hood wiring with high heat plastic loom (if not
done previously). Secure the harness with cable ties as needed to avoid
hot, sharp or moving components.
Reconnect the battery / batteries.
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Testing the installation
 Place the automatic transmission in “Park” or manual transmission in

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

neutral and apply the park brake. Turn the ignition key “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.
On automatic transmission trucks, the engine must be running to
complete the final step in the safety test. This will be done after the
prestart checks have been completed.
Turn the ignition key “OFF”.
The engine must be running to complete the final step in the
safety test. This will be done after the prestart 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
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.
Ensure that the following has been completed:
 Check the coolant.
 Check the compressor oil level at the tank sight glass.
 Do 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.
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After Starting the Engine Checklist
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40
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.
On the first start, 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) once system pressure is reached.
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.
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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 3/16 in orifice in the
outlet to simulate tool use (Figure 45).
Figure 45 - 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 3/16 in orifice
2.
Ensure that 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.
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Final Testing
Ensure that 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 under-hood operation to ensure that 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.
42
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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 46).
The line to the receiver tank must be installed as high as
possible to prevent water from entering the line.
1-way check
valve
Air Oil Separator
Tank
Air Receiver Tank
Install the line as
high as possible
Figure 46 – Air Receiver Tank
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43
Accessory Products
These accessory products for your under-hood compressor system are
available from VMAC. For more information or to order these products, call
1-877-912-6605 or email sales@vmacair.com.
Eliminator Aftercooler
Part Number A800070
Removes up to 80% of moisture from
compressed air. Quick installation, automatic
drain and compact design
Filter Regulator Lubricator
Part Number A700151
Removes lubricants, water and dirt from the
air stream. Adds atomized tool oil to lubricate
tools. Reduces pressure for longer tool life.
Hose Reel
Part Number A700007
Secure, compact, retractable hose storage in
a sturdy reel.
Air Receiver Tank
Part number A300047
10 gallon capacity in a compact tank,
complete with fittings and a gauge.
Part Number A300010
35 gallon capacity in a compact tank,
complete with fittings and a gauge.
3/4 in NPTF Check Valve not included
Part number 3600117
De-icer Kit
Part Number A700031
Insulated rope heater prevents freezing of
lines and regulator.
Service Kits
VR70 200 hour Part Number A700019
VR70 400 hour Part Number A700020
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
44
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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:
____________
Submitted by
Name: ____________________ Contact: _________________
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