Vmac VR70 Installation Manual
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Vmac VR70 Installation Manual

Underhood air compressor, system v90g120, 2016-2011 ford f250-f550 6.7l diesel
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YMAC
AIR
VEHICLE
MOUNTED
COMPRESSORS
System V90G120
2016-2011 Ford F250-F550 6.7L Diesel
www.
.com

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  • Page 1 YMAC VEHICLE MOUNTED COMPRESSORS System V90G120 2016-2011 Ford F250-F550 6.7L Diesel www. .com...

  • Page 3: Table Of Contents

    5.4 Completing and Testing the Installation ......64 Part 6: Finishing the Installation ..........66 6.1 Before Starting the Engine Checklist........66 6.2 Safety Test ................. 66 6.3 Setup, Performance Testing and Adjustments ....69 6.4 Auxiliary Air Receiver ............70 Accessory Products from VMAC ..........71...

  • Page 4: Installation Manual For Vmac System V90G120

    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 A good spot for this is usually on the inside of the door or on the panel underneath the steering wheel. (Figure 1.1). 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 (3 connectors). □ Remove the bolt from wheel well that secures inner fender to battery box. □ Remove passenger side battery box (save bolts for later use). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 12 (discard band and hose) (Figure 2.01). Upper Secondary Radiator Hose Cut Plastic Cuff To Remove Connector Figure 2.1 □ Install supplied hose back on connector and secure with supplied hose clamp (Figure 2.2). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 13 (two bolts securing to EGR and plastic ties securing to wire). Save bolts for attaching the inlet valve brace later and discard plastic. (Figure 2.3). Figure 2.3 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 14 Remove fan stator (the lower shroud can be left in place if the stator is rotated to clear the lower lip). □ Remove upper passenger side fan stator mount and save for use later. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 15 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 16: 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 17: 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 18 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 19: 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 20 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 21: Installing Main Bracket

    Ensure hose does not kink. Adjust the 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 22 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 23 Ford F250-F550 Superduty trucks equipped with 6.7L Powerstroke diesel engines as of 29- Sep-11 (Figure 3.10). Trucks built after this date may experience clearance issues between the VMAC main bracket and OEM stator mounting stud during installation. Original Stator Mount Stud New Stator Mount Stud Figure 3.10...
  • Page 24 Check to ensure the added hose protection is in the correct location. □ Modify fan stator as shown (Figure 3.12). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 25 □ Remove the 4 OEM crank pulley balancer bolts and discard. Install VMAC crank pulley on inside of OEM balancer. Ensure center-locating boss goes in OEM balancer and install the 4 supplied M12 crank pulley bolts. Torque to 22 lb. ft. (will tighten an additional 90 degrees in step to follow).
  • Page 26 It attaches to the front of the EGR where the wire guide was previously removed, (Figure 3.14), (use OEM bolts, use Loctite and torque to specifications). Lower portion of inlet brace bolts here. Figure 3.14 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 3.15). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 28 Ensure hose does not contact any hot, moving or sharp components. Do not tighten fitting until connected to separator tank. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 29 □ Route the VMAC belt around compressor, idler, tensioner and crank pulley. See belt routing diagram (Figure 3.16 – VR70 Belt Layout). Figure 3.16 – VR70 Belt Layout □ Remove OEM bolts and install idler bracket (part number horizontal when installed) over the OEM tensioner using replacement M8x 200mm bolts provided.
  • Page 30 Ensure hose does not contact any hot, moving or sharp components. □ Install solenoid assembly on passenger side engine cover using supplied fasteners (Figure 3.18 ) VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 31 □ Attach the glow plug module previously removed from battery box to underside of supplied glow plug bracket using three supplied M6 bolts and nuts (Figure 3.19). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 32 Use supplied M8 flat head bolt to hold the long leg of the glow plug bracket to the fender sub frame, but DO NOT TIGHTEN at this point.(Figure 3.19). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 33: 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 3.21). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 34 (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 3.22 & Figure 3.23). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 35 Depending on truck configuration cross- member location may differ (Figure 3.24). Suspension Radius Suspension Radius Remove Front Nut Remove Rear Nut Arm Mount Arm Mount Figure 3.24 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 36 See below: □ 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 37 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...

  • Page 38: Washer Bottle

    M8 bolts and nuts (Figure 3.25). □ 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 39 See below. □ First remove the bumper support bracket as described as in above text, then disconnect the fog light wiring harness at the right fog light. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 40 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. □ Complete installation as described. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 41: Air Filter Box

    With Hole in Steel Bottom Box. Figure 3.28 □ Cut foam section of air filter 1” below ridge that secures it in the plastic air filter box (Figure 3.29). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 42 Overlap is .7" VMAC Steel box OEM plastic box Back-up washer Rivet Drill 3/16" hole through both boxes Inside of box Outside of box Typical rivet assembly Figure 3.30 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 43 Cut raised edge off . Cut off raised portion here OEM air duct Figure 3.31 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 44 Plastic Tab OEM Air Duct to be modified Figure 3.32 □ Using a hammer, flatten the sheet metal, raised edge all around the lower hood strut area. (Figure 3.33). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 45 Align UHMW pad, supplied, with these two holes in inner fender and the large portion of pad forward of holes. Reinstall glow plug module fastener, (Figure 3.34). □ Install lower hood strut bracket with supplied fasteners, (Figure 3.34). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 46 8mm hex nut may need to be oriented to fit in the slot in hood. M8 nut Relocation Bracket M8 x 18mm bolts Figure 3.35 □ Reinstall passenger side hood strut. □ Remove the ground wire bolt from the firewall, (Figure 3.36). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 47 Proceed to the section for installing tank and hoses, and the section installing the electrical components before continuing. Completing these sections first is easier without the air filter box installed. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 48 Cut end and lip off of air filter box lid, (Figure 3.38). Remove Shaded Area. Grind Off Lip So Hose Can Slide Over. Clean And Ensure All Debris Is Out Of Inside Figure 3.38 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 49 Add the MAF extension cable to the mass flow sensor wire and reconnect to the sensor. If the wire is too tight reroute where it attaches at front of the truck (under filter box) to get more slack. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 50 □ Position intake tube for best clearance to brace and to firewall connector and tighten hose clamps. (Figure 3.41). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 51 Figure 3.41 Ensure intake tube is close to, and or resting on the clutch guard rubber pad. Loosen hose clamps and adjust tube position if required. (Figure 3.42) Figure 3.42 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 52 Add ‘paint pen’ or other marker to indicate proper alignment once final position is done. This will aid in repositioning the tube when it is removed for filter changes. Figure 3.43 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 53: Part 4: Installing The Tank And Hoses

    5/16 x 2 Bolt & Washer Washer Figure 4.2 □ Place the tank on a workbench with the front (oil filter end) of the tank to your right and remove the oil filter VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 54 Suspension Radius Suspension Radius Remove Front Nut Arm Mount Arm Mount Figure 4.3 Leave all tank mounts and fasteners loosened throughout the following aligning process to make adjustments easier. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 55: Installing The Hoses

    Where possible, use rubber coated P-clips. Follow the routing suggestions in this manual and cover all hoses with the supplied plastic loom. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 56: 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 57: Part 5: Installing The Control Components

    Part 5: Installing the Control Components Connect to accelerator pedal OEM Connector to accelerator pedal IGNITION CONNECTOR IN STEERING WHEEL Figure 5.1 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 58: Routing The Wiring

    • The hood switch connector rests near the driver’s side headlight • The remaining wiring follows the radiator cooling lines across the radiator towards the compressor VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 59: Installing The Components

    □ Find the two unused M8 vertical studs (2.75” apart) located inside the cab above the firewall plug. □ Install control box mounting bracket as shown in Figure 5.2. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 60 Route both of its two 6-pin connectors to the foot pedal. □ Connect the 4-pin connector with the mating connector on the wiring harness coming from the Control Box. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 61 □ If the vehicle comes equipped with a hood switch, splice and seal the OEM blue w/pink hood switch wire with VMAC’s grey hood-switch wire, See Figure 5.3. Ensure VMAC’s black hood- switch connector wire is left unexposed, as it is at 12V. Skip to section 5.2.4...
  • Page 62 Assembly to its mating connector with red and brown wires on the wiring harness. □ Connect the Clutch on the VR70 Compressor Assembly to the mating bullet connector with white wire on the wiring harness. □ Connect the Compressor Temperature Sensor on the VR70 Compressor Assembly to its mating 7 pin (4 wires) connector on the wiring harness.

  • Page 63: Connecting The In-Cab Wiring

    Remove insulation on the wire and solder it to the 60” long green-yellow “DIGITAL GROUND” wire coming from Control Box. Trim the green-yellow wire’s length as needed before soldering and sealing. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 64 (coming from the shrink-wrapped diode) to the OEM SEIC circuit CDC64 yellow with orange stripe wire on early builds, white with blue stripe wire on later builds, at the blunt-cut harness. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 65 It is held in place by three screws below and has hooks in the rear holding it onto the panel above Steering Wheel Ignition Switch Connector Figure 5.6 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 66: Completing And Testing The Installation

    Use remaining loom to cover wires inside of cab, such as: • Wires connecting VR Throttle Controller to Control Box. • Wires connecting relays to START/STOP splices. • Any remaining wires or wire-bundles VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 67 (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 68: Part 6: Finishing The Installation

    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. □ Install a test tool on the air tank outlet and close the ball valve.
  • Page 69 HOOD TO START. □ Close the truck’s hood. □ Press ON/ENTER and follow on-screen directions to restart the compressor system. □ Check that the LED Beacon module is not illuminated. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 70 Check the vehicle coolant after the vehicle reaches operating temperature. □ Check the compressor oil level after the vehicle has been shut down and the oil level has had time to stabilize. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 71: Setup, Performance Testing And Adjustments

    Allow the vehicle to run until the engine is at operating temperature. □ Operate the air compressor system until the oil is warm. □ Observe the pressure gauge. Pressure should be approximately 150 psi. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 72: Auxiliary Air Receiver

    Auxiliary Tank VR Tank with the Install the line as high as supplied check valve possible, NOT in the bottom of the auxiliary tank Figure 6.2 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 73: 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. Quick installation, automatic...
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  • Page 78 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: ______________________________________...
  • Page 80 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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