Vmac V900120 Installation guide

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VEHICLE MOUNTED AIR COMPRESSORS

VR70 UNDERHOOD

AIR COMPRESSOR

INSTALLATION MANUAL

System V900120

2015-2011 FORD F250-F550 6.7L DIESEL

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Installation Manual for VMAC 
System V900120 
 
2015-2011 Ford F250-F550 6.7L Diesel 
 
 
General Information .......................................................................... 4 
Before You Start ............................................................................ 4 
Additional Requirements ............................................................... 4 
Part 1: Warranty and System ID ...................................................... 5 
Part 2:  Preparing for Installation .................................................... 8 
Part 3:  Installing the Cooler, Bracket and Compressor ............... 13 
3.1 Installing the Oil Cooler ........................................................... 13 
3.2 Routing Battery Cables ............................................................ 14 
3.3 Continuing Oil Cooler Installation ............................................ 16 
3.4 Installing Main Bracket ............................................................ 18 
3.5 Battery Cable and Relocated Battery Box ............................... 30 
3.6 Washer Bottle .......................................................................... 35 
3.7 Air Filter Box ............................................................................ 38 
Part 4:  Installing the Tank and Hoses ............................................ 48 
4.1 Installing the Tank and Brackets ............................................. 48 
4.2 Installing the Hoses ................................................................. 50 
4.3 Adding Oil to the System ......................................................... 51 
Part 5:  Installing the Control Components .................................... 52 
5.1 Installing the Components ....................................................... 53 
5.2 Routing the In-cab Wiring ........................................................ 53 
5.3 Connecting the In-cab Wiring .................................................. 53 
5.4 Completing and Testing the Installation .................................. 55 
5.5 Safety Test .............................................................................. 56 
Part 6: Finishing the Installation ..................................................... 57 
6.1 Before Starting the Engine Checklist ....................................... 57 
6.2 After Starting the Engine Checklist .......................................... 57 
6.3 Setup, Performance Testing and Adjustments ........................ 58 
6.4 Auxiliary Air Receiver .............................................................. 59 
Accessory Products from VMAC ..................................................... 60 

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!

Document #1930165

Installation Manual for VMAC System V900120

2015-2011 Ford F250-F550 6.7L Diesel

Changes and Revisions

Version

Revision Details

Revised by/date

Checked by/date

Reviewed by/date

Implemented

H

ECN 13-102

CJH 07 Nov 2013

MH/DB 07 Nov 13

N/A

07 Nov 2013

J

ECN 14-018

JR 30 APR 2014

MH 06 May 2014

RD 06 May 2014

12 May 2014

K

ECN 18-135 Washer Btl

MSP 12 Jun 2018

KM/GB 12 Jun 2018

AWG 12 June 2018

13 June 2018

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 truck.

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)

OEM flywheel locking tool part number J42386.

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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.

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 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 in a visible location. Thoroughly clean the selected area

before affixing the label (figure 1.2)

Figure 1.2

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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).

□ Locate the blunt-cut OEM SEIC wire harness, on the driver’s

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), as to supply power

to the dash display. The resistance should read close to 0-ohms in

park and 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 read.

□ Mark transmission park signal wire for connection later in installing

control components section.

□ Disconnect batteries, (both driver and passenger side).

□ Drain coolant from both the primary and secondary radiators, (drain

for primary coolant on driver’s side, secondary coolant on passenger

side). Start with the secondary radiator, (drain on passenger side).

Save coolant to be reused later. Close drain caps when coolant has

been drained.

□ Remove passenger side battery bracket and battery.

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□ Disconnect and remove the mass air flow sensor from the top of the

filter box. Keep sensor as it will be reinstalled into supplied air box

lid.

□ Remove filter box, (both upper and lower sections).

□ Remove bracket that holds the lower section of the filter box.

Discard bracket and bolts.

□ Remove tube and resonator that connects the filter box to the turbo

intake.

□ Cover turbo intake.

□ Remove passenger side hood strut and hood strut ball stud from the

hood, (save for later use).

□ Remove lower hood strut ball stud from inner fender.

□ Remove positive terminal block and wiring connector panel from

passenger side battery box. To remove wiring panel pry up.

Positive terminal block has one clip and slides up to remove.

□ Disconnect windshield washer tube from joint above passenger side

battery box on top of firewall.

□ Unplug wiring harness from windshield washer pump and remove

wiring from front lower passenger side battery box.

□ Unplug glow plug module connectors from bottom of passenger side

battery box, (3 connectors).

□ Remove the bolt from wheel well that secures inner fender to battery

box, (save for later use).

□ Remove passenger side battery box.

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□ Remove glow plug module from bottom of passenger side battery

box, (Torx T30 bolts), (Save module for later use).

□ Disconnect hoses from secondary coolant reservoir, (attached to

passenger side of fan shroud), and remove reservoir from fan

shroud.

□ Remove upper secondary coolant hose, (top hose going to water

pump on passenger side of engine).

□ Cut plastic cuff securing hose on secondary rad hose carefully to

preserve fitting, (discard band and hose), (Figure 2.0.1).

Cut Plastic Cuff To

Remove Connector

Upper Secondary

Radiator Hose

Figure 2.0.1

□ Install supplied hose back on connector and secure with supplied

hose clamp, (Figure 2.0.2).

Supplied Hose

OEM Quick

Connect

Supplied Hose

Clamp

Figure 2.0.2

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□ Install hose coupling and flexible hose to open end of modified

secondary coolant hose. Leave about 1” gap between hoses and

secure with supplied hose clamps.

□ Remove plastic wire guide from front of EGR on passenger side of

engine (two bolts securing to EGR and plastic ties securing to wire).

Discard bolts and plastic. (Figure 2.3).

Figure 2.3

□ Using knife cut insulated heat shield if required to clear hose.

Install modified hose back on secondary water pump. Ensure

notches on OEM quick connector align with notches on secondary

water pump. Point elbow towards rear of truck (opposite to the

original direction). Ensure hose is not kinked. (Rotate the hose on

the OEM quick connect, if required this will remove kinks). Hose

must run underneath the injector wiring harness.

□ Ensure OEM locking clip is engaged on plastic elbow. Loop hose

towards front of truck.

□ Remove bolt securing power steering reservoir to upper fan shroud.

DO NOT remove hose from reservoir. Slide reservoir up out of clip

securing it to the upper fan shroud.

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□ Remove 5 bolts (3 on driver’s side and 2 on passenger side) and

wire clips securing upper fan shroud and remove upper fan shroud

from truck.

□ Unplug fan wire (unplug connector closer to the engine, not the one

right on the hub of the fan). Remove long bolt securing fan wiring

harness to engine and discard.

□ Remove the fan (right-hand thread) and pull it out of the engine bay.

For ease of fan removal and installation, it is recommended

that a pneumatic fan wrench removal set (such as Lisle 43300)

or a manual fan pulley holder (such as KD3900) is used.

□ Remove fan stator (the lower shroud can be left in place if the stator

is rotated to clear the lower lip).

□ Remove upper passenger side fan stator mount and save for use

later.

□ Release tension on OEM belt (leave belt routed correctly on

passenger side of engine).

□ Remove 2 bolts from secondary water pump, (Figure 2.4).

Remove OEM Bolts From

Secondary Water Pump

Figure 2.4

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Part 3: Installing the Cooler,

Bracket and Compressor

3.1 Installing the Oil Cooler

□ Remove lower primary coolant hose, (attached to the primary cooler

and engine), (Figure 3.1).

To

Engine

From

Radiator

Figure 3.1

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

coolant hose, (discard OEM quick connect), (Figure 3.2).

Cut Cuff

OEM Quick

Connect

Figure 3.2

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

(discard short section of hose with OEM quick connect),

(Figure 3.3).

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OEM Quick

Connect

Discard This

Section

8”

Figure 3.3

3.2 Routing Battery Cables

□ Apply loom to supplied battery cable extensions.

Note: The red and the black battery cables will follow the same

route!

□ Route the supplied positive/red battery cable between the frame and

body from the re-located battery location that will be under the driver

side. Leave 20” of cable to the rear of the body mount hanging

under driver side door.

□ Continue routing the cable above the truck electrical harness and

below the two metal power steering lines.

□ Continue routing, careful to avoid the steering column, around front

of the steering box until the cable reaches the electrical harness

under/beside the fan shroud.

□ Feed cable along fan shroud following other truck wiring harness.

□ Continue following truck wiring harness under the air intake and

metal bracket. Route along the inner fender plastic wire guide tray

under fender and follow OEM positive cable wire harness to

relocated battery positive terminal.

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□ Route the negative battery cable from the relocated battery location

and follow the positive battery cable. Continue routing under the fan

shroud, and, in such a way it will remain clear of the crank pulley

and any other sharp or moving objects.

□ Remove the OEM negative battery block bolt attaching the OEM

negative battery cable located beside the engine side coolant OEM

quick connect, (Figure 3.4).

For ease of removal the OEM negative battery block bolt

should be removed with the engine side coolant hose

disconnected. Figure 3.4 shown with coolant hose connected

to illustrate the OEM negative battery bolt location.

OEM Negative

Battery Engine

Block Bolt

Engine Side

Coolant Hose

Front of

Engine

Figure 3.4

□ Install the supplied negative battery cable lug on top of the existing

OEM negative battery cable lug. Orientate the cable so that it travels

down and under the existing vehicle battery tray facing the front of

the vehicle towards the fan shroud. Reuse the existing OEM

negative battery bolt.

□ Secure battery cables with tie-straps as required as to clear the

crank pulley and other moving parts.

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3.3 Continuing Oil Cooler Installation

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).

Fog Light Connector

Location

Impact Sensor

Location

Cross Member

Figure 3.5

□ Apply Loctite then install bolts through the flat mounting strap and

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

impact sensor. Note the impact sensor is located in the center of the

cross-member; the driver side wire connection is for the fog lights if

equipped, (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 reattached, (Figure 3.5).

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

clamp, (Figure 3.6).

!

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Figure 3.6

□ With the radiator side coolant hose secured tighten the cooler mount

bolts to specification.

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

clamp, (Figure 3.6). Note it may be necessary to trim the cooler end

of the coolant hose, do so as required if any kinking of the hose

occurs.

□ Apply hose protection to 1/2" oil hoses.

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

and orient as shown, (Figure 3.7).

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

orientate as show, (Figure 3.7). (Note the cooler hoses must be

installed before the fan shroud is installed).

Figure 3.7

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For ease of installation the cooler hoses should be installed after

the cooler is installed and before the fan and upper fan shroud

are installed.

3.4 Installing Main Bracket

□ Remove tensioner and idlers from VMAC bracket.

□ Disconnect A/C sensor.

□ Install supplied adhesive rubber pad on the air conditioning line that

runs in front of the modified upper secondary coolant hose

connector (at the water pump). Install adhesive rubber pad to

protect hose where it will rub against main bracket. Secure with zip

ties.

□ Remove Stud Bolt at front, passenger side engine cover, and cut off

stud flush to top of bolt head, then reinstall bolt. (Figure 3.8).

□ Install main bracket. On single alternator trucks use supplied

spacers behind top drivers side mount and lower front mount

between bracket and secondary water pump, (Figure 3.9).

For ease installation you may want to remove lower secondary

rad hose to get main bracket in place on engine. Reinstall hose

immediatly after installation of bracket.

Secondary coolant hose routes under compressor pad. Ensure

hose does not kink. Adjust hose clamps if necessary.

The wiring harness is routed above the VMAC bracket and the

front of the engine and specific attention must be paid to

ensuring the wiring harness is not pinched.

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

between the bracket and the engine. The coolant hose installed

earlier must run under compressor platform.

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