Vmac V900111 Installation guide

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 
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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.

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)

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

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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Vmac V900111 Installation guide

Vmac V900111 Installation guide

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