Vmac VR70 Installation Manual
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Vmac VR70 Installation Manual

Underhood air compressor
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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 0 7 5
1 9 9 9 - 2 0 0 3 . 2 5 F o r d F - 2 5 0 - F - 5 5 0 S u p e r D u t y
7 . 3 L P o w e r S t r o k e 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 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 7 5 1 9 9 9 - 2 0 0 3 .

  • Page 3: Table Of Contents

    Part 4: Installing the Control Components ......21 4.1 Installing the Control Unit ........... 21 4.2 Installing the Throttle Control ..........22 4.3 Connecting the Wiring ............22 4.4 Completing and Testing the Installation ......34 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 4: Installation Manual For Vmac System V900075 Ford 1999 - 2003.25

    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

    If you must move the tank, the lines may be too short. If this is the case, measure the hose shortfall and order a Hose Extender Kit. The following table shows the color code used by VMAC to define the different hose diameters. Hose Diameter Colour-Coded Label...

  • Page 6: Special Installation Notes

    The enclosed System Identification Number Plate must be attached to the vehicle at the time of installation. 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 two #6 pan head self-tapping screws.
  • Page 7 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.

  • Page 8: Part 1: Preparing For Installation

    11. Remove and discard the power steering return hose from the power steering pump. 12. Remove and discard the OEM alternator and power steering pump mounting bracket. Keep the fasteners. 13. Remove the upper and lower radiator hoses. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 9 M12 stud holding ground strap and transmission cooling lines M12 hex head cap screw holding ground strap Figure 1.2 16. Remove and discard the positive battery cable locating bracket from the same area. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 10 17. Clean the front of the engine block to ensure that the oil cooler and mounting bracket will fit flush. 18. Clean the driver’s side frame. 19. Remove the three OEM bolts from the crankshaft pulley. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 11: Part 2: Installing The Tank And Hoses

    2. Rotate the C-clamps so that the flat mounting surfaces are on the right side of the tank, as viewed from the back of the tank (Figure 2.2). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 12 6. Repeat this procedure with the second strap mount bracket and C-clamp. 7. Identify the tank mounting position which matches the vehicle (Figure 2.4). These locations are suggestions only. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 13 8. Remove the nuts and washers from the threaded end of the tank strap cables, insert them through the end of each tank flat bar strap with the single hole and pull them to the stops. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 14 12. Insert the threaded end of each cable strap through the tubes on the lower frame locating U-clips. A special clip is included for trucks with double frames. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 15 19. Remove each of the bolts (one at a time) holding the C-clamp to the tank strap mount, apply Loctite and replace the cap screws. 20. Make sure that the tank is level with the vehicle and tighten the bolts. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 16: Attaching Hoses To The Tank

    4. Bunch all hoses together and protect them where they pass over the cab mount. 5. Route all the hoses and tubes into the engine compartment. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 17: Part 3: Installing The Main Bracket And Compressor

    2. Attach the transmission lines to the right hand stub. This may require the bracket to be bent or modified slightly. 3. Install the ground cable, thread on two M10 Nylok nuts and tighten. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 18: Installing The Pulley And Bracket

    4. Install the main compressor mount bracket using the four OEM flange lock bolts. Torque them to specifications (Figure 3.2). 5. Install the power steering pump to the main bracket using the OEM fasteners. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 19 8. Install the supplied 3/8 x 36 inch power steering return hose between the power steering pump and the master cylinder. 9. Align the power steering hoses to clear the steering column. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 20: Installing The Compressor

    Alternator Idler Air conditioning Tensioner Water pump Idler Power steering Crankshaft pulley Figure 3.3 VR70 Air Compressor VR70 Tensioner VR70 Drive Belt VR70 Idler VR70 Crankshaft Pulley Figure 3.4 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 21 13. Install the upper radiator hose. Rotate the hose on the thermostat housing and radiator fitting until the hose clears both the compressor belt and the fan shroud. Tighten the clamps. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 22: Adding Oil To The System

    1. 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 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 23: Part 4: Installing The Control Components

    Figure 4.1 Keep wires away from the park brake mechanism. 4. Place the floor covering back into position and replace the inside left kick panel. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 24: Installing The Throttle Control

    2001.25 – 2003.25 and Figure 4.13 1999 - 2001. Refer to the appropriate diagram when connecting the wiring. 1. Unplug the cable from the foot pedal assembly and connect it to the throttle control VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 25 8. Connect the white wire with the blue bullet connector to the matching connection at the compressor clutch. The green “CMP” sensor wire is critical. The engine will not run without it connected properly. Follow this procedure carefully. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 26 (Figure 4.4. Do not overheat and be sure to protect the other nearby wires with a piece of cardboard or sheet metal. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 27 2001.25-2003.25 – white with a light blue stripe (Figure 4.5) • 1999-2001.00 – blue with pink stripe (Figure 4.6) White wire with a light blue stripe OEM ground OEM diagnostic connector Figure 4.5 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 28 NEUTRAL. FAILURE TO INSTALL AND VERIFY THE FUNCTION OF THIS SAFETY FEATURE CAN RESULT IN INJURY OR DEATH. IF YOU REQUIRE A SAFETY INTERCONNECT TO PERFORM THIS TASK, ORDER THE VMAC DRIVE DISABLE CIRCUIT. BE SURE TO PERFORM THE SAFETY TEST IN THE DDC INSTALLATION INSTRUCTIONS BEFORE PROCEEDING.
  • Page 29 (Figure 4.8). Install and remove the screw for the magnetic switch bracket in the hole to tap threads in the hole. Transmission arm Mounting location Figure 4.8 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 30 7. Slide the switch to the magnet and align the two pieces. This alignment does not need to be perfect and the magnet and switch should not quite touch (Figure 4.10). Tighten the screw with a screwdriver. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 31 (Figure 4.11). Solder and seal this connection. 2. Connect the remaining DDC wire to the black wire coming from the throttle control. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 32 2. Attach the black wire from the throttle control (with the female spade connector) to the black “Park Brake” jumper wire with a male connector on one end and a piggy-back connector on the other. Tape this connection. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 33 Tape this connection. 3. Route the wire to the vehicle park brake and connect the piggy- back connector to the switch. 4. Connect the OEM connector to the piggy-back connector. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 34 BLACK WIRE INTERFACE CABLE OR THROTTLE PRESSURE SENSOR Figure 4.12 – 2001.25 to 2003.25 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 35 BLACK WIRE INTERFACE CABLE OR THROTTLE PRESSURE SENSOR Figure 4.13 – 1999 to 2001 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 36: Completing And Testing 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 1-800-738-8622 or 250-740-3200. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622...
  • Page 37 (1 hour preferred) • road test the vehicle for approximately 14 miles (20 km) • check all components once the engine is turned off and the system has cooled VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 38 This page intentionally left blank...
  • 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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