Vmac VR70 User manual

V900091
2008 Ford F-250 - F-550
6.8L Triton V10 Gas
www.vmacair.com
VR70 UNDERHOOD
AIR COMPRESSOR
INSTALLATION MANUAL

VMAC – Vehicle Mounted Air Compressors
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Fax: [phone]
Installation Manual for VMAC
System V900091
Ford 2008
Triton 6.8 L V10 Superduty F250-F550
General Information..................................................................... 3
Before You Start....................................................................... 3
Part 1: Preparing for Installation............................................... 4
Part 2: Installing the Main Bracket, Compressor and Cooler 7
2.1 Installing the Main Bracket and Compressor ..................... 7
2.2 Installing Drive Belts and Pulleys ....................................... 9
2.3 Installing Other Components.............................................. 10
2.4 Installing the Cooler............................................................ 13
Part 3: Installing the Tank and Hoses....................................... 16
3.1 Installing the Tank and Mount Brackets ............................. 16
3.2 Installing the Hoses ............................................................ 18
3.3 Adding Oil to the System.................................................... 19
Part 4: Installing the Control Components .............................. 21
4.1 Installing the Components.................................................. 22
4.2 Connecting the In-cab Wiring............................................. 22
4.3 Connecting the Underhood Wiring ..................................... 24
4.4 Completing and Testing the Installation ............................. 24
Part 5: Finishing the Installation................................................ 26
5.1 Before Starting the Engine Checklist ................................. 26
5.2 After Starting the Engine Checklist..................................... 26
5.3 Setup, Performance Testing and Adjustments................... 27
5.4 System Identification and Warnings................................... 28
5.5 Auxiliary Air Receiver ......................................................... 29
Accessory Products from VMAC............................................... 30

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Document #1930137
Installation Manual for VMAC System V900091
Ford Triton 2008 6.8 L Superduty F250-F550
Changes and Revisions
Version Revision Details Revised by/date Approved Implemented
00 Original manual IB 09 May 2007 BC 24 May 2007 28 May 2007
A ECN 07-103 cooler change IB 5 June 2007 RD 12 July 2007 16 July 2007
B ECN 07-145 IB 05 Nov 2007 SH 23 Nov 2007 26 Nov 2007
Important Information
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 underhood mechanical work. Any
grinding, bending or restructuring operations for correct fit in modified
vehicles must follow standard shop practices.
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 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 1-800-738-8622.
Copyright 2007
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

VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: [phone]
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
vehicle. 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 9/16 5/8 ¾
Foot-pounds (ft-lb) 9 18 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 3/8 7/16 1/2 5/8 ¾
Foot-pounds (ft-lb) 40 60 90 180 320
Newton meter (N•m) 54 81 122 244 434
METRIC CLASS 10.9
Size M8 M10 M12 M14 M16
Foot-pounds (ft-lb) 19 41 69 104 174
Newton meter (N•m) 25 55 93 141 236
Hose Coding
Different frame designations will affect the tank mounting position. If
you have to move the tank, the lines may be too short. Measure the
hose shortfall and order a Hose Extender Kit. The following table
shows the color code used by VMAC to identify hose diameters.
Hose Diameter Colour-Coded Label
1/2 inch
5/8 inch
3/4 inch
1 inch
Blue
Blue
Green
Green

Part 1: 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.
□Disconnect the battery.
□Drain the coolant.
□Disconnect and discard the expansion bottle hose from the bottle
and the engine, then remove the air box with coolant expansion
bottle and the air ducting.
□Remove the inner fender mud guard on the driver side.
□Cut to separate the air box from the coolant expansion bottle
(Figure 1.1).
Figure 1.1
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□Cut away all of the webbing on the coolant expansion bottle
mount (Figure 1.2).
Remove material from these
support ribs to provide clearance
for the hood gas strut
Cut awa
y
all bottom rib sections
Cut away a triangular
section 1 inch from the
slot for the rubber grommet
1”
Figure 1.2
□Remove the upper radiator hose. Cut the quick-coupler
connector from the hose and discard the hose.
□Separate the lower radiator hose at the center connector to drain
coolant, then remove the lower radiator hose. Cut the quick
connects off both hoses.
□Unclip the wire harness from the lower fan shroud and all the
way around, then pull the harness clear.
□Drain and remove the power steering reservoir. Remove the
OEM power steering hose from the reservoir and replace it with
the supplied 3/4 inch hose.
□On trucks with hydro boost brakes, remove the 3/8 inch OEM
hose from between the master cylinder and the power steering
reservoir.
□Cut the hose close to the 90 degree molded elbow on the master
cylinder end and reverse the hose so that the elbow will attach to
the power steering reservoir.
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□Point the elbow down and away from the clutch. Connect the
other end to the master cylinder with the supplied connector and
hose.
□Remove the upper and lower bolts locating the fan shroud and
remove the coolant overflow hose from the upper fan shroud.
□Loosen the fan (RH thread). Unbolt the fan shroud and remove
the fan and shroud together.
□Remove the OEM ground connector to radio suppressor
attached to one of the studs and attach it to one of the studs by
the thermostat housing.
□Remove and discard the three OEM M10 bolts with the M8
studded ends from the driver’s side of the cylinder head.
□Clean the front of the engine on the driver’s side.
□Clean the center of the OEM crank pulley.
□Disconnect the wiring from the ABS module on the driver’s side
frame rail but do not disconnect the brake lines as they will flex
and allow the module to be moved.
□Remove the bolt securing the ABS module to the OEM mounting
bracket and lift it off the rubber bushings. Remove and discard
the ABS mounting bracket but keep the two rubber bushings for
installation later.
□Install the replacement ABS bracket in the same location as the
original using the OEM fasteners.
□Install the OEM rubber bushings on the ABS module and fit it
onto the pins on the replacement bracket. Carefully bend the
brake lines to align the OEM mounting bolt with the hole on the
new bracket and fasten the module in place.

Part 2: Installing the Main Bracket,
Compressor and Cooler
2.1 Installing the Main Bracket and Compressor
□Remove all the components from the bracket (Figure 2.1).
Figure 2.1
□Place the support bracket on the bottom of the driver’s side
cylinder head, insert the M16 bolt through the tube part of the
bracket into the OEM hole in the cylinder head and hand tighten
(Figure 2.2).
□Place the main bracket in position and bend the brake lines on
the ABS module as necessary to provide clearance.
□Place the main bracket in position to locate the mounting points
on the engine. Install and hand tighten the three M8 and one
M10 bolts in the front plate (Figure 2.2).
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M10
M8
M16
M10
Support Bracke
t
Main Bracket
Figure 2.2
□Route the wiring harness from the valve cover behind the top
edge of the bracket so that it is not pinched between the bracket
and the engine when the bracket is tightened in position.
□Install and hand tighten the two M10 compressor pad to support
bracket bolts.
□Check the fit between the support bracket and the main bracket,
make sure everything aligns properly, then torque the M16 bolt,
then the M10 bolts and finally the M8 bolts, in that order.
If you do not tighten the fasteners in the right order, the
mounting pad will be pulled out of alignment with the
front plate.
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□Remove the multi-wire block from the bracket on the frame by
pulling the nylon pin out of the bracket. Move it over and insert
the pin into the slotted hole to provide clearance for the
compressor.

□Install the short end of the supplied double 90 degree hose onto
the engine spigot on the driver’s side front of engine facing
forward, place clamps on the hose and install a 1 inch nylon
hose connector (Figure 2.5).
□Place the compressor in position on the mounting bracket.
□Thread the three M8 double-serrated nuts onto the compressor
mounting studs and torque to specifications.
2.2 Installing Drive Belts and Pulleys
□Install the VR crankshaft pulley onto the OEM pulley using three
M10 x 70 mm bolts with washers and torque to specifications.
Make sure that the bolt ends do not extend too far through the
crankshaft pulley so that they do not hit the timing cover.
□Install the tensioner assembly and idlers on the bracket and
torque the fasteners to specifications.
□Install the VR drive belt (Figure 2.3). Make sure that it is aligned
correctly and clears all components, including the cam position
sensor wire harness.
Compressor
Crankshaft
Back idler
Back idler
Back idler
Tensioner
Figure 2.3
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□Place the supplied fan spacer on the water pump pulley before
installing the fan.
2.3 Installing Other Components
□Remove the wire harness securing clip on the passenger side of
the engine just behind the battery box and ground mount point
(Figure 2.4).
□Bend the air conditioning line at the U-shaped pipe so that the
end closest to the front of the truck is about 1-1/2 inches lower.
□Route the wiring harness down beside the air conditioning line
and move the connectors at the firewall back to provide
clearance for the coolant expansion bottle.
Bend this A/C line down t
o
provide clearance
Install the threaded U-clip and attach
the end of the support bracket here
Move this harness down and out of the way
A
ttac
h
t
h
e
b
ott
l
e
h
ere w
i
t
h
t
h
e
OEM fastener through the OEM
hole
Figure 2.4
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VMAC – Vehicle Mounted Air Compressors
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□Install the threaded U-clip into the rear of the battery box and
Install the support bracket with the bent section upward.
□Place the coolant expansion tank in position on the support
bracket so that the OEM mounting hole lines up with the hole on
the fender that retained the wire harness.
□Mark the position of the support bracket hole on the plastic base
at the backside of the tank and drill a 1/8 inch hole at that spot.
□Mount the tank using the OEM mounting bolt in the fender hole
and the supplied self-tapping screw in the drilled hole.
□Install the short end of the supplied 90 degree hose onto the
coolant expansion bottle quick-connect fitting onto the bottle
(Figure 2.5) and position it so that it faces the front of the truck,
between the A/C and the battery box. Install hose clamps and a
1 inch nylon hose connector.
□Connect the supplied 1 inch hose to one of the nylon connectors.
Route the hose forward and down to the lower radiator cross
member, under the cross member and over the two lugs on the
front of the cross-member (Figure 2.5).
□Connect the other end of the supplied 1 inch hose to the
connector. Make sure that the hose is clear of all engine and
steering parts and secure it in place as required using nylon ties.
□Install all other OEM components. Check clearance between the
fan shroud and the crank pulley. If necessary, cut the tab from
the bottom of the fan shroud to provide clearance.
□After the fan shroud is installed, slot the power steering reservoir
into the fan shroud and secure it with two OEM 6mm bolts.
□Route the OEM power steering reservoir hose up behind the
compressor and insert the 3/4 inch plastic hose connector.
Connect the hose from the reservoir to the plastic hose
connector. Route the 3/4 inch hose from the power steering
reservoir to the connector and cut to length as required.

□Fasten the hose to the wiring harness on the valve cover with
nylon ties so it doesn’t contact any hot or moving parts.
Engine
Coolant
expansion
bottle
Nylon hose conectors
Cooler
Cross-member lu
g
s
Figure 2.5
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2.4 Installing the Cooler
□Position the cooler in the center of the cross-member so that it is
just above the sway-bar with the small spigot on the driver’s side
and the large spigot on the passenger side.
□Install bolts through the flat mounting straps (Figure 2.6) and
place them on the front of the cross-member on each side of the
impact sensor.
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Do not strike the impact sensor as this could cause the
airbags to actuate.
□Thread the bolts into the matching holes on the cooler mounts
and tighten them securely.
!
Figure 2.6
□Connect the cut ends of the lower radiator hose to the spigots on
the cooler and secure them with hose clamps.
□Cut the driver’s side hose at a suitable point just before the
cooler and insert the supplied diverter with the two small hose
spigots facing to the rear. Connect the OEM oil cooler hoses and
make sure that they clear the steering arms (Figure 2.7).

Cooler
Hose
f
rom tank
Hose from com
p
ressor
Diverter
Figure 2.7
□Insert the OEM top radiator hose quick-connect coupler into the
large diameter end of the supplied short 90 degree coolant hose
and install it on the radiator (Figure 2.8).
OEM quick-connect
Long 90 degree hose
Short 90 degree hose
Connector tube
Engine
Radiator
Figure 2.8
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□Install the small end of the longer 90 degree coolant hose onto
the thermostat spigot on the engine.
□Position the hoses so that they can be connected using the steel
connector tube. Make sure that the hoses will clear the power
steering and air intake MAF sensor. Secure all connections with
hose clamps.
□Fill the cooling system with the manufacturer recommended
coolant.

Part 3: Installing the Tank and
Hoses
3.1 Installing the Tank and Mount Brackets
The tank (Figure 3.1) will mount to the passenger side frame rail
behind the front cab mount. The recommended location is about 1
inch back from the end of the cab floor stiffener, a rib with an
attached ground wire.
1/4” and 3/16” tubes
3/4” hose fitting
1/2” hose fitting
C-clamp
Tank strap mount
Upper frame clip
Tank strap cable
Lower frame clip
Spacer
Oil filter
5/16” nuts and
washer
Figure 3.1
□Place the tank on a work bench with the front (oil filter end) of the
tank to your left and remove the oil filter.
□Remove the two 1/4 inch clamp bolts from the C-clamps. Expand
the clamps slightly and slide them over the front of the tank.
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□Place the two L-shaped tank strap mounts under the C-clamps
with the right-angle ends facing you and hanging over the edge
of the work bench. Apply Loctite and thread 5/16 x 1/2 inch bolts
with flat washers into the bottom hole on each bracket, but do
not tighten.
□Install the 1/4 inch clamp bolts into the C-clamps so that the
heads of the bolts face toward you and install the nuts but do not
tighten. Rotate the tank so that the directional arrow on the end
of the tank is parallel to the work bench and faces toward you.
3/16” tube
1/4” tube
Figure 3.2
□Apply Loctite and insert 5/16 x 1/2 inch bolts through the C-
clamps and thread them into the mount brackets, but do not
tighten.
□Install a suitable 3/4 inch fitting (not supplied) in the back of the
tank.
□Check tank alignment then tighten the C-clamp bolts and the
mounting bolts.
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□Insert the cable straps through the tube of the upper frame clips.
□Fit the cables onto the tank strap mounts with the cables in the
grooves of the mounts and the clips above the right-angle end of
the tank strap (Figure 3.1).
□Support the tank and L-bracket assembly in place on the outside
of the frame between the cab mounts, with the short part of the
L-bracket over the top of the frame.
Do not pinch the wiring harness on the top of the frame.
□Pass the upper frame clip between the frame rail and the body
and clip it onto the top of the frame. Insert the threaded end of
each cable strap through the tubes on the lower frame locating
U-clips. Install the spacers (if necessary for narrow frames) and
nuts and tighten just enough to hold the tank in position.
□Position the tank between the two cab mounts to provide
clearance for installing the lines and filter. Make sure that the
tank mounting system does not interfere with any transmission
components.
□When the tank is correctly positioned, tighten the securing cable
retaining nuts until the cables pull tight and snug around the
frame. Do not over-tighten.
□Install a second 5/16 inch nut and tighten it securely against the
first to act as a locknut.
3.2 Installing the Hoses
□Route the straight end of the 3/4 inch and the longest 1/2 inch
hoses over the cab mount and thread them into the matching
fittings on the tank but do not tighten.
□Insert the 1/4 and 3/16 tubes into the fittings on the back of the
tank and cover them with high temperature loom and route them
through the frame away from the exhaust system.
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