Vmac V900092 Installation guide

Type
Installation guide
VMAC Vehicle Mounted Air Compressors
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1
Installation Manual for VMAC
V900092
2008 Ford F250-F350 Triton 5.4 L 3-valve
(with 3 bolt crank pulley)
System V900102
2010 - 2008 Ford F250-F350 Triton 5.4 L 3-valve
(with center bolt crank pulley)
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 and Hoses....................................... 11
3.1 Assembling the Tank and Brackets .................................... 11
3.2 Installing the Tank .............................................................. 13
Part 4: Installing the Bracket, Compressor and Cooler .......... 14
4.1 Installing the Main Bracket and Compressor ..................... 14
4.2 Installing Drive Belts and Components .............................. 17
4.3 Completing the Installation ................................................. 18
4.4 Installing the Cooler ............................................................ 21
4.5 Installing the Hoses ............................................................ 22
4.6 Adding Oil to the System .................................................... 23
Part 5: Installing the Control Components .............................. 24
5.1 Installing the Components .................................................. 25
5.2 Connecting the In-cab Wiring ............................................. 25
5.3 Connecting the Underhood Wiring ..................................... 27
5.4 Completing and Testing the Installation ............................. 27
Part 6: Finishing the Installation ................................................ 29
6.1 Before Starting the Engine Checklist.................................. 29
6.2 After Starting the Engine Checklist .................................... 29
6.3 Setup, Performance Testing and Adjustments ................... 30
6.4 Auxiliary Air Receiver ......................................................... 31
Accessory Products from VMAC ............................................... 32
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Document #1930139
Installation Manual for VMAC Systems
V900092 Ford 2008 5.4L Triton F250-F550 (3 bolt crank pulley)
V900102 Ford 2008 - 2010 5.4L Triton F250-F550 (center bolt crank pulley)
Changes and Revisions
Version
Revision Details
Revised by/date
Approved
Implemented
D
ECN 08-190
SL 22 July 2008
TG 23 Jul 2008
24 July 2008
E
ECN 09-066
SL 18 June 2009
PD 6 Aug 2009
6 Aug 2009
F
ECN 10-132
SAR 23 Nov 2010
NC 24 Nov 2010
26 Nov 2010
G
ECN 12-156
SAR 13 Nov 2012
MH 16 Nov 2012
29 Nov 2012
H
ECN 13-013
SH 17 Jul 2013
SM 26 Aug 2013
26 Aug 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 that have had other changes without
additional modifications. If you have difficulty with the installation,
contact VMAC.
The VMAC 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 1-800-738-8622.
Copyright 2009
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 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
5/16
3/8
7/16
1/2
9/16
5/8
¾
Foot-pounds (ft-lb)
18
35
55
80
110
170
280
Newton meter (N•m)
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 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 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.
Apply battery warning label to driver side of primary cooling
reservoir.
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 1.1).
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Figure 1.1
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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 1.2)
Figure 1.2
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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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.
Remove the air box with coolant expansion bottle and the air
ducting.
Install the short end of the supplied double 90 degree hose onto the
engine spigot on the driver’s side front of engine facing forward, place
clamps on the hose and install a 1 inch nylon hose connector (Figure
2.1).
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Engine
Coolant
expansion
bottle
Nylon hose conectors
Figure 2.1
Separate the air box from the coolant expansion bottle by cutting
as shown in Figure 2.2.
Cut away all of the webbing on the coolant expansion bottle
mount (Figure 2.3).
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Figure 2.2
Remove material from these
support ribs to provide clearance
for the hood gas strut
Cut away all bottom rib sections
Cut away a triangular
section 1 inch from the
slot for the rubber grommet
1”
Figure 2.3
Remove the upper radiator hose.
Unclip the wire harness from the lower fan shroud and pull the
harness clear.
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Remove the upper and lower bolts locating the fan shroud and
remove the coolant overflow hose from the upper fan shroud.
Release the plastic locking tabs that hold the lower portion of the
fan shroud in place. Swing the lower section towards the radiator
on the hinges and tuck the extended clip behind the fixed lower
rim. Pull the shroud up past the fan
Remove the fan (right hand thread).
Remove the OEM ground connector to radio suppressor
attached to one of the studs by the thermostat housing, then
remove and discard the three OEM M10 bolts with the M8
studded ends from the driver’s side of the cylinder head.
Clean the front of the engine on the driver’s side.
Clean the center of the OEM crank pulley.
Cut the middle of the lower radiator hose just outside the plastic
joint and discard the plastic piece.
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Part 3: Installing the Tank and
Hoses
3.1 Assembling the Tank and Brackets
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.
Install the 1/4 inch clamp bolts into the C-clamps so that the
heads of the bolts face toward you, apply Loctite and install the
nuts. Leave the C-clamps loose enough so that they can be
repositioned on the tank.
Place the two tank mount brackets under the C-clamps with the
threaded hole ends facing you.
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Thread the four 5/16 x 1/2 inch bolts into the holes on each
bracket, but do not tighten.
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 fit before tightening the fasteners.
Place the tank in position on the frame about 1 inch back from
the floor support. Adjust the position of the clamps and brackets
for best fit and to ensure that the tank will be level when mounted
and to provide adequate clearance for hose connections and
filter installation.
Mark the position of the C-clamps on the tank and the position of
the brackets on the frame. Remove the tank assembly and place
it back on the workbench.
Rotate the tank so that the directional arrow on the end of the
tank is parallel to the work bench and faces toward you. The
arrow must point upward when the tank is installed.
Align the C-clamps with your marks and tighten the clamp bolts.
Remove the 5/16 x 1/2 inch bolts from the C-clamps, apply
Loctite and install the two bottom bolts with washers.
Apply Loctite and insert 5/16 x 1/2 inch bolts through the C-
clamps and thread them into the mount brackets. Adjust the C-
clamps so they are at the same position on both mount brackets
and tighten the mounting bolts.
Install a 3/4 inch fitting (not supplied) in the back of the tank.
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Figure 3.2
3.2 Installing the Tank
The front of the tank should be approximately 13-1/2
inches from the middle of the front cab mount bolt
(standard cab) so that the hoses will reach.
Install the lock washer on the top tank bolt.
Insert top bolt through the tank clip, apply loctite and start in the
top threaded hole of the tank mount bracket. Only thread top
bolt in 2 turns.
Lift the tank and bracket into position and hook the top bolts over
the frame as the tank is lifted. Ensure no wires or tubes are
trapped between top bolt and frame. Ensure the tank clips are
hooked over the back side of the frame (see Figure 2.2).
Install the J-bolt so it hooks around the back of the frame. Insert
threaded end through hole in the tank mount bracket that is
closest to the frame. Apply loctite and start the flange nut on the
J-bolt.
If necessary, reposition the tank on the frame to provide
adequate clearance for hose connections and filter installation.
When the tank is correctly positioned, tighten the top bolt and
flange nut. Do not over-tighten.
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Part 4: Installing the Bracket,
Compressor and Cooler
4.1 Installing the Main Bracket and Compressor
Figure 4.1
Remove the idlers and the tensioner assembly from the bracket
(Figure 4.1).
Place the support bracket on the bottom of the driver’s side
cylinder head, insert the M16 bolt through the tube part of the
bracket into the OEM hole in the cylinder head and hand tighten
(Figure 4.2).
Place the main bracket in position and bend the brake lines on
the ABS module as necessary to provide clearance.
Place the main bracket in position to locate the mounting points
on the engine. Install and hand tighten the three M8 and one
M10 bolts in the front plate (Figure 4.2).
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M10
M8
M16
M10
Support Bracket
Main Bracket
Figure 4.2
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.
Install and hand tighten the two M10 compressor pad to support
bracket bolts.
Check the fit between the support bracket and the main bracket,
make sure everything aligns properly, then torque the M16 bolt,
then the M8 bolts and finally the M10 bolts, in that order.
If you do not tighten the fasteners in the right order, the
mounting pad will be pulled out of alignment with the
front plate.
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Install short end of the supplied 90 degree hose onto the coolant
expansion bottle quick-connect fitting onto the bottle (Figure 1.1)
and position it so that it faces the front of the truck, between the
A/C and the battery box. Install hose clamps and a 1 inch nylon
hose connector.
Connect the supplied 1 inch hose to one of the nylon connectors.
Route the hose forward and down to the lower radiator cross
member, under the cross member and over the two lugs on the
front of the cross-member (Figure 4.3).
Cooler
Cross-member lugs
Figure 4.3
Connect the other end of the supplied 1 inch hose to the
connector. Make sure that the hose is clear of all engine and
steering parts and secure it in place as required using nylon ties.
Place the compressor in position on the mounting bracket.
Thread the three M8 double-serrated nuts onto the compressor
mounting studs and torque to specifications.
Install Upper Rad Hose Bracket on top of compressor as shown
using existing two bolts. Add P-Clamp and M6 fasteners. (See
Figure 4.4).
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M6 BOLT
M6 NYLOCK
P-CLAMP
UPPER RAD HOSE BRACKET
OEM BOLTS
SHOWN FOR REFERENCE
Figure 4.4
4.2 Installing Drive Belts and Components
System V900092 The OEM pulley has three bolt holes. Install
the VR crankshaft pulley onto the OEM pulley using three M10 x
70 mm bolts with washers and torque to specifications (Figure
4.4).
System V900102 The OEM pulley has a single center bolt.
Remove the OEM bolt and install the VR crankshaft pulley using
the supplied bolt with the OEM washer (Figure 4.5). Lightly oil
the bolt threads before installing and only install the bolt finger
tight. Rotate the pulley counter-clockwise until it locks against the
OEM pulley, then torque to 102 ft-lbs (138 N.m.).
V900092 V900102
Figure 4.5
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Install the tensioner assembly and idlers on the bracket and
torque the fasteners to specifications.
Install the VR drive belt (Figure 4.6). Make sure that it is aligned
correctly and clears all components, including the cam position
sensor wire harness.
Place the supplied fan spacer on the water pump pulley.
Compressor
Crankshaft
Back idler
Back idler
Back idler
Tensioner
Figure 4.6
4.3 Completing the Installation
Remove the wire harness securing clip on the passenger side of
the engine just behind the battery box and ground mount point
(Figure 4.7).
Bend the air conditioning line at the U-shaped pipe so that the
end closest to the front of the truck is about 1-1/2 inches lower.
Route the wiring harness down beside the air conditioning line
and move the connectors at the firewall back to provide
clearance for the coolant expansion bottle.
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Bend this A/C line down to
provide clearance
Attach the end of the
support bracket here
Move this harness out of the way Attach the bottle here with the
OEM fastener through the OEM
hole
Figure 4.7
Install the threaded U-clip into the rear of the battery box and
Install the support bracket with the bent section upward.
Place the coolant expansion tank in position on the support
bracket so that the OEM mounting hole lines up with the hole on
the fender that retained the wire harness.
Mark the position of the support bracket hole on the plastic base
at the backside of the tank and drill a 1/8 inch hole at that spot.
Mount the tank using the OEM mounting bolt in the fender hole
and the supplied self-tapping screw in the drilled hole.
Install the plastic 1 inch hose barb connector into the engine end
of the cut expansion tank fill hose, install a hose clamp and
tighten.
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Connect one end of the supplied 1 inch heater hose to the plastic
hose barb connector.
Route the hose around the back of the engine compartment and
along the passenger side of the engine to the oil fill cap so that it
gradually slopes upward from the driver’s side to prevent airlocks
when filling the cooling system.
Install the OEM quick-connect into the expansion tank and
connect the 1 inch heater hose. Rotate it so that it points to the
rear of the engine (for engine torque clearance) and tighten all
the clamps.
Install all other OEM components.
After the fan shroud is installed, the power steering reservoir is
slotted into the fan shroud and secured in place with two OEM
6mm bolts.
To prevent the power steering hose from rubbing on the fan
belts, remove the bolt securing the ABS module through the ABS
mounting bracket grommet. Install the supplied short flat bracket
to the ABS mounting bracket using the larger hole and secure
with the OEM mounting bolt.
Place the supplied rubber covered strap clip around the power
steering hose and fasten the clip to the bracket using the
supplied 1/4 inch bolt and nut.
Angle the bracket to give suitable clearance for the hose from
the belt then tighten the ABS bolt and 1/4 inch bolt and nut.
Modify upper rad hose & install with hose clamps as shown in
Figure 4.8.
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Vmac V900092 Installation guide

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Installation guide

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