Vmac VR70 Installation Manual
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Vmac VR70 Installation Manual

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V R 7 0 A n d V R 1 5 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 0 8 5 A n d V 9 1 0 0 0 6
2 0 0 5 F o r d F - 6 5 0 - F - 7 5 0
7 . 2 L C a t e r p i l l a r C 7 D i e s e l
w w w . v ma c a i r . c o m

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  • Page 1 V R 7 0 A n d V R 1 5 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 0 8 5 A n d V 9 1 0 0 0 6 2 0 0 5 F o r d F - 6 5 0 - F - 7 5 0 7 .

  • Page 3: Table Of Contents

    5.2 After Starting the Engine Checklist........35 5.3 Setup, Performance Testing and Adjustments....36 5.4 System Identification and Warnings........37 5.5 Auxiliary Air Receiver ............38 Accessory Products from VMAC ..........39 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 4: Installation Manual For Vmac Systems V900085 And V910005

    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 5: General Information

    Read this manual before attempting installation so that you can familiarize yourself with the components and how they fit on the truck. These instructions are for both the VR70 (V900085) and VR140 (V910005) systems. This manual should be read completely before attempting installation.

  • Page 6: Part 1: Preparing For Installation

    Part 1: Preparing for Installation This manual contains installation instructions for the VR70 system (V900085) and the VR140 system (V910005). There are differences in the installation. Make sure that you read these instructions before beginning the installation to identify the specific steps that apply to your system.
  • Page 7 Place the OEM crank pulley bolt ring plate on the front of the VR crank pulley. □ Apply Loctite to the supplied M10 x 100 mm bolts, thread them into the pulley holes and torque them to specifications. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 8: Part 2: Installing The Tank And Hoses

    Adjust the tank so that the front of the tank is 6 inches from the front C-clamp (Figure 2.1). Rotate the tank so that the “UP” arrow points upward. □ Tighten the C-clamps. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 9 Insulated double tube clamp 5/16" tube 1/4" tube 5/16" bolt, washer and nut Figure 2.2 □ Tighten all bolts □ Tighten the steel tube fittings on the back of the tank VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 10: Connecting The Hoses

    Select a route that will clear the exhaust and the turbocharger piping. □ When all the hoses have been routed and secured, tighten the fittings at the tank. OEM support brackets Air lines Figure 2.3 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 11: Part 3: Installing The Cooler, Bracket And Compressor

    □ Align the four mounting holes with the threaded holes in the engine, install the four M14 x 30 mm bolts and torque to specifications. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 12 Locate the heater supply hose that connects between the heater core and the back of the thermostat housing. □ Cut the hose 2 inches back from the connection at the thermostat housing and install the supplied T-connector. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 13 (Figure 3.3). Secure it with clamps. □ Install the supplied lower radiator hose between the cooler and the radiator, with the longest straight end attached to the radiator. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 14: Installing The Main Bracket And Compressor

    Position the fitting so that it points upward to clear the head and tighten the fitting. You may have to grind the corner from the front engine lifting bracket to provide clearance for the fitting. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 15 3.4). Place the main bracket in position on the front upper driver side of the engine timing cover and align the mounting holes. □ Adjust the air brake compressor cooling hose to clear the bracket and tighten the fitting. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 16 Tighten the air compressor coolant hose; with the hose tight against the front of the engine and clear of the OEM belt. □ Install the fan spacer and the fan. Torque to specifications. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 17 Adapter plate and bolts Figure 3.5 □ Insert the four M8 socket head bolts through the adaptor plate, thread them into the main bracket and torque to specifications. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 18 Install the M8 x 100 mm bolts through the compressor mount holes and the adapter plate and thread them into the bracket. Tighten them down evenly and then torque them to specifications. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 19: Connecting The Hoses

    Make sure that none of the hoses will interfere with moving parts or contact hot objects. Secure them with ties or clamps. Protect them where they might rub. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 20: Completing The Installation

    If you do not clear the air in the hose between the injector pump and the filter, air will enter the fuel system and the engine will not start. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 21 (Figure 3.8 - viewed from the front of the engine). □ Adjust the tubes to provide clearance for the compressor clutch and secure with clamps. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 22 Check all wiring harnesses, hoses and other items to make sure that they are secure and will not contact any moving parts. Tighten all fittings before adding oil to the system. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 23 Partially tighten the clamp, but leave it loose enough to adjust. □ Install the intake plastic duct to the turbo inlet and do not tighten. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 24 3-1/2” Cut at this line Discard this section Air cleaner end Resonator end Install the resonator 1/2” tube to this line Figure 3.10 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 25: Adding Oil To The System

    Remove the fill plug from the air inlet control valve and pour oil into the oil fill hole on the inlet control valve using a funnel. You must use the supplied VMAC compressor oil in this system. Failure to use this special oil will result in damage to the compressor and will void your warranty.

  • Page 26: Part 4: Installing The Control Components

    Part 4: Installing the Control Components VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 27: Installing The Control Boxes

    Mount the switching box under the dash to the right of the fuse panel using nylon ties (Figure 4.2). □ Mount the throttle control box under the dash to the right of the steering column (Figure 4.3) using nylon ties. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 28 Fuse Panel Dash support Control box Figure 4.2 Throttle control box Figure 4.3 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 29 • white wire from the throttle control box □ Secure all of the wiring under the dash so that it does not interfere with any moving parts. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 30: Connecting The Wiring Harnesses

    Fuse number is 102 (20 A) in the power distribution box. □ Crimp the red key switched 12V wire from the interface harness to the OEM wire using a butt-connector. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 31 □ Ensure that all engine compartment wires are away from hot spots and moving parts. Protect them with plastic loom and secure them with nylon ties. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 32 Identify the transmission type as either WTEC MD or Allison 2000/2400. These transmissions will have different connections. Pay careful attention to the following information. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 33 Note that there are two connectors on vehicles with WTEC transmissions; use the 7205 connector. WTEC MD WTEC MD 2000/2400 Connector Connector Connector 7206 7205 7306 Figure 4.9 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 34 Splice the black wire to the tan wire with two red stripes at the air brake pressure switch on the firewall (Figure 4.11). Seal the splice with electrical tape. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 35 Figure 4.10 Pressure switch Figure 4.11 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 36: Testing The Safety Circuit

    If the truck 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 1-800-738-8622 or 250-740-3200. VMAC – Vehicle Mounted Air Compressors...

  • Page 37: Part 5: Finishing The Installation

    Check the coolant after the engine reaches operating temperature. □ Check the compressor oil level after the engine has been shut down and the oil level has had time to stabilize. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 38: Setup, Performance Testing And Adjustments

    9. Once the 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 start to ramp-up when air pressure drops to approximately 140 PSI. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 39: System Identification And Warnings

    The System Identification Number Plate must be attached to the truck at the time of installation (Figure 5.2). This plate provides information which allows VMAC to assist in customer inquiries and the ordering of parts. Mark and drill two 7/64 inch holes, then secure the plate with self-tapping screws.

  • Page 40: Auxiliary Air Receiver

    The line from the VMAC tank to the auxiliary air receiver must have a one-way check valve installed (part #3600078) to prevent blow back from the auxiliary tank to stop moisture from entering the VMAC tank (Figure 5.4).

  • Page 41: 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 1-800-738-8622. Eliminator Aftercooler Removes up to 80% of moisture from compressed air. Quick installation,...
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  • Page 44 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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