Vmac V300001 Installation guide

Type
Installation guide
Installation Manual for VMAC
System V300001
2011 - 2015 Ford F250-F550 Pickup, Cab & Chassis
6.7L Power Stroke Diesel
www.vmacair.com
TM
COMPACT. POWERFUL.
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
1
Installation Manual for VMAC
System V300001
2011- 2015 Ford F250-F550 Pickup, Cab & Chassis
6.7L Power Stroke Diesel
General Information ............................................................................... 3
Before You Start ................................................................................... 3
Torque Specifications ........................................................................... 3
Special Tools Required ........................................................................ 3
Hose Information .................................................................................. 3
Important Safety Notice ......................................................................... 4
Safety Messages .................................................................................. 4
Ordering Parts ...................................................................................... 5
Warranty Registration .......................................................................... 5
Part 1: System Identification, Warranty and Warnings ...................... 6
Part 2: Preparing for Installation .......................................................... 8
Part 3: Belt Idler Installation ............................................................... 10
3.1 2012 - 2015 Trucks with Single Sided Belt ............................. 12
3.2 2011 Trucks with Dual Sided Belt ........................................... 13
Part 4: Installing the Compressor, Main Bracket, and Belt .............. 14
4.1 Installing the Compressor and Main Bracket .......................... 14
4.2 Belt Routing ............................................................................ 26
4.3 Wire guide installation ............................................................. 27
Part 5: Installing the WHASP Tank ..................................................... 31
Part 6: Recommended Accessory Installation .................................. 36
Part 7: Adding Oil to the System ........................................................ 37
Part 8: Installing the Control Components ........................................ 38
8.1 Installing the Control Box ....................................................... 39
8.2 Connecting the Wiring............................................................. 40
8.3 Installing the Relay Harness ................................................... 44
8.4 Installing the Throttle Controller .............................................. 45
Part 9: Completing the Installation ..................................................... 46
9.1 Installing the Compressor Air Filter ......................................... 46
9.2 Blowdown Muffler.................................................................... 49
Part 10: Testing the Installation .......................................................... 50
10.1 Final Testing ........................................................................... 52
Part 11: Setup, Performance Testing and Adjustments ................... 53
11.1 Throttle Control Adjustment .................................................... 54
Part 12: Auxiliary Air Receiver ............................................................ 55
Part 13: Accessory Products .............................................................. 56
Part 14: Warranty Registration ........................................................... 57
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
2
Installation Manual for VMAC System V300001
2011 - 2015 Ford F250-F550 Pickup, Cab & Chassis
6.7L Power Stroke Diesel
Document 1930247
Changes and Revisions
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 mechanical work. Any grinding,
bending or restructuring operations for correct fit in modified trucks
must follow standard shop practices.
Notice
Manuals are subject to change without notice.
Registered Trademarks
All trademarks mentioned in this manual are the property of their
respective owners. Their use by VMAC is for identification of the
manufacturers’ products only and does not imply any affiliation or
endorsement by said companies.
Loctite, Klean N’ Prime, 242 and PST are registered trademarks of
Henkel AG & Company KGaA.
PTFE is a registered trademark of E. I. du Pont de Nemours and
Company or its affiliates.
Nylok is a registered trademark of Nylok Fastener Corporation.
Copyright 2017
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
Revision
Revision Details
Revised
by
Checked by
Implemented
Eng.
Qual.
Mech.
Elec.
D
ECN 15-105
REF
KRM
N/A
N/A
10 Nov 2015
E
ECN 16-140 Park interlock update
MSP
N/A
AJH
AGM
24 Nov. 2016
F
ECN 17-094 Improved safety testing
MSP
N/A
AJH
SA
28 June 2017
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
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 engine models and different situations that
are listed in the manual. Open the package, unpack the components and
identify them.
Torque Specifications
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
3/4
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
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
M8
M10
M12
M14
M16
Foot-pounds (ft-lb)
19
41
69
104
174
Newton meter (N•m)
25
55
93
141
236
Special Tools Required
Pneumatic fan wrench (Lisle 43300 or equivalent)
1/8” drill bit
VMAC test tool
Push-lock fitting insert tool (New Line FT1268 or LOT-116, or
equivalent), if building new hoses with push-lock fittings.
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 our 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.
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
4
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 and service techniques. If a discrepancy is noted in this
manual, contact VMAC prior to initiating or proceeding with service.
Current information may clarify the issue. Any person with knowledge of
such discrepancies who performs 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 assure that
their safety and that of others is not being compromised and that there will
be no adverse effects on performance or the operational safety of the
equipment.
VMAC will not be held responsible for any liability, injuries, loss or damage
to individuals or to equipment as a result of the failure of any person to
properly adhere to the procedures 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 or require any more information on details that are not
included in this manual, please contact VMAC before beginning repairs.
Safety Messages
This manual contains various warnings, cautions and notices that must be
observed to reduce the risk of personal injury during service or repair and
the possibility that improper service or repair may damage the equipment
or render it unsafe.
This symbol is used to call your attention to instructions
concerning your 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 alert to the possibility of personal
injury or death. Be alert; your safety is involved. While it is
impossible to warn about every conceivable hazard, let good
common sense be your guide.
This symbol is used to call your attention to instructions on a
specific procedure that if not followed may damage or reduce
the useful life of the compressor.
This symbol is used to call your attention to additional
instructions or special emphasis on a specific procedure.
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
5
Ordering Parts
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 or online at www.vmacair.com
Warranty Registration
The VMAC warranty form is located at the back of this manual. This
warranty form must be completed and sent to VMAC at the time of
installation for any subsequent warranty claim to be considered valid.
There are four ways warranty forms can be submitted to VMAC:
Online
http://vmacair.com/support/warranty/
Email
tech@vmacair.com
Fax
(250) 740-3202
Mail
VMAC - Vehicle Mounted Air Compressors
1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
6
Part 1: System Identification,
Warranty and Warnings
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 you do not
miss any preparation steps.
Check through the illustrated parts list, ensure that no components
are missing, and that they are in the correct quantity. If any
components are missing, have the system ID ready and call
VMAC tech 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:
http://vmacair.com/support/warranty/
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 System Identification Number Plate must be
attached to the vehicle at the time of installation. This
plate provides information that allows VMAC to assist
in parts and repairs.
Mark and drill two 7/64-inch holes in an appropriate location,
close to the compressor. Secure the plate with supplied self-
tapping screws (Figure 1.1).
Figure 1.1 System Identification Plate
Install the VMAC belt routing diagram in a suitable location under
the hood.
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
7
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 1.2).
Figure 1.2
To alert any technicians that may service the vehicle, affix the
servicing caution/contact label in the engine compartment near the
hood latch in a visible location. Thoroughly clean the selected area
before affixing the label (Figure 1.3).
Figure 1.3
VMAC Vehicle Mounted Air Compressors
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Fax: 1-250-740-3201
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Part 2: Preparing for Installation
Disconnect battery leads and cover terminals to prevent electrical
shorts.
Remove the bolt securing the air intake resonator to the fan shroud.
This screw is located under the coolant tube at the driver’s side end
of the resonator.
Disconnect the mass air flow sensor and remove the clip holding the
wire to the air box lid.
Remove the air filter box cover, air filter, and intake tube (from the
air filter outlet to the turbo inlet on the engine).
Cover the turbo inlet, and the air-box lid outlet to prevent entry of
contaminants into the engine.
Drain coolant from the secondary radiator, (drain on passenger
side). Save coolant to be reused later. Close drain when coolant has
been drained.
Disconnect hoses from secondary coolant reservoir, (attached to
passenger side of fan shroud), and remove reservoir from fan
shroud.
Remove bolt securing power steering reservoir to upper fan shroud.
DO NOT remove the hoses from the reservoir. Slide reservoir up
out of clip securing it to the upper fan shroud.
Remove 5 bolts (3 on driver’s side and 2 on passenger side) and
wire clips securing upper fan shroud and remove upper fan shroud
from truck.
Unhook the coolant hose from the Upper Fan Shroud.
Disconnect the fan clutch wire and remove the bolt securing the fan
stator arm to the engine. Save the bolt as it will be re-used later.
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
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Remove the fan (right-hand thread) and pull it out of the engine bay.
For ease of fan removal and installation, it is
recommended that a pneumatic fan wrench removal set
(such as Lisle 43300) or a manual fan pulley holder (such
as KD3900) is used.
Remove the four fan stator nuts, and remove the fan stator by
rotating it to clear the lower lip of the lower fan shroud. It is not
necessary to remove the lower fan shroud.
Slide a sheet of cardboard between the fan and the radiator to
protect the radiator from accidental damage and remove Fan.
Remove the OEM Front End Accessory Drive (FEAD) belt.
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
10
Part 3: Belt Idler Installation
Dual alternator trucks will require conversion to single
alternator as the VMAC compressor mounts in the
secondary alternator location. Contact VMAC Technical
support at (888) 241-2289 or email [email protected] for
more information.
There are two different sets of instructions for installing the idlers
depending on truck year:
section 3.1 for 2012 or newer.
section 3.2 for 2011 trucks.
The Ford 6.7 is equipped with two belt idlers, the VMAC compressor
uses the OEM belt line, and is installed in the secondary alternator
location on the passenger side of the engine.
Ribbed idlers must be installed in the locations shown, and the idler on
the driver’s side of the engine must be removed and installed onto the
dual alternator idler post (Figure 3.1).
Figure 3.1 Idler location
VMAC Vehicle Mounted Air Compressors
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Fax: 1-250-740-3201
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Most trucks will come configured with the driver’s side idler positioned
for single alternator, for the installation of the compressor this idler must
be moved to the dual alternator position (Figure 3.2).
Figure 3.2 Dual alternator idler post
VMAC Vehicle Mounted Air Compressors
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Fax: 1-250-740-3201
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3.1 2012 - 2015 Trucks with Single Sided
Belt
Remove the two OEM smooth idlers from the engine (Figure 3.1).
Remove the OEM bolts from the smooth idlers.
Remove the bolts from the VMAC ribbed idlers.
Install the bolts from the OEM Ford idlers into the two supplied
VMAC ribbed idlers.
Install one ribbed idler on the passenger side of the engine in the
location which previously had a smooth idler (closest to the
secondary water pump) (Figure 3.1).
Install one ribbed idler on the dual alternator belt post (Figure 3.2)
(Figure 3.3) (Figure 3.4).
Figure 3.3 Drivers side of engine
If you are having trouble determining the position of the
idlers, please see figure 3.4 on the following page.
VMAC Vehicle Mounted Air Compressors
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Fax: 1-250-740-3201
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3.2 2011 Trucks with Dual Sided Belt
Remove the idler from the driver’s side of the engine (closest to the
alternator) (Figure 3.1).
Re-install the idler on the dual alternator belt post (Figure 3.1)
(Figure 3.2) (Figure 3.3) (Figure 3.4).
The VMAC supplied idlers are not required if the engine has ribbed
idlers already installed.
Figure 3.4 Drivers side of engine
VMAC Vehicle Mounted Air Compressors
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Fax: 1-250-740-3201
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Part 4: Installing the Compressor,
Main Bracket, and Belt
4.1 Installing the Compressor and Main
Bracket
Cut the tie wraps securing the OEM wiring bundle to the wiring tray,
and use a 10mm socket to remove the wiring tray. Keep the wiring
tray and bolt as they will be re-used later (Figure 4.1).
Figure 4.1 OEM wiring tray
OEM
Wiring
Tray
VMAC Vehicle Mounted Air Compressors
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The Compressor discharge fitting will be oriented towards
compressor clutch, use a 3/4” wrench to hold the fitting and a 7/8”
wrench to ensure the locking nut is tight (Figure 4.2).
Figure 4.2 Compressor discharge fitting
VMAC Vehicle Mounted Air Compressors
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Slide the discharge fitting through the hole in the compressor
bracket (Figure 4.3).
Figure 4.3 Installing the main bracket
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Apply Blue Loctite® to the four supplied M8 flat head bolts. Install
the compressor on the main bracket (Figure 4.4).
Figure 4.4 Installing compressor fasteners
M8 Flat head
bolts (4X) USE
LOCTITE®
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Remove the two secondary water pump bolts and the fan driver bolt.
Save the bolts as they will be re-used later (Figure 4.5).
Figure 4.5 Passenger front of engine
Apply plastic loom or equivalent hose protection to the 1/2" x 25”,
3/4" x 215” discharge hoses, and the 3/8" x 240” oil return hose
(hose protection not supplied)
When routing hoses, ensure cap-plugs are installed so
that contaminants do not get in the system. Take care
when routing hoses, as a hose failure may damage the
compressor.
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Vmac V300001 Installation guide

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Installation guide

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