Vmac V300004, Installation Manual

Page 1: ...Installation Manual for VMAC System V300004 2015 2016 Ford Transit 3 7 L Gas...

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Page 3: ...llation 8 Installing the Main Bracket 18 Installing the Compressor 21 Installing the Bulkhead Fittings 24 Hose Requirements 30 Installing the Tank and Hoses 31 Installing the Control Components 48 Ins...

Page 4: ...y precautions for mechanical work Any grinding bending or restructuring operations for correct fit in modified vehicles must follow standard shop practices Notice Copyright 2016 VMAC Global Technology...

Page 5: ...edures set out in this manual or standard safety practices Safety should be your first consideration in performing service operations If you have any questions concerning the procedures in this manual...

Page 6: ...5 The Compressor Assembly excluding Inlet and Clutch where applicable is warranted against manufacturer defects in materials and workmanship for the lifetime of the Compressor Assembly Restrictions ap...

Page 7: ...RADE 8 NATIONAL FINE THREAD Size 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 M6 M8 M10 M12 M14 M16 Foot pounds ft lb 4 5 19 41 69...

Page 8: ...l Support at 888 241 2289 Complete the warranty form The VMAC warranty form is located at the back of this manual as well as online at www vmacair com warranty This warranty form must be completed and...

Page 9: ...en 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 2 Figure 2 Operating Instruction Label To alert any technicians t...

Page 10: ...paring for Installation In the Cab Move the driver side seat fully to the rear and remove the 2 front T40 Torx Bolts Figure 4 Figure 4 Driver seat front Move the driver side seat fully forward and rem...

Page 11: ...tor The seat electrical harness is hooked to a stud on the bottom of the seat Ensure the harness is unhooked and the wire is allowed to hang loose under the seat Leave the seatbelt connected to the se...

Page 12: ...h the piece of carpet at the rear of the battery cover retaining plate Remove the metal bracket then lift the plastic tabs on the rear of the battery cover to remove the battery cover Figure 7 Figure...

Page 13: ...vacuum hose from the intake tube press the 2 locking tabs simultaneously and pull the connector back Figure 9 Figure 9 Vacuum hose Disconnect the PCV hose from the intake tube there is a small grey pl...

Page 14: ...Fax 1 250 740 3201 12 Loosen the 2 hose clamps on the intake tube Figure 11 Remove intake tube Figure 11 Cover the engine and air filter openings to prevent contaminants from entering into the engines...

Page 15: ...steering reservoir to the radiator support and use a cable tie to secure the reservoir to the windshield washer fill tube Figure 12 Figure 12 Washer reservoir Use a 10 mm socket to remove the 2 x M8 e...

Page 16: ...ove the 4 rib OEM drive belt discard belt Figure 14 Figure 14 Accessing the tensioner bolt Use a 14 mm flexible head gear wrench to access the tensioner bolt Access the tensioner bolt via the passenge...

Page 17: ...250 740 3201 15 From the bottom of the vehicle use a 15 mm serpentine belt wrench on the OEM tensioner Remove the 6 rib belt Keep this belt as it will be re used Figure 15 Figure 16 Figure 15 Using th...

Page 18: ...Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 16 Loosely install the supplied 4 rib belt on the crank pulley Route and tension the original 6 rib belt Figure 17 Figure 17 6 Rib...

Page 19: ...ssor clutch Ensure that the wiring is not attached to the compressor housing as the weight of the compressor may damage the harness Figure 18 Remove the air conditioning compressor from the engine it...

Page 20: ...ers The main bracket 4800701 is held onto the engine with 4 fasteners Use Loctite 242 blue on all fasteners Figure 19 Install the 3 supplied M8 x 45 socket head bolts finger tight through the main bra...

Page 21: ...igure 20 When installing the A C compressor ensure the clutch wire is routed so that it will not be pinched or damaged by any sharp edges or hot components Loosely install the rear and bottom bolts us...

Page 22: ...e compressor against the main bracket so the top bolt can be accessed through the machined opening in the top of the VMAC bracket Use a 10 mm open ended wrench to tighten the bolt Once the bolt is thr...

Page 23: ...Toll Free 1 888 241 2289 Fax 1 250 740 3201 21 Installing the Compressor Use Loctite 242 blue and install the 3 supplied M8 x 45 socket head bolts to secure the VMAC compressor onto main bracket Figu...

Page 24: ...cle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 22 Install the supplied 4 rib belt so that it is centered on the compressor clutch and tension the belt Figure 23 Figure 23 Belt...

Page 25: ...Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 23 Figure 24 Belt alignment To ensure the belt is properly aligned on the clutch pulley confirm there are 2 grooves visible on each side of...

Page 26: ...run from the compressor to the bulkhead fittings and from the fittings to the WHASP tank To maximize compressor performance hose lengths should be kept as short as possible if longer hoses are requir...

Page 27: ...k inside of a van body about 12 in behind the driver side seat Locate the area shown it is to the rear of fuel filler neck on the driver side floor The holes are shown for clarity and will be drilled...

Page 28: ...step drill drill bit or hole saw drill the following holes Forward mark 9 16 in 2 middle marks 5 8 in Rear passenger side mark 1 1 8 in Driver side mark 3 8 in Install a 3 8 in rubber grommet Not supp...

Page 29: ...250 740 3201 27 Fit the bulkhead fittings through the top of the hole and secure from the bottom with the supplied nuts Use thread sealant and install the 1 4 in fittings in the top and bottom of the...

Page 30: ...28 Separate the remote blowdown bulkhead fitting from the 1 4 in PTFE tube Remove the locking nut from the remote muffler assembly Figure 30 Figure 30 Bulkhead blowdown assembly Insert the bulkhead f...

Page 31: ...VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 29 Install the lock nut and serrated washer from underneath the vehicle Figure 32 Figure 32 Installing the fitting...

Page 32: ...r oil will degrade rubber lined hoses use only hoses with an AQP elastomer type liner Contact VMAC Tech Support at 1 888 241 2289 for further information Do not attempt to shorten the supplied hose un...

Page 33: ...in PTFE hose to the 90 push to connect fitting on the front of the compressor Ensure the hose fully seats in the fitting Lubricate the tube and firmly push it into the fitting so that it fully seats...

Page 34: ...888 241 2289 Fax 1 250 740 3201 32 Route the 3 4 in x 150 in 3 8 in x 150 in hoses and 1 4 in x 150 in PTFE hose downwards from the rear of the compressor in front of the passenger side engine mount...

Page 35: ...1 33 Route hoses along the front of the sub frame secure with 2 supplied P clips M6 x 14 bolts M6 nuts and washers in the 2 empty holes on the front of the sub frame Figure 35 Figure 36 Figure 35 Hose...

Page 36: ...Toll Free 1 888 241 2289 Fax 1 250 740 3201 34 Continue routing the hoses up to the driver side frame rail run the hoses above the suspension and steering components Figure 37 Figure 37 Hose routing...

Page 37: ...ide of the driver side frame rail secure with 2 supplied P clips in locations shown with the supplied 5 16 in x 3 4 in sheet metal screws into existing holes on the frame Figure 38 Figure 39 Figure 38...

Page 38: ...oll Free 1 888 241 2289 Fax 1 250 740 3201 36 Route the hoses above the fuel filler hose and around to the rear of the fuel filler housing Figure 40 Figure 41 Figure 40 Hose routing continued Figure 4...

Page 39: ...oll Free 1 888 241 2289 Fax 1 250 740 3201 37 Secure the hose with the supplied with P clip and 5 16 in x 3 4 in sheet metal screw in location shown Figure 41 Figure 42 Figure 42 Rear P clip and faste...

Page 40: ...fittings are tight fully seated and secure Figure 43 Figure 43 Hoses connected Ensure hoses are not pulled tight to allow for engine movement to be taken up by hose slack Ensure all hoses are routed...

Page 41: ...on the tank in an appropriate location Secure the tank by bolting the mounting feet to the installation surface use M8 or 5 16 in fasteners not supplied due to the potential variation of tank mounting...

Page 42: ...tem may overheat due to a lack of a fresh cool air supply Figure 44 Figure 44 WHASP ventilation A minimum of 6 in of clearance is recommended around the front of the WHASP tank to allow fresh cool air...

Page 43: ...mpressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 41 Figure 46 Minimum WHASP Tank mounting clearances 4 x M8 or 5 16 in Rectangular Mount Pattern 12 in 20 1 4 in 18 1 8 in 4 1 2 in 15 3 8 in Fan o...

Page 44: ...ecommends shortening these hoses as a preferred alternative to coiling up and securing the excess Shorter hose length will maximize system performance Route and connect the straight ends of the 3 4 in...

Page 45: ...Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 43 Figure 47 WHASP Tank 12 Male JIC Main discharge from Compressor 6 Male JIC Oil return to compressor 1 4 in Scavenge To compressor 8 Male JIC...

Page 46: ...utside of the vehicle will reduce cabin noise during blowdown and will ensure that any oil vapor will be safely discharged outside of the vehicle Remove the blowdown muffler from the side of the WHASP...

Page 47: ...g compound and install the provided 1 4 in Push To Connect fitting into the threaded hole which previously held the blowdown muffler Figure 49 Figure 49 Fitting installation Connect the 1 4 in PTFE tu...

Page 48: ...fitting Ensure the hose will not kink and cut the hose to length Ensure the hose is cut square and that there are no sharp edges Do not use side cutters as this will deform the hose Install the hose i...

Page 49: ...VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 47 This page intentionally left blank...

Page 50: ...VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 48 Installing the Control Components Figure 52 Wire Schematic Red Grn Yel White Yellow Grn Yel...

Page 51: ...VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 49 Figure 52 Wire Schematic Red Grn Yel Grn Yel White Yellow...

Page 52: ...n the way Remove the panel underneath the steering wheel Figure 53 Secure the throttle control with cable ties so that the SPEED 1 adjusting screw is accessible Figure 53 Figure 53 Steering Dash Panel...

Page 53: ...emove the panel under the headlight controls to route the wiring Figure 54 Loom the black wire from the throttle control with 1 4 in split loom or equivalent protection and route underneath the headli...

Page 54: ...0 3201 52 Remove the driver side door weather stripping from the channel and route the black wire between the channel and the driver side floor Figure 55 Route the wire underneath the driver side step...

Page 55: ...2289 Fax 1 250 740 3201 53 Route the wiring through the gap in the driver side seat support Figure 56 Figure 56 Driver side seat support Route the wire between the seat support and battery box towards...

Page 56: ...g OEM wires whenever practical The preferred method is to remove the pin from the connector using an appropriate tool and slide the shrink tube onto the wire Strip the wire at the desired location and...

Page 57: ...t stripe wire running to the park brake This is the park brake safety signal Find a grommet in the firewall where the Tach module cable bundle with short white and blue wires can be passed through Fig...

Page 58: ...40 3201 56 Locate the Powertrain Control Module behind the driver side headlight Figure 62 Figure 62 Powertrain Control Module The second plug from the front of the Power Train Control Module is C175E...

Page 59: ...stripe and 63 green wire with the white stripe per the pinout Figure 63 Figure 63 Electrical Connector 2015 MY C175E Solder and seal the short white wire from the tach module cable to pin 62 the yell...

Page 60: ...tach module cable to pin 70 the yellow wire with the purple stripe Solder and seal the short blue wire from the tach module cable to pin 69 the green wire with the brown stripe All model years Slide...

Page 61: ...tabs at the top rear of it to allow it to hang down and out of the way Figure 66 Figure 66 Glove box Route the long blue wire from the VMAC throttle above the driver side fuse box along the factory wi...

Page 62: ...will appear on the passenger side of the dash above the HVAC system Figure 68 Figure 68 Passenger dashboard Remove the access panel at the back of cup holder directly to the right of the glove box co...

Page 63: ...Free 1 888 241 2289 Fax 1 250 740 3201 61 Use 8 mm socket to remove the left bolt holding connector C210 Figure 70 Figure 70 C210 Left bolt Use 8 mm socket to remove the right bolt holding connector...

Page 64: ...Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 62 Gently pull the connector over towards the driver side and undo the 10 mm bolt to separate the connector Figure 72 Figure 72 Con...

Page 65: ...e pin 7 of connector C210 it will be populated with a grey wire with a brown stripe Figure 73 Figure 73 Male Harness C210 Figure 74 Female C210 Solder and seal the long blue wire from the throttle con...

Page 66: ...A mounting bracket may need to be fabricated bracket and hardware not included with kit Apply plastic loom or equivalent protection to all wiring prior to installation Figure 76 Installing the contro...

Page 67: ...Connect Blue to Blue 14 AWG Orange to Orange 14 AWG Black to Black 18 AWG White to White 18 AWG Figure 77 Connect the green wires with the yellow stripe from the control panel and tank harness to chas...

Page 68: ...ead hole with a suitable grommet Continue routing along the 3 hoses up to the compressor and connect it to the bullet connector on the black clutch wire Figure 79 Run the yellow 18 AWG wire from the W...

Page 69: ...d will not interfere with the operation of the truck Secure all wiring with cable ties and loom as required The battery and switched power are located underneath the driver side seat Route the red 14A...

Page 70: ...740 3201 68 Drill a 7 32 in hole in the rear passenger side corner of the driver side seat bracket Figure 81 Figure 81 Rear seat bracket Figure 82 Relay harness mounting 7 32 in hole M5 x 14 Pan Head...

Page 71: ...Free 1 888 241 2289 Fax 1 250 740 3201 69 Mount the relay harness using the supplied M5 x 14 pan head screw M5 flat washer and M5 Nylok nut Figure 82 Figure 83 Figure 84 Figure 83 Relay harness mount...

Page 72: ...8 241 2289 Fax 1 250 740 3201 70 Connect the 20 A fused wire to the positive battery terminal Figure 85 Figure 85 Black fused wire Connect the green wire with the yellow stripe from the relay module t...

Page 73: ...6 pin connector Figure 87 Figure 87 Key switched wire Plug the connector into the empty connector at the front passenger side of seat in between the battery box and the seat support Figure 88 Figure 8...

Page 74: ...Free 1 888 241 2289 Fax 1 250 740 3201 72 Installing VMAC Air Filter and Power Steering Reservoir Remove the 2 OEM bolts and front engine brace Install VMAC air filter bracket re use the OEM bolts Fi...

Page 75: ...bent end of the compressor intake hose onto the compressor inlet valve install the other end of the hose onto the air filter housing Ensure clamps are tight and that the hose and clamps will not cont...

Page 76: ...ree 1 888 241 2289 Fax 1 250 740 3201 74 Use Loctite 242 blue install the supplied power steering bracket on top of the compressor with the 3 supplied M6 x 8 button head screws Do not overtighten Figu...

Page 77: ...Toll Free 1 888 241 2289 Fax 1 250 740 3201 75 Install the OEM power steering reservoir onto the supplied bracket with the 2 x M6 x 14 bolts 4 x M6 flat washers and 2 x M6 Nylok nuts Figure 93 Figure...

Page 78: ...m Overfilling the system with oil can flood the sight glass window and make the system appear empty Remove the fill cap on the WHASP tank above the sight glass Using a funnel pour oil into the tank un...

Page 79: ...covers removed during installation Connect the battery s Safety Test Ensure the following has been completed Place the transmission in PARK and apply the park brake Turn the ignition key to ON but do...

Page 80: ...AC throttle from increasing engine rpm unless the transmission is in PARK and the park brake is engaged 2 people are required to perform this safety test 1 person must remain in the driver seat and be...

Page 81: ...e vehicle is in PARK or NEUTRAL Drain any air that may have accumulated during the previous tests Ensure the parking brake is engaged Turn on the compressor and open the ball valve Release the park br...

Page 82: ...transmission in PARK and fully apply the park brake 4 Allow the engine to run until it is at operating temperature 5 Operate the air compressor system until the oil is warm 6 Observe the pressure gaug...

Page 83: ...ly When making adjustments count the number of turns made on the screws Engine speed adjustments may be made so that the amount of air delivered by the system matches the requirements of the tools or...

Page 84: ...re is maintained during tool operation See page 80 of this manual for testing instructions Road test the vehicle for approximately 14 miles 20 km Watch the UNDERHOOD operation to ensure the belts rota...

Page 85: ...gives the compressor time to react by increasing the engine speed and producing air before the tool stalls It also has the advantage of lowering the duty cycle of the compressor system If the plumbin...

Page 86: ...the frequency of clutch and system cycling For information on installing a receiver tank see page 83 of this manual Receiver tanks are available for purchase through VMAC See page 85 of this manual fo...

Page 87: ...ir stream Adds atomized tool oil to lubricate tools Reduces pressure for longer tool life Compressor Service Kits 200 Hour Part number A700219 Includes compressor oil oil filter and air filter 400 Hou...

Page 88: ...r the 1 4 in PTFE tube 90 1 4 in Fitting Part number 5000020 45 Quick connect fitting for the 1 4 in PTFE tube Straight 1 4 in Fitting Part number 5000012 Straight Quick connect fitting for the 1 4 in...

Page 89: ...Province ______________ Installation Date _____ _____ _____ Day Month Year Owner Information Company Name __________________________________________ Address ___________________________________________...

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