System V900111
2014-2011 Ford SuperDuty F450-F550
6.8L Triton Gas V10 Engine
www.vmacair.com
VR70 UNDERHOOD
AIR COMPRESSOR
INSTALLATION MANUAL
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
1
Installation Manual for VMAC
System V900111
2014-2011 Ford SuperDuty F450-F550
6.8L Triton Gas V10 Engine
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 .......... 11
3.1 Installing the Oil Cooler ...................................................... 11
3.2 Installing the Main Bracket and Compressor ..................... 14
Part 4: Installing the Tank and Hoses ....................................... 21
4.1 Installing the Tank and Brackets ........................................ 21
4.2 Installing the Hoses ............................................................ 23
4.3 Adding Oil to the System .................................................... 25
Part 5: Installing the Control Components .............................. 26
5.1 Installing the Components .................................................. 27
5.2 Connecting the In-cab Wiring ............................................. 27
5.3 Connecting the Underhood Wiring ..................................... 28
Part 6: Finishing the Installation ................................................ 30
6.1 Reinstall OEM components. ............................................... 30
6.2 Before Starting the Engine Checklist .................................. 34
6.3 Safety Test ......................................................................... 34
6.4 After Starting the Engine Checklist ..................................... 35
6.5 Setup, Performance Testing and Adjustments ................... 36
6.6 Auxiliary Air Receiver ......................................................... 37
Accessory Products from VMAC ............................................... 38
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Document #1930175
Installation Manual for VMAC System V900111
Ford Triton V10 2014-2011 6.8L Superduty F450-F550
Changes and Revisions
Version
Revision Details
Revised by/date
Approved
Implemented
F
ECN 13-013
SH 23 Jul 2013
SM 26 Aug 2013
26 Aug 2013
G
ECN 13-117/14-024
AH 29 Jan 2013
MP/RD 31Mar2014
28 Apr 2014
H
ECN 18-134 Washer bottle
MSP 11June2018
GB/KM/AG11JUNE2018
11 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 underhood mechanical work. Any
grinding, bending or restructuring operations for correct fit in modified
vehicles 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.
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
!
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order models or those that have had other changes without
additional modifications. If you have difficulty with the installation,
contact VMAC.
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 2018
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
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)
Hose Information
Different frame designations and chassis configurations may affect
the tank mounting position. If you have to move the tank, the lines
may be too short. Measure the hose shortfall and order a Hose
Extender Kit.
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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” holes in the top of the cross member
behind the passenger-side headlight. Secure the plate with the
supplied self-tapping screws
□ Affix the VMAC belt routing diagram to an appropriate place near
the OEM belt diagram.
□ 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).
□ Drain the coolant. Save coolant to be reused later. Close drain
valves when coolant has been drained.
□ Remove the passenger side inner fender liner.
□ Remove the passenger side hood strut.
□ Unclip wire connector holders from the side of the battery box.
□ Disconnect and remove the battery, washer pump wire and hose
at pump. Then remove the battery box. Save the four M8 bolts
for use later.
□ Disconnect and remove the air intake tube that connects the
throttle body to the air box. Cover both openings to reduce the
risk of foreign objects getting into the engine or the clean side of
the filter.
□ Remove the small radiator overflow hose from the radiator and
shroud and tuck out of the way.
□ Remove the upper radiator hose.
□ Remove the power steering reservoir from the driver's side of the
fan shroud keeping all the lines connected. Temporarily tie the
reservoir up and out of the way of the shroud. Note: The cap will
leak if the reservoir is not kept upright.
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□ Remove the vacuum solenoid and tank from the passenger side
of the fan shroud (if equipped). Remove the solenoid and hoses
from the tank and temporarily move them out of the way. The
tank will be relocated in a later step.
□ Unclip the large wire bundle and radiator hose from the lower fan
shroud.
□ Swing the lower fan shroud section forward and lock it in place.
□ Remove the upper and lower bolts locating the fan shroud.
□ Undo the fan nut (RH thread). Remove the fan and shroud
together. Ensure that the radiator does not get damaged when
removing the fan.
□ Cut and remove the fan shroud tab on the swing out section of
the fan shroud. This must be removed to clear the VR crank
pulley (Figure 2.1).
Cut Off
Tab
Swing Out
Section Of Fan
Shroud
Cut Flush With
This Face
Figure 2.1
□ 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 2.2).
□ Remove the two studs from the front of the passenger side
cylinder head (Figure 2.2).
Removing the OEM drive belt will make installation of
the main bracket easier, but it can be installed with the
belt in place.
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□ Move the alternator wiring harness from the front of the valve
cover to behind the oil fill tube.
□ Unclip the cam sensor wire harness from the valve cover so it
can be tucked in tighter to the engine when installing the VR
main bracket (Figure 2.2).
Mount Suppressor Here
Remove These
Studs
Cam Sensor
Figure 2.2
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Part 3: Installing the Cooler, Bracket
and Compressor
3.1 Installing the Oil Cooler
□ Remove the passenger side lower radiator hose going from the
radiator to the diverter valve (Figure 3.1).
From
Radiator
To
Engine
Cut Cuff
Oil Cooler
Hoses
OEM
Quick
Connect
Figure 3.1
□ Cut the cuffs holding the OEM quick connect to the passenger side
radiator hose and the cuff holding the driver side radiator hose to
the diverter valve (Figure 3.1).
OEM Oil Cooler
Hoses
Plastic
Cuffs
Figure 3.2
□ Cut the two molded plastic cuffs clamping the oil cooler hoses to
the oil cooler diverter valve and the OEM quick connect (Figure
3.1). After cutting separate the hoses from the fittings
Do not damage the diverter valve or the hoses, as they
will be used again
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□ Cut the passenger side radiator hose 5-3/4” from the lower OEM
quick connect. Also cut and discard approximately 8” of hose.
Insert the OEM diverter with the two small hose spigots facing to
the rear into the 5-3/4” hose (Figure 3.3 & Figure 3.5). Secure
with hose clamps.
5 –3/4”
OEM Quick
Connect
8” Approx.
Discard
Reuse
Figure 3.3
□ Position the cooler in the center of the front cross-member so
that it is just above the sway bar with the oil ports facing up
(Figure 3.4).
Impact Sensor
Location
Cross Member
Fog Light
Connector
Location
Figure 3.4
□ Apply loctite then install bolts through the flat mounting straps
(Figure 3.4) 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 fog lights if equipped.
Do not strike the impact sensor as this could cause the
airbags to actuate.
!
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□ 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 passenger side coolant hose and secure with hose
clamps (Figure 3.5). When installing the passenger-side hose
section with two OEM quick connects flip the hose orientation.
The 45° fitting that previously went to the radiator will now
connect to the OEM diverter valve. This will allow more
clearance to VR driveline.
Existing Cut
Passenger Side
Radiator Hose
OEM
Diverter
Valve
Existing Cut
Passenger Side
Radiator Hose
Existing Driver
Side Radiator
Hose
Extend Oil Cooler
Lines With Hose
Barb Connectors
And Heater Hose
OEM Quick Connect That
Previously Connected To
Radiator
Figure 3.5
□ With the passenger side coolant hose secured tighten the cooler
mount bolts to specification.
□ Connect the driver side radiator hose to the cooler and secure
with a hose clamp. Trim as necessary if any kinking of hoses
occurs (Figure 3.5).
□ Extend the OEM oil cooler hoses with the supplied 3/4” hose
barb connectors and of heater hose. Secure with supplied hose
clamps. Route the oil cooler lines over the cooler (Figure 3.5).
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3.2 Installing the Main Bracket and Compressor
□ Remove the belt idler pulleys and belt tensioner from the main
bracket.
GENTLY Bend
These A/C Lines
Out To Provide
Clearance For The
Bracket
Figure 3.6
□ Gently straighten air conditioning line at firewall using VMAC tool
#5900245 (Figures 3.7a & 3.7b).
This tool must be used to avoid stressing the firewall fitting
or the evaporator inside the dash. Stressing these
components could lead to A/C system leakage or failure.
Please log in to the VMAC website to watch a video on the
use of this tool.
!
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Figure 3.7a
Figure 3.7b
You will need to bend the rest of the lines slightly to clear
the compressor and battery and to give the rubber hose
section a natural bend.
!
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□ Gently bend the air conditioning lines beside the passenger side
engine head outward by grasping them at the fittings and
bending them with your hands to provide adequate clearance for
the main bracket (Figure 3.6). You may need to test fit the
bracket more than once to make sure they have adequate
clearance.
□ Remove cam sensor wire for approximately 10” from harness
loom at front of valve cover. Recover cam sensor wire with 10” of
small loom and route original harness to alternator harness
behind oil fill tube and secure. Then route cam sensor wire
harness back to cam sensor.
□ Remove A/C pressure sensor harness out of main harness loom
for approximately 4” and recover A/C pressure sensor harness
with small loom and secure.
□ Fit the VR 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 the cam sensor wire is not pinched
between the VR bracket and the cylinder head. Apply Loctite to
the four mount bolts, insert them through the bracket and into the
engine and thread them in finger tight to hold the bracket in
position (Figure 3.8).
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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 3.8
Carefully position the cam sensor wire harness to avoid
pulling the wiring tight when the bracket is installed.
Make sure that the harness has some slack and can be
moved slightly 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
correctly centered on the locating boss.
□ Apply Loctite, install three supplied M10 x 75 mm bolts and flat
washers and torque to specification.
□ Ensure that the two oil cooler hoses are well clear of the VR
pulley.
□ Apply Loctite to the bolts and install the VR tensioner and idlers.
□ Ensure the 30mm washers are installed onto the idlers.
□ 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. There are two different length bolts used. 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 3.9).
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