Vmac DM00021 Installation Manual Download Page 3

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VMAC - Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: www.kb.vmacair.com

Table of Contents

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Modifying the Hoses, Installing the Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installing the PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Installing the Air Oil Separator Tank (AOST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Hose Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Routing and Connecting the Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Installing the Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Adding Oil to the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Installing the Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Completing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Recommended Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Air Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Testing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Performance Testing and System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Adjusting the Pressure Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Digital Throttle Control Operation and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Accessory Products from VMAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Summary of Contents for DM00021

Page 1: ...www vmacair com Installation Manual for VMAC System DM00021 2020 Ford Super Duty F250 F550 6 7 L Diesel...

Page 2: ......

Page 3: ...Air Oil Separator Tank AOST 19 Hose Requirements 22 Routing and Connecting the Hoses 23 Installing the Air Intake 29 Adding Oil to the System 31 Installing the Control Components 32 Completing the In...

Page 4: ...tion and service procedures and or for anyone with mechanical trade certification who has the tools and equipment to properly and safely perform the installation or service Do not attempt installation...

Page 5: ...the failure of anyone to properly adhere to the procedures set out in this manual or standard safety practices Safety should be the first consideration when performing any service operations If there...

Page 6: ...other products as defined by VMAC provided that i the purchaser fully completes and submits a warranty registration form within 3 months of purchase or 200 hours of operation whichever occurs first i...

Page 7: ...icket number VMAC System ID hours on the compressor and a detailed description of the work performed 6 VMAC Warranty does not cover consequential damages overtime charges mileage travel time towing re...

Page 8: ...the vehicle as many of the OEM parts will be reused during the installation of the VMAC system Read this manual prior to beginning the installation to ensure familiarity with the components and how th...

Page 9: ...ply Loctite 242 blue or equivalent on all fasteners except nylon lock nuts unless otherwise stated Torque values are with Loctite applied unless otherwise specified Table 1 Torque Table Standard Grade...

Page 10: ...Support Disconnect both batteries Apply Loctite 242 blue to all fasteners except nylon lock nuts unless otherwise stated Raise the front of the vehicle and support the axle on axle stands or appropri...

Page 11: ...ator side of the hose measure 5 1 4 in along the outside radius towards the center of the hose and mark with a grease pen Figure 2 Figure 2 Lower radiator hose modification 5 1 4 in To radiator Refer...

Page 12: ...center section of the lower radiator hose and slide it over the radiator side coolant tube securing it in place with cable ties Figure 4 Figure 4 Radiator side anti abrasion sleeve Coolant assembly re...

Page 13: ...air com 11 Mount the cooler to the cooler bracket Figure 6 Figure 7 Install radiator hoses and tube connectors Connect passenger and driver side radiator hoses and tubes to the VMAC cooler Route the s...

Page 14: ...w P N 1710878 short side to cooler Coolant tube P N 1720718 Coolant elbow P N 1710658 Connect the modified OEM hoses as indicated Figure 8 Disconnect the small flexible hose secured to the cable run t...

Page 15: ...nsure the hose is seated against the bead in the OEM hard line and secure using a hose clamp Figure 11 Figure 10 Plug the flexible hose Front of vehicle Plug Flexible hose OEM spring clamp Figure 11 P...

Page 16: ...upplied P clips bolts and clip nuts secure the heater hose to the radiator support Adjust all connections as necessary to confirm that all joints are engaged securely and that there are no twists kink...

Page 17: ...to the bracket Remove and discard the bracket from the bellhousing mounting studs Using the OEM fasteners install the supplied bracket onto the bellhousing mounting studs Figure 14 Figure 14 Install...

Page 18: ...r for re alignment later Unbolt the front of the drive shaft pivot it out of the way and secure it to allow room to install the PTO The PTO electrical installation will be covered in Installing the Co...

Page 19: ...sor forward onto the PTO until it is fully mated Figure 16 Figure 16 Install the compressor Using the 2 supplied fasteners and flat washers secure the compressor to the PTO Using a torque wrench ensur...

Page 20: ...er unthread the clip from the hole and discard it Position the oil fill bracket over the hole and align the smaller hole with the nearby OEM bolt head Figure 18 Figure 18 Install oil fill bracket OEM...

Page 21: ...ose supplied or recommended by VMAC may cause compressor damage and may void the warranty Figure 20 AOST installed Front of vehicle The AOST must be level for proper air oil separation and to ensure t...

Page 22: ...end in the frame Using the 2 supplied 3 8 in 6 in bolts install the rear tank mount and backing strap approximately 10 in ahead of the rear cab mount Leave the bolts finger tight to allow for minor ad...

Page 23: ...kb vmacair com 21 Rotate the tank so that the directional arrow on the rear of the tank is pointing upwards Figure 22 Figure 22 Securing the AOST Rear view AOST orientation is critical The arrow must...

Page 24: ...e shortened or replaced as necessary or hose extenders can be used VMAC recommends shortening these hoses as a preferred alternative to coiling up and securing the excess Shorter hose length will maxi...

Page 25: ...low for normal engine transmission movement Cut the tube squarely using only proper tubing cutters as side cutters will deform the tube Slide the collet out once the tube is fully inserted Figure 23 P...

Page 26: ...e spin on oil filter and set it aside Install a cap plug to prevent any contaminants entering the system Install the supplied Tee fitting onto the AOST in the orientation shown Figure 24 Using the sup...

Page 27: ...ct it to the Tee on the AOST Connect the 90 fitting from the longer 1 2 in hose cooler to compressor to the passenger side fitting on the oil cooler Connect the 90 fitting from the shorter 1 2 hose AO...

Page 28: ...ssion crossmember Figure 27 Apply the supplied spiral loom to the 3 4 in hose where it runs along the control arm mount and wraps around to the rear of the control arm to provide abrasion protection U...

Page 29: ...29 Connect the straight fitting on the 1 2 in hose to the matching fitting on the compressor Figure 29 Apply the supplied spiral loom to the 2 1 2 in hoses where necessary to protect them from abrasi...

Page 30: ...y hoses Using the supplied heat wrap protect the 1 4 in and 3 16 in PTFE where they pass below the exhaust Trim the PTFE tubes as necessary and connect them to their respective fittings on the back of...

Page 31: ...f the elbow Adjust the rubber elbow and tube assembly to ensure they are routed away from any hot sharp or moving components If required trim any extra length from the hose to allow for the best routi...

Page 32: ...is adequately secured away from hot sharp or moving components using rubber coated P clips or cable ties not supplied as required Cut the flexible hose to length and using the supplied gear clamp secu...

Page 33: ...he AOST Remove the cap plug used to cover the oil filter port on the AOST Apply a light film of compressor oil to the filter gasket and thread the filter onto the AOST until the gasket makes contact T...

Page 34: ...ds using only sealed crimp and solder butt connectors for all electrical connections To ensure a durable connection use only good quality crimping tools Apply loom to all wiring Use high temperature l...

Page 35: ...rey To Ground Remote Regulator Green 4 Pin Connector Connect to key switched 12 V e g Green wire with Orange stripe at CBP 22 Connect to Grey wire with Brown stripe SEIC CET 22 0 V PARK 12 V other gea...

Page 36: ...erter to the mounting bracket in the orientation shown Figure 38 Locate the mounting tab under the dashboard above the park brake Vehicles equipped with tow control options may have a tow module attac...

Page 37: ...ng tab Clip the tow control module into the tow control module bracket Control Box and PTO Indicator Panel Remove the plastic trim panel from the doorsill and the kick panel on the driver side Install...

Page 38: ...ol box Replace the doorsill trim and the kick panel Attach the 2 green wires with ring connectors running from the control box and the throttle control to a good ground under the dashboard Figure 40 L...

Page 39: ...inverter power wires Cover all of the engine compartment wires with plastic loom Routing and Connecting the PTO and Compressor Wires Route the following wires down the firewall and behind the inner f...

Page 40: ...e it up and out of the way under the dash with cable ties Replace all dash panels and covers removed during installation Fill the primary radiator with the saved coolant Connect the batteries To alert...

Page 41: ...art 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 o...

Page 42: ...he advantage of lowering the duty cycle of the compressor system Pressure Gauge While not critical to system performance a pressure gauge is important for fine tuning the system and simplifies any pot...

Page 43: ...as high as possible Air Receiver Tank AOST Check valve If an air receiver tank will be used with this system the following installation procedure must be used to prevent damage to the system The VMAC...

Page 44: ...tallation to ensure everything has been completed Check all wiring for security and protection Ensure nothing is touching the compressor body Install the VMAC Air Test Tool P N A700052 with the 70 cfm...

Page 45: ...irst engaged the engine speed should increase to 1 500 rpm and then drop down to VMAC base idle approximately 1 000 rpm once system pressure is reached With the system running check for Coolant leaks...

Page 46: ...he compressor operation to ensure that the belt alignment is good and nothing is rubbing or contacting hot components Check all components connections and fasteners once the engine is turned off and t...

Page 47: ...ximately 2 400 rpm Close the air valve slowly to allow the system pressure to rise Once system pressure is at maximum slowly open the ball valve on the test tool until the pressure on the gauge begins...

Page 48: ...5 psi 1205 kPa dependent upon requirements Rotate the setting bolt clockwise to increase pressure Rotate counter clockwise to decrease pressure Tighten the lock nut once adjustments are complete Open...

Page 49: ...duce the maximum VMAC rpm Safety features The throttle control has built in safety features that will disable the system if an unsafe condition is detected or either of the lock out parameters is not...

Page 50: ...the maximum system pressure is changed via the inlet regulator To maintain proper performance and rapid response to air demand ensure the RAMP UP PRESSURE is set at no more than 20 psi below the maxi...

Page 51: ...full flow shaft and swivel for maximum performance Accessory Products from VMAC Air Aftercooler Part number A800070 Improves tool performance and extends the life of air tools removes up to 80 of wate...

Page 52: ...sions 73 3 4 in 187 3 cm L 14 in 35 6 cm D Weight 95 lb 43 1 kg 10 Gallon 200 psi Air Receiver Tank w Mounting Feet Part number A300047 Air receiver tanks are used for lowering compressor duty cycle a...

Page 53: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 51 Notes...

Page 54: ...e Identification Number Submitted by Name Phone Email Address Product Information System Identification Number D M Compressor Serial Number P This form must be fully completed and returned to VMAC at...

Page 55: ......

Page 56: ...888 241 2289 tech vmacair com 877 740 3202 warranty vmacair com www vmacair com www kb vmacair com 1333 Kipp Road Nanaimo B C V9X 1R3 Canada Manufactured by...

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