Vmac V900130 Installation guide

VR70 UNDERHOOD

AIR COMPRESSOR

INSTALLATION MANUAL

System V900130

2011-2016 FORD F250-F550 6.7L Diesel

VMAC – Vehicle Mounted Air Compressors

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1

VR70 UNDERHOOD AIR

COMPRESSOR INSTALLATION

MANUAL

System V900130

2011 - 2016 F250-F550

6.7L Power Stroke Diesel

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

Before You Start ............................................................................... 5

Torque Specifications ....................................................................... 5

Special Tools Required ..................................................................... 5

Important Safety Notice .................................................................... 6

Safety Messages .............................................................................. 6

Ordering Parts ................................................................................... 7

Warranty Registration ....................................................................... 7

Part 1: Warranty and System ID ........................................................ 8

System ID and Operating Instructions .............................................. 8

Part 2: Preparing for Installation ..................................................... 10

2.1 Preparing for Installation ........................................................... 10

Part 3: Installing the Tank ................................................................ 12

Part 4: Modifying the Lower Radiator Hoses, Installing the Cooler,

and Connecting the Oil Hoses ........................................................ 18

Modifying the Lower Radiator hoses ............................................... 18

Installing the Cooler ........................................................................ 20

Installing the Cooler Oil Hoses ........................................................ 22

Part 5: Installing the Crank Pulley .................................................. 23

Additional belt routing diagrams ...................................................... 24

Part 6: Installing the Main Bracket and Fan Stator ........................ 25

Installing the Main Bracket .............................................................. 25

Installing the Main Bracket on Dual Alternator ................................ 31

Modifying and Installing the Fan Stator ........................................... 35

Alternator wire relocation and Insulation ......................................... 36

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Part 7: Installing the Compressor, Inlet Valve and Pressure

Sensor and Control Line .................................................................. 37

Installing the Compressor ............................................................... 37

Installing the Pressure Sensor ........................................................ 38

Installing the Inlet Valve .................................................................. 39

Installing the Control Line ............................................................... 40

Part 8: Installing the Insulation and Compressor Hoses .............. 41

Installing the Insulation ................................................................... 41

Installing the Compressor Discharge Hose..................................... 44

Installing the PTFE® hoses ............................................................ 49

Installing the Compressor Oil Return Hose..................................... 50

Part 9: Installing the Compressor Belt, Fan, and Fan Shroud ..... 51

Installing the Compressor Belt ........................................................ 51

Installing the Fan ............................................................................ 52

Installing the Fan Shroud ................................................................ 53

Part 10: Modifying the Battery Box and Intercooler ...................... 57

Modifying and Installing the Battery Box ......................................... 57

Modifying the Charge Air Cooler ..................................................... 59

Installing the Charge Air Cooler ...................................................... 61

Part 11: Adding Oil to the System ................................................. 62

Part 12: Installing the Intercooler Hoses, and Compressor Air

Filter ................................................................................................... 63

Installing the Remote Air Filter Bracket .......................................... 63

Heater hose from CAC straight spigot ............................................ 64

Cold Side Charge-Air-Cooler (CAC) Piping .................................... 66

Hot Side Charge-Air-Cooler (CAC) Piping ...................................... 73

Charge-Air-Cooler Clamp Orientation ............................................. 75

Installing the Remote Filter Hose .................................................... 76

Heater hose from CAC 90deg Spigot ............................................. 77

Part 13: Modifying the Upper Radiator Hose and Connector ...... 81

Modifying the Upper Radiator Hose ................................................ 81

Modifying the Upper Radiator Connector ....................................... 86

Part 14: Installing the Battery Cable Bracket and Cables ........... 93

Installing the Battery Cable Bracket ................................................ 93

Routing the Battery Cables ............................................................. 97

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Part 15: Installing the Battery Box ............................................... 101

Alternative Battery Mounting Locations ........................................ 103

Part 16: Installing the Control Components ................................ 104

Installing the Components ............................................................ 105

Routing the In-cab wiring .............................................................. 105

Connecting the In-cab wiring ........................................................ 106

Part 17 Completing and Testing the Installation ......................... 108

Completing the Installation ............................................................ 108

Safety Test .................................................................................... 109

Part 18: Finishing the Installation ................................................. 110

18.1 Before Starting the Engine Checklist .................................... 110

18.2 After Starting the Engine Checklist ....................................... 110

18.3 Final Testing ......................................................................... 111

Part 19: Setup, Performance Testing and Adjustments ............ 112

Part 20: Optional Accessory Installation ..................................... 113

Part 21: Auxiliary Air Receiver ...................................................... 114

Part 22: Accessory Products ......................................................... 115

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VR70 UNDERHOOD AIR COMPRESSOR INSTALLATION MANUAL

SYSTEM V900130

2011 - 2016 Ford F250 - F550 6.7L Power Stroke Diesel

Document 1930229

Changes and Revisions

Version

Revision Details

Revised by/date

Checked by/date

Reviewed by/date

Implemented

A

Engineering Release

MC 7 Oct 2014

MP 30 Jan 2015

RD 30 Jan 2015

5 Feb 2015

B

ECN 15-008

RF 13 Mar 2015

PD 21 Apr 2015

RD 23 Apr 2015

27 Apr 2015

C

ECN 15-059

REF 26 October 2015

CJH 5 Nov 2015

JPC 5 Nov 2015

5 Nov 2015

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

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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 removal set (such as Lisle 43300) or a

manual fan pulley holder (such as KD3900)

 M6 x 1.0 Die

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

[email protected]

Fax

(250) 740-3202

Mail

VMAC - Vehicle Mounted Air Compressors

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

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Part 1: Warranty and System ID

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.

System ID and Operating Instructions

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 customer inquiries and ordering of parts.

□ Install battery warning label to driver side primary coolant

reservoir.

□ 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 (Figure 1.1).

Figure 1.1 – System Identification Tag

□ Clean cross member beside the number plate 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

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 – Service Label

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Part 2: Preparing for Installation

2.1 Preparing for Installation

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).

□ Locate the blunt-cut OEM SEIC wire harness, on the driver’s side

just below the OBDII port. You will need to find the transmission

park signal, (blue with grey 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 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.

There are multiple blue wires with various coloured

stripes. The transmission park signal needs to be

electrically verified with a multi-meter to ensure the

correct wire is read.

□ Mark transmission park signal wire for connection later in installing

control components section.

□ Disconnect batteries, (both driver and passenger side).

□ Drain coolant from both the primary and secondary radiators,

(drain for primary coolant on driver’s side, secondary coolant on

passenger side). Start with the secondary radiator, (drain on

passenger side). Save coolant to be reused later. Close drain

when coolant has been drained. The primary coolant drain is

easiest to access by removing the front bumper from the

vehicle.

□ Remove driver’s side battery bracket and battery. Save the J-

bolts and fasteners as they will be used again.

□ Remove driver’s side battery box and primary coolant reservoir.

□ Disconnect hoses from secondary coolant reservoir, (attached to

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

shroud.

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□ Remove air box for easier access to secondary coolant hoses.

This also allows access to the lower primary radiator hose for

removal.

□ Remove upper secondary coolant hose, (top hose going to water

pump on passenger side of engine).

□ 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.

□ Unplug fan wire (unplug connector closer to the engine).

Remove long bolt securing fan wiring harness to engine and

discard. A spacer and longer bolt will be installed in this location

later in the install.

□ 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 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.

□ Remove upper driver’s side fan stator mount from the engine and

save for use later.

□ Release tension on OEM belt (leave belt routed correctly on

passenger side of engine).

□ Remove cold air charger coolant tubing.

□ Remove cold air charger 3” air tubing.

□ Remove cold air charger and battery box.

□ Optional: Remove passenger and driver’s side fender liner.

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Part 3: Installing the Tank

The tank will mount on the passenger side frame rail

under the cab and must be level. Variations in frame

design may affect the positioning of the brackets.

Always check fitment before tightening the fasteners.

□ The tank will mount to the passenger side frame rail behind the

suspension radius arm mount (Figure 3.1).

Figure 3.1 – Tank Brackets

□ Remove one of the two OEM Nuts attaching the transmission

cross-member to the frame. Depending on the truck configuration

cross-member location may differ (Figure 3.2).

Figure 3.2 – OEM Cross Member Nut

Leave all tank mounts and fasteners loosened

throughout the following aligning process to make

adjustments easier.

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□ Install front mount bracket with 5/16-inch X 2 bolt holding the front

of the mount to the frame and re-use the OEM transmission cross-

member nut (Figure 3.1) (Figure 3.2).

□ Apply blue Loctite® and thread the top bolt into the rear tank

mount bracket. Ensure the tank clip is hooked over the backside

of the frame and no wires or tubes are pinched or trapped (Figure

3.3)

Figure 3.3 – Tank Brackets Exploded View

□ Install the tank clip so it hooks around the back of the frame.

Insert the threaded end through the appropriate hole in the bottom

of the rear tank strap. Apply blue Loctite® and start the 3/8 flange

nut on the tank clip (Figure 3.4).

Figure 3.4 – Tank Clips

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□ Install front and rear c-clamps onto the brackets using the top 5/16

x 1/2” bolt and washer only, tighten but do not torque as the

bracket will need to be adjusted later in the installation (Figure

3.5).

Figure 3.5 – Tank c-clamps

□ Slide the front of the tank through rear bracket first, then through

front bracket (Figure 3.6).

Figure 3.6 – Sliding Tank

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□ Align the weld on the front of the tank with the edge of the c-clamp

(Figure 3.7).

Figure 3.7 – Clamp and Weld Alignment

□ Rotate the tank so that the directional arrow on the end of the tank

is pointing upwards (Figure 3.9).

□ Install front pinch bolt downward through the top of the c-clamp,

install the serrated nut on the bottom (Figure 3.8).

Figure 3.8 – Front Pinch Bolt

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□ Install rear pinch bolt downward through the top of the c-clamp,

install the serrated nut on the bottom (Figure 3.9).

Figure 3.9 – Rear Pinch Bolt

Tank orientation is critical, if the arrow is not pointing

up you may get oil in the discharge air, or compressor

failure due to oil starvation (Figure 3.9).

□ Install front and rear lower C-clamp bolts loosely (Figure 3.10).

Figure 3.10 – Bottom c-clamp fasteners

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□ Install all fasteners as shown below (Figure 3.11).

Figure 3.11 – Tank Fastener Overview

5/16 Nut

& Washer

3/8 Nut

3/8x4.5

bolts

5/16 x 2 Bolt

& Washer

5/16 x 1/2 Bolt

& Washer

5/16 x 1/2

Bolt &

Washer

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Part 4: Modifying the Lower

Radiator Hoses, Installing the

Cooler, and Connecting the Oil

Hoses

Modifying the Lower Radiator hoses

Separate the coupler in between the lower coolant

hose, to drain any remaining coolant in the hose.

□ Remove lower primary coolant hose, attached to the primary

radiator and engine (Figure 4.1).

To

Engine

From

Radiator

Figure 4.1 – Lower Primary Radiator Hose

Disconnect

coupler first

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Vmac V900130 Installation guide

Vmac V900130 Installation guide

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