Vmac V900092 Installation guide

Brand: Vmac

Model: V900092

Type: Installation guide

VMAC – Vehicle Mounted Air Compressors

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Fax: 1-250-740-3201

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

VMAC – Vehicle Mounted Air Compressors

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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

ECN 08-190

SL 22 July 2008

TG 23 Jul 2008

24 July 2008

ECN 09-066

SL 18 June 2009

PD 6 Aug 2009

6 Aug 2009

ECN 10-132

SAR 23 Nov 2010

NC 24 Nov 2010

26 Nov 2010

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

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.

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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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 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.

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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

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

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

Brand: Vmac

Model: V900092

Type: Installation guide

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Vmac V900092 Installation guide

Vmac V900092 Installation guide

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