Vmac V910016 Installation guide

VMAC – Vehicle Mounted Air Compressors

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1

Installation Manual for VMAC

System V910016

2016+ Ford F-650 / F-750 Cab & Chassis

6.8 L V10 Gas

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Installation Manual for VMAC

System V910016

Safety ................................................................................................. 3

Warranty ............................................................................................ 4

General Information .......................................................................... 5

Part 1: System Identification, Warranty and Warnings ................. 7

Part 2: Preparing for Installation ..................................................... 9

Part 3: Installing VMAC Crank Pulley and Fan Spacer .................. 11

Part 4: Modifying the Coolant Hoses and Installing the Cooler ... 12

Part 5: Installing the Main Bracket and Compressor ..................... 16

Part 6: Installing the Separator Tank, Brackets and Hoses .......... 20

Part 7: Adding Oil to the System ..................................................... 29

Part 8: Installing the Control Components ..................................... 30

Part 9: Completing and Testing the Installation ............................ 34

Part 10: Setup, Performance Testing and Adjustments ................ 36

Part 11: Optional Accessory Installation ........................................ 38

Part 12: Auxiliary Air Receiver ......................................................... 39

Part 13: Accessory Products ........................................................... 40

Part 14: Warranty Registration ........................................................ 41

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Document: 1930281

Changes and Revisions

Additional Application Information

• 2016+ Ford F-650 / F-750 Cab & Chassis 6.8 L V10 Gas

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® 242 is a registered trademark of Henkel AG & Company KGaA.

Ford® is registered trademarks of Ford Motor Company.

Important Information

The information in this manual is intended for certified VMAC installers who

have been trained in installation procedures and for people with mechanical

trade certification who have the tools and equipment to properly and safely

perform the installation. Do not attempt this installation if you do not have the

appropriate mechanical training, knowledge and experience.

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

restructuring operations for correct fit in modified vehicles must follow

standard shop practices.

Notice

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

Revision

Revision Details

Revised

by

Checked by

Implemented

Eng.

Tech.

Qual.

Mech.

Elec.

A

Engineer release

MSP

AJP

AJH

BPC

AMG

31 March 2016

B

ECN 16-093

MSP

JKR

AJH

RB

TPK

12 Sept 2016

C

ECN 17-067 MY update

MSP

DSA

N/A

GB

AMG

20 April 2017

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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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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

[email protected]

Fax

(250) 740-3201

Mail

VMAC - Vehicle Mounted Air Compressors

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

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General Information

Optional Equipment Compatibility

Whilst VMAC strives to design systems compatible with optional OEM

equipment (such as running boards), it is impractical to develop systems that

accommodate every OEM and aftermarket option or add-on. Whenever

possible, VMAC endeavors to advise of compatibility issues in the “Additional

Application Information” section of the manual. Even when specific optional

equipment is determined by VMAC to be incompatible, it does not preclude

the vehicle upfitter or end user from modifying the optional equipment to

make it compatible with the installed VMAC system. VMAC does not

warranty or accept responsibility or liability for the fitment, function or safety

of any products modified in any way not expressly outlined in the installation

manual.

Before You Start

Read this manual before attempting installation so that you can familiarize

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

variations for different engine models and different situations that are listed in

the manual. Open the package, unpack the components and identify them.

Special Tools Required

• Recommended: Pneumatic fan wrench (Lisle 43300 or equivalent)

Hose Information

Depending on other installed equipment, it might be necessary to move the

air/oil separation tank from its intended location. The hoses used in VMAC

compressor systems have a specific inner liner that is compatible with VMAC

compressor oil. Use of hoses other than those supplied or recommended by

VMAC may cause compressor damage and may void your warranty. Please

contact VMAC for replacement hoses and further information.

Ordering Parts

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

serial number, part number, description and quantity. To locate your nearest

dealer, call 1-877-912-6605 or online at www.vmacair.com.

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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

3/4

Foot-pounds (ft•lb)

9

18

35

55

80

110

170

280

Newton meter (N•m)

12

24

47

74

108

149

230

379

STANDARD GRADE 8 NATIONAL FINE THREAD

Size

3/8

7/16

1/2

5/8

3/4

Foot-pounds (ft•lb)

40

60

90

180

320

Newton meter (N•m)

54

81

122

244

434

METRIC CLASS 10.9

Size

M6

M8

M10

M12

M14

M16

Foot-pounds (ft•lb)

4.5

19

41

69

104

174

Newton meter (N•m)

6

25

55

93

141

236

Figure 1 – Torque Table

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Part 1: System Identification,

Warranty and Warnings

Preparation for installation is very important. Missing a step or an item can

cause problems in the installation or damage to components.

Check off each item as it is completed so that you do not miss

any preparation steps.

□ Check through the illustrated parts list, 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 tech support at

(888) 241-2289.

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

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

www.vmacair.com/ warranty/

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

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

valid.

The System Identification Number Plate must be attached to

the vehicle at the time of installation. This plate provides

information that allows VMAC to assist with parts and

repairs.

□ Mark and drill two 7/64 in holes in the flat portion of the fan shroud

above the OEM fan warning sticker. Secure the plate with supplied

self- tapping screws (Figure 1.1).

Figure 1.1 – System Identification Plate

□ Clean the fan shroud beside the OEM fan warning sticker and stick

the VMAC belt routing diagram to the cross member.

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 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. A good spot for this is usually on

the inside of the door or on the panel underneath the steering wheel

(Figure 1.2).

Figure 1.2 – Operating Instructions

 To alert any technicians that may service the vehicle, affix the warning

decal in the engine compartment near the hood latch in a visible

location. Thoroughly clean the selected area before affixing the label

(Figure 1.3).

Figure 1.3 – Service Label

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Part 2: 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

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.

Ensure that you have filled out the VMAC Warranty

Registration. Install the System Identification Number Plate

and Operational Instruction Decal. (Please see Part 1 for

details).

□ Disconnect both of the positive leads from the batteries and cover the

terminals to prevent electrical shorts.

□ Drain the coolant via the drain spigot on the driver’s side at the bottom

of the radiator. This can be drained into a clean container and set

aside for use later.

□ Optional: Remove driver side inner fender for easier access. The

power steering hose may be secured to the fender and will need to be

removed as well.

□ Disconnect the hoses at the engine and the locations indicated in

Figure 2.1. Once the clip has been removed from the diverter,

separate the diverter and remove the diverter hose assembly. (Figure

2.1)

Figure 2.1 – Lower radiator hose assembly

A sheet of cardboard should be placed in between the

radiator and the fan to protect the radiator fins from damage

while removing and installing the fan.

□ Undo the fan nut (RH thread) and carefully lean the fan against the

cardboard or remove it from the engine bay.

Disconnect

at diverter

Disconnect

at oil filter

Disconnect

at oil filter

Disconnect

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For ease of fan removal and installation, it is recommended

that a pneumatic fan wrench removal set (such as Lisle

43300) is used.

□ Relocate the Radio Interference Suppressor to the thermostat

housing. Apply Loctite 242 (blue) to the thermostat fastener. (Figure

2.2)

Figure 2.2 – Radio Interference Suppressor

□ Remove and discard the 4 accessory mounting studs. (Figure 2.3)

Figure 2.3 – Accessory mounting studs

Remove 4 Accessory Studs

Relocate RIS to here

Remove 4 Accessory Studs

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Part 3: Installing VMAC Crank Pulley

and Fan Spacer

Apply Loctite 242 (blue) to all fasteners

□ Clean the face of the OEM pulley and place the VR pulley in position.

Align the bolt holes and ensure that the pulley is correctly centered on

the locating boss.

□ Apply Loctite 242 (blue), install the three supplied M10 x 75 mm bolts

and flat washers and torque to 41 ft•lbs.

□ Install the fan spacer onto the water pump. (Figure 3.1)

Figure 3.1 – Fan Spacer

□ Thread the fan onto the spacer. Torque fan to 98ft•lbs.

Fan Spacer

VMAC Crank Pulley

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Part 4: Modifying the Coolant Hoses

and Installing the Cooler

Do not use air tools or electric impact guns to tighten hose

clamps, they can over-torque the clamp and may cause

coolant leaks. Use hand tools only.

4.1 Modifying the lower radiator hose

The OEM lower radiator hose needs to be modified to integrate the

VMAC oil cooler.

Apply Loctite 242 (blue) to all fasteners

□ Measure 2 in from OEM hose cuff and mark with a grease pen (or

similar marker). Ensure there will be enough hose left beside the OEM

cuff that a connector can be inserted. (Figure 4.1)

Figure 4.1 – Modifying the lower radiator hose

□ Mark the hose at the end of the 90° bend. (Figure 4.1)

□ Push the heat protection up and out of the way and cut the hose at

the 2 marked locations. Discard the short, angled piece of hose.

Mark hose for

modification

Hose A

Modified OEM

lower radiator hose

OEM cuff

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4.2 Assembling the hoses

□ Insert the curved end of the long tube connector (P/N# 1720707) into

the modified OEM lower radiator hose assembly and secure with a

gear clamp. (Figure 4.2)

Figure 4.2 – Modifying the lower radiator hose

□ Insert the straight end of the tube connector into the 90° side of the

supplied coolant hose (P/N# 1710868). Leave gear clamp loose until

final alignment. (Figure 4.2)

□ Insert 1 end of the short tube connector (P/N# 1720708) into the

straight side of hose “A”. Leave gear clamp loose until final alignment.

(Figure 4.3)

Figure 4.3 – Modifying the supplied radiator hose

□ Insert the tube connector into the straight side of the supplied coolant

hose P/N# 1710869. Leave gear clamp loose until final alignment.

(Figure 4.3)

Supplied coolant

hose P/N# 1710868

Long Tube Connector

P/N# 1720707

Hose A

Short Tube

Connector

P/N# 1720708

Modified OEM

lower radiator hose

Supplied coolant

hose P/N# 1710869

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□ Figure 4.4 shows the final assembly attached to the cooler for

reference only.

Figure 4.4 – Coolant hose assembly

□ Re-install the modified lower radiator hose assembly, routing the 2

OEM oil cooler hoses over the cross member. Ensure that the hose is

secured in the OEM hose clip.

Tube Connector

P/N# 1720708

Modified OEM

lower radiator hose

Tube Connector

P/N# 1720707

Hose A

Supplied coolant

hose P/N# 1710869

Supplied coolant

hose P/N# 1710868

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4.3 Installing the cooler

□ Position the cooler in the centre of the front cross-member in front of

the sway bar with the oil ports facing the rear of the truck. (Figure 4.5)

Figure 4.5 – Mounting the Oil Cooler

□ Apply Loctite 242 (blue) then install bolts through the flat mounting

straps and place them on the top of the cross-member. (Figure 4.5)

□ Thread the bolts into the matching holes on the cooler mounts. Leave

the bolts hand tight to allow the cooler to be repositioned if necessary

while installing the coolant hoses.

□ Connect the modified lower radiator hose to the spigot coming off the

bottom of the VMAC oil cooler and secure with a gear clamp.

□ Install “Hose D” onto the upper spigot on the left side of the VMAC oil

cooler. Route “Hose A” along side the engine and re-connect it to the

spigot beside the driver’s side cylinder head. (Figure 4.6)

Figure 4.6 – Mounting the Oil Cooler

□ Once alignment is correct, torque the cooler bolts and tighten all

gear clamps.

□ Refill the coolant system with the saved coolant (referenced in chapter

2). Additional coolant will be required.

To vehicle

thermostat

To lower

radiator hose

To vehicle

oil filter

To vehicle

oil filter

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Part 5: Installing the Main Bracket

and Compressor

Apply Loctite 242 (blue) to all fasteners

5.1 Installing the main bracket

□ To provide more room to access the compressor and hoses, remove

the bottom 2 bolts of the brake fluid reservoir and allow it to hang

loose. Figure 5.1

Figure 5.1 – Main bracket support

□ Apply Loctite 242 (blue) to the supplied M16 bolt. Thread the bolt,

main bracket support and spacer into the threaded M16 hole to the

left of the exhaust manifold. Leave the bolt loose to aid in fitting it to

the main bracket. (Figure 5.2)

Remove

bolts

Remove

bolts

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Figure 5.2 – Main bracket support

□ Remove the idlers and tensioner from the main bracket.

□ Apply Loctite 242 (blue) to the x3 M8 x 120 bolts. Mount the main

bracket into position. The bolts will thread into the block where the

accessory mount studs were located. Torque bolts to specification.

(Figure 5.3)

Figure 5.3 – Installing the main bracket

□ Apply Loctite 242 (blue) to the x2 M8 x 25 bolts and thread them into

the bottom of the main bracket. Torque to specification. (Figure 5.4)

Figure 5.4 – Installing the main bracket

□ Torque the M16 bolt to specification. (Figure 5.4)

□ Re-install the idlers and tensioner onto the main bracket.

□ Torque idlers and tensioner to specifications.

Torque first

Torque last

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5.2 Installing the compressor

2 people may be required to locate the compressor onto the

main bracket.

□ Remove the inlet valve from the compressor and cover the opening to

prevent any contamination. Apply Loctite 242 (blue) to the x4 M8 x

110 bolts and mount the compressor to main bracket. Torque to

specification. (Figure 5.5)

Figure 5.5 – Mounting the compressor

□ Install the inlet on the compressor and torque to specification. (Figure

5.6)

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Vmac V910016 Installation guide

Vmac V910016 Installation guide

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