Vmac VR70 Installation Manual
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Vmac VR70 Installation Manual

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See also: Owner's Manual , Installation Manual
V R 7 0 U N D E R H O O D
A I R C O MP R E S S O R
I N S T A L L A T I O N MA N U A L
S y s t e m V 9 0 0 1 2 0
2 0 1 5 - 2 0 1 1 F O R D F 2 5 0 - F 5 5 0 6 . 7 L D I E S E L
w w w . v ma c a i r . c o m

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Summary of Contents for Vmac VR70

  • Page 1 V R 7 0 U N D E R H O O D A I R C O MP R E S S O R I N S T A L L A T I O N MA N U A L S y s t e m V 9 0 0 1 2 0 2 0 1 5 - 2 0 1 1 F O R D F 2 5 0 - F 5 5 0 6 .

  • Page 3: Table Of Contents

    Part 6: Finishing the Installation ............. 57 6.1 Before Starting the Engine Checklist ........57 6.2 After Starting the Engine Checklist .......... 57 6.3 Setup, Performance Testing and Adjustments ......58 6.4 Auxiliary Air Receiver .............. 59 Accessory Products from VMAC ............. 60...

  • Page 4: Installation Manual For Vmac System V900120

    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.
  • Page 5 If you have difficulty with the installation, contact VMAC. 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.

  • Page 6: General Information

    Additional Requirements Special Tools Pneumatic fan wrench removal set (such as Lisle 43300) or a manual fan pulley holder (such as KD3900) OEM flywheel locking tool part number J42386. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 7: 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.
  • Page 8 Figure 1.1 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 9 To alert any technicians that may service the vehicle, affix the servicing caution/contact label in the engine compartment near the hood latch in a visible location. Thoroughly clean the selected area before affixing the label (figure 1.2) Figure 1.2 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 10: Part 2: Preparing For Installation

    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).
  • Page 11 Unplug glow plug module connectors from bottom of passenger side battery box, (3 connectors). □ Remove the bolt from wheel well that secures inner fender to battery box, (save for later use). □ Remove passenger side battery box. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 12 Remove Connector Figure 2.0.1 □ Install supplied hose back on connector and secure with supplied hose clamp, (Figure 2.0.2). Supplied Hose OEM Quick Clamp Connect Supplied Hose Figure 2.0.2 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 13 Remove bolt securing power steering reservoir to upper fan shroud. DO NOT remove hose from reservoir. Slide reservoir up out of clip securing it to the upper fan shroud. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 14 Release tension on OEM belt (leave belt routed correctly on passenger side of engine). □ Remove 2 bolts from secondary water pump, (Figure 2.4). Remove OEM Bolts From Secondary Water Pump Figure 2.4 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 15: Part 3: Installing The Cooler, Bracket And Compressor

    Cut Cuff Connect Figure 3.2 □ Cut the radiator side coolant hose 8” from the OEM quick connect, (discard short section of hose with OEM quick connect), (Figure 3.3). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 16: Routing Battery Cables

    Continue following truck wiring harness under the air intake and metal bracket. Route along the inner fender plastic wire guide tray under fender and follow OEM positive cable wire harness to relocated battery positive terminal. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 17 Reuse the existing OEM negative battery bolt. □ Secure battery cables with tie-straps as required as to clear the crank pulley and other moving parts. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 18: Continuing Oil Cooler Installation

    (Figure 3.5). □ Install the radiator side coolant hose and secure with supplied hose clamp, (Figure 3.6). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 19 Connect the longest 1/2" hose to the driver side of the cooler and orientate as show, (Figure 3.7). (Note the cooler hoses must be installed before the fan shroud is installed). Figure 3.7 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 20: Installing Main Bracket

    Secondary coolant hose routes under compressor pad. Ensure hose does not kink. Adjust hose clamps if necessary. The wiring harness is routed above the VMAC bracket and the front of the engine and specific attention must be paid to ensuring the wiring harness is not pinched.
  • Page 21 Torque front bolts to specification first. □ Next, torque lower side bolts to specification. It is possible to get extension with flex head through from inside wheel well for lower side bolts. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 22 Check to ensure the added hose protection is in the correct location. □ Modify fan stator as shown, (Figure 3.10). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 23 The fan stator spacer may need to be pressed into the stator mounting hole due to variation of OEM component. Figure 3.11 - Mounting fan stator to main bracket VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 24 VMAC crank pulley is mounted to. When the pulley is installed on the balancer and the engine is running there may be a front to back wobble of the VMAC crank pulley which can cause damage to the driveline components.
  • Page 25 Figure 3.14 – Dual Alternator – OEM Belt Routing □ Tighten crank pulley bolts an additional 90 degrees. □ Remove lower portion of inlet brace from air end and install on VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 26 The hose will route up over the compressor behind the clutch guard and through the supplied P-Clip, (Figure 3.16). This hose must be protected from damage from any fasteners or other sharp edges. P-Clip Figure 3.16 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 27 (through the bracket) and the shortest bolt goes in the hole on the passenger side closest to the front of the truck,(Figure 3.17). Figure 3.17 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 28 200mm bolts provided. Use Loctite and torque to specifications. (VMAC belt must be routed prior to installation of this bracket). □ Tension VMAC belt and ensure it is seated properly on all idlers and clears all hoses. VMAC – Vehicle Mounted Air Compressors...
  • Page 29 Use the OEM fastener to tap threads into the existing OEM hole 1- 3/4” above the ground wire hole. Remove OEM fastener and retain. (6mm tap may also be used). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 30 Route the short section of 3/16” Teflon line from the ‘T’ to the matching fitting on the passenger side of the inlet valve. Apply loom to the line for protection. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 31 Install OEM bolt that was removed from inside wheel well that goes through the inner fender and secures into the glow plug bracket (previously secured into the battery box). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 32: Battery Cable And Relocated Battery Box

    If the battery cable clamping portions are not cut of it will look like the diagram below. Be sure to wrap any exposed ‘positive’ clamp with black electrical tape to prevent short circuiting. (Figure 3.23). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 33 (where the bumper support bracket is attached). □ The battery box will mount to the driver side frame rail behind the suspension radius arm mount, (Figure 3.25). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 34 5/16 x 2 Bolts & member Nut 5/16 Washers (2 Places) Figure 3.25 Suspension Radius Remove Front Nut Suspension Radius Remove Rear Nut Arm Mount Arm Mount Figure 3.26 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 35 □ VMAC cannot list or approve all the possible alternative battery locations. It is up to the installer to follow safe/best practices. VMAC will not warranty any improperly installed battery boxes and/or cables or any failures relating to the installation.
  • Page 36 A label must be installed to clearly advise the operator/service technician of the new location of the battery. Refer to the “Warranty and System ID” section of the installation manual for location of the VMAC supplied label. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 37: Washer Bottle

    M8 bolts and nuts, (Figure 3.27). Up to 1” of the plastic brace, behind the bumper, can be cut- off to help with installing the washer bottle and bracket. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 38 Fill washer bottle with saved washer fluid. Water Bottle Installation with Fog Lights: To install the water bottle, the passenger side fog light mount must be modified. See below. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 39 After cutting, clean and de-burr all edges and reinstall for light assembly behind bumper with the three OEM bolts. □ Plug the fog light wiring harness back into the back of the fog light. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 40: Air Filter Box

    □ Cut off plastic tab from wiring guide that is clipped into fender frame on passenger side of truck, (Figure 3.32). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 41 (Figure 3.31). Figure 3.31 □ Insert modified foam filter section into rear of supplied filter box. Foam goes in original location of plastic section (groove fits in plastic lip). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 42 Figure 3.32 □ Using a hammer, flatten the sheet metal, raised edge around the lower hood strut area. (Figure 3.33). Sheetmetal edge to be flattened Figure 3.33 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 43 (Figure 3.35). Install relocating bracket with supplied fasteners as shown. Note the 8mm hex nut may need to be oriented to fit in the slot in hood. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 44 Apply Loctite blue and install supplied bolt through air box bracket, (Figure 3.36), into second OEM threaded hole in inner fender, (Figure 3.32), towards rear of air filter box. □ Tighten front air filter box mounting bolt. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 45 Remove the OEM filter minder from the OEM air box lid. □ Install OEM air filter. □ Re-install the filter minder on the air box lid assembly, use the supplied hose clamp, (Figure 3.37). Figure 3.37 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 46 Fit the free end of the intake tube loosely into the inlet bellows. □ Position the intake tube for best clearance to brace and to firewall connector, (Figure 3.39). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 47 Before tightening the clamps, make sure the silicon elbow is positioned to provide an adequate sealing surface under each clamp. Align the clamps with the edges of the silicon elbow. (Figure 3.40) Figure 3.40 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 48 Ensure that the clamps are tightened after adjustment. □ Add ‘paint pen’ or other marker to indicate proper alignment once final position is set. (Figure 3.42). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 49 When the position of the intake system is finalized, apply the supplied heat shrink to the two T-bolt clamps (Figure 3.40). The T-bolt clamps should never be removed when servicing the air filter. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 50: Part 4: Installing The Tank And Hoses

    □ Remove the two 1/4" clamp bolts from the C-clamps. Expand the clamps slightly and slide them over the front of the tank. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 51 □ Support the tank and tank mount assembly in place on the outside of the frame behind the radius arm mount (Figure 4.1) VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 52: Installing The Hoses

    If the tank is relocated and requires hose extensions, see section ‘Additional Requirements’ on pg. 4. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 53: Adding Oil To The System

    4.3 Adding Oil to the System You must use the VMAC supplied and approved compressor oil in this system. Failure to use this special oil will result in damage to the compressor and will void your warranty.

  • Page 54: Part 5: Installing The Control Components

    Part 5: Installing the Control Components Figure 5.1 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 55: Installing The Components

    Connect the Throttle Controller cable to the foot pedal assembly. □ Connect the green ground wires from the Throttle Controller and the interface connector to a dashboard ground point. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 56 Throttle Controller. □ Solder and seal the white “OEM clean tach out” wire from the Throttle Controller to the OEM SEIC circuit CE913 blue wire at the blunt-cut harness. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 57: Completing And Testing The Installation

    (electrical system will be live at this point). Use floor jack to hold battery box in place and secure to mount previously installed. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 58: Safety Test

    If the vehicle fails the test, check the wiring to make sure that all the connections are correct and secure. If you require additional assistance, contact your local VMAC dealer. Call 1- 888-241-2289 or 250-740-3200. VMAC – Vehicle Mounted Air Compressors...

  • Page 59: Part 6: Finishing The Installation

    OEM base idle (about 650 RPM) and the control box green light should stay on. Repeat this test in all gear selector positions to make sure that the engine does not idle up unless the selector is in PARK. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 60: Setup, Performance Testing And Adjustments

    (Figure 6.1). Figure 6.1 Install the test tool in the tank outlet fitting. Make sure that the ball valve is closed.\ VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 61: Auxiliary Air Receiver

    The line from the VMAC tank to the auxiliary air receiver must have a one-way check valve installed to prevent blow back from the auxiliary tank to stop moisture from entering the VMAC tank (Figure 6.2).

  • Page 62: Accessory Products From Vmac

    Accessory Products from VMAC The following accessory products for your VR compressor system are available from VMAC. For more information or to order these products, call 1-888-241-2289. Eliminator Aftercooler Part Number A800070 Removes up to 80% of moisture from compressed air.
  • Page 63 VMAC Product Warranty Registration This form must be fully completed and returned to VMAC at the time of installation. Warranty will be void if this form is not received by VMAC within 30 days of installation. VMAC Dealer Information Company Name: ______________________________________...
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  • Page 68 Ma n u f a c t u r e d b y P H 2 5 0 - 7 4 0 - 3 2 0 0 F X 2 5 0 - 7 4 0 - 3 2 0 1 T F 1 - 8 0 0 - 7 3 8 - 8 6 2 2 1 3 3 3 K i p p R o a d , N a n a i mo , B C , V 9 X 1 R 3 C a n a d a w w w .

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