Vmac DM00001 Installation guide

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

1

Installation Manual for VMAC

System DM00001

2011 - 2016 Ford SuperDuty

6.7L Diesel with PTO

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

1

Installation Manual for VMAC System DM00001

2011 - 2016 Ford SuperDuty

6.7 L Diesel with PTO

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

Limited Lifetime Warranty .............................................................. 5

Warranty Registration .................................................................... 5

Part 1: System Identification, Warranty and Warnings ............................................... 6

Part 2: Preparing for Installation .................................................................................... 8

2.1 Cab Clearance ......................................................................... 10

Part 3: Installing the Cooler, PTO, Compressor, and Regulator ................................ 12

3.1 Modifying the coolant hoses .................................................... 12

3.2 Installing the cooler .................................................................. 14

3.3 Installing the PTO .................................................................... 16

3.4 Installing the Compressor ........................................................ 17

3.5 Installing the Regulator ............................................................ 19

3.6 Installing the Air Intake ............................................................ 20

Part 4: Installing the Tank and Hoses ............................................................................ 23

4.1 Installing the Tank and Brackets ............................................. 23

4.2 Installing the Hoses ................................................................. 28

4.3 Adding Oil to the System ......................................................... 31

Part 5: Installing the Control Components ................................................................... 32

5.1 Wiring diagrams ....................................................................... 32

5.2 Installing the Components ....................................................... 34

5.3 Routing the In-cab Wiring ........................................................ 36

5.4 Connecting the In-cab Wiring .................................................. 37

5.5 Engine Bay PTO / Compressor Connections .......................... 39

Part 6: Completing and Testing the Installation ........................................................... 40

6.1 Finishing the installation .......................................................... 40

6.2 Safety Test .............................................................................. 40

6.3 Before Starting the Engine Checklist ....................................... 41

6.4 After Starting the Engine Checklist .......................................... 41

Part 7: Setup, Performance Testing and Adjustments ................................................ 42

7.1 Final Testing ............................................................................ 43

Part 8: Optional Accessory Installation ......................................................................... 44

Part 9: Air Receiver Tank................................................................................................. 45

Part 10: Accessory Products .......................................................................................... 46

Part 11: Warranty Registration ....................................................................................... 47

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Installation Manual for VMAC System DM00001

2011 - 2016 Ford SuperDuty

6.7 L Diesel with PTO

Document: 1930284

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®, Loctite® Klean N’ Prime™, Loctite® 242 and Loctite PST® are

registered trademarks of Henkel AG & Company KGaA.

Nylok® is a registered trademark of Nylok Fastener Corporation.

Ford® is registered trademarks of Ford Motor Company.

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.

B

ECN 16-029 PTO adaptor plate upgrade

MSP

KRM

AJH

GB

AMG

10 May 2016

C

ECN 18-125 Add prp wire to Fig 5.3

MSP

N/A

SM

GB

AWG

14 June 2018

D

ECN: 20-201 PTO mount update

MSP

CAM MSP

N/A N/A 21 Oct. 2020

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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-pound (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-pound (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-pound (ft-lb)

4.5

19

41

69

104

174

Newton meter (N•m)

6

25

55

93

141

236

Special Tools Required

• Required: VMAC DM70 Ford Cab Clearancing tool (5900272).

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 non-standard length hoses, replacement hoses

or for 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 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, be alert!

Your personal safety is involved”. Read the message that follows

and be alert to the possibility of personal injury or death. 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

Limited Lifetime Warranty

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.

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

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

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

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

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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 to ensure that 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

technical 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/warranty/

This warranty form must be completed and returned 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 2 7/64 in 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 Plate

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□ As part of the installation process, ensure that the operating

instruction label 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 Instruction Label

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

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 – Warning 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 operating instruction label. (Please see Part 1 for

details).

Due to variations in service body design and other

equipment, VMAC cannot recommend mounting locations

for the remote air filter housing. You will need to determine

this location and order sufficient ducting to route from the

remote air filter housing to the compressor air inlet. Include

enough additional ducting to allow for appropriate routing

away from hot, sharp or moving parts. (Figure 2.1)

Figure 2.1 – Determine Remote Air Filter location

□ Determine your remote air filter duct length:

• For optimum performance, the duct length should be minimized.

• The kit includes 8 ft. of hose, which can be cut to length.

• Longer hose may be purchased from VMAC, or a hose supplier.

▪ VMAC P/N: 1700650

▪ New Line P/N: NL6025-200

□ Locate the blunt-cut OEM SEIC wire harness, on the driver 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), to supply power to the

dash display. The resistance should read close to 0 Ω in park and

Approximate location

of compressor inlet

Possible remote

air filter location.

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open circuit in all other gears. If this is correct, put the car 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 used.

□ Mark the transmission park signal wire for connection later in “Part 5

Installing the Control Components”.

□ Disconnect both the driver and passenger side batteries.

□ Drain coolant from the primary radiator into a clean container for re-

use later. The drain can be found on the driver side of the radiator.

Close the drain spigot once the coolant has been drained.

□ Remove the tab on the shift linkage bracket beside the PTO port to

provide clearance to install the PTO and compressor. (Figure 2.2)

Figure 2.2 – Modify shift linkage

Cut off tab

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2.1 Cab Clearance

It is extremely important to ensure that no foreign particles

or debris can enter the PTO port on the transmission.

□ Apply the park brake and chock the rear wheels.

□ Remove the 6 bolts retaining the cover on the PTO port. A small

amount of transmission fluid may drip from the cover and seal plates.

Retain the seal plate.

□ Using the seal plate from the transmission cover to protect the

transmission port, install the clearancing tool onto the PTO port using

the 6 supplied bolts. Make sure the clearancing ram is installed in the

bracket before install. (Figure 2.3)

Figure 2.3 – Modifying the cab clearance

□ Using a jack or porta-power unit, raise the clearancing ram until the

cab stops moving. On an empty chassis cab, this is approximately 1

in. (Figure 2.4)

Figure 2.4 – Modifying the floor clearance

Install using the 6

supplied M10 bolts

Ram

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□ Mark the current position for reference. (Figure 2.5)

Figure 2.5 – Modifying the floor clearance

□ Continue to raise the clearancing ram 2 notches (approx. 1/2 in) on

the side of the bracket as shown. (Figure 2.6.)

Figure 2.6 – Modifying the floor clearance

□ Lower the clearancing ram slowly.

□ Remove the clearancing tool from the PTO port and cover the port

until ready to proceed with the PTO installation.

Mark a line from

the bottom step

1/2 in

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Part 3: Installing the Cooler, PTO,

Compressor, and Regulator

3.1 Modifying the coolant hoses

□ Remove the lower primary coolant hose that is attached to the primary

cooler and engine. (Figure 3.1)

Figure 3.1 – Modifying the lower radiator hose

□ Cut the plastic cuff securing the OEM quick connect to the engine side

coolant hose. Discard the OEM quick connect. (Figure 3.2)

Figure 3.2 – Modifying the lower radiator hose

From radiator

To engine

OEM quick

connect

Cut cuff

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□ Cut the radiator side coolant hose 8 in from the OEM quick connect

and discard the short section of hose with the OEM quick connect.

(Figure 3.3)

Figure 3.3 – Modifying the lower radiator hose

8 in

Discard this section

OEM quick

connect

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3.2 Installing the cooler

□ Apply the supplied loom to the 1/2 in oil hoses.

□ Connect the shortest 1/2 in hose to the passenger side of the cooler

and orient as shown. Leave the fitting hand tight until ready for final

alignment once the Air Oil Separator Tank (AOST) is in place. (Figure

3.4).

Figure 3.4 – Attaching the cooler hoses

□ Connect the longest 1/2 in hose to the driver side of the cooler and

orient as shown. Leave the fitting hand tight until ready for final

alignment once the AOST is in place. (Figure 3.4)

Do not strike the impact sensor as this could cause the

airbags to actuate.

□ Position the cooler in the center of the cross-member so that it is just

above the sway bar with the oil ports facing up. (Figure 3.5)

Figure 3.5 – Mounting the oil cooler

!

Impact

sensor

Fog light

connector

location

Cross member

Short 1/2 in hose

long 1/2 in hose

Apply Loctite

to the 4 bolts

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□ Apply Loctite to the 4 bolts and install them, along with the washers,

through the flat mounting straps on the front of the cross member on

each side of the impact sensor. (Figure 3.5)

□ Thread the bolts into the matching holes on the cooler mounts hand

tight only, this will allow the cooler to be repositioned if necessary

after the coolant hoses have been attached. (Figure 3.5)

□ Install the radiator side coolant hose and secure with supplied hose

clamp. (Figure 3.6)

Figure 3.6 – Attaching the cooler hoses

□ Once the radiator side coolant hose is secured, torque the cooler

mount bolts to specification.

□ Install the engine side coolant hose and secure using the supplied

hose clamp. (Figure 3.6)

If any kinking of the hose occurs, trim the cooler end of the

coolant hoses as required.

□ Torque the cooler mounting bolts to specification.

To radiator

To engine

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3.3 Installing the PTO

It is extremely important to ensure that no foreign particles

or debris can enter the PTO port on the transmission.

□ Raise the front of the vehicle and support the axle on axle stands (or

appropriate blocking).

Ensure the truck is fully supported on axle stands before

working under it.

On 4x4 vehicles, mark the front drive shaft with a grease pen

(or similar permanent marker) for re-alignment later. Unbolt

the front of the drive shaft and pivot it out of the way to allow

room to install the compressor.

□ Follow the mechanical portion of the OEM PTO installation

instructions.

The PTO electrical installation will be covered in “Part 5

Control Components” and differs from the OEM PTO

instructions.

□ Slide the washers onto the 3 supplied bolts and apply Loctite to the

threads.

□ Using 2 of the bolts in the locations shown, mount the adaptor plate to

the PTO; ensure the adaptor plate is snug but do not torque the bolts

(Figure 3.7).

Figure 3.7 – Mounting the PTO Adaptor Plate

□ Install the remaining bolt and washer.

□ Using a torque wrench, torque the 3 bolts to 40 ft. lb.

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3.4 Installing the Compressor

□ Temporarily install the (×2) supplied guide pins into the top (longer

pin) and lower left (shorter pin) threaded holes in the adapter plate

(Figure 3.8).

Figure 3.8 – Install alignment guides

□ To assist with mating the compressor and the PTO, align a groove in

the PTO spline shaft with a tooth on the compressor’s input shaft. The

top mounting hole for the compressor can be used as a reference.

□ Apply a generous amount of spline grease (supplied with the PTO) to

both splines. Ensure the grooves of each are fully filled.

Thread guide

pins until they

are flush with

back face of

adaptor plate

Thread guide

pins until they

are flush with

back face of

adaptor plate

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□ Slide the compressor forward onto the guide pins, and push forward

until the compressor is fully mated with the PTO adaptor (Figure 3.9).

Figure 3.9 – Install alignment guides

□ Apply blue Loctite and install 1 of the 3 supplied bolts with flat washer

into the available threaded hole (Figure 3.10).

Figure 3.10 – Securing the compressor

□ Apply Loctite to the remaining 2 compressor mount bolts.

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Vmac DM00001 Installation guide

Vmac DM00001 Installation guide

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