Vmac V910020 Page 67 Installation Instructions Manual Download

Page: 67 / 100

VMAC - Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: www.kb.vmacair.com

Figure 98 — Installing the CAC relocation bracket assembly

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Attach the CAC relocation and washer bottle bracket assembly to the CAC

support bracket installed in the vehicle and to the inner fender (Figure 98).

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Route the OEM battery cables under the brake lines at the HCU.

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Install the OEM battery clamps onto the VMAC battery posts.

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Connect the OEM windshield washer hoses to the VMAC washer reservoir.

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Cut the OEM windshield washer pump motor harness at the plug.

Connect the VMAC windshield washer harness to the OEM windshield washer

harness with the butt connectors:

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OEM black wire with green stripe to supplied black wire.

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OEM blue wire with white stripe to supplied red wire.

The OEM low washer fluid harness will not be reconnected.

☐

Connect the VMAC windshield washer harness to the washer pump motor.

Summary of Contents for V910020

Page 1: ...www vmacair com AIR INNOVATEDTM www vmacair com Installation Manual for VMAC System V910020 2017 Ford Super Duty F 250 F 550 6 7 L Diesel AIR INNOVATEDTM...

Page 2: ......

Page 3: ...and VMAC Degas Bottle 25 Modifying the Fan Shroud and Fan Stator 31 Installing the Main Bracket Idler Bracket and Compressor 35 Installing the Air Oil Separator Tank 42 Hose Requirements 45 Connecting...

Page 4: ...hese materials are provided by VMAC for informational purposes only without representation or warranty of any kind and VMAC shall not be liable for errors or omissions with respect to the materials Th...

Page 5: ...lure of any person 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...

Page 6: ...oducts 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 service...

Page 7: ...Service Ticket CSR number VMAC System ID hours on the compressor mileage on the vehicle and a detailed description of the work performed 6 VMAC Warranty does not cover consequential damage overtime ch...

Page 8: ...nstallation manual Before Starting 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...

Page 9: ...ers torque values for OEM fasteners Apply Loctite 242 blue or equivalent on all engine mounted fasteners Torque values are with Loctite applied unless otherwise specified Standard Grade 8 National Coa...

Page 10: ...port at 888 241 2289 The VMAC warranty form must be completed and returned to VMAC at the time of installation for any subsequent warranty claim to be considered valid Complete the warranty form The V...

Page 11: ...e panel underneath the steering wheel Figure 4 Figure 2 Battery relocation warning label To alert any technicians that may service the vehicle affix the servicing caution contact label in the engine c...

Page 12: ...y the service brake to supply power to the dash display The resistance to ground should read close to 0 in PARK and open circuit in all other gears If this is correct put the vehicle in PARK and turn...

Page 13: ...the driver side battery tray and degas bottle assembly This will not be reused but can be retained should the vehicle be reverted to stock Mark the washer fluid pump wire harness for modification in...

Page 14: ...sing to the outside of the frame just after the forward body mount Installation will continue later in the manual Figure 7 Figure 7 Routing the negative battery Reinstall the inner fender liner bolts...

Page 15: ...r steering reservoir cap will leak if the reservoir is not kept upright Remove the upper radiator shroud Disconnect the radiator fan harness and remove and discard the OEM bolt Figure 8 Figure 8 Disco...

Page 16: ...upper forward mount position Figure 10 Figure 10 Adaptive power steering pump Unbolt the power steering pump and secure it out of the way Adaptive power steering bushing OEM location Adaptive power s...

Page 17: ...pressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 15 Remove the primary drain back hose running between the engine and the OEM degas bottle Figure 11 Figure 11 Remove...

Page 18: ...ir from entering the brake system as brake fluid is forced out of the system 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 ge...

Page 19: ...macair com 17 Figure 12 Relocating the HCU Remove the bolt and 2 nuts securing the HCU and lift it clear of the shock tower Figure 12 Apply Loctite 242 blue to the supplied flat head fastener and inst...

Page 20: ...macair com 18 Gently shift the 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 14 Install the bolt and 2 nuts Fi...

Page 21: ...rom the OEM quick connector cuff on the radiator side of the hose measure 4 1 2 in along the outside radius towards the center of the hose and mark with a grease pen Figure 17 Figure 17 Lower radiator...

Page 22: ...t the radiator hose in the two marked locations ensuring that cuts are square to the hose section Install the modified radiator side of the lower radiator hose onto the radiator Install the modified e...

Page 23: ...r in place and discard Route the engine side coolant tube P N 1720719 up between the crossmember and the radiator support on the driver side of the vehicle and insert it into the modified radiator hos...

Page 24: ...e The end with the sharpest bend goes toward the radiator Figure 21 on page 21 Reinstall the transmission cooler using the supplied spacers and fasteners Figure 22 Installing the Cooler Position the c...

Page 25: ...amp 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 25 Connect one end o...

Page 26: ...er 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 27 Figure 27 Connect hose to VMAC co...

Page 27: ...y Tray Air Intake and VMAC Degas Bottle Modifying the passenger side battery tray Remove the snorkel and lower duct assembly from the battery tray Figure 28 Remove the battery hold down U bolt This wi...

Page 28: ...ut line along the base of the of the battery tray Figure 30 Figure 31 Mark a vertical cut line along the forward side of the engine face of the battery tray Figure 30 Figure 31 Cut the tray along the...

Page 29: ...VMAC degas bottle and battery post relocation bracket into the modified battery tray Figure 32 Install and secure the VMAC degas bottle to the bracket Figure 33 Figure 32 Installing the degas bottle b...

Page 30: ...elocation Install the OEM negative battery terminal using the supplied post and fastener Figure 34 Reinstall the ground strap to the inner fender Install the passenger side OEM positive battery cable...

Page 31: ...mary drain back hose modification Figure 37 Modified primary drain back hose Install a hose barb and the supplied 45 in length of hose and secure with hose clamps Install the remaining hose barb and t...

Page 32: ...ne and up to the original engine inlet The A C lines may need to be deflected slightly to facilitate routing Figure 38 Secure the primary drain back hose to the transmission cooler lines using the sup...

Page 33: ...r the VMAC crank pulley between the 2 lower stator mounts Figure 40 Figure 40 Stator modifications From the bottom left stator mount count 4 vanes in a clockwise direction and mark the left side of th...

Page 34: ...or count clockwise 6 vanes and mark the outer edge tracing the profile of the cowl Figure 41 Using a die grinder or similar tool cut the hard plastic lip flush with the cowl of the stator Figure 41 Cu...

Page 35: ...is enough clearance Figure 43 Fan shroud modification Figure 44 Fan shroud modification Remove the power steering mounting boss and cut out the shaded area Figure 43 Figure 44 Use the VMAC power steer...

Page 36: ...b vmacair com 34 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 w...

Page 37: ...Loctite 242 blue to all engine mounted fasteners Main bracket installation Ensure the alternator slide bushing is flush with the inside face of the alternator mount Figure 46 Remove the upper bolt se...

Page 38: ...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 47 Pull the alternator up and rotate it...

Page 39: ...to the VMAC main bracket using the 3 OEM bolts Reinstall OEM cable tray bolt Protect the battery cables in the cable tray using a piece of the scrap radiator hose retained from earlier in the installa...

Page 40: ...ressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 38 Install and tension the OEM belt Figure 51 or Figure 52 Figure 51 OEM single alternator belt routing Figure 52 OEM...

Page 41: ...l Compressor Due to the weight of the compressor VMAC recommends having an assistant hold the compressor in place while the bolts are threaded Position the compressor on the mounting bracket and secur...

Page 42: ...olts nearest to the air filter Installing the bolts in the wrong location will damage the compressor housing when tightened Figure 54 Install the inlet Figure 55 Air filter cover relief cut If Require...

Page 43: ...using the supplied fasteners Torque the crank pulley bolts to 22 ft lb Additional torque instructions below Remove the tensioner and idlers from the FEAD bracket Install the FEAD bracket onto the VMAC...

Page 44: ...of hoses other than those supplied or recommended by VMAC may cause compressor damage and may void the warranty Please contact VMAC for replacement hoses and further information When installing the AO...

Page 45: ...own for clarity Front of vehicle 4 3 8 in washers 4 3 8 in 6 in bolts 4 3 8 in 1 1 2 in bolts Spacer bar The top bolt on the forward tank mount will need to be installed from the inside of the frame F...

Page 46: ...from the rear Leave the tank clamps finger tight so the tank can be shifted forward or back when installing the hoses Rotate the tank so that the directional arrow on the rear of the tank is pointing...

Page 47: ...is not effective the hoses can be 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 exce...

Page 48: ...side cutters as they will deform the tube Slide the collet out once the tube is fully inserted Figure 61 Push to connect fittings O ring Push To Connect Fittings Figure 61 Lubricate the tube and firm...

Page 49: ...n the 3 4 in hose to the compressor discharge port Route the discharge hose from the compressor down and in between the engine and steering column Figure 62 Figure 62 Routing the hoses If necessary ge...

Page 50: ...ssary with cable ties 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 Figure 64 Figure 64 Connecting the hoses Secur...

Page 51: ...y relocation bracket is designed to accommodate a multitude of frame variations Due to the universal nature of the bracket it will protrude slightly from the side of the vehicle Final battery location...

Page 52: ...ox Insert 1 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 Figure 67 Figure 67 Installing the front battery box Figure 68...

Page 53: ...p of the battery box cover Figure 69 Ensure the 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 an...

Page 54: ...er rear 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 71 Mounting the rear battery box Depe...

Page 55: ...the rear battery box If equipped remove the cable run tray from the body mount It should be secured with push in fasteners and cable ties Figure 73 Figure 74 Modifying the cable run tray Remove the fa...

Page 56: ...1 5 x 30 bolts through the battery mount brackets into the battery mount joiner bracket and torque to specification Figure 75 Figure 76 Installing the rear battery box Thread the nuts onto the bolts...

Page 57: ...ttery box Install the backing straps and tighten the assembly to the frame to prevent the bracket from shifting Torque the mounting fasteners to specification The rear battery box mounting location ma...

Page 58: ...uard and remove the 2 OEM fasteners underneath the forward park brake cable standoff and set them aside Figure 79 If required install the supplied clip nuts Figure 80 or Figure 81 Figure 79 Vehicle su...

Page 59: ...the master battery disconnect assembly If the vehicle was supplied with a skid plate use the OEM fasteners to install the master battery disconnect assembly Figure 82 If the vehicle was not supplied...

Page 60: ...short Figure 84 Installing the batteries Wrap the ring terminal end of the 2 2 AWG positive battery cables with tape to prevent electrical shorts Figure 84 Figure 85 Installing the batteries Apply die...

Page 61: ...mended to prevent personal injury or damage to the battery Figure 86 Mounting the front battery box Raise the forward battery box and mount it onto the brackets Install the top rear fastener and tight...

Page 62: ...asteners Figure 88 Install the safety cables onto the brackets When connecting the positive battery cable to the starter solenoid avoid overtightening the nut as this can damage the starter solenoid F...

Page 63: ...AC hoses Figure 90 Continue routing the cable over the frame and to the rear of the forward body mount where it will join up with the main grounding cable and continue toward the main battery disconne...

Page 64: ...ct and secure it in place with the flange nut Figure 92 Install the supplied carriage bolt into the main battery disconnect Connect the 1 0 AWG negative battery cable to the negative post on the top o...

Page 65: ...r 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...

Page 66: ...ted below the plane of the bracket so they do not interfere with the CAC hose connections Figure 96 CAC and washer bottle relocation brackets Mount the washer reservoir bracket to the CAC relocation b...

Page 67: ...the brake lines at the HCU Install the OEM battery clamps onto the VMAC battery posts Connect the OEM windshield washer hoses to the VMAC washer reservoir Cut the OEM windshield washer pump motor harn...

Page 68: ...lamp from the cold side of the CAC and mount it onto the supplied VMAC cold side hose Install the CAC onto the VMAC CAC relocation bracket Figure 99 Figure 100 Installing the CAC Secure the CAC to the...

Page 69: ...ve covering from the intake port Remove the quick connect fitting from the OEM hose and reinstall it on the vehicle Save the hose clamp for reuse Figure 101 Install the VMAC supplied cold CAC hose and...

Page 70: ...e tube is inserted 1 1 2 in into the silicone hose Figure 103 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 h...

Page 71: ...Figure 105 Install the OEM hot CAC tube into the 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 p...

Page 72: ...l the assembly onto the turbo port The wire locking bail should be heard to click into place as it secures the quick connect onto the turbo port Figure 107 Install the OEM CAC tube onto the CAC Rotate...

Page 73: ...ater hose onto the 90 hose barb and secure with a hose clamp Install the straight hose barb into the hose extension and connect it to the OEM hose that runs along the top of the radiator routing it un...

Page 74: ...he 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 aft...

Page 75: ...maged Do not use a test light to probe for power on vehicle circuits the increased current draw of the test light may damage components Whenever possible solder all electrical connections and protect...

Page 76: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 74 Figure 114 Electrical schematic...

Page 77: ...door If using the preferred control box location route the cables from the control box along the doorsill under the trim panel behind the kick panel and up under the dash If routing the cables along...

Page 78: ...control to the OEM ground located on the dashboard support Remove the glove box compartment to gain access to the wire run behind it Figure 116 Figure 116 SEIC pass through Run the wires from the thr...

Page 79: ...green plug connector to the corresponding connector coming from the rear of the compressor Connect the grey cable with the black connector to the matching connector on the pressure transducer at the...

Page 80: ...e Network There are 2 Tee fittings in the degas hose network that will be reused One of the Tee s has a built in orifice which dictates its orientation this Tee is labeled Figure 117 Figure 117 Degas...

Page 81: ...888 241 2289 VMAC Knowledge Base www kb vmacair com 79 Figure 119 Modifying the degas hose network Figure 120 Modifying the degas hose network Remove the hose connected to the Tee labeled RAD and conn...

Page 82: ...ose coming out of the radiator where it starts to curve across the radiator Figure 121 Connect the spigot labeled RAD to the short radiator hose and the spigot labeled ENG to the hose running to the e...

Page 83: ...nnections with hose clamps Reinstall the lower bumper air dam Fill both coolant reservoirs with the coolant saved earlier Confirm that all OEM hoses and wires that were shifted during install are secu...

Page 84: ...ttery cables Close the boot cover to protect against debris and weather Connect the negative battery cables to the negative terminal on the top of the main battery disconnect and secure it with the ny...

Page 85: ...g Locate the MAX RPM and VR IDLE adjustment screws located on the Throttle Control Figure 127 Using a mini slot screwdriver rotate the MAX RPM adjustment screw 5 full turns counterclockwise Using a mi...

Page 86: ...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 87: ...ows down This is normal operation Prior to performing any service work on the system discharge any stored air in the air receiver tank The VMAC compressor system will automatically depressurize when i...

Page 88: ...checks have been completed Testing the Installation Place the vehicle in a safe operating position and adequately block the wheels Ensure that there are no people around the vehicle before beginning t...

Page 89: ...ctions starting on page 88 Ensure any stored air is drained from the system prior to adding oil Add oil as necessary to bring the level to the FULL line in the sight glass and check for leaks Ensure a...

Page 90: ...le for approximately 14 miles 20 km Observe the compressor while it is operating to ensure the belts rotate properly pulleys rotate smoothly and nothing is rubbing or contacting hot parts Check all co...

Page 91: ...When the pressure reaches 150 psi factory setting the system will close the inlet valve poppet and reduce the engine speed to VMAC base idle Once the system pressure is at maximum slowly open the bal...

Page 92: ...full turns Figure 130 The Throttle Control uses 20 turn adjustment screws turning the screws past this point will not damage the Throttle Control 2017 Throttle Tune While counting the turns rotate th...

Page 93: ...ll 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...

Page 94: ...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 95: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 93 Notes...

Page 96: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 94 Notes...

Page 97: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 95 Notes...

Page 98: ...received by VMAC within 30 days of installation VMAC s Warranty policy and registration can be viewed online at www vmacair com warranty VMAC Dealer Information Company Name City State Province Owner...

Page 99: ......

Page 100: ...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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