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Installation Manual for VMAC
System V90G120
2015-2011 Ford F250-F550 6.7L Diesel
General Information..................................................................... 4
Before You Start ....................................................................... 4
Additional Requirements .......................................................... 4
Part 1: Warranty and System ID ................................................. 5
Part 2: Preparing for Installation ............................................... 8
Part 3: Installing the Cooler, Bracket and Compressor .......... 14
3.1 Installing the Oil Cooler ...................................................... 14
3.2 Routing Battery Cables ...................................................... 15
3.3 Continuing Oil Cooler Installation ....................................... 17
3.4 Installing Main Bracket ....................................................... 19
3.5 Battery Cable and Relocated Battery Box .......................... 30
3.6 Washer Bottle ..................................................................... 35
3.7 Air Filter Box ....................................................................... 38
Part 4: Installing the Tank and Hoses....................................... 50
4.1 Installing the Tank and Brackets ........................................ 50
4.2 Installing the Hoses ............................................................ 52
4.3 Adding Oil to the System .................................................... 53
Part 5: Installing the Control Components .............................. 54
5.1 Routing the Wiring .............................................................. 55
5.2 Installing the components ................................................... 56
5.3 Connecting the In-cab Wiring ............................................. 60
5.4 Completing and Testing the Installation ............................. 63
Part 6: Finishing the Installation ................................................ 65
6.1 Before Starting the Engine Checklist.................................. 65
6.2 Safety Test ......................................................................... 65
6.3 Setup, Performance Testing and Adjustments ................... 68
6.4 Auxiliary Air Receiver ......................................................... 69
Accessory Products from VMAC ............................................... 70
Document #1930190
Installation Manual for VMAC System V90G120
2015-2011 Ford F250-F550 6.7L Diesel
Changes and Revisions
Version
A
B
C
D
E
Revision Details
Release
ECN 12-071
ECN 12-084, ECN 12-127
ECN 12-170
ECN 13-013, ECN 14-018
Revised by/date
SAR 23 Feb 2012
SAR 23 May 2012
SAR 11 Jun 2012
SAR 06 Feb 2013
JR 30 Apr 2014
Checked by/date Reviewed by/date Implemented
MH 3 Apr 2012
OJ 29 May 2012
MH 11 Oct 2012
SM 08 Feb 2013
MH 06 May 2014
N/A
N/A
N/A
N/A
RD 06 May 2014
12 April 2012
29 May 2012
11 Oct 2012
08 Feb 2013
12 May 2014
Important Information
!
This symbol is used to call your attention to instructions
concerning your personal safety. Watch for this symbol; it
points out important safety precautions, it means “attention,
become alert! Your personal safety is involved. Read the
message that follows and be alert to the possibility of personal
injury or death. Be alert; your safety is involved. While it is
impossible to warn about every conceivable hazard, let good
common sense be your guide.
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. Do not
attempt this installation if you do not have the appropriate
mechanical training, knowledge and experience.
Follow all safety precautions for under hood mechanical work. Any
grinding, bending or restructuring operations for correct fit in modified
trucks must follow standard shop practices.
!
2
All hoses, tubes, and wires that are rerouted or shifted
during installation must be secure so that they do not
contact excessively hot areas or sharp edges. 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
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Fax: 1-250-740-3201
These instructions are a general guide for installing this system on
standard production trucks and do not contain information for
installation on non-standard trucks. This system may not fit special
order models or those which have had other changes without
additional modifications. 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.
To order parts, contact your VMAC dealer. Your dealer will ask for
the VMAC serial number, part number, description and quantity. To
locate your nearest dealer, call 1-888-241-2289.
Copyright 2012
All trademarks used in this manual are the property of the respective copyright holder.
The contents of this manual may not be reproduced in any form without the express
written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3.
Printed in Canada
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3
General Information
Before You Start
Read this manual before attempting installation so that you can
familiarize yourself with the components and how they fit on the
truck. Identify variations for different model years and different
situations that are listed in the manual. Open the package, unpack
the components and identify them.
All fasteners must be torqued to specifications. Use manufacturers
torque values for OEM fasteners. Apply Loctite 242 or equivalent on
all engine-mounted fasteners. Torque values are with Loctite
applied unless otherwise specified.
STANDARD GRADE 8 NATIONAL COARSE THREAD
Size
1/4
5/16 3/8
7/16 1/2
Foot-pounds (ft-lb)
9
18
35
55
80
Newton meter (N•m)
12
24
47
74
108
9/16
110
149
5/8
170
230
¾
280
379
STANDARD GRADE 8 NATIONAL FINE THREAD
Size
3/8
7/16
Foot-pounds (ft-lb)
40
60
Newton meter (N•m)
54
81
1/2
90
122
5/8
180
244
¾
320
434
METRIC CLASS 10.9
Size
Foot-pounds (ft-lb)
Newton meter (N•m)
M12
69
93
M14
104
141
M16
174
236
M8
19
25
M10
41
55
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.
4
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Hose Information
!
Depending on other installed equipment, it might be
necessary to move the air/oil separation tank from its
intended location. The hoses used in VMAC compressor
systems have a specific inner liner that is compatible with
our compressor oil. Use of hoses other than those supplied
or recommended by VMAC may cause compressor damage
and may void your warranty. Please contact VMAC for
replacement hoses and further information.
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.
System Identification and Operating Instructions
The System Identification Number Plate must be attached to the
vehicle at the time of installation. This plate provides information that
allows VMAC to assist in customer inquiries and the ordering of
parts.
□ Mark
and drill two 7/64” holes in the top of the cross member in
front of the OEM air filter box. Secure the plate with supplied
self-tapping screws
□ Clean
cross member beside the number plate and stick the
VMAC belt routing diagram to the cross member.
□ Apply
battery warning label to driver side of primary cooling
reservoir.
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5
□ Asoperational
part of the installation process, ensure that the safety and
instruction decal is affixed in an obvious location so
that it can be seen by vehicle operators. 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
6
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□ Toservicing
alert any technicians that may service the vehicle, affix the
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
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7
Part 2: Preparing for Installation
Preparation for installation is very important. Missing an item can
cause problems in the installation or even damage to components.
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).
□ Locate
the blunt-cut OEM SEIC wire harness, on the driver’s
side just below the OBDII port. You will need to find the
transmission park signal (blue with grey stripe wire).
□ Use
a multi-meter to verify the transmission park signal. Turn the
key to the RUN position (do not start the truck), as to supply
power to the dash display. The resistance should read close to
0-ohms in park and open circuit in all other gears. If this is
correct, put the car in park and turn the key to the off position.
There are multiple blue wires with various coloured stripes.
The transmission park signal needs to be electrically
verified with a multi-meter to ensure the correct wire is read.
□ Mark
transmission park signal wire for connection later in Part 5:
Installing the Control
Components.
□ Disconnect batteries (both driver and passenger side).
□ Drain
coolant from both the primary and secondary radiators
(drain for primary coolant is on driver’s side, secondary coolant is
on passenger side). Start with the secondary radiator. Save
coolant to be reused later. Close drain caps when coolant has
been drained.
8
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□ Remove passenger side battery bracket and battery.
□ Disconnect the mass air flow sensor from the top of the filter box.
□ Remove filter box (both upper and lower sections).
□ Remove
tube and resonator that connects the filter box to the
turbo intake.
□ Cover turbo intake.
□ Remove
passenger side hood strut and hood strut ball stud from
the hood, (save for later use).
□ Remove lower hood strut ball stud from inner fender.
□ Remove
positive terminal block and wiring connector panel from
passenger side battery box. To remove wiring panel pry up.
Positive terminal block has one clip and slides up to remove.
□ Disconnect
windshield washer tube from joint above passenger
side battery box on top of firewall.
□ Unplug
wiring harness from windshield washer pump and
remove wiring from front lower passenger side battery box.
□ 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.
□ Remove passenger side battery box (save bolts for later use).
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□ Remove
glow plug module from bottom of passenger side
battery box (Torx T30 bolts) (save module for later use).
□ Disconnect
hoses from secondary coolant reservoir (attached to
passenger side of fan shroud) and remove reservoir from fan
shroud.
□ Remove
upper secondary coolant hose (top hose going to water
pump on passenger side of engine).
□ Cut
plastic cuff securing hose on secondary rad hose carefully to
preserve fitting (discard band and hose) (Figure 2.1).
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).
10
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Supplied Hose
Clamp
OEM Quick
Connect
Supplied Hose
Figure 2.2
□ Install
hose coupling and flexible hose to open end of modified
secondary coolant hose. Leave about 1” gap between hoses
and secure with supplied hose clamps.
□ Remove
plastic wire guide from front of EGR on passenger side
of engine (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
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□ Using
knife cut insulated heat shield if required to clear hose.
Install modified hose back on secondary water pump. Ensure
notches on OEM quick connector align with notches on
secondary water pump. Point elbow towards rear of truck
(opposite to the original direction). Ensure hose is not kinked,
(rotate the hose on the OEM quick connect, if required, to
remove any kinks). Hose must run underneath the injector wiring
harness.
□ Ensure
OEM locking clip is engaged on plastic elbow. Loop hose
towards front of truck.
□ 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.
□ Remove
5 bolts (3 on driver’s side and 2 on passenger side) and
wire clips securing upper fan shroud and remove upper fan
shroud from truck.
□ Unplug
fan wire (unplug connector closer to the engine, not the
one right on the hub of the fan). Remove long bolt securing fan
wiring harness to engine and discard.
□ Remove
the fan (right-hand thread) and pull it out of the engine
bay.
For ease of fan removal and installation, it is recommended
that a pneumatic fan wrench removal set (such as Lisle
43300) or a manual fan pulley holder (such as KD3900) is
used.
□ 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.
12
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□ 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
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Part 3: Installing the Cooler,
Bracket and Compressor
3.1 Installing the Oil Cooler
□ Remove
lower primary coolant hose (attached to the primary
cooler and engine) (Figure 3.1).
To
Engine
From
Radiator
Figure 3.1
□ Cut
the plastic cuff securing the OEM quick connect to engine
side coolant hose (discard OEM quick connect) (Figure 3.2).
OEM Quick
Connect
Cut Cuff
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).
14
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Discard This
Section
OEM Quick
Connect
8”
Figure 3.3
3.2 Routing Battery Cables
□ Apply loom to supplied battery cable extensions.
Note: The red and the black battery cables will follow the
same route!
□ Route
the supplied positive/red battery cable between the frame
and body from the re-located battery location that will be under
the driver side. Leave 20” of cable to the rear of the body mount
hanging under driver side door.
□ Continue
routing the cable above the truck electrical harness and
below the two metal power steering lines.
□ Continue
routing, careful to avoid the steering column, around
front of the steering box until the cable reaches the electrical
harness under/beside the fan shroud.
□ Feed
cable along fan shroud following other truck wiring
harness.
□ 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.
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□ Route
the negative battery cable from the relocated battery
location and follow the positive battery cable. Continue routing
until under the fan shroud and in such a way it will remain clear
of the crank pulley and any other sharp or moving objects.
□ Remove
the OEM negative battery block bolt attaching the OEM
negative battery cable located beside the engine side coolant
OEM quick connect (Figure 3.4).
For ease of removal the OEM negative battery block bolt
should be removed with the engine side coolant hose
disconnected. Figure 3.4 shown with coolant hose
connected to illustrate the OEM negative battery bolt
location.
Front of
Engine
Engine Side
Coolant Hose
OEM Negative
Battery Engine
Block Bolt
Figure 3.4
□ Install
the supplied negative battery cable lug on top of the
existing OEM negative battery cable lug. Orientate the cable so
that it travels down and under the existing vehicle battery tray
facing the front of the vehicle towards the fan shroud. 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.
16
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3.3 Continuing Oil Cooler Installation
!
Do not strike the impact sensor as this could cause the
airbags to actuate. (Figure 3.5)
□ Position
the cooler in the center of the cross-member so that it is
just above the sway bar with the oil ports facing up (Figure 3.5).
Impact Sensor
Location
Fog Light Connector
Location
Cross Member
Figure 3.5
□ Apply
Loctite then install bolts through the flat mounting strap
and place them on the front of the cross member on each side of
the impact sensor. Note the impact sensor is located in the
center of the cross-member; the driver side wire connection is for
the fog lights if equipped (Figure 3.5).
□ Thread
the bolts into the matching holes on the cooler mounts
hand tight only, this will allow the cooler to be repositioned if
necessary after the coolant hoses have been attached (Figure
3.5).
□ Install
the radiator side coolant hose and secure with supplied
hose clamp (Figure 3.6).
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17
Figure 3.6
□ With
the radiator side coolant hose secured tighten the cooler
mount bolts to specification.
□ Install
the engine side coolant hose and secure with supplied
hose clamp (Figure 3.6). Note, it may be necessary to trim the
cooler end of the coolant hose, do so as required if any kinking
of the hose occurs.
□ Apply hose protection to 1/2" oil hoses.
□ Connect
the shortest 1/2" hose to the passenger side of the
cooler and orientate as shown (Figure 3.7).
□ 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
18
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For ease of installation the cooler hoses should be installed
after the cooler is installed and before the fan and upper fan
shroud are installed.
3.4 Installing Main Bracket
□ Remove tensioner and idlers from VMAC bracket.
□ Disconnect A/C sensor.
□ Install
supplied adhesive rubber pad on the air conditioning line
that runs in front of the modified upper secondary coolant hose
connector (at the water pump). Install adhesive rubber pad to
protect hose where it will rub against main bracket. Secure with
zip ties.
□ Remove
Stud Bolt at front, passenger side engine cover, and cut
off stud flush to top of bolt head, then reinstall bolt. (Figure 3.8).
□ Install
main bracket. On single alternator trucks use supplied
spacers behind top drivers side mount and lower front mount
between bracket and secondary water pump, (Figure 3.9).
For ease of installation, you may want to remove lower
secondary rad hose to get the main bracket in place on the
engine. Reinstall the hose immediately after installation of
the bracket.
Secondary coolant hose routes under compressor pad.
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.
□ Check
to make sure that no wires or OEM objects are pinched
between the bracket and the engine. The coolant hose installed
earlier must run under compressor platform.
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19
Remove Stud Bolt, Cut off Stud Flush
with Head and Reinstall.
Figure 3.8
!
Installation of the front and lower side mounting bolts must
follow the order below.
□ Use
long (130mm) M8 bolts and washers provided for front two
mounts. If installing on a single alternator truck use supplied
spacers behind bracket for 130mm bolts. Use Loctite and hand
tighten only. (Figure 3.9).
□ Use
shorter (40mm) M8 bolts for lower side engine mounts. Use
Loctite and hand tighten only.
□ 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.
20
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Washers
Single Alternator
Spacers
Front Mounts
M8 x 130 Bolts
Side Mounts
M8 x 40 Flange
Head Bolts
Figure 3.9
□ Reconnect A/C sensor.
□ Reinstall
passenger side upper fan stator mount through main
bracket into the original threaded hole.
A running change has resulted in changes to the OEM stator
mounting studs on Ford F250-F550 Superduty trucks
equipped with 6.7L Powerstroke diesel engines as of 29Sep-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
□ For
V900120/V90G120/V910010 systems shipped prior to 9Dec-11 being installed on trucks built after 29-Sep-11 the OEM
stator mounting stud can be modified for proper fitment. Grind
down the washer outside diameter as shown until proper fitment
is achieved, (Figure 3.11).
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DO NOT remove the entire washer. If the washer is removed
this bolt could damage the VR bracket when tightened down
resulting in VR bracket and/or water pump failure.
Part Number Location
Stator Mounting Stud
Must Fit In Bore Here
Grind O.D. of Washer Here
Figure 3.11
□ Install
idlers and tensioner using Loctite and torque to
specifications.
□ Flex
the air condition line that goes over the main bracket in
towards the engine to ensure clearance to the main bracket and
compressor. Check to ensure the added hose protection is in
the correct location.
□ Modify fan stator as shown (Figure 3.12).
22
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3/4”
½”
Cut Through Below Fins
Supporting Mounts
3-1/2”
Cut Through Just Below
For Fan Wire Clip
Cut Stator Section Down
To The Rubber Flap,
Approx 3-1/2” From Stator
Mount Surface
See Detail View
Detail View
Figure 3.12
□ Install fan stator using OEM nuts.
□ 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).
Some concerns have been raised regarding the OEM 2011
Ford 6.7 harmonic balancer. The concern is related to the
flatness of the balancer surface which the 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.
If you are experiencing this issue please contact VMAC
technical support at 1-888-241-2289.
□ Tension
OEM belt and ensure belt seated properly on all pulleys,
(Figure 3.13 – OEM Belt Routing).
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Figure 3.13 – OEM Belt Routing
□ Tighten crank pulley bolts an additional 90 degrees.
□ Remove
lower portion of inlet brace from air end and install on
engine. 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
24
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□ Connect
straight end of shorter 1/2” oil hose to the fitting on the
side of the compressor. The hose will route up over the
compressor behind the clutch guard and must be protected from
damage from threaded ends of the fasteners that attach clutch
guard.
□ Route
the straight end of the longer 1/2” oil hose, following the
shorter 1/2” hose, along the top of the frame rail, next to the
shock tower and rearward to the front of the separator tank,
beside the forward cab mount and connect to fitting on tank.
It is very important to tape or cover the opening in the top of
the compressor to ensure that nothing can enter the
compressor housing as this may cause severe damage to
the internal parts or failure of the compressor.
□ Bolt
Compressor in position using the three supplied M8 socket
head cap screws (no bolt goes in the inside rear location). Use
Loctite and torque to specifications (Inlet valve needs to be
removed to allow rear compressor bolt installation).
□ Replace
inlet valve. Install fasteners finger tight only. (Do not use
Loctite on these four (4) bolts).
It must be noted that this system uses three different length
bolts in the inlet valves. The longest bolts go in the two
holes closest to the engine (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).
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Longest Bolts
Shortest Bolt
Figure 3.15
!
Never use an impact wrench to install inlet bolts.
The torque spec for inlet bolts is 19 ft. lbs.
□ Join
the brace on the EGR to the one on the inlet valve using the
supplied M8 bolts, washers and nylock nuts. Finger tight only.
Ensure the brace bracket bolts are not preloaded before
tightening the inlet valve bolts.
□ Tighten all four (4) inlet valve bolts and torque to specification.
□ Tighten
the two fasteners joining the brace together and torque
to specification.
□ Connect
the 45 degree end of the 3/4” discharge hose to the
fitting on the rear of the compressor and route down towards the
outside of the frame rail under the passenger side of the truck.
Ensure hose does not contact any hot, moving or sharp
components. Do not tighten fitting until connected to separator
tank.
26
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□ 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. 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.
□ Install
fan spacer and fan. Use supplied fan wire spacer
between fan wire bracket and engine using supplied M8x170mm
bolt. Use Loctite and torque to specifications.
□ Reconnect fan wire.
□ Cut
rectangle out of soft rubber section on back of fan shroud.
Section should be 1/2" deep 4" long (Figure 3.17).
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Remove Shaded
Area
4”
1/2"
Figure 3.17
□ Install
upper fan shroud. Secure power steering reservoir and
secondary coolant reservoir.
□ Connect
hoses to secondary coolant reservoir. Route flexible
upper coolant hose under main compressor bracket across in
front to the reservoir. Secure hose to A/C line to ensure hose will
not contact clutch or any other moving components.
□ Fill the primary and secondary radiators with saved coolant.
□ Apply
loom and route the 1/4” and 3/16” Teflon hoses from the
compressor down the back of the passenger side inner fender,
along the outside of the frame rail under the passenger side of
the truck. Ensure hose does not contact any hot, moving or
sharp components.
□ Remove
two Torx screws holding the OEM component on top of
the passenger side engine cover. Install the solenoid valve and
mount supplied under the OEM component and reinstall the Torx
screws.
□ Connect
the 3/16” (the smaller of the two) Teflon line to the
straight fitting on the solenoid valve which is mounted on the
passenger side engine cover. The 1/4" Teflon line that comes
attached to the 90 degree fitting in the solenoid valve connects to
the 90 degree fitting on the passenger side of the inlet valve,
close to the clutch.
28
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□ Connect
the 1/4”, (the larger of the two), Teflon line to the fitting
on the inlet valve, (fitting on driver’s side of the inlet valve close
to the engine).
□ 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 3.18).
Use Supplied M8 Flat Head Bolt Here
Positive Terminal Lock Nut
Negative Post
Goes To Stud
On Firewall
Install Glow Plug Module
This Side Using M6 Bolts
Tie Strap Negative Battery Cable Harness Here .
Figure 3.18
□ Using
a hammer, flatten the raised, rolled edge around the
fender sub frame to provide clearance for the glow plug bracket.
□ Connect the three connectors to the glow plug module.
□ Install
glow plug bracket. Use supplied M6 nut to secure the
back leg to the stud on the firewall, (Figure 3.18).
□ 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 3.18).
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□ 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).
3.5 Battery Cable and Relocated Battery Box
□ Unscrew the positive lock nut from terminal on glow plug module.
□ Modify
both OEM battery cable ends (positive and negative) by
removing the threaded stud from the battery cable ends and then
enlarging the stud holes to allow them to fit over each of the
studs on the glow plug module. (Figure 3.19).
Figure 3.19
□ Ifthethediagram
battery cable clamping portions are not cut of it will look like
below. Be sure to wrap any exposed ‘positive’ clamp
with black electrical tape to prevent short circuiting. (Figure
3.20).
30
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Figure 3.20
!
Use caution when modifying the battery cable ends. Use a
vice or other means to hold and support the cable end when
drilling. A ‘step drill’ is recommended.
□ Connect
the supplied positive battery cable extension to the
positive terminal and secure down with lock nut. Connect OEM
battery clamp to positive post with the supplied nylock nut.
□ Using
the supplied tie strap, attach the negative battery cable
harness to the glow plug module bracket.
□ Attach
washer bottle pump extension cable to OEM plug. Route
cable down between radiator and frame so that the plug ends up
hanging down behind the bumper on the outside of the
passenger side frame (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 3.21 & Figure 3.22).
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Battery Box
Mount
Suspension Radius
Arm Mount
Front Bracket
Mount
(Note: Battery Box Not Shown For Clarity)
Figure 3.21
M10 Fender
Washer
M10 x 45
Bolt
M10 Nut
5/16 Nuts
(2 Places)
3/8 Washer
5/16 Washers
(4 Places)
5/16 x 3/4 Bolts
& 5/16 Washers
(4 Places)
5/16 x 2 Bolts & OEM Crossmember Nut
5/16 Washers
(2 Places)
Figure 3.22
□ Remove
1 of 2 OEM nuts attaching the transmission crossmember to the frame. Depending on truck configuration crossmember location may differ (Figure 3.23).
Suspension Radius
Arm Mount
Remove Front Nut
Suspension Radius
Arm Mount
Remove Rear Nut
Figure 3.23
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□ Remove
the plastic hold down for the wiring harness on the
inside of the frame that interferes with the front bracket mount
bolt. Secure the wiring harness with supplied P-clamp onto back
of the mount bolts.
□ Bolt battery box mount in place as shown in Figure 3.21.
Remove the two cables that are attached to the supplied
battery box, and discard as they are not used in this
application.
□ Place
battery in battery box and secure with supplied battery
hold down clamp. Do not connect battery at this point and do
not lift battery up onto battery box mount at this point!
In some applications/industries it is preferable to keep the
bottom and frame of the truck clear of additional
components and, in those cases it is acceptable to relocate
the battery to a better location on or in the service body of a
truck, instead of onto the frame rail. 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.
□ The
installer must use best practices when routing the battery
cables, and must ensure that the function of the vehicle's
electronics, and other systems, are not adversely affected by the
location of the battery and the cables. Do NOT attach the
ground wire to the frame. It MUST be connected to the same
point as the OEM ground wire or to the location shown in
the installation manual. If there are specific questions
regarding the routing of the cables, please contact the Ford
Truck
Body
Builder
Advisory
Service
at:
www.fleet.ford.com/truckbbas/
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□ Itlonger
is not recommended that the supplied cables be extended. If
cables are required, new cables should be made. Use a
minimum of a #2 AWG conductor. Use crimp terminals only. Do
not use wire-clamp type terminals. Keep cables as short as is
practical. The supplied battery box, or an equivalent, should be
used for additional protection. The installer must ensure that
nothing can be accidentally dropped across the two terminals or
have the positive post otherwise shorted to ground. If the battery
is not relocated as per the installation manual, be sure to note
this in the warranty registration to better assist with potential
Tech Support calls.
□ Atechnician
label must be installed to clearly advise the operator/service
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.
34
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3.6 Washer Bottle
□ Trace
around passenger side front bumper support bracket
where it attaches to frame with a paint pen for alignment during
reinstallation.
□ Remove bolts and nuts holding bumper support bracket to frame.
□ Install
supplied check valve into hose attached to hood by the
windshield. Ensure arrow on check valve points in direction of
washer nozzles. Fitting pushes into hoses (no clamps required).
□ Route
supplied windshield washer hose from check valve, along
fender on fender liner and down to behind the bumper (where
the bumper support mounts).
□ Drain
OEM washer bottle (save fluid) and remove windshield
washer pump from OEM washer bottle washer (keep elbow and
coupler attached to pump).
□ Remove
windshield washer pump from supplied washer bottle
and replace with OEM Ford windshield washer pump. Install
grommet and then pump.
□ Remove
aftermarket fill cap from washer bottle and attach to fill
fitting provided.
□ Attach
rubber coupling and reducer to inlet of washer bottle
using hose clamps (Figure 3.24).
□ Install
supplied carriage bolts through washer bottle mounting
plate and then attach washer bottle to plate using supplied M8
bolts and nuts (Figure 3.24).
Can cut 1” off plastic brace behind bumper, this will help
install washer bottle and bracket.
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Carriage Bolts
M8 Bolts
Note Orientation
Of Plate
Figure 3.24
□ Route
1" fill hose down beside radiator on the passenger side
from inside engine bay to washer bottle location and attach to
washer bottle using hose clamp.
□ Install
washer bottle with carriage bolts going through bumper
support. Secure with supplied M10 nuts & torque to specs.
□ Attach washer hose and electrical connector to pump.
□ Install
washer bottle fill fitting to top of 1" hose and secure with
hose clamp.
□ Remove
rubber from provided P-Clip. Using P-Clip secure fill
hose to bolt holding on fan shroud. Hose should be close to
radiator on driver’s side of the bolt, and next to bolt facing rear of
truck.
□ 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.
□ First
remove the bumper support bracket as described as in
above text, then disconnect the fog light wiring harness at the
right fog light.
36
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Fog Light Support Bracket
Cut and remove this portion
6 1/2”
2 1/2”
2 3/4”
Rear View
Side View
Figure 3.25
□ Remove
the three bolts holding the fog light support bracket in
place. Remove the fog light assembly.
□ Refer
to Figure 3.25 for the area required to be removed from
the support bracket.
□ 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.
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3.7 Air Filter Box
□ Remove
rubber intake sleeve from side of OEM air box (Figure
3.26).
Rubber Sleeve
Figure 3.26
□ Cut
OEM lower air filter box as seen in Figure 3.27. Cut at 3.75”
below top (just above the radius). Cut away main filter section
leaving the foam filter section. Leave the divider intact between
the two sections.
□ Cut
tab (with bolt hole in it) off flush on the side of the filter box,
(Figure 3.27).
□ Cut corner off air filter box as dimensioned, (Figure 3.27).
Trim Ribs Off Flush
Cut Tab Off Flush
Cut Corner Off - 1-3/4" Wide X 3/8" Tall
Trim Ribs Around Hole
3-3/4"
Cut Line
Match-Drill 3/8" Hole
With Hole in Steel
Bottom Box.
Cut To Match Opening
After Installing Steel
Bottom Box.
Figure 3.27
□ Cut
foam section of air filter 1” below ridge that secures it in the
plastic air filter box (Figure 3.28).
38
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1.0”
Cut 1” Below
Filter Box
Discard
Figure 3.28
□ Insert
supplied metal air filter box inside bottom of cut OEM
plastic filter box. The overlap should be 3/4”. Drill three 3/16”
holes on each side for the supplied rivets. Insert the supplied
3/16” pop rivets from the inside so the rounded ends are on the
inside of the box. Ensure that the back-up washer is tight
against the plastic box as the rivet is installed to ensure a tight
assembly. See Figure 3.29.
Match Drill 3/8" Through Hole
In Metal Air Box Lower Section.
Drill 3/16" Holes For Rivets Through
Both Metal And Plastic (6X)
Cut Ribs Away Around Hole For
Clearance (1.25" Dia.).
Install Rubber Intake Sleeve
Into Opening of Steel Box
Cut Plastic Here
To Match Opening
VMAC Steel box
Metal Box Goes Inside Plastic,
Overlap is .7"
OEM plastic box
Back-up washer
Rivet
Drill 3/16" hole through both boxes
Inside of box
Outside of box
Typical rivet assembly
Figure 3.29
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□ Transfer
position of 3/8” hole in metal air box to outside of plastic
air filter box and match drill. Cut ribs around hole to allow 1.25”
diameter for front spacer to fit flat against plastic wall, (Figure
3.29).
□ Route
wire for mass flow sensor under OEM air intake behind
headlight and pull towards back of vehicle and leave beside
compressor.
□ Cut
off plastic tab from wiring guide that is clipped into fender
frame on passenger side of truck (Figure 3.31).
□ Install
rubber intake sleeve previously removed from air box into
opening in front of metal filter box. Groove in rubber fits in
opening and rubber clips into front holes in bottom of filter box.
□ Remove
OEM air duct and cut raised lip and then trim raised
plastic on bottom face of duct, ( Figure 3.30 & Figure 3.31).
□ Note:
It may be required to trim up to 1/2” off the length of the
OEM air duct to allow the air filter box to move forward to line-up
the bolt hole in the inner fender with the hole in the air box.
Cut raised edge off .
Cut off raised portion here
OEM air duct
Figure 3.30
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□ Insert
modified foam filter section into rear of modified filter box.
Foam goes in original location of plastic section (groove fits in
plastic lip).
□ Reinstall OEM air duct.
Second threaded
OEM hole
Forward threaded
OEM hole
Cut Off Vertical
Plastic Tab
OEM Air Duct to be modified
Figure 3.31
□ Using
a hammer, flatten the sheet metal, raised edge all around
the lower hood strut area. (Figure 3.32).
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Sheetmetal edge
to be flattened
Figure 3.32
□ Ensure there are no sharp edges remaining.
□ Remove countersunk fastener holding long leg of the glow plug
bracket to inner fender.
□ 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 3.33).
□ Install lower hood strut bracket with supplied fasteners, (Figure
3.33).
42
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M8 x 16 Hexhead Bolt
Lower Hood Strut
Relocating Bracket
M8 x 20 Flathead Bolt
UHMW Guard Pad
Glow Plug Module
Figure 3.33
□ Remove
hood strut ball stud from passenger side of hood and
install into strut relocating bracket, (Figure 3.34). 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.
M8 nut
Relocation Bracket
M8 x 18mm bolts
Figure 3.34
□ Reinstall passenger side hood strut.
□ Remove the ground wire bolt from the firewall, (Figure 3.35).
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□ 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).
□ Install supplied brace bracket and ground wire using the OEM
fastener into lower hole.
□ Then install the supplied fastener into the new threaded hole
above it. The brace should sit flush against the firewall with the
ground strap on top of the brace.
□ Ensure the brace does not make contact with the electrical
connector on the firewall. Do not remove the ground cable,
(Figure 3.35).
INTAKE TUBE
BRACE BRACKET
PASSENGER
SIDE FIREWALL
OEM
GROUND
WIRE
Figure 3.35
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.
44
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□ Install lower air filter box assembly.
□ Install
front spacer and supplied bolt (Figure 3.36) through 3/8”
hole in metal lower air filter box and into forward OEM threaded
hole in inner fender, (Figure 3.31).
□ Install
rear spacer clamp and supplied bolt and washer, (Figure
3.36), into second OEM threaded hole in inner fender, (Figure
3.31), towards rear of air filter box and clamp vertical plastic wall
just above air filter box lid slots.
Rear Spacer Clamp
Supplied Bolt and Flatwasher .
Modified Air
Filter Box
Supplied Bolt
Front Spacer
M8 Nut for
P-Clip mounting
Rear Spacer Clamp
Cross-Section Detail
Supplied Bolt & P-Clip
Figure 3.36
□ Cut end and lip off of air filter box lid, (Figure 3.37).
Remove Shaded Area. Grind Off
Lip So Hose Can Slide Over.
Clean And Ensure All Debris Is
Out Of Inside
Figure 3.37
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□ Trim
1/4” off each of the four tabs on the filter box lid, (Figure
3.38). Tabs should be minimum 1/2” long.
□ Ensure all debris is cleaned from modified air box lid.
□ Remove the OEM filter minder from the air box lid.
□ Install OEM air filter.
□ Install modified air filter box lid & filter minder parts (Figure 3.38).
Trim 1/4" of each of the 4 tabs here
Supplied adaptor
OEM filter minder
Supplied hose
Figure 3.38
Note: If interference is encountered between the air filter
lid plastic ribs and mounting hardware or fittings on the
compressor or rear spacer clamp fastener, then trim the
necessary plastic ribs to allow easier installation or
removal of the air filter lid. Do not cut through the sealing
edge that sits against the air filter.
□ 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.
46
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□ Install
P-Clip to hold oil line going to cooler and use supplied M8
bolt to go through P-Clip (Figure 3.36).
□ Reinstall resonator attached to turbo inlet.
□ Position rubber elbow & hose clamps onto air filter box lid, do not
tighten.
□ Install new air intake tube into rubber elbow end at air box first
and then into rubber bellows for engine. (Figure 3.39).
Ensure air box is not pushed down and out of ‘Rear Spacer
Clamp’ (Figure 3.36).
Figure 3.39
!
Intake tube must be positioned as far from the intake tube
brace and the firewall connector as possible before
tightening the hose clamps.
□ Position intake tube for best clearance to brace and to firewall
connector and tighten hose clamps. (Figure 3.40).
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Figure 3.40
!
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 3.41)
Figure 3.41
48
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□ Check hood clearance to intake tube and adjust tube into rubber
elbow if required.
□ Add ‘paint pen’ or other marker to indicate proper alignment once
final position is done. (Figure 3.42).
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 3.42
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49
Part 4: Installing the Tank and
Hoses
4.1 Installing the Tank and Brackets
□ The
tank (Figure 4.1) will mount to the passenger side frame rail
behind the suspension radius arm mount
Rear Tank Mount
Front
Suspension Radius Arm
Mount
Front Tank Mount
(Note: Tank Not Shown For Clarity)
Figure 4.1
Tank Clips &
3/8 x 4-1/2
Bolts
3/8 Nut
5/16 x 1/2 Bolt &
Washer
5/16 Nut &
Washer
5/16 x 1/2 Bolt &
Washer
5/16 x 2 Bolt &
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
50
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□ Remove
the two 1/4" clamp bolts from the C-clamps. Expand
the clamps slightly and slide them over the front of the tank.
□ Apply
Loctite and insert the 5/16"x1/2" top bolts through the
c-clamps and thread them into the mount brackets, do not
tighten. Leave out the lower bolts until tank is located in
correct position.
□ Install
the discharge check valve fitting assembly into the
rear of the tank at the discharge port. Tighten the assembly
until the pressure transducer points towards the top of the
tank.
□ Install
a suitable 3/4" fitting (not supplied) into the end of the
discharge check valve fitting assembly.
The tank will mount on the passenger side frame rail
under the cab and must be level. Variations in frame
design may affect the positioning of the brackets.
Always check fit before tightening the fasteners.
□ Remove
1 of 2 OEM Nuts attaching the transmission crossmember to the frame. Depending on the truck configuration
cross-member location may differ (Figure 4.3).
Remove Front Nut
Suspension Radius
Arm Mount
Remove Rear Nut
Suspension Radius
Arm Mount
Figure 4.3
Leave all tank mounts and fasteners loosened
throughout the following aligning process to make
adjustments easier.
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□ Support
the tank and tank mount assembly in place on the
outside of the frame behind the radius arm mount (Figure 4.1).
□ Adjust
the position of the rear tank mount bracket for best fit and
to ensure that the tank will be level when mounted and to provide
adequate clearance for hose connections and filter installation.
□ Mark
the position of the c-clamps on the tank and the position of
the brackets on the frame. Remove the tank assembly and place
it back on the workbench.
□ Install
the 5/16" x1/2" lower c-clamp bolts and tighten all
remaining c-clamps mounting bolts.
□ Lift
the tank and tank mount brackets into position and install the
5/16” bolt holding the front of the mount to the frame and the
OEM transmission cross-member nut (Figure 4.2).
□ Apply
Loctite and thread the top bolt into the rear tank mount
bracket. Ensure the tank clip is hooked over the backside of the
frame and no wires or tubes are pinched or trapped (Figure 4.2).
□ Install
the tank clip so it hooks around the back of the frame.
Insert the threaded end through the appropriate hole in the
bottom of the rear tank strap. Apply Loctite and start the flange
nut on the tank clip (Figure 4.2).
□ Ifadequate
necessary, reposition the tank on the frame to provide
clearance for hose connections and filter installation.
When the tank is correctly positioned ensure all bolts are torqued
to specification.
4.2 Installing the Hoses
!
52
All hoses, tubes, and wires that are rerouted or shifted
during installation must be secure so that they do not
contact excessively hot areas or sharp edges. Where
possible, use rubber coated P-clips. Follow the routing
suggestions in this manual and cover all hoses with the
supplied plastic loom.
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□ Route
the straight end of the 3/4" hose from the compressor to
the matching fitting on the tank.
□ Route
the 3/16" and 1/4" tubes from the compressor air inlet
control valve to the matching fittings on the rear of tank.
□ Tighten
all hose connections at the tank, cooler and compressor.
Prevent the hoses from twisting during tightening.
□ Bunch
all hoses together, secure them with tie-straps and protect
them where they may rub. Make sure that they are clear of hot
exhaust parts or moving parts.
□ Apply
a light film of compressor oil to the filter gasket and install
the filter on the tank. Tighten the filter an additional ¾ turn after
the gasket contacts the base.
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.
□ 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. Turn
the compressor clutch clockwise with a ratchet and a 1/2" socket
using the hex head bolt at the center of the compressor clutch
during the fill process to pump the oil into the system.
□ Allow
5 minutes for the oil to drain into the tank, then, check the
level at the sight glass at the front of the tank. Continue adding
oil until the level is correct.
□ Install the fill plug in the inlet control valve and tighten it securely.
!
Do not overfill the system. Overfilling the system with oil
can flood the sight glass window and make the system
appear empty.
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53
54
To Temp. Sensor
4 pin GRN Conn
To Inlet 2 Pin
Conn - BRN & RED
To Buzzer Ring
Conn - BLK & RED
START
YEL
BLU
ORG
4
To AOST 3 pin BLK
pressure connector
DISPLAY
BOX
4
REMOTE ON,
YEL
STOP
3 Amp
Fuse
To OEM SEIC blue wire w/
grey stripe CLS05
PARK ONLY, BLU
THROTTLE
CONTROLLER
PARK BRAKE, BRN
To OEM SEIC blue wire CE913
TACH, WHT
GROUND, GRN-YEL
4
Cut OEM wire
Inside steering column
Splice/solder joints
Both go to OEM Ignition Switch Harness
BLU-WHT
GRN-RED or BLU-RED
To OEM SEIC yellow wire w/ orange stripe on early
builds or white wire w/ blue stripe on later builds
CDC64
IGN SW 12V, RED
To OEM SEIC white wire w/ purple stripe
CMC25
Diode
ORG
To Clutch Bullet Conn - WHT
RED +
BLK -
HOT
12V
RELAYS
4
Purple w/ green stripe
DIGITAL GND,
GRN-YEL To pin 3
OEM Connector
to accelerator
pedal
ACCY
CAB TEMP,
BLUE (2X)
16
CONTROL BOX
Connect to
accelerator
pedal
To Beacon 2 Pin
Conn - GRY & RED
To Hood Sw. 2 Pin
Conn – GRY & BLK
Firewall
Part 5: Installing the Control
Components
YEL
BLU
BLU
ORG
IGNITION CONNECTOR
IN STEERING WHEEL
7
Figure 5.1
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Keep wires away from the park brake mechanism. Route
wires clear of the steering column and pedals so they do
not contact moving parts. Before drilling holes make sure
that there are no OEM wire bundles where you will be
drilling.
5.1 Routing the Wiring
□ Determine
suitable installation locations for the Buzzer and
Beacon modules.
The Buzzer should be located such that it is audible to
individuals around the vehicle.
The Beacon should be located such that it is visible to
individuals around the vehicle.
□ Extend
the blunt-cut red and black BUZZER wiring on the control
box harness with 18AWG wiring. Solder and seal.
□ Crimp the ring terminals provided to the end of the Buzzer wires.
□ Extend
the blunt-cut grey and red BEACON wiring on the control
box harness with 18AWG wiring. Solder and seal.
□ Cut
an opening in the firewall plug and route harness wires from
the cab to the engine bay for the following:
Hood switch
Inlet valve solenoid
Pressure sensor
Compressor temperature sensor
Clutch
Buzzer
Beacon
□ Route these wires to their destinations. One suitable way is:
Route the Beacon and Buzzer wires to their installation
locations.
Route the remaining wires along the perimeter of the engine
bay to the front of the truck.
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
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The inlet valve solenoid, clutch, and compressor
temperature connectors rest near the compressor.
The remaining pressure sensor cable can go down along
with the pressure line until it reaches the chassis. Then run
along the chassis towards the rear of the truck to the location
of the Discharge Check Valve.
□ Solder
and seal the pigtail provided in the AUS Electrical Pack to
the end of the Beacon wires placed through firewall.
5.2 Installing the components
5.2.1 Control Box Mount
□ Fasten
the control box to the control mount bracket using screws
provided in its fastener pack.
□ Fasten
the relay sockets onto the mount bracket using remaining
screws in the fastener pack.
□ Install relays into the relay-sockets.
Verify the terminals in the relay-sockets did not get pushed
loose from the relay-sockets during relay installation.
□ Install
the control box wiring harness’ three rectangular
connectors into their respective mates on the control box.
□ Fasten
the heat-shrunk diode with a nylon-tie to either the fuse
holder or the back side of the narrow column on the control
mount. The diode assembly can be identified by its short orange
and long red wires coming out of heat-shrunk tubing.
□ 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.
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EXISTING FORD
STUDS ABOVE
KICKER PANEL
STOP
RELAY
START
RELAY
HOT 12V
RELAY
Figure 5.2
5.2.2 VR Throttle Controller
□ Install
the Throttle Controller underneath the dash with nylonties.
□ 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.
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Ensure wiring and in-cab installed electronics keep away
from, and do not interfere with, the operation of the park
brake mechanism, brake & accelerator pedals, and steering
column.
5.2.3 Hood Switch
Shrink Sleeve
Blue w/Pink
OEM Wire
Soldered Joint
Grey - VMAC Wire To Be Added
Figure 5.3
□ Ifsealthethevehicle
comes equipped with a hood switch, splice and
OEM blue w/pink hood switch wire with VMAC’s grey
hood-switch wire, See Figure 5.3. Ensure VMAC’s black hoodswitch connector wire is left unexposed, as it is at 12V. Skip to
section 5.2.4
□ Ifprovided
the vehicle doesn’t come equipped with hood switch, using the
screw, install hood switch in a pre-existing hole in the
engine bay, near the driver’s headlight. See Figure 5.4
58
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Figure 5.4
□ Visually
verify the switch is suitably installed such that it’s
actuated when the hood is closed.
□ Connect
the hood switch’s connector to its mating connector on
the main wiring harness in the engine bay.
5.2.4 Compressor Connections
□ Connect
the Inlet Valve Solenoid on the VR70 Compressor
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.
5.2.5 Pressure Sensor
□ Connect
the Pressure Sensor on the Discharge Check Valve to
the mating connector on the wiring harness.
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5.2.6 Beacon and Buzzer Modules
Verify the Beacon and Buzzer installation locations make
them visible and audible to individuals around the vehicle.
□ Install the Beacon and Buzzer in suitable locations.
□ Connect
the Beacon with the mating connector on wiring
harness.
□ Connect
the Buzzer wires (with ring terminals) routed earlier.
The red wire goes to positive on Buzzer, and black wire goes to
negative on Buzzer.
5.2.6 Display Box
□ Connect
the Display Box to the 4-wire connector coming from
the control box.
□ Install
the Display Box in a suitable location with provided
screws.
Mount the Display Box inside the cab or a cabinet protected
from extreme weather. The Display Box is splash-proof, but
not fully sealed. Ensure that it will not get kicked or hit by
tools and equipment.
5.3 Connecting the In-cab Wiring
□ Unplug
the OEM foot pedal connector from the foot pedal
assembly.
□ Find
the purple-green wire attached to pin 3 on the truck
harness. If needed, pull back any cover on the cable going into
the dash to expose the wires.
Verify with a multi-meter that the resistance between pin 3
on truck harness and truck ground is close to 0 Ohms.
□ 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.
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□ Connect
the Throttle Controller’s connector to the foot pedal
assembly.
□ Connect
the Throttle Controller’s remaining connector to the
OEM harness for the foot pedal assembly.
□ Locate
the blunt-cut OEM SEIC wire harness, on the driver’s
side just below the OBDII port (Figure 5.5). You will need to find
the following wires:
ignition-switched 12V OEM SEIC circuit CDC64 –
 yellow wire with orange stripe on early builds
 white wire with blue stripe on later builds
tachometer signal OEM SEIC circuit CE913 – blue wire
transmission park signal OEM SEIC circuit CLS05 – blue
with grey stripe (marked previously)
park brake switch OEM SEIC CMC25 – white wire with
purple stripe
SEIC blunt-cut wires
bundle
HOOD
Figure 5.5
□ Solder
and seal the long red ‘KEY SWITCHED 12V’ wire
(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.
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□ Connect
the ring terminal on the green-yellow ground wire
coming from the control box to any grounded bolt underneath the
dash.
□ Solder
and seal the white ‘TACH’ wire coming from the control
box to the OEM SEIC circuit CE913 blue wire at the blunt-cut
harness.
□ Solder
and seal the black ‘PARK BRAKE’ wire from the control
box to the OEM SIEC circuit CMC25 white wire with a purple
stripe at the blunt-cut harness
□ Solder
and seal the long blue ‘PARK NEUTRAL’ wire coming
from the Throttle Controller to the transmission park signal found
earlier. This should be the OEM SEIC circuit CLS05 blue wire
with grey stripe in the blunt-cut bundle.
□ Remove
the panel underneath the steering column that also
covers the ignition key switch. It is held in place by three screws
below and has hooks in the rear holding it onto the panel above
it.
Steering
Wheel
Ignition
Switch
Connector
Figure 5.6
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□ Find
the ignition switch connector on the left side of the steering
column, as shown in Figure 5.6. Of its 6 wires, locate:
Pin 4 wire green-red or blue-red (Middle)
Pin 7 wire blue-white (Bottom)
□ Cut
the wire coloured green-red or blue-red and solder then seal
the yellow and orange pigtails to the two new ends of this wire.
Yellow pigtail solders onto wire going into dash.
Orange pigtail solders onto wire going to the
connector/steering wheel.
□ Cut
the blue-white wire and solder then seal the two “blue”
pigtails to the two ends of this wire. It doesn’t matter which pigtail
is attached where for this wire.
□ Route the four (4) wires towards the igni0tion connector.
□ Connect
these wires by matching the colours and labels to the
pigtails soldered earlier.
Yellow wires connect together
Orange wires connect together
Blue wires labeled connect together
5.4 Completing and Testing the Installation
□ Cover
all under hood and under chassis wiring with plastic loom.
Secure the harnesses with nylon ties. Avoid wiring contact with
hot or moving parts.
□ Route
the loomed harness above the coolant lines towards the
front of the truck. Follow the radiator coolant lines across the
radiator towards the compressor.
□ Pull
all excess wiring back into the cab, bundle the wiring
together and tie it up out of the way under the dash.
□ 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
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□ Secure the harness and loom with tie-straps.
□ Replace
all dash panels and other covers removed during
installation.
□ Install
and re-connect the batteries. Connect cables to battery
that was relocated to under driver’s side door (electrical system
will be live at this point). Use floor jack to hold battery box in
place and secure to mount previously installed.
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Part 6: Finishing the Installation
6.1 Before Starting the Engine Checklist
Make sure that the following have been completed:
□ Check the vehicle coolant.
□ Check the compressor oil level.
□ Do
a final inspection to make sure that everything has been
completed and tightened.
□ Perform a final belt alignment check.
□ Check all wiring for security and protection.
□ Check
all wiring and in-cab installed electronics keep away from,
and do not interfere with, the operation of the park brake
mechanism, brake & accelerator pedals, and steering column.
6.2 Safety Test
!
Place the vehicle in a safe operating position and block the
wheels. Ensure that there are no people around the vehicle
before beginning the 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.
□ Install a test tool on the air tank outlet and close the ball valve.
□ Place
the automatic transmission in Park and apply the park
brake. Turn the ignition key “ON” but do not start the engine.
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□ Check
the display box to see if it has initiated a system check. If
there is no display, there is no power to the control box. The
display box should display SYSTEM CHECK then SYSTEM
READY.
□ Start the engine and allow it to reach operating temperature
□ Press
ON/ENTER on the display box. The display box should
show SYSTEM RUNNING and start the compressor system.
Engine RPM will increase for a few moments while the
compressor system comes up to pressure, then RPM will
settle to the VR Idle RPM. This is normal operation.
□ With the system running, release the Park Brake.
□ The
system should shut down and the display box show,
ERRORS DETECTED.
□ Press
ON/ENTER and the display box should show, PARK
BRAKE NOT ENABLED.
□ Re-engage the park brake.
□ Press
ON/ENTER and follow on-screen directions to restart the
compressor system.
□ While the system is running, pull the truck’s hood release lever.
□ The system should shut down and show, ERRORS DETECTED.
□ Press
ON/ENTER and the display box should show, CLOSE
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.
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□ Do
not use any air and wait until system enters STANDBY. (By
default, this Delay to Standby is 10 minutes)
□ Truck engine should turn off.
□ Check
the LED Beacon gives four quick flashes then a pause.
This should repeat once every second.
□ Operate
the system with an air tool or with the test tool to drop
the air pressure below the RESTART PRESSURE setting. (By
default, this is 120 PSI)
□ The
control system should sound the Buzzer and turn off the
Beacon.
□ Now
the system should crank and start the engine. Wait for the
engine to settle to VR-IDLE RPM.
□ Place
your foot firmly on the brake pedal, shift the automatic
transmission out of PARK and into REVERSE. The engine
should drop to OEM base idle (about 650 RPM). Repeat this test
in all gear selector positions to make sure that the engine does
not idle up unless the selector is in PARK.
□ Place the transmission into PARK.
□ Operate
the system with an air tool or with the test tool for at
least 1/2 hour (1 hour preferred).
□ Road test the vehicle for approximately 14 miles (20 km).
□ Inspect
the underhood operation to make sure that belts rotate
properly and nothing is rubbing or contacting hot parts.
□ Check
all components once the engine is turned off and the
system has cooled.
□ 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.
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6.3 Setup, Performance Testing and Adjustments
This system has been adjusted at the factory for general operation. If
your tests indicate that adjustment is necessary, refer to the owner’s
manual for specific instructions on how to adjust the system.
You can test the system operation using the tools that will be
operated by the system or you can test operations using an orifice in
the outlet to simulate tool use (Figure 6.1).
Figure 6.1
□ Install the test tool in the tank outlet fitting.
□ Make sure that the ball valve is closed.
□ Place
the manual transmission in NEUTRAL or the automatic
transmission in PARK and fully apply the park brake.
□ 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.
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□ Open
the ball valve on the test tool and observe the engine
tachometer. Engine speed should increase to about 1,800 to
2,200 RPM.
□ Close the air valve slowly to allow the system pressure to rise.
□ 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.
6.4 Auxiliary Air Receiver
!
If you intend to use an auxiliary air receiver with this system
you must observe the following installation procedure to
prevent damage to the system.
The line to the auxiliary tank must not be installed in the bottom of
the tank, but must be installed as high as possible to prevent water
from entering the line.
Auxiliary Tank
VR Tank with the
supplied check valve
Install the line as high as
possible, NOT in the
bottom of the auxiliary tank
Figure 6.2
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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
drain and compact design
Filter Regulator Lubricator
Part Number A700151
Removes lubricants, water and dirt from the air
stream. Adds atomized tool oil to lubricate
tools. Reduces pressure for longer tool life.
Hose Reel
Part Number A700007
Secure, compact, retractable hose storage in a
sturdy reel.
Air Receiver Tank
Part Number A300010
Thirty-five gallon capacity in a compact tank,
complete with fittings and a gauge.
De-icer Kit
Part Number A700031
DE-ICING
HEATER
Insulated rope heater prevents freezing of lines
and regulator.
Service Kits
VR140 200 hour Part Number A700059
VR140 400 hour Part Number A700060
VR70 200 hour Part Number A700019
VR70 400 hour Part Number A700020
Using OEM service products will extend the life
of your system. Includes oil, filters, seals and
O-rings. 200 hour and 400 hour service interval
kits are available.
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