Vmac V900101 Installation guide

VMAC – Vehicle Mounted Air Compressors

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Fax: 1-250-740-3201

1

Installation Manual for VMAC

System V900101

2010-2008 Ford F250-F550 Superduty

6.8L Triton V10

General Information..................................................................... 4

Before You Start ....................................................................... 4

Additional Requirements .......................................................... 4

Part 1: Warranty and System ID ................................................. 6

Part 2: Preparing for Installation ............................................... 9

Part 3: Installing the Cooler, Bracket and Compressor .......... 12

3.1 Installing the Oil Cooler ...................................................... 12

3.2 Installing the Main Bracket and Compressor ..................... 14

Part 4: Installing the Tank and Hoses....................................... 22

4.1 Assembling the Tank and Brackets .................................... 22

4.2 Installing the Tank .............................................................. 24

4.3 Installing the Hoses ............................................................ 25

4.4 Adding Oil to the System .................................................... 26

Part 5: Installing the Control Components .............................. 27

5.1 Installing the Components .................................................. 28

5.2 Connecting the In-cab Wiring ............................................. 28

5.3 Connecting the Underhood Wiring ..................................... 30

5.4 Completing and Testing the Installation ............................. 30

Part 6: Finishing the Installation ................................................ 32

6.1 Before Starting the Engine Checklist.................................. 32

6.2 After Starting the Engine Checklist .................................... 32

6.3 Setup, Performance Testing and Adjustments ................... 33

6.5 Auxiliary Air Receiver ......................................................... 34

Accessory Products from VMAC ............................................... 35

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!

Document #1930158

Installation Manual for VMAC System V900101

2010-2008 Ford F250-F550 Superduty 6.8L Triton V10

Changes and Revisions

Version

Revision Details

Revised by/date

Approved

Implemented

D

ECN 09-109

SL 22 Oct 2009

TG 27 Oct 2009

2 Nov 2009

E

ECN 09-103

SL 17 Nov 2009

TG 17 Nov 2009

19 Nov 2009

F

ECN 11-124

SAR 28 Oct 2011

PID 31 Oct 2011

31 Oct 2011

G

ECN 12-156

SAR 15 Nov 2012

MH 16 Nov 2012

30 Nov 2012

H

ECN 13-013

SH 23 Jul 2013

SM 13 Sep 2013

17 Sep 2013

Important Information

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 additional

instructions or special emphasis on a specific procedure.

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 under hood mechanical work. Any

grinding, bending or restructuring operations for correct fit in modified

trucks must follow standard shop practices.

All hoses, tubes, and wires that are rerouted or shifted

during installation must be secure so that they do not

contact excessively hot areas or sharp edges. Where

possible, use rubber coated P-clips. Follow the routing

suggestions in this manual and cover all hoses with the

supplied plastic loom.

!

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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 which have had other changes without

additional modifications. If you have difficulty with the installation,

contact VMAC.

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.

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.

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

1/4

5/16

3/8

7/16

1/2

9/16

5/8

¾

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

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

Additional Requirements

Special Tools

Pneumatic fan wrench removal set (such as Lisle 43300) or a

manual fan pulley holder (such as KD3900)

VMAC A/C bending tool (5900245)

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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.

□ Affix the VMAC belt routing diagram to an appropriate place near

the OEM belt diagram.

□ Apply battery warning label to driver side of primary cooling

reservoir.

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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 1.1).

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 in a visible location. 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

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 Operational Instruction Decal. (Please see Part

1 for details).

□ Drain the coolant.

□ Remove the passenger side inner fender liner.

□ Disconnect and remove the battery and battery box.

□ Remove the windshield washer fluid bottle from the battery box

by drilling or cutting the plastic rivets.

□ Disconnect and remove the air intake ducting from the top of the

engine.

□ Separate the lower radiator hose at the center connector. Care

should be taken as some coolant may still remain in the hose.

Remove the diverter and quick connect fitting by cutting the hose

just behind the locking rings. Remove the locking rings and small

ends of hose remaining on the diverter. Leave the two small oil

cooler lines attached to the diverter. For more detail see (Figure

3.2).

□ Remove the power steering reservoir from the driver’s side of the

fan shroud and move it out of the way. Also remove the vacuum

pump and reservoir (if equipped) from the passenger side of the

fan shroud.

□ 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.

□ Loosen the fan (RH thread). Unbolt the fan shroud and remove

the fan and shroud together. Removing the upper radiator hose

may make it easier to get the shroud out.

□ Remove the radio interference suppressor from its mounting

location on the front of the passenger side cylinder head.

Remove one of the bolts from the alternator upper brace and

mount the suppressor under the bolt (Figure 2.1).

□ Remove the two studs from the front of the passenger side

cylinder head (Figure 2.1).

Removing the OEM drive belt will make installation of

the main bracket easier, but it can be installed with the

belt in place.

Remove these studs

Mount suppressor here

Figure 2.1

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□ Clean the front of the engine on the passenger’s side.

□ Clean the center of the OEM crank pulley.

□ Remove heater hose from engine spigot and move out of the

way (Figure 3.11).

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Part 3: Installing the Cooler,

Bracket and Compressor

3.1 Installing the Oil Cooler

□ Remove all the clips holding the lower radiator hose to the cross-

member.

□ Push the lower radiator hose rearward and position the cooler in

the center of the cross-member so that it is just above the sway

bar.

□ Install bolts through the flat mounting straps (Figure 3.1) and

place them on the front of the cross-member on each side of the

impact sensor.

Do not strike the impact sensor as this could cause the

airbags to actuate.

□ Apply Loctite (medium), to the bolts and thread them into the

matching holes on the cooler mounts and tighten them securely.

Figure 3.1

!

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□ Cut the coolant hose connected to the engine about 2” down

from the inside of the bend. Connect the diverter to this hose and

connect the quick connect to the cooler using the supplied elbow

and secure them with hose clamps (Figure 3.2).

□ Ensure the two oil cooler lines are secured away from rubbing

the power steering pump pulley or any other components on the

OEM accessory belt line.

Before Modification

After Modification

Diverter

Hose

Clamps

Figure 3.2

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□ Reinstall the OEM hose loom over lower radiator hose.

3.2 Installing the Main Bracket and Compressor

□ Remove the belt idler pulleys and belt tensioner from the main

bracket.

Bend this

AC line out

to provide

clearance for

the bracket

Figure 3.3

□ Gently bend the air conditioning line beside the passenger side

head out about 1” to provide adequate clearance for the main

bracket (Figure 3.3).

□ Move the cam position sensor wire to the top of the valve cover

and the alternator wiring harness from the front of the valve

cover to behind the oil fill spigot (Figure 3.4).

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Figure 3.4

□ Fit the bracket in place on the front of the passenger side head

by tilting and lowering it down over the oil fill tube into position.

Ensure that it clears all wires and other OEM components. After

applying Loctite (medium), insert the four bolts and thread them

in a few turns to hold the bracket in position (Figure 3.5).

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Compressor

Mount Bolts

100mm Bracket

Mount Bolts

55mm Bracket

Mount Bolt

45mm Bracket

Mount Bolt

30mm Washers

M10 Bolts

Figure 3.5

□ Check to make sure that no wires or OEM objects are pinched

between the bracket and the engine.

Make sure that you route the wire harness on the front

of the passenger side head to avoid pulling the wiring

tight when the bracket is installed. Make sure that the

harness has some slack when the bracket is against the

head.

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□ Torque the bracket mounting bolts to specifications.

□ If previously removed, install the OEM belt.

□ Clean the face of the OEM pulley, place the VR pulley in

position, align the bolt holes and ensure that the pulley is sitting

flush.

□ Apply Loctite (medium), install three M10 x 75 mm bolts and flat

washers and torque to specification.

□ Apply Loctite (medium), install the VR tensioner and pulleys

(Figure 3.5).

□ Remove the inlet valve from the compressor and immediately

cover the opening to prevent debris from entering the

compressor.

□ Install the compressor on the bracket and thread in the three

mounting bolts and torque to specifications.

□ Re-install the compressor inlet valve.

If the bolts used to attach the inlet valve to the air end

are installed incorrectly major damage to the air end can

occur.

It must be noted that most systems use two different

length bolts in the inlet valves. The longer bolts go in

the two holes closest to the air filter and the two shorter

bolts go in the holes furthest away from the air filter

(figure 3.6).

Figure 3.6

!

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Never use an impact wrench to install inlet bolts.

The torque spec for inlet bolts is 19 ft lbs.

□ Install the VR compressor belt (Figure 3.7).

On the belt installation the bottom idler and tensioner

must be done last otherwise it may be impossible to get

the belt on.

Figure 3.7

Move Wire

Harness Here

Secure with

Zip Ties

Figure 3.8

!

Install belt here last

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□ Move the wire loom from the top of the battery support frame.

Make sure that there is clearance between the bracket and the

wires (Figure 3.8).

□ Install the windshield washer bottle on the replacement battery

box using the supplied M8 x 16 mm bolts and nylon locknuts.

It is normal to have to bend the rear mount tab on the

washer bottle into position. This is necessary for

sufficient clearance with the frame cross member.

□ If the truck is not equipped with a vacuum pump and reservoir

the bracket does not need to be installed provided that the raised

plastic edges of the wire harness support are cut down (Figure

3.9).

Remove Ridge

Here

Figure 3.9

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□ Install the battery box assembly and the vacuum pump and

reservoir bracket (Figure 3.10). Install the OEM clip nut from the

original mounting location on the fan shroud.

□ Cut the tab off the bottom of the fan shroud and then install the

fan spacer, fan and fan shroud together. Ensure that the large

wire bundle is placed into its holder on the bottom of the fan

shroud.

Once the fan and spacer are installed it will not be

possible to lower the shroud past the fan.

□ Install the vacuum pump and reservoir (if equipped) onto the new

bracket. Ensure that all vacuum lines are routed to clear all sharp

edges and moving parts.

Battery tray

OEM clip nut from shroud

Frame mount

Windshield washer

bottle mount holes

Fender mount

(Re-use OEM bolt)

Windshield washer

bottle mount holes

Vacuum

reservoir

mount

bracket

Figure 3.10

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Vmac V900101 Installation guide

Vmac V900101 Installation guide

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