Vmac 9047 Installation guide

Type
Installation guide
Installation Manual
For The
System #9047
UNDERHOOD AIR COMPRESSOR
1999-2000 FORD SUPER DUTY F250-F550
7.3 L POWER STROKE DIESEL
TEL: 250-754-6997
FAX: 250-754-6972
TOLL FREE: 800-738-8622
1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3
DOCUMENT 19585
Installation Manual Document 19585
VR7000 Underhood Air Compressor
System Number 9047
Application: 1999-2000 Ford Super Duty F250-F550 7.3 L Power Stroke Diesel
Publication Date: August 2000
Origination Documents: #19585 - introduction
#19586 - compressor installation
#19587 - air tank and line installation
#19588 - control components installation
#19589 - illustrated parts list
#19130 - warranty registration
Notice:
Manuals and products are subject to change without notice.
Copyright 2000
The contents of this manual may not be reproduced in any form without the express written
permission of VMAC
Registered Trademarks:
VR7000, VMAC and Throttle Commander are registered trademarks of VMAC.
Ford, Super Duty, F250-F550, Power Stroke Diesel are registered trademarks of Ford Motor
Company
Loctite, Prime N’ Clean, 242 and PST are registered trademarks of Loctite Corporation.
Nylok is a registered trademark of Nylok Fastener Corporation.
Contents
GENERAL INFORMATION ........................................................................................3
INTRODUCTION ...............................................................................................................5
INSTALLATION NOTES ...................................................................................................... 5
ORDERING PARTS ......................................................................................................... 6
WARRANTY ................................................................................................................. 7
CHANGES AND IMPROVEMENTS ...........................................................................................7
PART 1: INSTALLING THE COMPRESSOR AND OIL COOLER ...........................9
1.1 PREPARING FOR INSTALLATION ................................................................................... 11
1.2 INSTALLING THE OIL COOLER ......................................................................................14
1.3 INSTALLING AND MOUNTING COMPONENTS .......................................................................15
1.4 INSTALLING THE COMPRESSOR ....................................................................................17
PART 2: INSTALLING THE AIR TANK AND LINES .............................................19
2.1 INSTALLING THE TANK BRACKETS AND TANK ....................................................................21
2.2 CONNECTING THE AIR AND OIL LINES ............................................................................ 25
2.3 ADDING OIL TO THE SYSTEM ......................................................................................28
PART 3: INSTALLING THE CONTROL UNIT ........................................................31
3.1 INSTALLING THE THROTTLE CONTROL UNIT ...................................................................... 33
3.2 CONNECTING THE WIRING HARNESS ..............................................................................34
3.3 INSTALLING THE THROTTLE COMMANDER ........................................................................35
3.4 ATTACHING THE WHITE WIRE ......................................................................................36
3.5 CONNECTING THE WIRING ......................................................................................... 38
3.6 COMPLETING THE INSTALLATION ..................................................................................41
ILLUSTRATED PARTS LIST ..................................................................................43
WARRANTY REGISTRATION .................................................................................49
1
2
General Information
System #9047
1999-2000 FORD
SUPER DUTY F250-F550
7.3 L POWER STROKE DIESEL
UNDERHOOD AIR COMPRESSOR
3
DOCUMENT 19585a
4
This symbol indicates that there is additional information or special emphasis
on a specific procedure.
This symbol indicates that there is a possibility of personal injury or damage to
the equipment if the indicated warning is not followed.
General Information
Introduction
This book provides installation instructions for:
VMAC underhood air compressor installation kit
This kit has been designed for:
1999 Ottawa Truck equiped with a 5.9 cummins 12 valve diesel engine with or without air
conditioning.
Installation steps
The installation procedure in this manual has three main steps:
Part 1: Installing the Air tank, Oil Cooler and lines
Part 2: Installing the control and electrical components
Part 3: Installing the compressor mounting bracket, Alternator bracket and connecting the lines
Terms and symbols
This manual uses the following terms and symbols:
OEM - Original Equipment Manufacturer
HHCS - Hex Head Cap Screw (also called a hex bolt)
SHCS - Socket Head Cap Screw (also called an Allen head bolt)
5
DOCUMENT 19585a
NOTE
WARNING
!
Installation notes
1. It is important that you complete all the installation steps before operating the system.
2. Follow all safety precautions for underhood mechanical work.
3. Use Loctite 242 or equivalent on all engine-mounted fasteners.
4. All hoses, tubes and wires which are re-routed or shifted during installation must be
secured so that they do not contact excessively hot areas or sharp edges. Where
possible, follow the routing suggestions in this manual.
5. These installation instructions are intended as a general guide. In some instances, due
to variations in vehicle manufacture or if prior modifications have been made to the
vehicle, it may be necessary to carry out grinding, bending or rearranging operations
for correct fit. These operations must follow sound, standard shop practices.
6. Left and right definitions in this manual are determined when sitting in the driver’s
seat, facing forward.
7. All fasteners must be of the correct size and torqued according to the specifications
shown below. Torque specifications are in foot pounds (ft-lb).
The above fastener torque values are applicable when Loctite is used.
If the threads are dry, add 20% to the torque values.
6
DOCUMENT 19585a
STANDARD GRADE 8 NATIONAL COARSE THREAD
Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4
Foot-pounds 9 18 35 55 80 110 170 280
STANDARD GRADE 8 NATIONAL FINE THREAD
Size 3/8 7/16 1/2 5/8 3/4
Foot-pounds 40 60 90 180 320
METRIC CLASS 10.9
Size M8 M10 M12 M14 M16
Foot-pounds 19 41 69 104 174
WARNING
!
Ordering parts
To order parts, contact VMAC at:
Telephone 250-754-6997
Facsimile 250-754-6972
Office Hours 8:00 AM to 4:30 PM Pacific Time
Please quote the VMAC part number, the description and the quantity.
Warranty
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.
The enclosed System Identification Number Plate must be attached to the vehicle at the time of
installation. Locate the plate on the dash near the control box (Figure 1) . Drill the two hole
locations using a 7/64” drill bit. Place the plate in position and fix in place with the two supplied
#6 pan head self tapping screws.
This plate provides information, which allows VMAC to assist in customer inquiries and
ordering parts. It is important that this plate is affixed to the vehicle.
Figure 1 Location of System Identification Number Plate
Changes and improvements
These products and documents are subject to changes or improvements without notice.
7
DOCUMENT 19585a
NOTE
S/N
8
Part 1
Installing
the Compressor and Oil
Cooler
System #9047
1999-2000 FORD
SUPER DUTY F250-F550
7.3 L POWER STROKE DIESEL
UNDERHOOD AIR COMPRESSOR
9
DOCUMENT 19586
10
Part 1: Installing the Compressor and Oil Cooler
1.1 Preparing for installation
1. Disconnect the batteries and remove the battery from the driver’s side box.
2. Drain the coolant from the radiator.
3. Remove the OEM fasteners from the coolant expansion bottle and move it out of the way.
Do not disconnect the hoses from the bottle.
4. Loosen the clamps holding the left intercooler tube at the air intake on the engine and at the
intercooler beside the radiator and remove the intercooler tube.
11
Removing OEM components
5. Remove and discard the plastic cover and attaching nuts from the center top area of the
engine.
6. Remove the OEM belt
7. Remove the cooling fan and the fan shroud.
NOTE
Removing the cooling fan will provide additional clearance for removing and installing
components.
Remove This Cover
Remove Coolant Expansion Tank
DOCUMENT 19586
12
8. Disconnect the air inlet horn from the front of the air cleaner and battery box. Leave this
part in place. This is optional for ease of removal and installation. Remove the air cleaner
box and the battery box from the drivers side of the vehicle.
Removing OEM components
9. Remove the alternator from its mount and lay it back on top of the engine. Keep the OEM
fasteners for alternator installation.
10. Remove the power steering pump pulley (noting the position of the pulley on the shaft), then
remove the power steering pump from the bracket. Keep the OEM fasteners for the power
steering pump installation. You will require the correct puller to remove the power steering
pump pulley.
11. Remove the power steering return hose from the power steering pump. Remove and
discard the metal portion of the hose.
12. Fasten the pump out of the way or lay it on the frame. Do not allow it to hang from the
pressure hose.
13. Remove and discard the OEM alternator and power steering pump mounting bracket and
the OEM bracket fasteners.
14. Peen the edge of the valve cover flat against the cylinder head in the area where the
compressor mounting bracket will attach. This allows the compressor mounting bracket to
sit flush with the cylinder head surface.
15. Remove and discard the upper and lower radiator hoses.
Remove The Air Cleaner And Batter
y
Boxes
DOCUMENT 19586
13
Removing the OEM bracket
16. Exchange the forward right bolt and rear left stud on the aluminum cover at the top front of
the engine.
Exchanging fasteners
Exchange these two fasteners
Front
OEM Alternator And
Power Steering Pump
Mounting BracketOEM
Fasteners
Cylinder Head
Mounting Area
Engine Block Mount
FRONT
LEFT SIDE
OF ENGINE
Peen Back This Area Of The Cover
DOCUMENT 19586
14
17. Remove and discard the 12 mm bolt from lower alternator bracket (lower right side of the
engine) and the 12 mm cap screw (lower left side of the engine) which retain the ground
straps (Figure 1.5).
18. Remove and discard the positive battery cable locating bracket from the same area.
Figure 1.5
19. Clean the front of the engine block thoroughly to ensure that there is no contamination in the
areas where the cooling tank and mounting bracket will fit. If the mounting area is dirty, the
bracket will not mount flush, resulting in fouling of the pulley or belt.
1.2 Installing the oil cooler
1. Install the oil cooler on the engine. Insert the supplied M12 x 30 mm hex head cap screws
and 12 mm serrated washer through the ground strap fittings on the drivers side and fasten
the oil cooler in place. Fit the supplied M12x 80 hex head cap screw with the 7/16 flat
washer through the cooler mount strap and the ground strap on the passengers side. Fit to
the lower alternator bracket where the bolt was removed from previosly, tighten both bolts.
Torque the fasteners to specifications.
Figure 1.6
12 mm bolt securin
g
lower alternator bracket
to the engine and holding ground strap
and transmission cooling lines
12 mm hex head cap screw
holding ground strap
DOCUMENT 19586
M12 x 30 HHCS
M12 x 0 HHCS
To en
g
ine block
To radiator
15
2. Place hose clamps on both hoses. Connect the right side cooler hose to the bottom radiator
outlet and the left side hose to the engine block connection. Tighten all the hose clamps
securely.
3. Fit two (2) 4 inch lengths of 1/2 inch rubber hose around the transmission line for protection
where they pass the cooler bracket. Use ties to hold the rubber in position on the lines
Connecting the hoses
1.3 Installing and mounting components
1. Install the crankshaft pulley using three (3) supplied M10 x 20 mm socket head cap screws.
Torque them to specifications.
2. Install four (4) 3/8 inch flat washers on the four (4) supplied M10 x 30 mm hex head cap
screws for the compressor mounting bracket. Apply Loctite to the fasteners.
3. Install the supplied VR7000 mounting bracket using the four (4) M10 x 30 mm hex head
cap screws. Torque them to specifications.
4. Install the power steering pump to the compressor mounting brackets using the OEM
fasteners.
5. Install the power steering pump pulley. The outer edge of the power steering pump pulley
must be flush with the end of the pump shaft.
DOCUMENT 19586
Lower radiator hose
Hose to
engine
block
1/2” oil line fittings
16
Installing the VR7000 components
6. Install the alternator onto the compressor mounting bracket using the OEM fasteners.
NOTE
7. Insert the supplied hose barb into the power steering rubber return hose which is attached
to the brake booster.
8. Install the supplied 3/8 x 11 inch power steering return hose on the other end of the hose
barb.
9. Install one of the OEM hose clamps on the end which will attach to the power steering
pump fitting. Install the hose on the pump.
10. Re-align the power steering hoses to clear the steering column.
The alternator must be mounted 180 degrees (upside-down) from the original mounting
position. Rotate the alternator 180 degrees in a counterclockwise direction.
Four (4) M10 x 30
Hex Head Cap Screws
DOCUMENT 19586
17
1.4 Installing the compressor
1. Apply Loctite to the burred-ends of the three (3) 8 mm studs and thread them in the holes
in the bottom of the compressor. Tighten them securely using two (2) jam nuts.
2. Install the compressor to the mounting bracket using three (3) supplied 8 mm nuts and 5/16
inch flat washers. Use Loctite on these fasteners and torque them to specifications.
3. Remove the M12 x 80 mm hex head cap screw which retains the compressor belt
tensioner. Apply Loctite, install the fastener and torque it to specifications.
4. Remove the 1/2” x 1-1/4NC hex head cap screw which retains the idler. Apply Loctite,
install the fastener and torque it to specifications.
5. Install the OEM belt. Be sure to use the correct routing.
Figure 1.9
6. Install the VR7000 belt. Be sure to use the correct routing (Figure 1.10).
Figure 1.10
VR7000
Crankshaft
Pulley
VR7000
Ten si on er
VR7000 Air
Compressor
VR7000
Idler
VR7000
Drive Belt
DOCUMENT 19586
Crankshaft pulley
Power steering
Water pump
Alternator
Idler
Idler
Tensioner
Air conditioning
Belt Idler Pulley
Generator
7. Install the fan and the fan shroud.
8. Install clamps on the supplied upper radiator hose and fit it on the engine and radiator
fittings.
9. Rotate the hose on the thermostat housing and radiator fitting until the hose clears both the
compressor belt and the fan shroud. Tighten the clamps.
Installing components
18
DOCUMENT 19586
10. Install the intercooler tube and tighten the clamps. Be sure that the tube clears the back of
the compressor and power steering pump and the bead inside the rubber OEM bellows sits
in the groove properly before tightening the clamps.
If the locating rib on the inside of the flexible tube does not seat correctly in the groove on
the intercooler tube, it is possible that the connection will come undone, allowing unfiltered
air into the engine. This can result in engine damage.
NOTE
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Vmac 9047 Installation guide

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Installation guide

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