Vmac 9057 Installation guide

Type
Installation guide
Installation Manual
For The
System #9057
UNDERHOOD AIR COMPRESSOR
2000 FORD SUPER DUTY F650-F750
with 5.9 CUMMINS and AIR BRAKES
TEL: 250-754-6997
FAX: 250-754-6972
TOLL FREE: 800-738-8622
1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3
DOCUMENT 19527
Installation Manual
VR7000 Underhood Air Compressor
System Number 9057
Application: 2000 FORD SUPER DUTY F650-F750
5.9 CUMMINS ISB WITH AIR BRAKES
Publication Date: May 2000
Origination Documents: 19527a - Introduction
19528 - Installing the control components
19529 - Installing the air tank and lines
19530 - Installing the compressor
19531 - Illustrated parts list
19130 - Warranty registration
Registered Trademarks:
VR7000, VMAC and Throttle Commander are registered trademarks of VMAC.
Super Duty, F650 and F750 are registered trademarks of Ford Motor Company
Cummins is a registered trademark of Cummins Motor Company.
Loctite, Prime N’ Clean, 242 and PST are registered trademarks of Loctite Corporation.
Nylok is a registered trademark of Nylok Fastener Corporation.
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
Contents
GENERAL INFORMATION ................................................................................................. 3
INTRODUCTION ........................................................................................................................ 5
INSTALLATION NOTES ................................................................................................................ 6
ORDERING PARTS ...................................................................................................................... 7
WARRANTY ............................................................................................................................. 7
CHANGES AND IMPROVEMENTS ................................................................................................... 7
PART 1: INSTALLING THE CONTROL COMPONENTS .............................................. 9
1.1 INSTALLING THE COMPONENTS ......................................................................................... 11
1.2 CONNECTING THE WIRING ............................................................................................... 13
1.2.1 AUTOMATIC TRANSMISSIONS .................................................................................. 13
1.2.2 MANUAL TRANSMISSIONS ...................................................................................... 16
1.3 CONNECTING TO THE PCM ............................................................................................ 16
WIRING DIAGRAM ......................................................................................................... 18
PART 2: INSTALLING THE AIR TANK, COOLER AND LINES ................................. 19
2.1 INSTALLING THE BRACKETS .............................................................................................. 21
2.2 INSTALLING THE TANK .................................................................................................... 23
2.3 INSTALLING THE OIL COOLER ........................................................................................... 25
2.4 CONNECTING THE LINES .................................................................................................. 25
PART 3: INSTALLING THE COMPRESSOR ................................................................. 27
3.1 PREPARING FOR INSTALLATION ......................................................................................... 29
3.2 INSTALLING THE BRACKET ............................................................................................... 30
3.3 INSTALLING THE COMPRESSOR .......................................................................................... 31
3.4 COMPLETING THE INSTALLATION ..................................................................................... 33
PART 4: ILLUSTRATED PARTS LIST ............................................................................. 35
WARRANTY REGISTRATION .......................................................................................... 41
1
2
General Information
System #9057
2000 FORD SUPER DUTY F650-F750
with 5.9 CUMMINS and AIR BRAKES
UNDERHOOD AIR COMPRESSOR
3
DOCUMENT 19527A
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
VMAC Throttle Control
This kit has been designed for:
2000 FORD SUPER DUTY F650-F750 5.9 CUMMINS ISB WITH AIR
BRAKES
Installation steps
The installation procedure in this manual has four main steps:
Part 1: Installing the control components
Part 2: Installing the tank, cooler and lines
Part 3: Installing the bracket and compressor
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)
NOTE
WARNING
!
5
DOCUMENT 19527A
Installation notes
1. It is important that you complete all the installation steps before operating the system.
2. Follow all safety precautions for under-hood 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).
6
Type Grade 8 plated Class 10.9 unplated
Size In Cast or
Steel
In
Aluminum
In Cast or
Steel
In
Aluminum
3/8 48 45
7/16 77 70
1/2 117 95
M8 25 20
M10 45 40
M12 80 70
M14 145 130
DOCUMENT 19527A
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 Standard Time (Monday - Friday)
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 top of the fan shroud on the passenger side of the vehicle
(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 #6 pan head self tapping screws provided.
This plate provides information, which allows VMAC to assist in customer inquiries and/
or ordering of parts. It is important that this plate is affixed to the vehicle.
Figure 1 Location of System Identification Number Plate on fan shroud
Changes and improvements
These products and documents are subject to changes or improvements without notice.
7
DOCUMENT 19527A
NOTE
8
Part 1
Installing the Control
Components
System #9057
2000 FORD SUPER DUTY F650-F750
with 5.9 CUMMINS and AIR BRAKES
UNDERHOOD AIR COMPRESSOR
9
DOCUMENT 19528
10
Removing the trim panels
Modifying the trim
Part 1: Installing the Control Components
DOCUMENT 19528
11
1.1 Installing the components
1. Remove the plastic trim panel from along
the floor on the inside of the drivers
door. Also remove the kick panel on the
drivers side.
2. Locate the control unit on the floor near
the back of the drivers seat base, with
the wiring coming out of the bottom of the
unit.
3. Using the control unit as a template, drill
four (4) 3/16 inch holes.
4. Mount the control unit using the four (4)
supplied #6 self-tapping screws.
5. Route the wiring along the body panels
underneath the trim panel.
6. Place the trim panel in position and mark
the location of the wiring harness where it
enters the control unit.
7. Using a sharp knife, cut approximately a
1/2 inch slot for the cable. Also trim out
the sharp plastic teeth where the cable
enters.
8. Mount the throttle control under the dash
to the left of the steering column. Fasten
it in place using nylon ties.
Cut a slot in the trim panel
Remove the sharp teeth
Remove This
Door-frame Base Panel
Remove This
Inside Left Kick
Panel
Control unit in place
12
DOCUMENT 19528
Interface connector wiring
Throttle control unit in place
Cut a slit in the steering boot
9. Plug the white interface connector into
the matching connector from the control
unit.
10. Cut a small slit (about 1 inch long) in the
steering column boot on the left side of
the column when viewed from the
engine compartment.
11. Route the following wires over the
steering column and down the firewall
to the boot, then through the slit into the
engine compartment:
• grey wire harness from the throttle
control with three wires (no
connector)
• grey wire with the black pressure
transducer connector
• grey wire harness with the small green
four-pin temperature probe connector
from the control unit
• single white compressor clutch wire
from the interface connector
12. Secure all of the wiring under the dash
so that it does not interfere with the
steering or other operator controls.
13. Leave the wiring in the engine
compartment for connection to
components as they are installed.
Red
Green
Black
White
Inline fuse
To ground
To park brake switch
White
Red
To m a t c h i n g
connector at
switch box
To compressor clutch
To swi tc h e d
power source
To throttle controller
DOCUMENT 19528
13
Recommended fuse panel location
Locating the wire in the harness
1.2 Connecting the wiring
1. Locate the OEM ground behind the kick
panel and remove the nut from the ground
stud.
2. Place the green ground wire from the
interface connector and the green ground
wire from the throttle control on the OEM
ground stud and replace the nut.
3. Connect the red wire from the interface
cable to the red wire at the throttle
control.
4. Remove the fuse box cover and locate a
fuse in the fuse panel which has battery
voltage only when the key is in the “on”
position.
5. Remove the fuse and install the fuse tap
on the battery side of the fuse, then
reinstall the fuse.
6. Route the red wire with the inline fuse
holder to the fuse box and plug it onto the
fuse tap.
7. Replace the fuse box cover.
1.2.1 Automatic transmissions
1. Locate the light blue wire with the orange
tracer in the wiring harness below the
steering column in the engine
compartment.
Check all wires to make sure that
they are protected from any
potential damage.
Also
make sure that they do not interfere
with any moving parts and are
secured out of the way
DOCUMENT 19528
14
2. Test the wire using an Ohm meter and a
test probe.
There must be continuity (1 Ohm or
less) at the wire with the
transmission selector in neutral, but
no continuity (infinity) with the
transmission selector in all other
positions.
3. Mount the Drive Disable Circuit
(DDC) under the dash near the throttle
control using nylon ties.
4. Connect the blackwire with the male
spade connector from the DDC to the
black wire with the female spade
connector at the interface cable.
5. Connect the yellow wire from the DDC
to the yellow wire at the interface
cable.
6. Route the blue wire with the male
spade connector through the slit in the
steering column boot.
7. The recommended procedure for
connecting the blue wire to the light
blue wire with the orange tracer is by
soldering and sealing with a shrink
sleeve.
An alternate method is to install the
supplied blue T-tap connector to the
light blue wire with the orange
tracer and plug the male connector
of the blue wire into the T-tap.
Using the T-tap and spade connector
Soldering the wires
Blue VR7000 wire Shrink sleeve
Light blue wire with an orange tracer
WARNING
VENT ALL AIR FROM
THE AIR BRAKE
SYSTEM BEFORE
CUTTING THE PARK
BRAKE LINE
15
DOCUMENT 19528
8. Fit the wiring back into the loom and tape
as necessary.
9. Route the black wire with the ring
connector through the firewall.
10. Locate the air line from the park brake
control valve to the inverting relay valve
where it passes through the firewall into
the engine compartment. This is usually
the orange 3/8 inch line
USE THE OEM AIR BRAKE
SYSTEM SCHEMATIC TO
LOCATE THE CORRECT LINE.
OBSERVE AIR BRAKE SAFETY
PRECAUTIONS.
11. Cut the line about half-way between the
firewall and where it routes under the cab.
12. Install the supplied pressure switch to the
ends of the line using the compression T-
fitting attached to the pressure valve.
13. Connect the black VR7000 wire with the
ring connector to the empty terminal on
the pressure switch.
14. Connect the wire from the other terminal
on the pressure switch to a good ground.
Air Brake Schematic
DOCUMENT 19528
16
1.2.2. Manual transmission
1. Connect the long black jumper wire with
the ring connector to the black wire at the
interface connector. Tape this
connection.
2. Route the black wire through the firewall
3. Follow steps 10-14 in Section 1.2.1
Automatic transmission.
1.3 Connecting to the PCM
1. Locate the PCM (electronic control
module) on the drivers side of the engine.
2. Remove the cover on the back of the
forward computer connector block B.
3. Using a 4 mm Allen key, remove the
screw holding the front pin connector to
the computer and remove the connector
from the computer.
4. Locate the pin holes in the connector
numbered 9, 10 and 45 Using a small
probe, push the red plastic plugs out of
the connector.
5. Insert the white wire from the throttle
controller into pin number 9 until the
connector on the end of the wire locks
into place.
Locating the connector
Locating pins 9, 10 and 45
9
10
45
Connector removed
B
A
17
DOCUMENT 19528
6. Insert the red wire from the throttle
controller into pin number 10 until the
connector on the end of the wire locks
into place.
7. Insert the black wire from the throttle
controller into pin number 45 until the
connector on the end of the wire locks
into place.
8. Using the appropriate service tool,
program the PCM to enable the
REMOTE ACCELERATOR
FUNCTION. If you do not have this
tool, contact your local Cummins
service representative.
9. Insert the connector into the PCM and
tighten the hex head fastener.
10. Make sure that all wiring is properly
secured, clear of moving parts, hot
areas and any portion of the vehicle or
engine that could damage the wiring.
Protect the wiring as required with
plasting loom and secure it in place
using tape or nylon ties.
It is very important that
you enable the
REMOTE ACCELERATOR
FUNCTION.
DO NOT enable the
REMOTE PTO FUNCTION
or the system will not
operate.
If you remove the VR7000
kit you must reverse the
enabling process or the
“Engine Stop” light will
illuminate and the alarm
buzzer will activate and
operate continuously.
DOCUMENT 19522
18
FIREWALL
BULKHEAD
GRN
IGNITION OFF - NO VOLTAGE
IGNITION ON - BATTERY VOLTAGE
OEM FUSE PANEL
RED
THROTTLE
CONTROL
RED
WHT
BLU
CONTROL BOX
TEMPERATURE
PROBE
4 PIN
CONNECTOR
(GREEN)
COMPRESSOR
CLUTCH
BULLET
CONNECTO
R
OEM HARNESS
SPADE CONNECTOR
QUICK CONNECTOR
LIGHT BLUE/ORANGE TRACER
CONTINUITY WITH THE
TRANSMISSION IN NEUTRAL
DDC
PARK BRAKE
BLK
SPADE
CONNECTOR
BLK
SPADE
CONNECTOR
STD. TRANS. ONLY
NO DDC
20A
FUSE
PCM
PRESSURE
TRANSDUCER
GRN
RED
YEL
RED BULLET
CONNECTOR
GRAY
BLK
RED
WHT
INTERFACE
CONNECTOR
PARK BRAKE
PRESSURE
SWITCH
TO GROUND
Wiring Diagram
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Vmac 9057 Installation guide

Type
Installation guide

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