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Vmac UNDERHOOD 150, Installation Manual

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Vmac UNDERHOOD 150 Installation Manual Download Page 55

VMAC - Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: www.kb.vmacair.com

53

The battery box and battery are heavy. Use caution when lifting 

into position or lowering. Assistance is recommended to prevent 

personal injury or damage to the battery.

Figure 76  —  Mounting the front battery box

 

☐

Raise the battery box and mount it onto the brackets. 

 

☐

Install the top rear fastener and tighten the other box mount fasteners (Figure 76).

 

☐

Install the safety cables onto the brackets.

The supplied battery cables include enough cable to allow the 

battery box to be lowered from the mount without having to 

disconnect the terminals from the engine bay.

 

☐

Pull the excess battery cable to the inside of the frame and secure them using 

the supplied cable ties.

Do not secure the excess battery cables to the brakes lines, or any 

harnesses as they could inadvertently be damaged if the battery box 

is lowered from the mounts prior freeing the excess battery cable. 

 

☐

Install the battery lid and secure it using the supplied fasteners. 

Summary of Contents for UNDERHOOD 150

Page 1: ...www vmacair com Installation Manual for VMAC System V910030 2020 Ford Super Duty F250 F550 6 7 L Diesel UNDERHOOD UNDERHOOD UNDERHOOD UNDERHOOD 50 50 50 50 1 1 1 1 TM TM TM TM AIR COMPRESSORS ...

Page 2: ......

Page 3: ...Idler Bracket and Compressor 32 Installing the Air Oil Separator Tank AOST 40 Hose Requirements 43 Routing and Connecting the Hoses 44 Relocating the Battery 48 Modifying and Installing Charge Air Cooler and Washer Bottle 54 Adding Oil to the System 59 CAC and Hoses 60 Installing the Control Components 69 Completing the Installation 73 Recommended Accessories 76 Air Receiver Tank 77 Testing the In...

Page 4: ...ation The information in this manual is intended for certified VMAC installers who have been trained in installation 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 or service without the appropriate mechanical training knowledge and experience Follow ...

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 are any questions concerning the procedures in this manual or more information is required please contact VMAC Technical Support prior to beginning work Safety Messages This manual contains various w...

Page 6: ...d 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 ii services are completed in accordance with the Owner s Manual iii proof of purchase of applicable service kits are made available to VMAC upon request The VMAC Lifetime Warranty is applicable to new...

Page 7: ...Ticket 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 recovery cleaning or shop supplies 7 Dealers submit warranty claims on behalf of the Vehicle Owner End User affected by the defective part s The dealer ensures that all warranty credits are refunded ba...

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 they will fit on the vehicle Identify any variations from the application list such as vehicle model engines or optional equipment e g dual alternator active steering assist etc Open the package unpack...

Page 9: ... are intended for VMAC supplied components or for use as a guide in the absence of a torque value provided by an OEM Apply 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 8 National Coarse Thread Size in 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 Foot pounds ...

Page 10: ...ers securing the grille and pull gently to remove the grille from the vehicle there are 2 fasteners located behind plastic covers on the grille face Remove the driver side headlight there is 1 fastener hidden behind the rubber trim between the fender and the bumper Drain the primary and secondary radiators into separate clean containers Set the coolant aside for use later Remove the upper radiator...

Page 11: ...uct and set it aside Disconnect the secondary cooling system hose running between the secondary degas bottle and Charge Air Cooler CAC Figure 2 Figure 2 Disconnect upper coolant circuit hoses Disconnect upper coolant circuit hoses Remove the secondary degas bottle and hose Figure 3 Figure 3 Remove the secondary degas bottle Figure 4 Remove the vacuum assembly Disconnect hose Unclip assembly Second...

Page 12: ...ttle it is the only part needed from this assembly Remove the inner fender liner fasteners and pull the fender liner out of the way to access the fasteners securing the washer fluid reservoir Disconnect and remove the washer fluid reservoir and battery tray support bracket retain the fasteners Figure 5 Drain the washer fluid into a clean receptacle and retain for use later Set the fluid reservoir ...

Page 13: ...r Keeping the power steering lines connected remove the power steering reservoir from the driver side of the fan shroud Temporarily tie the power steering reservoir up and out of the way of the shroud Figure 7 Disconnect fan harness Remove the fan and harness assembly Remove the fan shroud stator Remove the OEM FEAD belt Take note of the location of the OEM idler on the power steering pump primary...

Page 14: ... will improve access to the fasteners Do not remove the power steering fluid lines from the power steering pump For vehicles equipped with the optional Adaptive Power Steering power steering pump relocate the upper rear bushing to the upper forward mount position Figure 9 Figure 9 Adaptive power steering pump Unbolt the power steering pump and secure it out of the way retain the fasteners Adaptive...

Page 15: ...e main bracket bolt holes and set them and the fasteners aside for later Remove the primary drain back hose running between the engine and the OEM degas bottle Figure 11 Figure 11 Remove the primary drain back hose Using the supplied 1 2 in loom cover the section of harness Figure 12 Using the supplied 1 4 in loom cover the small sections of harness at the rear of the engine Figure 12 Figure 12 Re...

Page 16: ... Do not pump the brakes at any time while the brake lines are loose as air may be drawn into the system Have an assistant gently depress the service brake as the brake line is loosened rotated into a relaxed position and then quickly retightened Adjust one brake line at a time If there is a significant amount of brake fluid escaping from the fitting the pedal is being pressed too hard and or the f...

Page 17: ...ase www kb vmacair com 15 Figure 13 Steering assist module Determine whether the vehicle is equipped electronic power assist steering EPAS Figure 13 If the vehicle is equipped with EPAS turn to the next page If the vehicle is not equipped with the EPAS skip to page 19 Steering assist module ...

Page 18: ... com 16 Figure 14 Relocating the HCU Vehicles equipped with EPAS Remove the 2 nuts securing the HCU module to the bracket Figure 14 HCU nut Figure 15 Relocating the HCU Remove the bolt and 2 nuts securing the HCU base bracket to the shock tower and set them aside Remove the HCU base bracket Figure 15 HCU nut ...

Page 19: ... Base www kb vmacair com 17 Mark and cut the HCU base bracket in the location shown Figure 16 Figure 16 Modifying the HCU bracket Mark and cut HCU bracket Using the supplied flat head fastener install the HCU relocation bracket Figure 17 Figure 17 Relocating the HCU HCU relocation bracket ...

Page 20: ...not to bend or kink the brake lines Align the bracket with the second set of mounting holes Figure 18 Using the OEM fasteners retained earlier secure the HCU base bracket to the shock tower Figure 19 Figure 18 Relocating the HCU Figure 19 Relocating the HCU Reinstall both nuts Reinstall bolt Using the OEM fasteners retained earlier secure the HCU module to the bracket ...

Page 21: ...ehicles without EPAS Remove the bolt and 2 nuts securing the HCU base bracket to the shock tower and set them aside Remove the HCU base bracket Figure 20 Figure 20 Relocating the HCU Using the supplied flat head fastener install the HCU relocation bracket Figure 21 Figure 21 Relocating the HCU HCU relocation bracket ...

Page 22: ...e HCU towards the firewall taking care not to bend or kink the brake lines Align the bracket with the second set of mounting holes Figure 22 Figure 22 Relocating the HCU Using the OEM fasteners retained earlier secure the HCU base bracket to the shock tower Figure 23 Figure 23 Relocating the HCU Reinstall both nuts Reinstall bolt ...

Page 23: ...gure 25 Figure 25 Primary drain back hose modification Install the barbed hose coupler into the modified end of the coolant drain back hose Figure 25 Install the 1 in heater hose onto the hose coupler with the curve of the hose aligned as shown Do not tighten the hose clamps Figure 25 Slide the abrasion mesh onto the heater hose Install the drain back hose assembly onto the engine with the OEM qui...

Page 24: ...ed on the hose From the radiator 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 27 Figure 27 Lower radiator hose modification 5 1 4 in To radiator Remove the passenger side inner fender Uncouple the lower radiator hose assembly at the engine and radiator and remove the assembly from the engine bay Figure 26 Refer to Figur...

Page 25: ...adiator hose onto the engine Remove the anti abrasion sleeve from the center section of the lower radiator hose and slide it over the radiator side coolant tube securing it in place with cable ties Figure 29 Figure 28 Lower radiator hose modification Mesh abrasion sleeve From the end of the engine side of the hose measure 6 3 4 in along the outside radius towards the center of the hose and mark wi...

Page 26: ...river side coolant tube Wrap the 6 in section around the straight section of the driver side coolant tube and secure with cable ties Figure 30 Figure 30 Engine side anti abrasion sleeve 6 in coolant hose abrasion sleeve Install the cooler bracket onto the black front crossmember below the body coloured radiator support Figure 31 Figure 31 Install cooler Mount the cooler to the cooler bracket Figur...

Page 27: ...steel tube connectors between the cross member and the radiator support Figure 33 Figure 34 VMAC cooler assembly Figure 33 Install radiator hoses and tube connectors Modified radiator side OEM hose Modified engine side OEM hose Coolant tube P N 1720732 Coolant elbow P N 1710895 short side to cooler Coolant tube P N 1720731 Coolant elbow P N 1710878 Connect the modified OEM hoses as indicated Figur...

Page 28: ...lamp Disconnect flexible hose Cable run for reference Front of vehicle Insert the supplied aluminum plug into the flexible hose section and secure using the OEM spring clamp Figure 36 Connect one end of the supplied hose to the metal coolant tube Ensure the hose is seated against the bead in the OEM hard line and secure using a hose clamp Figure 37 Figure 36 Plug the flexible hose Front of vehicle...

Page 29: ...smember and over the cooler towards the passenger side of the vehicle Connect the hose to the small spigot on the passenger side of the cooler using a hose clamp Figure 38 Figure 38 Connect hose to VMAC cooler Front of vehicle Using the supplied P clips and clip nuts secure the heater hose to the radiator support Adjust all connections as necessary to confirm that all joints are engaged securely a...

Page 30: ...or the VMAC crank pulley between the 2 lower stator mounts Figure 39 Figure 39 Stator modifications From the bottom left stator mount count 4 vanes in a clockwise direction and mark the left side of the vane with a grease pen Figure 39 Mark the left side of the upper left stator mount s vane Remove the material between the marked lines Figure 39 1 2 in 3 1 2 in 3 4 in ...

Page 31: ...tor count clockwise 6 vanes and mark the outer edge tracing the profile of the cowl Figure 40 Using a die grinder or similar tool cut the hard plastic lip flush with the cowl of the stator Figure 40 Cut a rectangle out of the soft rubber section on the back of the fan shroud Figure 41 Figure 40 Stator modifications Figure 41 Fan shroud modification 1 2 in 8 in ...

Page 32: ... is enough clearance Figure 42 Fan shroud modification Figure 43 Fan shroud modification Remove the power steering mounting boss and cut out the shaded area Figure 42 Figure 43 Use the VMAC power steering bracket as a template to locate and mark the location of the top hole Figure 43 Drill the marked location using a 1 4 in drill bit Figure 43 Follow the edge of the molded bracket Drill shroud See...

Page 33: ...macair com 31 Install the supplied steering reservoir bracket to the shroud using 2 of the supplied fasteners Place the 2 supplied fender washers on the radiator side of the fan shroud and secure with the supplied nylon lock nuts Figure 44 Figure 44 Installing the power steering fluid reservoir bracket ...

Page 34: ...ts unless otherwise stated Main bracket installation Ensure the alternator slide bushing is flush with the inside face of the alternator mount Figure 45 If required adjust the bushing position using the OEM fastener and a shim block Remove the upper bolt securing the OEM cable tray to the primary water pump in preparation for VMAC bracket installation Figure 45 Reset alternator slide bushing Ensur...

Page 35: ... the pulley facing up Align the VMAC main bracket over the top of the alternator with the mating surface facing down Lower the bracket over the alternator Figure 46 Pull the alternator up and rotate it counter clockwise until the alternator mount holes are aligned with the VMAC bracket Figure 47 Figure 46 Mounting the alternator Figure 47 Mounting the alternator ...

Page 36: ...ses the same mount location as the OEM bracket Figure 48 Figure 48 Installing the OEM idler Figure 49 Installing the cable tray Dual alternator idler location Slide the supplied heat shrink tube onto the OEM alternator harness Using the supplied jumper harness fastener serrated washer and nut connect the primary alternator wiring Figure 49 OEM bracket bolt holes Single alternator idler location OE...

Page 37: ... the water pump Figure 50 Using the 3 OEM bolts install the power steering pump onto the VMAC main bracket Protect the battery cables and alternator harness using a piece of the scrap radiator hose retained earlier in the installation and secure with cable ties Reinstall the power steering pump pulley if removed Install the OEM idler onto the VMAC main bracket in the location noted when the idler ...

Page 38: ...pressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 36 Install and tension the OEM belt Figure 52 or Figure 53 Figure 52 OEM single alternator belt routing Figure 53 OEM dual alternator belt routing ...

Page 39: ...or in place while the bolts are threaded Position the compressor on the mounting bracket and secure with the 4 supplied bolts note the location of the shorter bolt and torque the compressor bolts to specification Figure 54 The compressor is secured with bolts of 2 different lengths Installing the bolts in the wrong location may prevent the compressor from being properly secured to the main bracket...

Page 40: ...bolts nearest to the air filter Installing the bolts in the wrong location will damage the compressor housing when tightened Figure 55 Install the inlet Figure 56 Air filter cover relief cut If Required Loosen the nut securing the filter cover rotate the cover to align the relief cut with the brake fluid reservoir and retighten the nut Figure 56 Shorter bolts Longer bolts Due to differences in veh...

Page 41: ...adequate clearance for the FEAD belt between the crank pulley and the fan stator Modify the fan stator as necessary Torque the crank pulley bolts to 22 ft lb Tighten all 4 crank pulley bolts an additional 90 Remove the tensioner and idlers from the VMAC FEAD bracket Install the VMAC FEAD bracket onto the VMAC main bracket Figure 57 Reinstall the idlers and tensioner and torque to specification Ins...

Page 42: ...OST Figure 59 AOST installed Front of vehicle The AOST must be level for proper air oil separation and to ensure that the oil level will display accurately in the sight glass Apply Loctite 242 blue to all fasteners except nylon lock nuts unless otherwise stated Prior to proceeding with the AOST installation review this chapter as well as the A700250 accessory instructions included with this kit to...

Page 43: ...he forward tank mount will need to be installed from the inside of the frame Figure 60 Install the tank mounting brackets on the frame Figure 60 The front tank mount bracket mounts between the radius arm mount and the transmission crossmember The rear tank mount bracket mounts just before the bend in the frame Mount the inner portion of the tank mounting bracket clamp onto the tank mounts Figure 6...

Page 44: ...w kb vmacair com 42 Rotate the tank so that the directional arrow on the rear of the tank is pointing upwards Figure 61 Figure 61 Securing the AOST Rear view AOST orientation is critical The arrow must be pointing up to prevent compressor failure due to oil starvation or oil in the discharge air ...

Page 45: ...ssary 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 maximize system performance Avoid using 90 fittings wherever possible as they cause flow restrictions and negatively impact performance The following hoses are included with this compressor kit 1 2 in 54 in 1 2 in 85 in 1 in 87 in 1 4 ...

Page 46: ...g to allow for normal engine 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 62 Push to connect fittings O ring PTFE Tubing Loom and Push To Connect Fittings PTFE tubing should only be cut using proper tubing cutters Side cutters utility knives etc will deform the tube preventing a prop...

Page 47: ...the discharge hose from the compressor to the firewall and toward the transmission Figure 63 Figure 63 Routing the hoses If necessary gently deflect the brake lines away from the discharge hose to provide adequate clearance Firewall Steering column Discharge hose From compressor Apply the supplied loom to the 1 4 in and 3 16 in PTFE tubes Connect the PTFE tubes their respective fittings on the inl...

Page 48: ...he 1 in hose using cable ties Install the 90 brackets onto the transmission cooler studs Figure 64 Figure 64 Routing the hoses Figure 65 Routing the hoses hose removed for clarity Route the hose along the engine oil pan and toward the passenger side frame rail Using the supplied P clips and fasteners secure the hose to the 90 brackets Figure 65 Transmission cooler Engine oil pan 2 M8 1 25 16 bolt ...

Page 49: ...OST Connect the 1 in hose to the AOST Trim the PTFE tubes as necessary and connect them to their respective fittings on the AOST Connect the 90 fitting on the longest 1 2 in hose to the driver side fitting of the cooler and route it along the frame to the AOST Connect the 90 fitting on the shorter 1 2 in hose to the passenger side of the cooler and run it up to the oil return fitting on the compre...

Page 50: ... 0 AWG For cable runs beyond 24 ft 7 3 m double up the cables If relocating the battery to a different location such as the service body refer to the wire size table below Table 2 The wire gauges VMAC recommends are designed to provide an equivalent resistance to that provided by the firewall mounting kit which has been extensively tested by VMAC If using the frame as the ground return path ensure...

Page 51: ...e firewall Figure 69 Figure 69 Mount battery disconnect bracket Supplied fasteners OEM ground strap not shown Apply the 5 8 in loom to the VMAC battery extension cables Connect the VMAC and OEM battery cables to the battery disconnect bracket Figure 70 Figure 70 Mount battery disconnect bracket VMAC positive battery cable extension OEM positive battery cable VMAC negative battery cable extension O...

Page 52: ...es down to the driver side frame rail Disconnect the positive OEM battery terminal from the VMAC battery disconnect Cover the positive OEM battery terminal and secure it out of the way to prevent an electrical short Driver Side Battery Relocation Insert the M10 x 1 5 x 150 bolt into the bottom of the rear battery box mount this will be inaccessible once the battery box is attached and attach the b...

Page 53: ...he battery mounts and fasteners will not crimp or pinch any wire harness or brake lines that run along the top of the frame rail Run the fasteners below any harness brake lines Rear bracket P N 1200978 Front bracket P N 1200977 M10 x 1 5 x 150 2 M10 x 1 5 x 130 Install the backing straps and tighten the assembly to the frame to prevent the bracket from shifting Torque the mounting fasteners to spe...

Page 54: ...r fastener securing the battery box to the mounting brackets and lift the battery box up and to the rear of the vehicle to remove it from the bracket Figure 74 Place the battery in the battery box and install the hold down clamp Route the battery cables under the frame rail Apply dielectric grease to the battery terminals and connect them to the battery Figure 75 Figure 75 Installing the battery b...

Page 55: ...the other box mount fasteners Figure 76 Install the safety cables onto the brackets The supplied battery cables include enough cable to allow the battery box to be lowered from the mount without having to disconnect the terminals from the engine bay Pull the excess battery cable to the inside of the frame and secure them using the supplied cable ties Do not secure the excess battery cables to the ...

Page 56: ... onto the fan driver Install the fan Install the fan harness using the VMAC fan wire spacer washer and bolt Connect the fan harness Install the upper fan shroud Install the power steering reservoir into the bracket Ensure the power steering reservoir is not being pulled or stressed by the hoses Secure the reservoir in place with the supplied fastener Figure 77 Apply Loctite 242 blue to all fastene...

Page 57: ...eservoir Using a cable tie secure the vacuum hose to the oil fill tube Rotate the vacuum tube and reconnect the vacuum hose to the vacuum assembly Figure 78 Figure 78 Position foam abrasion sleeve Foam abrasion sleeve Figure 79 Installing the windshield washer bottle bracket Slide the foam abrasion sleeve on the vacuum hose up until it is in front of the brake fluid reservoir Figure 78 Using the O...

Page 58: ... with the CAC hose connections Figure 80 Installing degas bottle bracket Using the OEM fasteners install the supplied degas tank bracket ensure the drain back hose is positioned to the rear of the bracket Figure 80 Mount the lower harness and hood latch cable push mounts to the degas tank bracket Using the supplied fasteners install the windshield washer bottle Figure 81 Figure 81 Install the wind...

Page 59: ...e 82 Install the windshield washer bottle If equipped with a cable running below the washer bottle apply the supplied 1 2 in loom to it and position the loom to provide abrasion protection and secure it in place using the supplied cable ties Connect the washer bottle hose and electrical connectors Using the supplied fasteners mount the CAC relocation bracket Figure 83 Figure 83 Install the degas r...

Page 60: ... degas tank 4 M8 1 25 20 bolts Install the drain back hose onto the degas tank Figure 85 Figure 85 Connect the drain back hose Ensure the vacuum hose that runs toward the front of the vehicle routes between the brake fluid reservoir and the degas tank Secure the vacuum brake assembly to the mounting bracket on the degas tank Using cable ties secure any other vacuum system components as necessary ...

Page 61: ... the cardboard warning tag Apply a light film of compressor oil to the filter gasket and thread the filter onto the AOST until the gasket makes contact Tighten the filter an additional 3 4 to 1 turn after the gasket contacts the base Remove the cap from the oil fill port located on the Inlet valve Figure 86 Fill the system with the supplied oil when dry the system will take approximately 9 L 9 5 q...

Page 62: ...ing the CAC Secure the CAC to the CAC relocation bracket Install the fastener nearest the firewall first using a VMAC supplied fastener Reuse the OEM fastener in the upper mount location Figure 88 Install this fastener first Reuse OEM fastener Ensure there is approximately 1 8 in clearance between the CAC and the washer bottle but that they are not touching if necessary adjust the brackets in the ...

Page 63: ...stalling the CAC Figure 90 Installing the CAC hoses All hoses must be secured to prevent contact with any hot sharp or moving parts CAC coolant hose Install the quick connect onto the CAC Figure 90 Remove the lower driver side radiator vibration mount fastener Using the supplied P clip and OEM fastener secure the front CAC tube to the radiator vibration mount if necessary deflect the hard line coo...

Page 64: ...fication Figure 92 Installing the secondary coolant hose Rotate the hose CAC side on the Tee into the orientation shown Figure 92 Straight hose barb Rotate hose Install the straight hose barb into the modified secondary cooling hose and secure it with a gear clamp Figure 92 Install the supplied heater hose onto the straight hose barb and secure it using a gear clamp Install the supplied abrasion s...

Page 65: ...he secondary cooling Tee and secure it to the degas tank bracket using the supplied P clip and fastener Figure 93 Secure the OEM MAF harness to the heater hose as required Secure the supplied abrasion sleeve onto the CAC side hose Figure 94 Figure 93 Installing the secondary coolant hose Route the hose down past the power steering reservoir then up toward the top of the radiator Figure 93 Figure 9...

Page 66: ... intake port Remove the quick connect fitting from the OEM hose and reinstall it on the vehicle Save the hose clamp for reuse Figure 96 Install the secondary cooling hose assembly onto the CAC and secure it with a gear clamp Ensure all of the lower fasteners on the shroud are tight Install the 90 barb into the secondary cooling hose extension Trim the hose running from the secondary coolant reserv...

Page 67: ...www kb vmacair com 65 Install the VMAC supplied cold CAC hose and secure with OEM hose clamps Figure 98 OEM Clamp VMAC CAC cold hose OEM clamp Remove the staking from the OEM hose clamp Figure 97 Figure 97 Installing the CAC hoses Remove staking Remove staking Figure 98 Installing the CAC hoses ...

Page 68: ...ses 3 in 1 1 2 in Positive beaded end Separate the engine side coupler from the OEM steel duct Install the VMAC hot CAC tube into the OEM silicone hose on the engine side OEM hot CAC quick connect and secure with the OEM hose clamp Ensure the internal bead on the silicone coupler engages the bead on the VMAC tube Figure 100 Figure 100 Installing the CAC hoses OEM clamp VMAC clamp Close the hood an...

Page 69: ...VMAC silicone hose Ensure the silicone hose has equal coverage of both components Install the gear clamps with the screw heads facing the firewall to provide the best fit Figure 102 Figure 101 Install circlip Install the circlip into the negative bead of the OEM steel duct Figure 101 Figure 102 Installing the CAC hoses Install circlip into negative bead ...

Page 70: ... place as it secures the quick connect onto the turbo port Figure 103 Figure 103 Installing the CAC hoses Install the OEM CAC tube onto the CAC Rotate the CAC tube as necessary to ensure there is adequate clearance between the tube and the compressor inlet and fittings Figure 104 Figure 104 Installing the CAC hoses Verify that there is adequate clearance between the degas tank and the hood Verify ...

Page 71: ...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 Ǜ Use high temperature loom in areas where high temperatures may be expected Ǜ Use spiral loom in areas with high vibration In line Butt Splice Connections Cut the wire approximately 2 in from the connector Strip approxima...

Page 72: ...M connector from Accelerator pedal Black White Red Black Red Green Green Blue Red Light Blue Grey To Ground Connect to SEIC White wire with Violet stripe CMC25 0 V when Park Brake engaged 12 V otherwise Temperature Probe Clutch wire Green 4 Pin Connector Connect to SEIC Green wire with Orange stripe CPB22 IGN switched 12 V Connect to SEIC Grey wire with Brown stripe CET22 0 V PARK 12 V other gears...

Page 73: ... the kick panel Attach the green wire with ring connector running from the control box to a good ground under the dashboard Locate the OBD II port generally located under the dashboard beneath the steering wheel column Remove the fasteners securing the OBD II port to the dashboard this provides easier access to the wires at the back Peel back the tape on the harness a few inches The wires populati...

Page 74: ...ire with brown stripe CET22 Route the following wires into the engine compartment via a grommet in the firewall Grey cable with the green plug connector from the control box Grey cable with the black connector from the throttle controller White wire with a bullet connector from the interface cable Cover all of the engine compartment wires with plastic loom Compressor connections Route the 2 grey c...

Page 75: ...lant saved from the secondary coolant system Check all wiring hoses and tubes to ensure that they will not contact any hot or moving components and will not interfere with the operation of the vehicle Ensure all wiring hoses and tubes are secured with cable ties and protected with loom as required Cover all VMAC under hood wiring with high heat plastic loom if not done previously Secure the harnes...

Page 76: ...ate must be attached to the vehicle at the time of installation This plate provides information that allows VMAC to assist with parts and repairs Locate a conspicuous area in the engine bay where the tag will be easily noticed to install the System ID tag Mark and drill 2 7 64 in holes and secure the plate with the supplied self tapping screws Figure 108 Figure 109 Advisory label Install the belt ...

Page 77: ...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 on the inside of the door or on the panel underneath the steering wheel Figure 111 Figure 111 Operating Instruction label ...

Page 78: ...the 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 potential troubleshooting Install a 200 psi pressure gauge downstream of the air discharge valve Pressure Regulator and or Lubricator or FRL The compressor can produce air pressures up to approximately ...

Page 79: ... 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 compressor system will automatically depressurize when it is shutdown therefore the hose from the VMAC AOST to the air receiver tank must have a check valve installed this prevents blow back and mois...

Page 80: ...orm a final inspection of the installation 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 150 cfm 0 250 in orifice installed and the ball valve closed Ensure all of the compressor outlets are closed Ensure the parking brake is engaged and the transmission is in P...

Page 81: ... normally to air demand When the VMAC system is first 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 Compressor oil leaks Allow the compressor to run until the system reaches full system pressure Engine speed should reduce to between 900 rpm to 1 000 r...

Page 82: ...the 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 the system has cooled Check the coolant level after the engine has been operated Check the compressor oil level after the engine has been shut down and the oil level has had time to stabilize When fir...

Page 83: ...mately 1 800 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 to drop Engine speed should ramp when the pressure drops to approximately 140 psi Performance Testing and System Adjustment System operation can be tested using the tools that will be operated by the s...

Page 84: ...educe 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 met the vehicle must be in PARK and the park brake must be engaged If an unsafe condition is detected the STATUS LED will turn off and engine speed will return to idle Once all unsafe conditions have...

Page 85: ...o increase engine speed RAMP UP PRESSURE should only be adjusted if 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 maximum system pressure The RAMP UP PRESSURE can be set to 100 PSI 120 PSI 140 PSI or 160 PSI via the or buttons in the RAMP UP PRESSURE ...

Page 86: ...ull flow shaft and swivel for maximum performance Accessory Products from VMAC Air Aftercooler Part number A800185 Improves tool performance and extends the life of air tools removes up to 80 of water from compressed air includes automatic water drain Max air flow 185 cfm 200 psi Port size 3 4 in NPT inlet and outlet Electrical 12 V Dimensions 17 in 43 2 cm L 8 0 in 20 3 cm W 14 5 in 36 8 cm H Wei...

Page 87: ...nsions 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 and removing water from compressed air Recommended for optimum operation of VMAC Hydraulic Air Compressors VMAC Diesel Driven Air Compressors UNDERHOOD40 UNDERHOOD70 including Green Series Air Compres...

Page 88: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 86 Notes ...

Page 89: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 87 Notes ...

Page 90: ...ed by VMAC within 3 months of receiving the vehicle or 200 hours of operation whichever occurs first VMAC s Warranty policy and registration can be viewed online at www vmacair com warranty Warranty Registration Owner End User Information Company Name City State Province Phone Email Address Date vehicle was put into service Day Month Year Submitted by Name Phone Email Vehicle Information Optional ...

Page 91: ......

Page 92: ...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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