VMAC – Vehicle Mounted Air Compressors
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Installation Manual for VMAC
System V900081
2007 - 2005 Ford F250-F550 Super Duty
Triton 6.8L V10
General Information..................................................................... 3
Before You Start ....................................................................... 3
Part 1: Warranty and System ID ................................................. 4
Part 2: Preparing for Installation ............................................... 7
2.1 Preparing for Installation .................................................... 7
Part 3: Installing the Tank .......................................................... 9
3.1 Installing the Lines and Brackets........................................ 9
3.2 Installing the Tank .............................................................. 11
Part 4: Installing the Cooler, Bracket and Compressor .......... 12
4.1 Installing the Oil Cooler ...................................................... 12
4.2 Installing the Main Bracket and Compressor ..................... 14
4.3 Installing Drive Belts and Components .............................. 15
4.4 Installing the Hoses ............................................................ 16
4.5 Installing Other Components .............................................. 17
4.6 Adding Oil to the System .................................................... 20
Part 5: Installing the Control Components .............................. 21
5.1 Installing the Components .................................................. 22
5.2 Connecting the In-cab Wiring ............................................. 23
5.3 Connecting the Underhood Wiring ..................................... 26
5.4 Completing and Testing the Installation ............................. 26
Part 6: Finishing the Installation ................................................ 28
6.1 Before Starting the Engine Checklist.................................. 28
6.2 After Starting the Engine Checklist .................................... 28
6.3 Setup, Performance Testing and Adjustments ................... 29
6.4 System Identification and Warnings ................................... 30
6.5 Auxiliary Air Receiver ......................................................... 31
Accessory Products from VMAC ............................................... 32
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Document #1930077
Installation Manual for VMAC System V900081
2007 - 2005 Ford F250-F550 Super Duty Triton 6.8L V10
Changes and Revisions
Version
Revision Details
Revised by/date
Approved
Implemented
00
Original manual
IB 02 Dec 2004
BC 08 Dec 2004
14 Dec 2004
A
Update to 2006
IB 15 Sep 2005
SC 20 Sep 2005
23 Sep 2005
B
ECN 07-145
IB 05 Nov 2007
SH 23 Nov 2007
26 Nov 2007
C
ECN 08-037
SL 20 Feb 2008
SH 22 Feb 2008
22 Feb 2008
D
ECN 12-156
SAR 13 Nov 2012
MH 16 Nov 2012
29 Nov 2012
E
ECN 13-013
SH 17 Jul 2013
SM 26 Aug 2013
5 Sep 2013
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 1-888-241-2289.
Copyright 2007
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
VMAC – Vehicle Mounted Air Compressors
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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
9/16
5/8
¾
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
¾
Foot-pounds (ft-lb)
40
60
90
180
320
Newton meter (N•m)
54
81
122
244
434
METRIC CLASS 10.9
Size
M8
M10
M12
M14
M16
Foot-pounds (ft-lb)
19
41
69
104
174
Newton meter (N•m)
25
55
93
141
236
Hose Information
Depending on other installed equipment, it might be
necessary to move the air/oil separation tank from its
intended location. The hoses used in VMAC
compressor systems have a specific inner liner that is
compatible with our compressor oil. Use of hoses other
than those supplied or recommended by VMAC may
cause compressor damage and may void your
warranty. Please contact VMAC for replacement hoses
and further information.
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Part 1: Warranty and System ID
□ Complete the warranty form. 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.
System Identification and Warnings
The System Identification Number Plate must be attached to the
vehicle at the time of installation (Figure 1.1). This plate provides
information that allows VMAC to assist in customer inquiries and the
ordering of parts.
□ Mark and drill two 7/64-inch holes in the top of the cross member
in front of the OEM air filter box. Secure the plate with supplied
self- tapping screws
□ Clean cross member beside the number plate and stick the
VMAC belt routing diagram to the cross member.
System ID number plate
Left Front
Figure 1.1
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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 (Figure 1.2).
Figure 1.2
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□ To alert any technicians that may service the vehicle, affix the
servicing caution/contact label in the engine compartment near
the hood latch where it will be visible. Thoroughly clean the
selected area before affixing the label (Figure 1.3)
Figure 1.3
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 1-888-241-2289.
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Part 2: Preparing for Installation
2.1 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.
□ Disconnect the battery.
□ Drain the coolant.
□ Disconnect the engine-to-air cleaner ducting from the air cleaner
box and remove the air cleaner box and both mount brackets.
Remove the rubber grommets from the bottom rear bracket.
□ Remove the power booster steel line from the retaining bracket
and carefully bend it towards the firewall (Figure 2.1).
Hydraulic brake booster Bend
Figure 2.1
□ Reposition the group of brake lines from in front of the master
cylinder to behind the sensor on the bottom of the master
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cylinder by carefully bending them out of the way. Move the
rubber vibration isolator to prevent the lines from touching.
□ Remove the upper radiator hose and disconnect the lower
radiator hose from the radiator but not the engine.
□ Remove the 1 inch coolant fill reservoir to engine hose from the
engine, disconnect the 5/16” hose and remove the coolant fill
bottle.
□ Remove the fan and the fan shroud together.
□ Remove the OEM ground connector from the front driver’s side
of the cylinder head and attach it under the alternator bracket so
that it touches bare metal.
□ Remove and discard the three M10/M8 studded bolts from the
driver’s side of the timing cover.
□ Remove the radiator hold-down brackets, raise the radiator just
enough to clear the locating pins and move it sideways so that it
sits above the mount brackets.
□ Remove the rubber protective flaps attached to the cross-
member under the radiator.
□ Protect the inside surface of the radiator with a piece of
cardboard.
□ Clean the front of the engine on the driver’s side.
□ Clean the center of the OEM crank pulley.
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Part 3: Installing the Tank
3.1 Installing the Lines and Brackets
The tank (Figure 3.1) will mount to the passenger side frame rail
behind the front cab mount.
1/4” and 3/16” tubes
3/4” hose fitting
1/2” hose fitting
C-clamp
Tank strap mount
Upper frame clip
Tank strap cable
Lower frame clip
Spacer
Oil filter
5/16” nuts and
washer
Figure 3.1
□ Place the tank on a work bench with the front (oil filter end) of the
tank to your left and remove the oil filter.
□ Remove the two 1/4 inch clamp bolts from the C-clamps. Expand
the clamps slightly and slide them over the front of the tank.
□ Position the front clamp approximately 11 inches from the filter
end of the tank and the rear clamp approximately 12 inches from
the front clamp.
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□ Place the two L-shaped tank strap mounts under the C-clamps
with the right-angle ends facing you and hanging over the edge
of the work bench. Apply Loctite and thread 5/16 x 1/2 inch bolts
with flat washers into the bottom hole on each bracket, but do
not tighten.
□ Install the 1/4 inch clamp bolts into the C-clamps so that the
heads of the bolts face toward you and install the nuts but do not
tighten. Rotate the tank so that the directional arrow on the end
of the tank is parallel to the work bench and faces toward you.
3/16” tube
1/4” tube
Figure 3.2
□ Apply Loctite and insert 5/16 x 1/2 inch bolts through the C-
clamp and thread them into the mount brackets, but do not
tighten.
□ Install a suitable 3/4 inch fitting (not supplied) in the back of the
tank.
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□ Check tank alignment then tighten the C-clamp bolts and the
5/16 inch mounting bolts.
□ Insert the cable straps through the tube of the upper frame clips.
□ Fit the cables onto the tank strap mounts behind the steel lines,
with the cables in the grooves of the mounts and the clips above
the right-angle end of the tank strap (Figure 3.1).
3.2 Installing the Tank
□ Support the tank and L-bracket assembly in place on the outside
of the frame between the cab mounts, with the short part of the
L-bracket over the top of the frame.
□ Pass the upper frame clip between the frame rail and the body
and clip it onto the top of the frame. Insert the threaded end of
each cable strap through the tubes on the lower frame locating
U-clips. Install spacers (if necessary for narrow frames), washers
and nuts; then tighten just enough to hold the tank in position.
□ Position the tank between the two cab mounts to provide
clearance for installing the lines and filter. Make sure that the
tank mounting system does not interfere with any transmission
components.
□ When the tank is correctly positioned, tighten the securing cable
retaining nuts until the cables pull tight and snug around the
frame. Do not over-tighten. Install a second 5/16 inch nut and
tighten it securely against the first to act as a locknut.
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Part 4: Installing the Cooler,
Bracket and Compressor
4.1 Installing the Oil Cooler
□ Apply Loctite, insert M10 bolts into the top of the two mount
brackets (Figure 4.1) and thread them into the holes in the top of
the cooler mounting bracket. Hand-tighten the bolts leaving
about a 1/4 inch gap between the bracket and the cooler so that
the brackets can be repositioned easily.
□ Position the brackets so that they are horizontal (parallel with the
top of the cooler) and point to the passenger side of the truck.
Lift the cooler into position on the inside of the cross-member
under the radiator (slide it toward the passenger side) fit the
brackets over the cross-member and pivot them down so that
they align with the holes in the bottom of the cooler mounting
bracket.
□ Insert M10 bolts through the bottom holes and thread them into
the mount bracket.
□ Adjust the cooler so that the passenger side bracket is against
the power steering cooler bracket and tighten the mounting bolts
(Figure 4.2).
□ Connect the OEM hose to the passenger side cooler spigot,
adjust for best fit and secure it with a hose clamp.
□ Loosen the clamp on the other cooler hose, attach it to the
radiator, adjust for best fit and secure it with clamps.
□ Place the radiator back on the mounts and install the securing
brackets.
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M10 x 90 mm bolts
with washers
Mount brackets
Cross-member
Cooler mount bracket
Figure 4.1
To engine
To radiator
Cross-member
1/2” hose to compressor 1/2” hose from tank
Figure 4.2
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4.2 Installing the Main Bracket and Compressor
Tensioner assembly
Back
idlers
Ribbed
idler
Support bracket
Engine timing cover
OEM belt
M16
M8x110
M10x35 M10x30
Figure 4.3
□ Remove the idlers and the tensioner assembly from the bracket
(Figure 4.3).
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□ Place the support bracket on the bottom of the driver’s side
cylinder head, apply Loctite and insert the M16 bolt through the
tube part of the bracket into the OEM hole in the cylinder head
and hand tighten.
□ Place the main bracket in position to locate the mounting points
on the engine, apply Loctite and install the M8 x 110 mm socket
heat bolts with washers where the OEM studs were removed,
just enough to hold it in position. Push the bracket against the
engine, check to make sure it fits properly, apply Loctite and
install the M10 x 35 mm hex head bolt with washer in the lower
mounting point.
□ Route the wiring harness from the valve cover behind the top
edge of the bracket so that it is not pinched between the bracket
and the engine when the bracket is tightened in position.
□ Check the fit of the bracket on the engine and support bracket to
make sure that everything aligns properly.
□ Apply Loctite, install the two M10 x 30 mm bolts with washers
through the base plate into the support bracket.
□ Torque the M8 socket head bolts, then M10 hex head bolt, then
the M16 bolt and finally the M10 x 30 bolts.
□ Place the compressor in position on the mounting bracket.
□ Apply Loctite, thread the three M8 double-serrated nuts onto the
compressor mounting studs and torque to specifications.
4.3 Installing Drive Belts and Components
□ Install the VR crankshaft pulley onto the OEM pulley. Apply
Loctite, install three M10 x 70 mm bolts with washers and torque
to specifications.
□ Install the tensioner assembly (including the locknut on the back
of the bracket) and idlers on the bracket and torque the fasteners
to specifications. Use Loctite on all fasteners.
□ Install the VR drive belt (Figure 4.4).
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Compressor
Crankshaft
Ribbed idler
Back idler
Back idler
Back idler
Tensioner
Figure 4.4
Make sure that all components are clear of any moving
parts, including the VR belt. Make sure that no
components are in contact with the compressor body.
4.4 Installing the Hoses
□ Route the 45 degree end of the 3/4 inch hose around the cab
mount and the straight end of the longest 1/2 inch hose over the
cab mount and thread them into the matching fittings on the tank
but do not tighten.
□ Insert the 1/4 and 3/16 inch tubes into the fittings on the back of
the tank and install high temperature loom around tubes. Route
the tubes along with other hoses over the cab mount
□ and outside the frame in to the engine compartment and across
the rear of the engine.
□ Route the 1/2 hose along the passenger side frame rail to the
underside of the radiator, clear of suspension pinch points.
□ Route the 3/4 inch hose from the VR tank to the compressor and
connect it to the matching fitting.
!
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□ Connect the shortest 1/2 inch hose between the compressor and
the driver’s side of the cooler (90 degree connection on the
cooler).
□ Route the 3/16 and 1/4 inch tubes up over the engine (clear of
the exhaust manifold) and connect them to the matching fittings
on the compressor air inlet control valve.
□ Tighten all hose connections at the tank, cooler and compressor.
Prevent the hoses from twisting during tightening. Bunch all
hoses together, secure them with tie-straps and protect them
where they might rub. Make sure that they are clear of hot
exhaust parts or moving parts, including the steering column.
Secure the hoses using 1-5/8 inch insulated P-clips as required.
□ Apply a light film of compressor oil to the filter gasket and install
the filter on the tank. Tighten the filter an additional 3/4-1 turn
after the gasket contacts the base.
4.5 Installing Other Components
□ Drain and remove the power steering reservoir. Disconnect all
the hoses from the reservoir.
□ Bend the top mounting tab of the OEM front air cleaner bracket
90 degrees (Figure 4.5).
Bend 90 degrees and bolt
to replacement bracket
Mount to hole in front
support near driver side
fender
Figure 4.5
□ Install the power steering reservoir bracket using one OEM bolt
and one M8 x 30 mm bolt (Figure 4.6).
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Radiator
Body air cleaner support
OEM bolts
OEM grommets
Air cleaner
mounting bracket
OEM hose to
brake booster
OEM hose to P/S pump
Supplied hose with hose barb
connect to OEM cooler hose
Modified
OEM bracket
P/S reservoir
bracket
3/8”x1”NC
with nut
3/8”x1”NC
with nut
M8x20
with nut
M8x30
OEM bolt
M6x30
P/S reservoir
M8x20 button-head
Figure 4.6
□ Insert the OEM grommets and install the air cleaner mounting
bracket using two OEM bolts and one M8 x 20 mm button-head
bolt (Figure 4.6).
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□ Install the modified OEM bracket to the power steering reservoir
bracket using one M8 x 20 mm bolt with nut and one 3/8 x 1 inch
NC bolt with nut through the body (Figure 4.6).
□ Install the power steering reservoir using one M6 x 30 mm bolt in
the bottom and one 3/8 x 1 inch bolt with nut in the top (Figure
4.6).
□ Cut about 5 inches from the end of the large power steering hose
and attach it to the power steering reservoir.
□ Connect the supplied 13 inch hose between the reservoir and
the power steering cooler line with the supplied barb fitting.
□ Route the hose from the master cylinder over the brake lines and
connect it to the reservoir.
□ Remove the 1 inch coolant reservoir hose from the reservoir and
install the supplied S-shaped hose with straight barb fitting,
pointing down (Figure 4.7).
Intake tube
VR compressor
Brake M/C
Coolant reservoir
Supplied hose with barb
Figure 4.7
□ Cut 3-3/4 inches from the bottle end and 5/8 inch from the end
marked “engine” on the OEM hose. Reverse the hose and
connect the “engine” end to the barb fitting.
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□ Install the coolant reservoir and attach the 1 inch hose to the
engine. Adjust for best fit and tighten the clamps. Attach the
remaining hose to the reservoir.
□ Remove the air intake tube from the front of the air cleaner box.
Measure 1 inch from the flared end off the tube, cut at this
location. Remove the locating lug and any cuttings from the
inside of the tube.
□ Insert the tube between the rubber bellows on the air intake duct
and the outlet of the air cleaner box. Install the box, connect the
components and tighten the clamps.
□ Install the supplied fan spacer on the water pump pulley, then
install the fan and shroud. Install upper radiator hose and any
other OEM components that were removed. Make sure that the
lower hose is in the OEM clip on the shroud.
□ Fill the cooling system with the recommended coolant.
4.6 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 to speed 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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