Vmac V300001 Installation guide

Installation Manual for VMAC

System V300001

2011 - 2015 Ford F250-F550 Pickup, Cab & Chassis

6.7L Power Stroke Diesel

www.vmacair.com

TM

COMPACT. POWERFUL.

VMAC – Vehicle Mounted Air Compressors 
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1 
Installation Manual for VMAC 
System V300001 
2011- 2015 Ford F250-F550 Pickup, Cab & Chassis 
6.7L Power Stroke Diesel 
General Information ............................................................................... 3 
Before You Start ................................................................................... 3 
Torque Specifications ........................................................................... 3 
Special Tools Required ........................................................................ 3 
Hose Information .................................................................................. 3 
Important Safety Notice ......................................................................... 4 
Safety Messages .................................................................................. 4 
Ordering Parts ...................................................................................... 5 
Warranty Registration .......................................................................... 5 
Part 1: System Identification, Warranty and Warnings ...................... 6 
Part 2: Preparing for Installation .......................................................... 8 
Part 3: Belt Idler Installation ............................................................... 10 
3.1 2012 - 2015 Trucks with Single Sided Belt ............................. 12 
3.2 2011 Trucks with Dual Sided Belt ........................................... 13 
Part 4: Installing the Compressor, Main Bracket, and Belt .............. 14 
4.1 Installing the Compressor and Main Bracket .......................... 14 
4.2 Belt Routing ............................................................................ 26 
4.3 Wire guide installation ............................................................. 27 
Part 5: Installing the WHASP Tank ..................................................... 31 
Part 6: Recommended Accessory Installation .................................. 36 
Part 7: Adding Oil to the System ........................................................ 37 
Part 8: Installing the Control Components ........................................ 38 
8.1  Installing the Control Box ....................................................... 39 
8.2 Connecting the Wiring............................................................. 40 
8.3 Installing the Relay Harness ................................................... 44 
8.4 Installing the Throttle Controller .............................................. 45 
Part 9: Completing the Installation ..................................................... 46 
9.1 Installing the Compressor Air Filter ......................................... 46 
9.2 Blowdown Muffler.................................................................... 49 
Part 10: Testing the Installation .......................................................... 50 
10.1 Final Testing ........................................................................... 52 
Part 11: Setup, Performance Testing and Adjustments ................... 53 
11.1 Throttle Control Adjustment .................................................... 54 
Part 12: Auxiliary Air Receiver ............................................................ 55 
Part 13: Accessory Products .............................................................. 56 
Part 14: Warranty Registration ........................................................... 57 
 
   

VMAC – Vehicle Mounted Air Compressors

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2

Installation Manual for VMAC System V300001

2011 - 2015 Ford F250-F550 Pickup, Cab & Chassis

6.7L Power Stroke Diesel

Document 1930247

Changes and Revisions

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 trucks

must follow standard shop practices.

Notice

Manuals are subject to change without notice.

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 or

endorsement by said companies.

Loctite, Klean N’ Prime, 242 and PST are registered trademarks of

Henkel AG & Company KGaA.

PTFE is a registered trademark of E. I. du Pont de Nemours and

Company or its affiliates.

Nylok is a registered trademark of Nylok Fastener Corporation.

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

Revision

Revision Details

Revised

by

Checked by

Implemented

Eng.

Tech.

Qual.

Mech.

Elec.

D

ECN 15-105

REF

KRM

N/A

JPC

N/A

10 Nov 2015

E

ECN 16-140– Park interlock update

MSP

N/A

AJH

GB

AGM

24 Nov. 2016

F

ECN 17-094 Improved safety testing

MSP

N/A

AJH

GB

SA

28 June 2017

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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® 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

M8

M10

M12

M14

M16

Foot-pounds (ft-lb)

19

41

69

104

174

Newton meter (N•m)

25

55

93

141

236

Special Tools Required

• Pneumatic fan wrench (Lisle 43300 or equivalent)

• 1/8” drill bit

• VMAC test tool

• Push-lock fitting insert tool (New Line FT1268 or LOT-116, or

equivalent), if building new hoses with push-lock fittings.

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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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 service.

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, 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 service or repair and

the possibility that improper 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. While 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.

This symbol is used to call your attention to additional

instructions or special emphasis on a specific procedure.

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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 1-800-738-8622 or online at www.vmacair.com

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 four ways warranty forms can be submitted to VMAC:

Online

http://vmacair.com/support/warranty/

Email

tech@vmacair.com

Fax

(250) 740-3202

Mail

VMAC - Vehicle Mounted Air Compressors

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

VMAC – Vehicle Mounted Air Compressors

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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, ensure that no components

are missing, 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:

http://vmacair.com/support/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

in parts and repairs.

□ Mark and drill two 7/64-inch holes in an appropriate location,

close to the compressor. Secure the plate with supplied self-

tapping screws (Figure 1.1).

Figure 1.1 – System Identification Plate

□ Install the VMAC belt routing diagram in a suitable location under

the hood.

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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

□ To alert any technicians that may service the vehicle, affix the

servicing caution/contact label 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

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Part 2: Preparing for Installation

□ Disconnect battery leads and cover terminals to prevent electrical

shorts.

□ Remove the bolt securing the air intake resonator to the fan shroud.

This screw is located under the coolant tube at the driver’s side end

of the resonator.

□ Disconnect the mass air flow sensor and remove the clip holding the

wire to the air box lid.

□ Remove the air filter box cover, air filter, and intake tube (from the

air filter outlet to the turbo inlet on the engine).

□ Cover the turbo inlet, and the air-box lid outlet to prevent entry of

contaminants into the engine.

□ Drain coolant from the secondary radiator, (drain on passenger

side). Save coolant to be reused later. Close drain when coolant has

been drained.

□ Disconnect hoses from secondary coolant reservoir, (attached to

passenger side of fan shroud), and remove reservoir from fan

shroud.

□ Remove bolt securing power steering reservoir to upper fan shroud.

DO NOT remove the hoses from the reservoir. Slide reservoir up

out of clip securing it to the upper fan shroud.

□ Remove 5 bolts (3 on driver’s side and 2 on passenger side) and

wire clips securing upper fan shroud and remove upper fan shroud

from truck.

□ Unhook the coolant hose from the Upper Fan Shroud.

□ Disconnect the fan clutch wire and remove the bolt securing the fan

stator arm to the engine. Save the bolt as it will be re-used later.

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□ Remove the fan (right-hand thread) and pull it out of the engine bay.

For ease of fan removal and installation, it is

recommended that a pneumatic fan wrench removal set

(such as Lisle 43300) or a manual fan pulley holder (such

as KD3900) is used.

□ Remove the four fan stator nuts, and remove the fan stator by

rotating it to clear the lower lip of the lower fan shroud. It is not

necessary to remove the lower fan shroud.

□ Slide a sheet of cardboard between the fan and the radiator to

protect the radiator from accidental damage and remove Fan.

□ Remove the OEM Front End Accessory Drive (FEAD) belt.

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Part 3: Belt Idler Installation

Dual alternator trucks will require conversion to single

alternator as the VMAC compressor mounts in the

secondary alternator location. Contact VMAC Technical

support at (888) 241-2289 or email [email protected] for

more information.

There are two different sets of instructions for installing the idlers

depending on truck year:

• section 3.1 for 2012 or newer.

• section 3.2 for 2011 trucks.

The Ford 6.7 is equipped with two belt idlers, the VMAC compressor

uses the OEM belt line, and is installed in the secondary alternator

location on the passenger side of the engine.

Ribbed idlers must be installed in the locations shown, and the idler on

the driver’s side of the engine must be removed and installed onto the

dual alternator idler post (Figure 3.1).

Figure 3.1 – Idler location

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Most trucks will come configured with the driver’s side idler positioned

for single alternator, for the installation of the compressor this idler must

be moved to the dual alternator position (Figure 3.2).

Figure 3.2 – Dual alternator idler post

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3.1 2012 - 2015 Trucks with Single Sided

Belt

□ Remove the two OEM smooth idlers from the engine (Figure 3.1).

□ Remove the OEM bolts from the smooth idlers.

□ Remove the bolts from the VMAC ribbed idlers.

□ Install the bolts from the OEM Ford idlers into the two supplied

VMAC ribbed idlers.

□ Install one ribbed idler on the passenger side of the engine in the

location which previously had a smooth idler (closest to the

secondary water pump) (Figure 3.1).

□ Install one ribbed idler on the dual alternator belt post (Figure 3.2)

(Figure 3.3) (Figure 3.4).

Figure 3.3 – Drivers side of engine

If you are having trouble determining the position of the

idlers, please see figure 3.4 on the following page.

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3.2 2011 Trucks with Dual Sided Belt

□ Remove the idler from the driver’s side of the engine (closest to the

alternator) (Figure 3.1).

□ Re-install the idler on the dual alternator belt post (Figure 3.1)

(Figure 3.2) (Figure 3.3) (Figure 3.4).

□ The VMAC supplied idlers are not required if the engine has ribbed

idlers already installed.

Figure 3.4 – Drivers side of engine

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Part 4: Installing the Compressor,

Main Bracket, and Belt

4.1 Installing the Compressor and Main

Bracket

□ Cut the tie wraps securing the OEM wiring bundle to the wiring tray,

and use a 10mm socket to remove the wiring tray. Keep the wiring

tray and bolt as they will be re-used later (Figure 4.1).

Figure 4.1 – OEM wiring tray

OEM

Wiring

Tray

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□ The Compressor discharge fitting will be oriented towards

compressor clutch, use a 3/4” wrench to hold the fitting and a 7/8”

wrench to ensure the locking nut is tight (Figure 4.2).

Figure 4.2 – Compressor discharge fitting

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□ Slide the discharge fitting through the hole in the compressor

bracket (Figure 4.3).

Figure 4.3 – Installing the main bracket

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□ Apply Blue Loctite® to the four supplied M8 flat head bolts. Install

the compressor on the main bracket (Figure 4.4).

Figure 4.4 – Installing compressor fasteners

M8 Flat head

bolts (4X) USE

LOCTITE®

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□ Remove the two secondary water pump bolts and the fan driver bolt.

Save the bolts as they will be re-used later (Figure 4.5).

Figure 4.5 – Passenger front of engine

□ Apply plastic loom or equivalent hose protection to the 1/2" x 25”,

3/4" x 215” discharge hoses, and the 3/8" x 240” oil return hose

(hose protection not supplied)

When routing hoses, ensure cap-plugs are installed so

that contaminants do not get in the system. Take care

when routing hoses, as a hose failure may damage the

compressor.

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Vmac V300001 Installation guide

Vmac V300001 Installation guide

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