Vmac Underhood 70 User manual

www.vmacair.comwww.vmacair.com
Installation Manual for VMAC
System
V900132
2020+Ford F250 – F350 Super Duty
6.2 L Gas V8
UNDERHOODUNDERHOODUNDERHOODUNDERHOOD
70707070
TMTMTM
TM
AIR COMPRESSORS

VMAC - Vehicle Mounted Air Compressors
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Table of Contents
Safety .........................................................................3
Warranty ......................................................................4
General Information ...........................................................6
Preparing for Installation.......................................................8
Relocating the ABS Hydraulic Control Unit (HCU) .............................14
Installing the Main Bracket and Compressor................................... 21
Modifying the Hoses, Installing the Degas Bottle, and Cooler .................27
Installing the Air Oil Separator Tank (AOST) ...................................33
Hose Requirements .......................................................... 35
Routing and Connecting the Hoses ...........................................36
Adding Oil to the System .....................................................39
Installing the Control Components ........................................... 40
Air Receiver Tank ............................................................ 44
Recommended Accessories .................................................. 45
Completing the Installation .................................................. 46
Testing the Installation........................................................47
Performance Testing and System Adjustments ............................... 50
Digital Throttle Control Operation and Adjustments........................... 51
Accessory Products from VMAC ............................................. 53
Warranty Registration ....................................................... 56

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Document: 1930410
Changes and Revisions
Revision Revision Details Revised by
Checked by
Implemented
Eng. Tech. Qual.
Mech. Elec.
AInitial Release MSP BJG ASE RDB LPH 24 Jan 2020
BECN: 20-037 MSP MRH N/A MSP AWM 30 Jan 2020
C ECN: 20-054 HCU and cooler instructions MSP CAM N/A MSP N/A 4 Mar 2020
Additional Application Information
• 2020+Ford F250 – F350 Super Duty with 6.2 L Gas V8.
• Single battery application only. Dual battery vehicles will require accessory
A900016
Important Information
The information in this manual is intended for certified VMAC installers who
have been trained in installation and service procedures and/or for anyone with
mechanical trade certification who has the tools and equipment to properly and
safely perform the installation or service. Do not attempt installation or service
without the appropriate mechanical training, knowledge and experience.
Follow all safety precautions. Any fabrication for correct fit in modified vehicles
must follow industry standard “best practices”.
Notice
Copyright © 2020 VMAC Global Technology Inc. All Rights Reserved. These
materials are provided by VMAC for informational purposes only, without
representation or warranty of any kind, and VMAC shall not be liable for errors
or omissions with respect to the materials. The only warranties for VMAC
products and services are those set forth in the express warranty statements
accompanying such products and services, if any, and nothing herein shall be
construed as constituting an additional warranty. Printing or copying of any page
in this document in whole or in part is only permitted for personal use. All other
use, copying or reproduction in both print and electronic form of any part of this
document without the written consent of VMAC is prohibited. The information
contained herein may be changed without prior notice.
Printed in Canada
Registered Trademarks
All trademarks mentioned in this manual are the property of their respective
owners. VMAC’s use of manufacturers’ trademarks in this manual is for
identification of the products only and does not imply any affiliation to, or
endorsement of said companies.
Loctite®, Loctite®242 and Loctite®567 are registered trademarks of Henkel AG &
Company KGaA.
Eaton Aeroquip® is a registered trademark of EATON AEROQUIP INC.
Ford® and Super Duty® are registered trademarks of Ford Motor Company.

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Important Safety Notice
The information contained in this manual is based on sound engineering principles,
research, extensive field experience and technical information. Information
is constantly changing with the addition of new models, assemblies, service
techniques and running OEM changes. If a discrepancy is found in this manual,
contact VMAC Technical Support prior to initiating or proceeding with installation,
service or repair. Current information may clarify the issue. Anyone with knowledge
of such discrepancies, who proceeds to perform service and repair, assumes all
risks.
Only proven service procedures are recommended. Anyone who departs from the
specific instructions provided in this manual must first ensure that their safety and
that of others is not being compromised, and that there will be no adverse effects
on the operational safety or performance of the equipment.
VMAC will not be held responsible for any liability, consequential damages, injuries,
loss or damage to individuals or to equipment as a result of the failure of anyone
to properly adhere to the procedures set out in this manual or standard safety
practices.
Safety should be the first consideration when performing any service operations.
If there are any questions concerning the procedures in this manual, or more
information is required, please contact VMAC Technical Support prior to beginning
work.
Safety Messages
This manual contains various warnings, cautions and notices that must be observed
to reduce the risk of personal injury during installation, service or repair and the
possibility that improper installation, service or repair may damage the equipment
or render it unsafe.
This symbol is used to call attention to instructions concerning
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 aware of the possibility of personal injury or death. As it is
impossible to warn of every conceivable hazard, common sense and
industry standard safety practices must be observed.
This symbol is used to call attention to instructions on a specific
procedure that if not followed may damage or reduce the useful life
of the compressor or other equipment.
This symbol is used to call attention to additional instructions or
special emphasis on a specific procedure.
Safety

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VMAC Standard Warranty (Limited)
For complete warranty information, including both VMAC Standard
Warranty (Limited) and VMAC Lifetime Warranty (Limited)
requirements, please refer to our current published warranty located
at: www.vmacair.com/warranty
If you do not have access to a computer, please contact us and we will
be happy to send you our warranty.
VMAC’s warranty is subject to change without notice.
VMAC Lifetime Warranty (Limited)
A VMAC Lifetime Limited Warranty is offered
on the base air compressor only and only on
UNDERHOOD™, Hydraulic Driven, Transmission
Mounted, Gas and Diesel Engine Driven Air
Compressors, Multifunction Power Systems, and
other products as defined by VMAC, provided that
(i) the purchaser fully completes and submits a
warranty registration form within 3 months of purchase, or 200 hours of operation,
whichever occurs first; (ii) services are completed in accordance with the Owner’s
Manual; (iii) proof of purchase of applicable service kits are made available to
VMAC upon request.
The VMAC Lifetime Warranty is applicable to new products shipped on or after
1 October, 2015.
Warranty Registration
The VMAC warranty registration form is located near the back of this manual. This
warranty registration form must be completed and sent to VMAC at the time of
installation for any subsequent warranty claim to be considered valid.
There are 4 ways the warranty can be registered with VMAC:
www.vmacair.com/warranty
[e-mail]
(877 ) 740-3202
VMAC - Vehicle Mounted Air Compressors
1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3
LIFETIME
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WARRANTY
Warranty

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VMAC warranty work must be pre-authorized by VMAC. Claims are
processed via our dealer network. If you are not a VMAC dealer,
please select one to work with via our Dealer Locator:
https://www.vmacair.com/dealer-locator/
1. Communicate with VMAC Technical Support at 1-888-241-2289 or
[e-mail] to help diagnose/troubleshoot the problem prior to repair.
VMAC technical support will require the VMAC System ID, hours on the
compressor and mileage on the vehicle.
2. VMAC will provide direction for repair or replacement of the failed components.
3. If requested, failed parts must be returned to VMAC for evaluation.
4. Dealers may login to the VMAC website to view the "VMAC Labour Time Guide"
(under “Agreements”) to see the allowable warranty labour times.
5. Warranty invoices must include the Service Ticket number, VMAC System ID#,
hours on the compressor, and a detailed description of the work performed.
6. VMAC Warranty does not cover consequential damages, overtime charges,
mileage, travel time, towing/recovery, cleaning or shop supplies.
7. Dealers submit warranty claims on behalf of the Vehicle Owner/End User
affected by the defective part(s). The dealer ensures that all warranty credits
are refunded back to the Vehicle Owner/End User who made the initial warranty
claim.
In order to qualify for Lifetime Warranty (Limited), the completed
warranty registration form must be received by VMAC within 3
months of the buyer receiving the Product(s), or 200 hours of
operation, whichever occurs first.
If the completed warranty registration form has not been received
by VMAC within 3 months of the buyer receiving the Product(s),
or 200 hours of operation, the warranty period will be deemed to
commence 30 days from the date of shipment from VMAC.
Failure to follow the warranty claim process may result in denial of
the warranty claim.
VMAC Product Warranty Policies & Warranty Registration can be found on the
VMAC website (see previous page for URL).
VMAC Warranty Claim Process

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General Information
Optional Equipment Compatibility
While VMAC strives to design systems compatible with optional OEM equipment
(such as running boards), it is impractical to develop systems that accommodate
every OEM and aftermarket option or add-on. Whenever possible, VMAC endeavors
to advise of compatibility issues in the “Additional Application Information” section
of the manual. Even when specific optional equipment is determined by VMAC
to be incompatible, it does not preclude the vehicle upfitter or end user from
modifying the optional equipment to make it compatible with the installed VMAC
system. VMAC does not warranty or accept responsibility or liability for the fitment,
function or safety of any products modified in any way not expressly outlined in the
installation manual.
Before Starting
Read this manual prior to beginning the installation to ensure familiarity with the
components and how they will fit on the vehicle. Identify any variations from the
application list such as vehicle model, engines, or optional equipment (e.g., dual
alternator, active steering assist, etc.).
Open the package, unpack the components and identify them using the Illustrated
Parts List (IPL) included in the Fastener Pack.
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 VMAC 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.
Ordering Parts
To order parts, contact a VMAC dealer. The dealer will ask for the VMAC serial
number, part number, description and quantity. Locate the nearest dealer online at
www.vmacair.com/dealer-locator or call 1-877-912-6605.

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Special Tools Required
• Pneumatic fan wrench (Lisle 43300 or equivalent)
Torque Specifications
All fasteners must be torqued to specifications. Use manufacturers’ torque values
for OEM fasteners.
The torque values supplied in Table 1 are intended for VMAC supplied components,
or for use as a guide in the absence of a torque value provided by an OEM.
Apply Loctite 242 (blue) or equivalent on all fasteners (except nylon lock nuts)
unless otherwise stated.
Torque values are with Loctite applied unless otherwise specified.
Table 1 — Torque Table
Standard Grade 8 National Coarse Thread
Size (in) 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4
Foot pounds (ft•lb) 918 35 55 80 110 170 280
Newton meter (N•m) 12 24 47 74 108 149 230 379
Standard Grade 8 National Fine Thread
Size (in) 3/8 7/16 1/2 5/8 3/4
Foot pounds (ft•lb) 40 60 90 180 320
Newton meter (N•m) 54 81 122 244 434
Metric Class 10.9
Size (mm) M6 M8 M10 M12 M14 M16
Foot pounds (ft•lb) 4.5 19 41 69 104 174
Newton meter (N•m) 625 55 93 141 236

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Preparation for installation is very important. Missing a step
or an item can cause problems in the installation or damage to
components.
☑
Check off each item as it is completed so that no steps are
missed.
☐ Review the contents of the system using the illustrated parts list to ensure all
components are present and in the correct quantity. If any components are
missing, have the system ID ready and call VMAC Technical Support at
[phone].
The System Identification Plate must be attached to the vehicle at
the time of installation. This plate provides information that allows
VMAC to assist with parts and repairs.
☐ Locate a conspicuous area in the engine bay (where the tag will be easily
noticed) to install the System ID tag.
☐ Mark and drill (×2) 7/64 in holes and secure the plate with the supplied self-
tapping screws (Figure 1).
Figure 1 — System Identification Plate
Preparing for Installation
☐ To alert any technicians that may service the vehicle, affix the servicing advisory
decal in a conspicuous area in the engine bay (where the decal will be easily
noticed) (Figure 2).
Apply Loctite 242 (blue) to all fasteners (except nylon lock nuts)
unless otherwise stated.
Figure 2 — Advisory label

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☐ As part of the installation process, ensure that the safety and operational
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 3).
Figure 3 — Operating Instruction label
Figure 4 — Heavy-duty water pump Label
☐ As part of the installation process, ensure that the caution decal regarding the
heavy-duty water pump is affixed in an obvious location so that it can be seen
by maintenance personnel (Figure 4).

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Do not use a test light to probe for power on vehicle circuits as the
increased current draw of the test light may damage components.
☐ Locate the blunt-cut OEM SEIC wire harness, on the passenger side in the foot
well. Find the transmission park signal, (grey with brown stripe wire).
☐ Use a multi-meter to verify the transmission park signal. Turn the key to the
“IGN2” position, (do not start the truck), so as to supply power to the dash
display. The resistance to ground should read close to 0 Ω in “PARK” and open
circuit in all other gears. If this is correct, put the vehicle in “PARK” and turn the
key to the “OFF” position.
☐ Mark the transmission “PARK” signal wire for connection later in installing
control components section.
☐ Disconnect the battery (or both batteries if equipped with dual batteries).
☐ Drain the coolant into a clean container and set aside for use later.
☐ Remove the upper radiator hose and set it aside as this will be modified in a
later chapter.
☐ Keeping the power steering lines connected, remove the power steering
reservoir from the driver side of the fan shroud. Temporarily tie the reservoir up
and out of the way of the fan shroud.
The power steering reservoir cap will leak if the reservoir is not kept
upright.
Vehicles equipped with dual batteries will have an integrated degas
bottle and battery tray which requires a different mounting bracket
and different modification instructions.
Please contact VMAC to order A900016.
☐ Remove the degas bottle and set it aside (on vehicles equipped with dual
batteries, remove the battery and battery tray / degas bottle assembly);
discard the OEM fasteners.
☐ Swing the lower section of the fan shroud forward and tape it to the upper
shroud.
☐ Remove the resonator from the air intake system and cover the openings to
prevent debris entering the system.
☐ Remove the fan and shroud as one unit.
☐ Remove the fan harness bracket (13 mm nut on stud with bracket).
☐ With the accessory belt tensioned, loosen the (×4) water pump pulley bolts.
☐ Remove the Front End Accessory Drive (FEAD) belt.
☐ Remove the (×4) water pump pulley fasteners and retain for reuse.
☐ Remove the water pump pulley and set aside it for reuse.
☐ Remove the (×4) water pump fasteners and the water pump.
☐ Inspect and clean the water pump and engine block sealing surfaces.

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Included in this kit is a heavy-duty water pump (with an integrated
fan spacer), this replaces the OEM water pump (Figure 5).
Figure 5 — OEM / Heavy Duty water pump comparison
OEM water pump Heavy duty water pump
Prior to seating the water pump in the engine, ensure the bolt holes
are aligned as the water pump cannot be rotated once seated in the
engine cavity.
☐ Lubricate the new water pump O-ring with clean engine coolant and install the
supplied heavy-duty water pump (Figure 6).
Figure 6 — Install water pump

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Figure 7 — Remove idler
Tighten the water pump fasteners in 2 stages using a criss-cross pattern*:
☐ *Install the fasteners finger tight.
☐ *Torque fasteners to 18 ft•lb.
☐ Remove the idler mounted on the driver side head (Figure 7).
Figure 8 — RIS relocation
☐ Relocate the Radio Interference Suppressor (RIS) to the fasteners directly above
the idler (Figure 8).
Relocate
the RIS here
☐ Install the water pump pulley, leaving the fasteners finger tight.
☐ Reinstall the idler, leaving the fastener finger tight.
OEM RIS
location

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☐ Install, and tension the OEM FEAD belt (Figure 10).
Figure 9 — Install tensioner plate
☐ Torque the water pump pulley fasteners to 18 ft•lb.
☐ Remove and discard the idler bolt, leaving the belt tensioned and the idler on
the post.
☐ Install the tensioner plate on the OEM tensioner (Figure 9).
Figure 10 — OEM belt routing

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Relocating the ABS Hydraulic
Control Unit (HCU)
Depending on the application, the following steps may not be
necessary. If the HCU is mounted towards the firewall
(Figure 19 on page 18), proceed to the next chapter. If the HCU
bracket is mounted using the holes shown in Figure 14, follow the
steps in this chapter.
Failure to follow these instructions may result in brake system
contamination, component damage, and/or death.
It may be necessary to rotate the brake lines that connect the
master cylinder to the ABS HCU module to avoid kinking the flexible
rubber hoses as the HCU is shifted to its new position. The following
process will help avoid air entering the brake system as brake fluid
will be forced out of the system rather than air permitted to enter
the system.
Do not pump the brakes at any time while the brake lines are loose
as air may be drawn into the system.
Have an assistant gently depress the service brake as the brake
line is loosened, rotated into a relaxed position and then quickly
retightened. Adjust one brake line at a time. If there is a significant
amount of brake fluid escaping from the fitting, the pedal is being
pressed too hard and/or the fitting has been loosened too much.
Do not allow the brake master cylinder to run dry during these steps
as the master cylinder may be damaged if operated without fluid.
Use only clean brake fluid from an unopened container that meets
Ford specifications.
Use extreme caution while adjusting the brake lines to prevent
damaging them.
If there is any concern that the brake lines may have been kinked or
damaged in any way, contact a local Ford dealer or licensed repair
facility to have the issues rectified.
If there is any concern that air may have entered the brake system,
consult a local Ford dealer or licensed repair facility for vehicle
specific HCU brake bleeding instructions.

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Figure 11 — Steering assist module
Determine whether the vehicle is equipped electronic power assist steering (EPAS)
(Figure 11)*:
☐ *If the vehicle is equipped with EPAS, turn to the next page.
☐ *If the vehicle is not equipped with the EPAS, skip to page 19.
Steering assist
module

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Figure 12 — Relocating the HCU
Vehicles equipped with EPAS
☐ Remove the (×2) nuts securing the HCU module to the bracket (Figure 12).
HCU nut
Figure 13 — Relocating the HCU
☐ Remove the bolt and (×2) nuts securing the HCU base bracket to the shock
tower and set them aside. Remove the HCU base bracket (Figure 13).
HCU nut

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☐ Mark and cut the HCU base bracket in the location shown (Figure 14).
Figure 14 — Modifying the HCU bracket
Mark and cut
HCU bracket
☐ Using the supplied flat head fastener, install the HCU relocation bracket
(Figure 15).
Figure 15 — Relocating the HCU
HCU relocation
bracket

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☐ Gently shift the HCU towards the firewall taking care not to bend or kink the
brake lines. Align the bracket with the second set of mounting holes (Figure 16).
☐ Using the OEM fasteners retained earlier, secure the HCU base bracket to the
shock tower (Figure 17).
Figure 16 — Relocating the HCU
Figure 17 — Relocating the HCU
Reinstall
both nuts
Reinstall
bolt
☐ Using the OEM fasteners retained earlier, secure the HCU module to the bracket.