Vmac V910006 Installation guide

Brand: Vmac

Model: V910006

Type: Installation guide

VMAC – Vehicle Mounted Air Compressors

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Fax: 1-250-740-3201

Installation Manual for VMAC System

V910006

2003.25-2007 Ford SuperDuty F250-F550

6.0L Power Stroke V8

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

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

Part 1: Warranty and System ID ................................................. 5

Part 2: Preparing for Installation ............................................... 8

2.2 Modifying the Passenger Battery Tray ............................... 11

2.3 Mounting the Vacuum Tank ............................................... 13

2.4 Glow Plug Modules ............................................................ 16

2.5 Relocating the ICP Sensor ................................................. 16

Part 3: Installing the Tank and Hoses....................................... 18

3.1 Installing the Brackets ........................................................ 18

3.2 Installing the Tank .............................................................. 21

Part 4: Installing the Cooler, Bracket and Compressor .......... 22

4.1 Installing the Oil Cooler ...................................................... 22

4.2 Installing the Crank Pulley .................................................. 26

4.3 Installing the Main Bracket ................................................. 26

4.4 Installing the Compressor ................................................... 30

4.5 Completing the Installation ................................................. 32

4.6 Adding Oil to the System .................................................... 37

Part 5: Installing the Control Components .............................. 39

5.1 Installing the Components .................................................. 41

5.2 Connecting the Under-hood Wiring .................................... 45

5.3 Connecting the In-cab Wiring ............................................. 46

5.4 Completing and Testing the Installation ............................. 49

Part 6: Finishing the Installation ................................................ 51

6.1 Before Starting the Engine Checklist.................................. 51

6.2 After Starting the Engine Checklist .................................... 51

6.3 Setup, Performance Testing and Adjustments ................... 52

6.4 Auxiliary Air Receiver ......................................................... 53

Accessory Products from VMAC ............................................... 54

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Document #1930048

Installation Manual for VMAC System V910006

Ford 2003.25 – 2007 6.0L Power Stroke Diesel

Changes and Revisions

Version

Revision Details

Revised by/date

Approved

Implemented

ECN 08-325

SL 03 Dec 2008

PD 3 Dec 2008

5 Dec 2008

ECN 10-118

SAR 22 Nov 2010

NC 22 Nov2010

30 Nov 2010

ECN 11-050

SH 19 Apr 2011

SM 21 Apr 2011

27 Apr 2011

ECN 13-013

SH 21 Aug 2013

SM 26 Aug 2013

27 Aug 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 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

order models or those that have had other changes without

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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

Foot-pounds (ft-lb)

110

170

280

Newton meter (N•m)

108

149

230

379

STANDARD GRADE 8 NATIONAL FINE THREAD

Size

3/8

7/16

1/2

5/8

Foot-pounds (ft-lb)

180

320

Newton meter (N•m)

122

244

434

METRIC CLASS 10.9

Size

M10

M12

M14

M16

Foot-pounds (ft-lb)

104

174

Newton meter (N•m)

141

236

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 will cause compressor damage

and will 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 (Figure 1.1). 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

behind the passenger-side headlight. Secure the plate with the

supplied self tapping screws

□ Clean cross member beside the number plate and stick the

VMAC belt routing diagram to the cross member.

System ID number plate

Left Front

Figure 1.1

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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 1.2)

Figure 1.2

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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 1.3)

Figure 1.3

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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).

Keep all removed and unused OEM items if the truck is to be

returned to original equipment.

This manual contains specific installation instructions

for different model years. Make sure that you read

these instructions before beginning the installation and

identify the sections that apply to your vehicle.

□ Drain the cooling system, remove the upper and lower radiator

hose and disconnect the coolant expansion tank hose from the

top of the radiator.

□ Disconnect the batteries and remove the passenger side battery.

□ Remove the plastic air deflector from the upper section of the fan

shroud. Keep this part if the vehicle is to be returned to stock

condition.

□ Remove the two screws securing the upper section of the fan

shroud to the radiator. There are two options for removing the

fan shroud (you can remove the air cleaner to make this easier):

a. Carefully pry the shroud upward to release the rubber seal

from the groove in the stator. Push the top corner of the

shroud back to clear the upper hose spigot and pull the

shroud out. Be careful not to crack the shroud.

b. Locate the molded lines on the fan shroud, one on each side

about 6 inches (15cm) down from the top (Figure 2.1). Use a

suitable tool to cut the fan shroud between these lines

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(Figure 2.1). Do not cut the rubber seal. Remove the upper

shroud section along with the rubber seal, then remove the

lower fan shroud section.

Upper shroud

Lower shroud

Rubber seal

Cut along molded line

Figure 2.1

□ Disconnect the fan clutch wiring harness from the fan stator and

the fan clutch wiring plug connector. Remove the fan.

□ Remove the rear fan stator (large plastic section with cooling fins

behind the fan) and store it for future use if the vehicle is to be

returned to stock condition.

□ Remove the four bolts from the water pump pulley and replace

them with the supplied low profile head bolts.

□ Remove the OEM serpentine belt.

□ Remove the OEM belt tensioner assembly.

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□ Remove the intercooler tube on the passenger side and keep the

2-1/2 inch OEM clamps. Discard the intercooler tube, the

connecting hose from the intercooler and the two larger T-bolt

clamps.

Cover the turbo outlet and the intercooler inlet to

protect the system.

□ Disconnect and remove the glow plug relay module with the

mounting bracket. Detach the module from the mounting bracket,

discard the bracket but keep the nuts.

□ Unscrew the engine oil fill tube. Plug the oil filler opening to

protect the engine.

□ On automatic transmission models, remove the transmission

dipstick from the passenger side valve cover and install the

supplied bracket (using the OEM nut) with the spacer facing

down and away from the valve cover. Attach the transmission

dipstick to the lower spacer of the bracket using the supplied

fasteners.

□ Remove the wiring harness retainers from the studs at the front

of the valve cover. Cut the tape back far enough so that you can

reroute the harness behind the transmission dipstick tube and

over the valve cover. Most of the wiring and the glow plug

connectors should be behind and below the alternator.

□ Cut off the upper threaded section of the two front valve cover

bolts (just below the alternator) flush with the hex nut.

□ Remove the steel heater return pipe with rubber O-ring. Save the

O-ring and the M6 bolt. Disconnect the steel pipe from the heater

hose and discard the pipe.

□ Install the OEM O-ring onto the replacement heater hose barb

connector and install it into the front of the engine where the

heater hose pipe was removed (Figure 2.2). Cut a short piece of

3/4 inch hose from the supplied 8 inch piece, fit it onto the hose

barb and secure it with a clamp.

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Figure 2.2

□ Insert the long end of the supplied replacement steel heater pipe

into the short 3/4" heater hose and position the short end with

the tab along the alternator, pointing toward the firewall.

□ If equipped, remove the sound proofing from the underside of the

hood.

□ Remove the plastic clips holding the flexible mud deflectors to

the top and bottom of the radiator cross-member.

□ For easier installation of the cooler, remove the bolts from the

small power steering cooler in front of the radiator cross-member

and leave it loose in position. You can also remove the radiator

hold-downs and raise the radiator for better access.

□ Some trucks may have a crossbeam behind the air dam and

under the radiator while others may have a crossbeam that also

retains the tow-hooks. This can be removed to provide easier oil

cooler installation.

2.2 Modifying the Passenger Side Battery Tray

□ Remove the passenger side battery tray.

□ Turn the battery tray over and cut off the fender bracket along

the bottom crease of the battery tray (Figure 2.3).

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Figure 2.3

□ Install the supplied battery bracket to the inner side of the

passenger fender using the two OEM M8 bolts (Figure 2.4).

□ Install the passenger side battery tray reversed 180 degrees and

fasten it in place with 5/16 x 1 inch bolts with 3/8 inch flat

washers and 5/16 inch lock washers and nuts. The battery tray

hold-down clamp should face to the rear of the vehicle and the

tray should be on a slight angle. Slide the tray as far forward as

possible.

You may have to trim off some of the plastic web on the

windshield washer bottle to clear the edge of the battery

tray.

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Battery bracket

Figure 2.4

□ Drill an 11/32 inch diameter hole through the OEM support

bracket using an existing hole in the battery tray as a guide.

Install a 5/16 x 1 inch bolt with 3/8 inch flat washer and 5/16 inch

lock washer and nut. Tighten all fasteners.

2.3 Mounting the Vacuum Tank

If the truck does not have air conditioning, you must

still relocate the vacuum tank on the plastic fender liner

to clear the compressor but will not have to replace the

short hose or use the mount bracket.

□ Remove the vacuum tank from the passenger side fender and

save the nuts for reinstallation.

□ Disconnect the hoses from the vacuum tank and discard the

short hose from the vacuum pump to the vacuum tank.

□ Remove the three bolts mounting the air conditioning

receiver/dryer from the heater housing.

If necessary, remove the fender liner for better access.

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□ Carefully bend the forward facing top larger air conditioning line

out towards the inner fender until parallel to the fender. Twist on

the vertical section while supporting the receiver/dryer canister

and push inwards. This can be accomplished using a long pry

bar protected where it rests between the two vertical sections of

the lines (Figure 2.5).

First bend

Support first

bend by pushing

here

Second bend

pull up on the

bottom of the

cannister toward

the front

Position the cannister in front of the wiring plug

Place the clamp above the electrical

connector facing forward

Figure 2.5

□ Bend the other line by pulling upward and forward on the

receiver/dryer canister to provide adequate clearance.

□ Remove and discard the plastic shroud from the receiver/dryer.

□ Remove the bolt and clamping components from the supplied

heavy duty clamp and slide the clamp up onto the receiver drier

with the open side towards the front of the vehicle, above the

electrical connection.

□ Install the clamping bolt in the clamp and through the vacuum

tank bracket. Leave the clamp loose enough so that you can

adjust the position (Figure 2.5).

□ Remove the front bolt holding the vacuum pump bracket to the

passenger side fender. Place the supplied vacuum tank bracket

in position over the OEM vacuum pump bracket and install the

OEM bolt.

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□ Mount the vacuum tank bracket using the original OEM M6 nuts

with the hose connections at the bottom, angled at approximately

45 degrees (Figure 2.6). If required, bend up OEM vacuum pump

and OEM vacuum pump bracket approximately 20 degrees to

clear the air conditioning condenser (Figure 2.7).

Figure 2.6

Figure 2.7

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□ Install the supplied 1/8 inch rubber hose between the vacuum

pump and the vacuum tank and connect the other hoses.

2.4 Glow Plug Modules

□ Mount the glow plug module to the supplied bracket using the

two OEM M6 nuts so that the module will face toward the center

of the engine when the bracket is installed.

□ Install the assembly on the passenger side engine valve cover

studs beside the engine oil fill-tube using OEM nuts.

□ Wrap any loose OEM wires with tape and connect the glow plug

relays. Make sure that the wire harness is secured behind the

alternator where it will not touch the compressor or turbocharger.

□ Install the oil fill tube.

2.5 Relocating the ICP Sensor

Bendthebatterytraytabup

Keep the flat on the bolt head horizontal

Figure 2.8

□ On trucks built after 2004.25, remove the ICP sensor from the

passenger side valve cover.

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Check the rubber seal in the valve cover for damage

and replace if necessary.

□ Install the sensor in the supplied banjo fitting and torque to 9

foot-lbs.

□ Install the banjo, with copper seal, into the valve cover. Attach

the electrical connector, position the fitting so that the sensor

points toward the turbo (towards the rear of the truck and up at

about a 45 angle), and torque the banjo fitting bolt to 20 ft-lbs.

Make sure that the OEM O-ring is on the sensor and do

not lose the copper sealing gasket on the supplied

banjo fitting. Make sure that the ICP sensor is properly

sealed and tightened to prevent oil leaks, as improper

installation and sealing can void OEM warranty.

□ Ensure that the top and bottom flats on the ICP bolt are

horizontal. If required, tighten the bolt slightly to make them

horizontal.

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Part 3: Installing the Tank and

Hoses

3.1 Installing the Brackets

For 2005-2007 F450 – F550 model trucks see the special

installation instructions for the rear tank mount.

□ Remove the bolts, washers and nuts from the tank clamps.

□ Lay the tank brackets on a flat surface with the wide flanges

away from each other (Figure 3.1). The front and rear brackets

are different and are stamped “Front” and “Rear”.

Upper frame clip

Inner tank clamp

Lower frame clip

Spacer (not used on wide frames)

5/16” x 1/2”

Figure 3.1

□ Insert the cable straps through the upper frame clips and place

one cable on each tank bracket with the cables in the grooves.

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□ Place one inner tank clamp onto the front tank bracket. Apply

Loctite to the 5/16 x 1/2 inch hex head bolts (with flat washers)

and attach the inner clamp to the front tank bracket. Tighten all

the bolts.

3.1.1 All Trucks Except 2005 - 2007 F450 and F550

□ Place the inner tank clamp on the rear tank bracket. Apply

Loctite and attach the clamp to the bracket using 5/16 x 1/2 inch

hex head bolts. Tighten all the bolts.

□ Clean the area on the frame between the two cab mounts on the

passenger side and place the front bracket on the frame in front

of the transmission cross-member and as far forward on the

frame as possible. Place the upper frame clip on the frame rail

and make sure the frame seats in the groove.

□ Wrap the cable under the frame, insert the lower frame clip and

make sure the frame is seated in the clip. Install a spacer (if

necessary) a washer and a nut. Tighten the nut securely (do not

over-tighten) and install a second nut as a lock.

□ Place the rear bracket behind the transmission cross-member

and as far back as possible. Attach in the same manner as the

front bracket.

The tank brackets must be positioned far enough apart

to provide good support for the tank, but must not be

positioned in any location where the tank will not be

level when installed.

3.1.2 2005 - 2007 F450 and F550

□ Place spacers on the rear tank bracket as shown in Figure 2.2;

1/2 inch spacers on the top and bottom front holes, 5/8 inch

spacer on the top rear hole and a 3/4 inch spacer on the bottom

rear hole.

□ Place the inner tank clamp on the spacers, apply Loctite and

install 5/16 x 1 inch bolts with washers through the two front

holes, 1/2 inch spacers and into the bracket.

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□ Apply Loctite and install a 5/16 x 1-1/4 inch bolt with washer

through the top rear hole, 5/8” spacer and into the bracket.

□ Apply Loctite and install a 5/16 x 1-1/4 inch bolt with washer

through the bottom rear hole, 3/4 inch spacer and into the

bracket. Tighten all the bolts.

Rear tank bracket

Inner tank clamp

5/8” spacer

1/2” spacers

3/4” spacer

5/16” x 1”

5/16” x 1-1/4”

Figure 3.2

□ Clean the area on the frame between the two cab mounts on the

passenger side and place the front bracket on the frame as

shown in Figure 3.3. Place the upper frame clip on the frame rail

and make sure the frame seats in the groove.

□ Wrap the cable under the frame, insert the lower frame clip and

make sure the frame is seated in the clip. Install a spacer (if

necessary) a washer and a nut. Tighten the nut securely (do not

over-tighten) and install a second nut as a lock.

□ Place the rear bracket on the frame as shown in Figure 3.3 and

attach in the same manner as the front bracket.

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Vmac V910006 Installation guide

Brand: Vmac

Model: V910006

Type: Installation guide

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Vmac V910006 Installation guide

Vmac V910006 Installation guide

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