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Summary of Contents for Vmac VR150
- Page 1 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 1 0 0 0 7 2 0 0 7 F o r d F - 6 5 0 - F - 7 5 0 7 .
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Page 3: Table Of Contents
5.2 After Starting the Engine Checklist........28 5.3 Setup, Performance Testing and Adjustments....30 5.4 System Identification and Warnings........31 5.5 Auxiliary Air Receiver ............32 Accessory Products from VMAC ..........33 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201... -
Page 4: Installation Manual For Vmac System V910007
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
Measure the hose shortfall and order a Hose Extender Kit. The following table shows the color code used by VMAC to identify hose diameters. Hose Diameter Colour-Coded Label... -
Page 6: Part 1: Installing The Control Components
Part 1: Installing the Control Components VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201... -
Page 7: Locating The Modules And Wires
PTO top engine limit = 2750 (default) • If the engine is programmed before the VMAC throttle is installed, the system will check for a signal when the ignition is on in PTO mode. The check engine light will illuminate but will shut off once the throttle is installed. - Page 8 Figure 1.2 Fuse panel Control box Figure 1.3 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
- Page 9 (Figure 1.6). Test the wire with the engine running (wheels blocked). It should read 12 Volts in PARK and NEUTRAL and 0 Volts in all gears. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
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Page 10: Installing Components
If the truck has a manual transmission, cut the long blue wire from the throttle controller to about six inches and connect it to the short blue wire with the crimp connector. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201... -
Page 11: Connecting The Wiring
• control box the white wire with the bullet connector from the • interface connector if equipped with air brakes, the black wire from the • interface cable VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201... - Page 12 White Orange Black Figure 1.7 □ Splice the long blue wire to the wire from pin 41 at the transmission control module and seal the connection with tape. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
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Page 13: Part 2: Preparing For Installation
Remove any small brackets that locate hoses and wiring in the front upper engine sector. □ Remove the OEM L-brackets securing the coolant expansion bottle hose to the cross-member under the engine. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201... - Page 14 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...
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Page 15: Part 3: Installing The Tank And Hoses
Adjust the tank so that the front of the tank is 6 inches from the front C-clamp (Figure 3.1). 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 16 Insulated double tube clamp 5/16" tube 1/4" tube 5/16" bolt, washer and nut Figure 3.2 □ 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...
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Page 17: 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 3.3 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201... -
Page 18: Part 4: Installing The Cooler, Bracket And Compressor
(Figure 4.1). To radiator Crossmember Figure 4.1 □ Fasten the cooler in place with two M10 x 25 mm hex bolts, washers and Nylok nuts. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201... - Page 19 Cut the hose 2 inches back from the connection at the thermostat housing and install the supplied T-connector. □ Connect the hose from the cooler to the T-connector and secure all hoses with clamps. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
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Page 20: Installing The Main Bracket And Compressor
VR bracket and insert two M10 x 30 mm socket head bolts with flat washers through the top of the main bracket and thread them into the brace bracket. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201... - Page 21 During tightening, make sure that alignment is correct and there are no gaps. Do not use the bolts to force gaps to close, check and correct the reason for the gap. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
- Page 22 Remove the inlet valve from the compressor to provide access for fastening the compressor to the bracket (Figure 4.4). Immediately cover the opening on the compressor to prevent contamination. Inlet valve and bolts Compressor Figure 4.4 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
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Page 23: 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 24: 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. □ Install all intercooler tubes and tighten the clamps. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201... - Page 25 Adjust the tubes to provide clearance for the compressor clutch and secure with clamps. □ Install the 1/2 inch aluminum block to the bottom coolant bottle mounting position on the radiator with two M8 x 30 mm bolts. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
- Page 26 Tighten all fittings before adding oil to the system. □ Install the VR eight-rib compressor belt (Figure 4.7). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
- Page 27 Tighten all bolts and clamps securely. □ Cut the short, plastic air intake tube that attaches the air cleaner to the resonator (Figure 4.8). Discard the bent section. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
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Page 28: 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 29 Do not overfill the system, as this can flood the sight glass window and make the system appear empty. □ Install the fill plug in the inlet control valve and tighten it securely. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
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Page 30: Part 5: Finishing The Installation
Push the “ON” button on the control box. The green LED on the control box should illuminate and engine speed should increase to 2,000 rpm, then drop back down to 900 rpm in about five seconds. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201... - Page 31 If the truck fails the safety tests, check the wiring to make sure that all the connections are correct. If you require additional assistance, contact your local VMAC dealer. Call 1-800-738-8622 or 250-740-3200. VMAC – Vehicle Mounted Air Compressors...
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Page 32: 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 33: 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 34: 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 35: 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,... - Page 36 This page intentionally left blank...
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- Page 40 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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