Vmac V990002 Installation guide

Category
Toys & accessories
Type
Installation guide
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
1
Installation Manual for VMAC
System V990002
Ford 2005 - 2006 6.0L Power Stroke Diesel
Odin Foam - Without Dual Alternators
General Information..................................................................... 3
Before You Start ..................................................................... 3
Part 1: Preparing for Installation ............................................... 4
1.1 Preparing for Installation ................................................. 4
1.2 Modifying the Passenger Battery Tray ........................... 7
1.3 Mounting the Vacuum Tank ............................................ 9
1.4 Glow Plug Modules .......................................................... 12
1.5 Relocating the ICP Sensor .............................................. 12
1.6 Installing the Crank Pulley .............................................. 12
Part 2: Installing the Tank and Hoses....................................... 13
2.1 Installing the Brackets ..................................................... 13
2.2 Installing the Tank ............................................................ 16
Part 3: Installing the Cooler, Bracket and Compressor .......... 18
3.1 Installing the Oil Cooler ................................................... 18
3.2 Installing the Main Bracket .............................................. 20
3.3 Installing the Compressor ............................................... 23
3.4 Completing the Installation ............................................. 26
3.5 Adding Oil to the System ................................................. 31
Part 4: Installing the Control Components .............................. 32
4.1 Installing the Components .............................................. 33
4.2 Connecting the Under-hood Wiring................................ 34
4.3 Connecting the In-cab Wiring ......................................... 35
4.4 Completing and Testing the Installation ........................ 39
Part 5: Finishing the Installation ................................................ 41
5.1 Before Starting the Engine Checklist ............................. 41
5.2 After Starting the Engine Checklist ................................ 41
5.3 Setup, Performance Testing and Adjustments ............. 42
5.4 System Identification and Warnings .............................. 43
5.5 Auxiliary Air Receiver ...................................................... 44
Accessory Products from VMAC ............................................... 45
VMAC Vehicle Mounted Air Compressors
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Fax: 1-250-740-3201
2
Document #1930091
Installation Manual for VMAC System V990002
Ford 2005 - 2006 6.0L Power Stroke Diesel
Odin Foam Without Dual Alternators
Changes and Revisions
Version
Revision Details
Revised by/date
Approved
Implemented
00
Original manual
IB 18 Apr 2005
SM 10 May 2005
12 May 2005
a
2005 rear tank bracket
IB 07 Jun 2005
BC 09 Jun 2005
11 Jun 2005
b
2006 revisions
IB 09 Sep 2005
SM 11 Sep 2005
15 Sep 2005
c
2006 revisions
IB 04 Oct 2005
SC 04 Oct 2005
07 Oct 2005
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 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 1-800-738-8622.
Copyright 2005
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: 1-250-740-3201
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
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
5/16
3/8
7/16
1/2
9/16
5/8
¾
Foot-pounds (ft-lb)
18
35
55
80
110
170
280
Newton meter (N•m)
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
1/4 inch
5/16 inch
1/2 inch
5/8 inch
3/4 inch
1 inch
Yellow
Orange
Blue
Blue
Green
Green
VMAC Vehicle Mounted Air Compressors
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Part 1: Preparing for Installation
1.1 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.
Drain the cooling system, remove the upper and lower radiator
hose and disconnect the coolant expansion tank hose from the
top of the radiator.
Disconnect the batteries and remove the passenger side battery.
Remove the plastic air deflector from the upper section of the fan
shroud. Keep this part if the vehicle is to be returned to stock
condition.
Remove the two screws securing the upper section of the fan
shroud to the radiator. There are two options for removing the
fan shroud (you can remove the air cleaner to make this easier):
a. Carefully pry the shroud upward to release the rubber seal
from the groove in the stator. Push the top corner of the
shroud back to clear the upper hose spigot and pull the
shroud out. Be careful not to crack the shroud.
b. Locate the molded lines on the fan shroud, one on each side
about 6 inches (15cm) down from the top (Figure 1.1). Use a
suitable tool to cut the fan shroud between these lines
(Figure 1.1). Do not cut the rubber seal. Remove the upper
shroud section along with the rubber seal, then remove the
lower fan shroud section.
Disconnect the fan clutch wiring harness from the fan stator and
the fan clutch wiring plug connector. Remove the fan.
Remove the rear fan stator (large plastic section with cooling fins
behind the fan) and store it for future use if the vehicle is to be
returned to stock condition.
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Upper shroud
Lower shroud
Rubber seal
Cut along molded line
Figure 1.1
Remove the four bolts from the water pump pulley and replace
them with the supplied low profile head bolts.
Remove the OEM serpentine belt.
Remove the OEM belt tensioner assembly.
Remove the intercooler tube on the passenger side and keep the
2-1/2 inch OEM clamps. Discard the intercooler tube, the
connecting hose from the intercooler and the two larger T-bolt
clamps.
Cover the turbo outlet and the intercooler inlet to
protect the system.
Disconnect and remove the glow plug relay module with the
mounting bracket. Detach the module from the mounting bracket,
discard the bracket but keep the nuts.
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Unscrew the engine oil fill tube. Plug the oil filler opening to
protect the engine.
On automatic transmission models, remove the transmission
dipstick from the passenger side valve cover and install the
supplied bracket (using the OEM nut) with the spacer facing
down and away from the valve cover. Attach the transmission
dipstick to the lower spacer of the bracket using the supplied
fasteners.
Remove the wiring harness retainers from the studs at the front
of the valve cover. Cut the tape back far enough so that you can
reroute the harness behind the transmission dipstick tube and
over the valve cover. Most of the wiring and the glow plug
connectors should be behind and below the alternator.
Cut off the upper threaded section of the two front valve cover
bolt (just below the alternator) flush with the hex nut.
Remove the steel heater return pipe with rubber O-ring. Save the
O-ring and the M6 bolt. Disconnect the steel pipe from the heater
hose and discard the pipe.
Figure 1.2
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Install the OEM O-ring onto the replacement heater hose barb
connector and install it into the front of the engine where the
heater hose pipe was removed (Figure 1.2). Cut a short piece of
3/4 inch hose from the supplied 8 inch piece, fit it onto the hose
barb and secure it with a clamp.
Insert the long end of the supplied replacement steel heater pipe
into the short 3/4" heater hose and position the short end with
the tab along the alternator, pointing toward the firewall.
If equipped, remove the sound proofing from the underside of the
hood.
Remove the plastic clips holding the flexible mud deflectors to
the top and bottom of the radiator cross-member.
For easier installation of the cooler, remove the bolts from the
small power steering cooler in front of the radiator cross-member
and leave it loose in position. You can also remove the radiator
hold-downs and raise the radiator for better access.
Some trucks may have a crossbeam behind the air dam and
under the radiator while others may have a crossbeam that also
retains the tow-hooks. This can be removed to provide easier oil
cooler installation.
1.2 Modifying the Passenger Battery Tray
Remove the passenger side battery tray.
Turn the battery tray over and cut off the fender bracket along
the bottom crease of the battery tray (Figure 1.3).
Install the supplied battery bracket to the inner side of the
passenger fender using the two OEM M8 bolts (Figure 1.4).
Install the passenger side battery tray reversed 180 degrees and
fasten it in place with 5/16 x 1 inch bolts with 3/8 inch flat
washers and 5/16 inch lock washers and nuts. The battery tray
hold-down clamp should face to the rear of the vehicle and the
tray should be on a slight angle. Slide the tray as far forward as
possible.
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You may have to trim off some of the plastic web on the
windshield washer bottle to clear the edge of the battery
tray.
Figure 1.3
Battery bracket
Figure 1.4
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Drill an 11/32 inch diameter hole through the OEM support
bracket using an existing hole in the battery tray as a guide.
Install a 5/16 x 1 inch bolt with 3/8 inch flat washer and 5/16 inch
lock washer and nut. Tighten all fasteners.
1.3 Mounting the Vacuum Tank
If the truck does not have air conditioning, you must
still relocate the vacuum tank on the plastic fender liner
to clear the compressor but will not have to replace the
short hose or use the mount bracket.
Remove the vacuum tank from the passenger side fender and
save the nuts for reinstallation.
Disconnect the hoses from the vacuum tank and discard the
short hose from the vacuum pump to the vacuum tank.
Remove the three bolts mounting the air conditioning
receiver/dryer from the heater housing.
If necessary, remove the fender liner for better access.
Carefully bend the forward facing top larger air conditioning line
out towards the inner fender until parallel to the fender. Twist on
the vertical section while supporting the receiver/dryer canister
and push inwards. This can be accomplished using a long pry
bar protected where it rests between the two vertical sections of
the lines (Figure 1.5).
Bend the other line by pulling upward and forward on the
receiver/dryer canister to provide adequate clearance.
Remove and discard the plastic shroud from the receiver/dryer.
Remove the bolt and clamping components from the supplied
heavy duty clamp and slide the clamp up onto the receiver drier
with the open side towards the front of the vehicle, above the
electrical connection.
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First bend
Support first
bend by pushing
here
Second bend
pull up on the
bottom of the
cannister toward
the front
Position the cannister in front of the wiring plug
Place the clamp above the electrical
connector facing forward
Figure 1.5
Install the clamping bolt in the clamp and through the vacuum
tank bracket. Leave the clamp loose enough so that you can
adjust the position (Figure 1.5).
Remove the front bolt holding the vacuum pump bracket to the
passenger side fender. Place the supplied vacuum tank bracket
in position over the OEM vacuum pump bracket and install the
OEM bolt.
Mount the vacuum tank bracket using the original OEM M6 nuts
with the hose connections at the bottom, angled at approximately
45 degrees (Figure 1.6). If required, bend up OEM vacuum pump
and OEM vacuum pump bracket approximately 20 degrees to
clear the air conditioning condenser (Figure 1.7).
Install the supplied 1/8 inch rubber hose between the vacuum
pump and the vacuum tank and connect the other hoses.
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Figure 1.6
Figure 1.7
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1.4 Glow Plug Modules
Mount the glow plug module to the supplied bracket using the
two OEM M6 nuts so that the module will face toward the center
of the engine when the bracket is installed.
Install the assembly on the passenger side engine valve cover
studs beside the engine oil fill-tube using OEM nuts.
Wrap any loose OEM wires with tape and connect the glow plug
relays. Make sure that the wire harness is secured behind the
alternator where it will not touch the compressor or turbocharger.
Install the oil fill tube.
1.5 Relocating the ICP Sensor
On trucks after 2004.5, the ICP sensor is located on the passenger
side valve cover.
Remove the ICP sensor. Make sure that the sealing O-ring
gasket is on the sensor.
Thread the sensor into the supplied banjo fitting and tighten.
Install the banjo fitting into the valve cover. Make sure that the
copper sealing gaskets are in good condition and are in place.
Point the ICP sensor toward the rear of the truck and torque the
banjo fitting to 15 ft-lbs.
1.6 Installing the Crank Pulley
Clean the face of the OEM pulley, install the VR pulley, align the
bolt holes and ensure that the pulley is sitting flush. Apply
Loctite, install three M10 x 70 mm bolts and flat washers and
torque to specification.
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Part 2: Installing the Tank and
Hoses
2.1 Installing the Brackets
For 2005-2006 F450 and F550 model trucks see the
special installation instructions for the rear tank mount.
Remove the bolts, washers and nuts from the tank clamps and
the P-clips from the stand-off brackets.
Lay the tank brackets on a flat surface with the wide flanges
away from each other (Figure 2.1). The front and rear brackets
are different and are stamped “Front” and “Rear”.
Upper frame clip
P-clip and
stand-off
bracket
Inner tank clamp
Lower frame clip
Spacer (not used on wide frames)
5/16” x 1/2”
Figure 2.1
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Insert the cable straps through the upper frame clips and place
one cable on each tank bracket with the cables in the grooves.
Place one inner tank clamp onto the front tank bracket. Place
one stand-off bracket under the top front hole.
Apply Loctite to the 5/16 x 1/2 inch hex head bolts (with flat
washers) and attach the inner clamp to the front tank bracket
(the top front bolt also mounts the stand-off bracket). Tighten all
the bolts.
2.1.1 All Trucks Except 2005 - 2006 F450 and F550
Place the inner tank clamp on the rear tank bracket with the
stand-off bracket under the top rear hole. Apply Loctite and
attach the clamp to the bracket using 5/16 x 1/2 inch hex head
bolts. Tighten all the bolts.
Clean the area on the frame between the two cab mounts on the
passenger side and place the front bracket on the frame in front
of the transmission cross-member and as far forward on the
frame as possible. Place the upper frame clip on the frame rail
and make sure the frame seats in the groove.
Wrap the cable under the frame, insert the lower frame clip and
make sure the frame is seated in the clip. Install a spacer (if
necessary) a washer and a nut. Tighten the nut securely (do not
over-tighten) and install a second nut as a lock.
Place the rear bracket behind the transmission cross-member
and as far back as possible. Attach in the same manner as the
front bracket.
The tank brackets must be positioned far enough apart
to provide good support for the tank, but must not be
positioned in any location where the tank will not be
level when installed.
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2.1.2 2005 2006 F450 and F550
Place spacers on the rear tank bracket as shown in Figure 2.2;
1/2 inch spacers on the top and bottom front holes, 5/8 inch
spacer on the top rear hole and a 3/4 inch spacer on the bottom
rear hole.
Place the inner tank clamp on the spacers with the stand-off
bracket under the top rear hole.
Apply Loctite and install 5/16 x 1 inch bolts with washers through
the two front holes, 1/2 inch spacers and into the bracket.
Apply Loctite and install a 5/16 x 1-1/4 inch bolt with washer
through the top rear hole, stand-off bracket, 5/8” spacer and into
the bracket.
Apply Loctite and install a 5/16 x 1-1/4 inch bolt with washer
through the bottom rear hole, 3/4 inch spacer and into the
bracket. Tighten all the bolts.
Stand-off bracket
Rear tank bracket
Inner tank clamp
5/8” spacer
1/2” spacers
3/4” spacer
5/16” x 1”
5/16” x 1-1/4”
Figure 2.2
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Clean the area on the frame between the two cab mounts on the
passenger side and place the front bracket on the frame as
shown in Figure 2.3. Place the upper frame clip on the frame rail
and make sure the frame seats in the groove.
Wrap the cable under the frame, insert the lower frame clip and
make sure the frame is seated in the clip. Install a spacer (if
necessary) a washer and a nut. Tighten the nut securely (do not
over-tighten) and install a second nut as a lock.
Place the rear bracket on the frame as shown in Figure 2.3 and
attach in the same manner as the front bracket.
7.5” 4”
Tops will be about
1/4” closer together
Figure 2.3
2.2 Installing the Tank
Install the front outer tank clamp with both bolts and washers and
leave the bolts very loose.
Lift the tank and slide it into the front clamp.
Install the rear outer tank clamp.
Position the tank for sufficient clearance at both ends and rotate
the tank until the arrow molded into the rear of the tank is
pointing upward. Tighten the clamp bolts.
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Thread the fittings of the 1/4 and 5/16 inch steel tubes into the
matching fittings on the rear of the tank with the flexible hose end
to the front of the truck. (Figure 2.4).
Install the P-clips on the two steel lines and fasten them to the
stand off brackets. Adjust the tubes in the P-clips as necessary
and tighten the fittings and P-clip bolts.
Figure 2.4
Connect the straight end of the longest 5/8 inch hose to the
matching fitting on the front of the tank. Route this hose along
the frame rail, over and inside the cab mounting bracket and
around the steering idler arm to the front of the vehicle. Do not
tighten the fitting.
Connect the straight end of the 1-1/4 inch hose to the matching
fitting on the front of the tank. Route this hose outside the cab
mount, up behind the mud guard and fender liner towards the
rear of the engine and along the passenger side valve cover. Do
not tighten the fitting.
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Part 3: Installing the Cooler,
Bracket and Compressor
3.1 Installing the Oil Cooler
Insert M10 x 90 mm bolts into the top of the two mount brackets
(Figure 3.1) and place them over the cross-member that runs
under the radiator, outboard of each power steering mounting
bracket.
M10 x 90 mm bolts
with washers
Spacers
Mount brackets
Figure 3.1
Place the cooler in position with the threaded fittings facing to the
rear of the vehicle (Figure 3.2) and thread the top bolts into the
top outermost holes on the cooler mount. Leave the bolts loose
enough so that you can move the cooler on the cross-member.
Insert bolts into the lower holes and install the spacers. Thread
them into the outermost lower holes on the cooler mount.
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To engine
To radiator
Cross-member
Coolant
bypass
hose
connection
1/2” hose to compressor 1/2” hose from tank
Figure 3.2
Loosen the clamp on the hoses attached to the cooler. Connect
the hose to the lower radiator spigot, adjust for best fit and
tighten the clamps.
On some models, the hose will interfere with the
steering linkage. If necessary, cut some material off the
radiator end of the hose to move the hose forward and
away from the steering linkage.
Install the OEM lower hose between the engine spigot and the
cooler and secure it with clamps.
Connect one end of the longest supplied heater hose to the
spigot on the side of the cooler and secure it with a clamp. Route
the hose up to the engine.
Connect the 90 degree end of the 5/8 inch hose from the VR
tank to the passenger side fitting on the cooler. Do not tighten
the fitting.
Connect the 90 degree end of the short 5/8 inch hose to the
cooler and route it up the passenger side of the engine
compartment. Do not tighten the fitting.
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Adjust the cooler as required to provide a good fit with all hoses
and tighten the mounting bolts.
3.2 Installing the Main Bracket
Due to vehicle assembly variations, the rear right corner
of the main bracket may interfere with the right hand
rocker cover. Make sure that there is clearance between
the bracket and rocker cover before tightening down the
bracket. If necessary, grind a small amount of material
off the bracket where the interference exists until
adequate clearance is achieved.
Remove the idlers, idler mount bracket and tensioner from the
main bracket.
Mount the main bracket to the right-hand side of the engine
using three M10 x 55mm flange lock bolts (with Loctite) in the
two upper holes and one in the lower outer-most hole. Check to
make sure that the bracket is not interfering with any OEM parts.
Carefully bend the air conditioning lines as necessary to provide
clearance for the bracket and compressor. You may have to
adjust line position again once the compressor is installed.
Do not twist, break or damage the air conditioning lines.
Make sure that the connections at the receiver/drier are
not damaged or cracked while repositioning the lines.
Route the A/C compressor wiring harness behind the bracket.
Make sure it is not pinched by the bracket.
Install the M10 x 35mm flange head bolt into the lower inner-
most attachment point (Figure 3.3) and torque to specifications.
Install the OEM belt tensioner.
Install the OEM 8-rib belt (Figure 3.4).
Install the idler mount bracket to the main bracket using three
M8 x 25 mm socket head bolts and install the idler (Figure 3.5).
!
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Vmac V990002 Installation guide

Category
Toys & accessories
Type
Installation guide

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