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
VMAC – Vehicle Mounted Air Compressors
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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.
!
VMAC – Vehicle Mounted Air Compressors
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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.
Copyright 2010
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
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
4
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)
VMAC – Vehicle Mounted Air Compressors
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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
VMAC – Vehicle Mounted Air Compressors
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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.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
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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
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
!
VMAC – Vehicle Mounted Air Compressors
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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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