Vmac V900081 Installation guide

Brand: Vmac

Model: V900081

Type: Installation guide

Vmac V900081 Features Vmac V900081 is a vehicle mounted air compressor system designed for Ford F250-F550 Super Duty Triton 6.8L V10 trucks manufactured between 2005 and 2007. Compressor: The VMAC V900081 features a high-performance compressor that is driven by the vehicle's engine. The compressor is designed to deliver a high volume of compressed air, making it suitable for a wide range of applications, including:

Powering air tools
Inflating tires
Operating pneumatic devices

Air Tank: The system includes an air tank that stores compressed air, providing a reserve of air for use when needed. The air tank is equipped with a pressure gauge and a safety valve to ensure safe operation.

Powering air tools
Inflating tires
Operating pneumatic devices

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

VMAC – Vehicle Mounted Air Compressors

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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

Original manual

IB 02 Dec 2004

BC 08 Dec 2004

14 Dec 2004

Update to 2006

IB 15 Sep 2005

SC 20 Sep 2005

23 Sep 2005

ECN 07-145

IB 05 Nov 2007

SH 23 Nov 2007

26 Nov 2007

ECN 08-037

SL 20 Feb 2008

SH 22 Feb 2008

22 Feb 2008

ECN 12-156

SAR 13 Nov 2012

MH 16 Nov 2012

29 Nov 2012

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.

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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Fax: 1-250-740-3201

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

Foot-pounds (ft-lb)

110

170

280

Newton meter (N•m)

108

149

230

379

STANDARD GRADE 8 NATIONAL FINE THREAD

Size

3/8

7/16

1/2

5/8

Foot-pounds (ft-lb)

180

320

Newton meter (N•m)

122

244

434

METRIC CLASS 10.9

Size

M10

M12

M14

M16

Foot-pounds (ft-lb)

104

174

Newton meter (N•m)

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.

VMAC – Vehicle Mounted Air Compressors

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Fax: 1-250-740-3201

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

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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Vmac V900081 Installation guide

Brand: Vmac

Model: V900081

Type: Installation guide

Powering air tools
Inflating tires
Operating pneumatic devices

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Vmac V900081 Installation guide

Vmac V900081 Installation guide

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