Vmac V900056 Installation guide

Type
Installation guide
Installation Manual
For The
System #V900056
UNDERHOOD AIR COMPRESSOR
2001 - 2002 FORD SUPER DUTY F650-F750
with 5.9 CUMMINS and HYDRAULIC BRAKES
TEL: 250-740-3200
FAX: 250-740-3201
TOLL FREE: 800-738-8622
1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3
DOCUMENT 1900683
Installation Manual
VR70 Underhood Air Compressor
System Number V900056
Application: 2001-2002 FORD SUPER DUTY F650-F750
5.9 CUMMINS ISB WITH HYDRAULIC BRAKES
Publication Date: Revised by S. Large May/2002
Origination Documents: 1900683a - General Information
1900683b - Installing the control components
1900683c - Installing the air tank and lines
1900683d - Installing the compressor
1900683e - Illustrated parts list
1900130 - Warranty registration
Registered Trademarks:
VR70, 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 2002
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 ...................................................................................... 15
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 #V900056
2001-2002 FORD SUPER DUTY F650-F750
with 5.9 CUMMINS and HYDRAULIC BRAKES
UNDERHOOD AIR COMPRESSOR
3
DOCUMENT 1900683
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:
2001-2002 FORD SUPER DUTY F650-F750 5.9 CUMMINS ISB WITH HYDRAULIC
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
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 following
specifications. Torque specifications are in foot pounds (ft-lb) and are only applicable when
Loctite is used. If the threads are dry, add 20% to the torque values. Check that system
hoses are all tight before running the system. Refer to setup procedure in the Owners
Manual before attempting to run this air system.
8. Different frame designations will affect the tank mounting position. You may have to move
the tank rearward from the standard position on your application. If you must move the
tank, the lines may be too short. If this is the case, measure the hose shortfall and order a
“Hose Extender Kit”, P/N (A410XXX)*
*The last three digits in the P/N indicate the length of the extension.
Example: A410055 is a 55-inch hose extender kit.
Trucks equipped with air brakes will require accessory pack # A700043. This
accessory pack contains the pressure switch used to sense engagement of the park
brake in air brake equipped vehicles.
6
NOTE
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
Ordering parts
To order parts, contact VMAC at:
Telephone 250-740-3200
Facsimile 250-740-3201
Office Hours 5:00 AM to 4:30 PM Pacific Standard Time (Monday - Friday)
8:00 AM to 7:30 PM Eastern 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
NOTE
8
Part 1
Installing the Control
Components
System #V900056
2001 - 2002 FORD SUPER DUTY F650-F750
with 5.9 CUMMINS and HYDRAULIC BRAKES
UNDERHOOD AIR COMPRESSOR
9
DOCUMENT 1900683
10
11
Wiring Diagram
FIREWALL BULKHEAD
THROTTLE
TEMPERATURE
PROBE
3 PIN
CONNECTOR
(BLACK)
7 PIN
CONNECTOR
(GREEN)
COMPRESSOR
CLUTCH
PRESSURE SENSOR
INLET VALVE CONTROL PANEL
3550539
PARK BRAKE
OEM
PARK BRAKE
WIRE
BLU DDC
3550541
TRANS. CONNECTOR
LIGHT BLUE/ORANGE TRACER
CONTINUITY WITH THE
TRANSMISSION IN NEUTRAL
16GA WHT
YEL BLK
SOLDER CONNECTION
PREFERED OR
T-TAP CONNECTOR BLU
BLK
YEL
T510031
AUTOMATIC TRANSMISSIONS ONLY
STD. TRANS. ONLY
NO DDC
22-18
TRANSPARK
BRAKE
JUMPER
PARKING
BRAKE
TRANSMISSION
PARK/NEUTRAL
WIRE
TO VR70
SYSTEM
YELLOW WIRE
VR70
BLACK
WIRE
CLUTCH
DDC
PRESSURE
SENSOR
DDC
XXXX
XXXX
XXXX
LEGEND
WIRE
LABEL
OEM FUSE
PANEL
INTERFACE
CABLE
RED WIRE
IGNITION OFF:
NO VOLTAGE
IGNITION ON:
BATTERY VOLTAGE
THROTTLE
COMMANDER
GROUND
12VOLTS
GROUND
PCM
CHASSIS
GROUND
Removing the trim panels
Modifying the trim
Part 1: Installing the Control Components
12
1.1 Installing the components
See previous page for wiring
diagram.
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.
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
NOTE
13
Throttle control unit in place
Cut a slit in the steering boot
8. Mount the throttle control under the
dash to the left of the steering column.
Fasten it in place using nylon ties.
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.
14
Recommended fuse panel location
Locating the wire in the harness
Connection at the park brake switch
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.
Drive Disable Circuit wiring
15
Connect to matching yellow
wire from the throttle control
Yellow
Attach OEM park brake wire
Black
Black
Piggy-back
connector
Connect to the OEM
park brake switch
Connect to black park brake wire
from the interface connector
Connect to the light blue wire with the
orange tracer from the transmission
switch
Blue
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 black wire 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.
16
Using the T-tap and spade connector
Soldering the wires
8. Fit the wiring back into the loom and tape
as necessary.
9. Route the black wire with the piggy-back
connector under the floor mat to the park
brake.
10. Remove the OEM connector from the
park brake switch.
11. Connect the VR70 wire with the
piggyback connector to the park brake
switch and connect the OEM park brake
wire to the piggyback connector. Replace
the cover and screws over the parking
brake lever assembly.
1.2.2. Manual transmission
1. Connect the long black jumper wire with
the piggy-back spade connector to the
black wire at the interface connector.
Tape this connection.
2. Route the black wire with the piggy-back
connector under the floor mat to the park
brake.
3. Remove the OEM connector from the
park brake switch.
4. Connect the VR70 wire with the
piggyback connector to the park brake
switch and connect the OEM park brake
wire to the piggyback connector.
Replace the cover and screws over the
parking brake lever assembly.
Blue VR70 wire Shrink sleeve
Light blue wire with an orange tracer
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
17
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.
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.
Locating the connector
Locating pins 9, 10 and 45
9
10
45
Connector removed
BA
18
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 VR70 kit
you must reverse the
enabling process or the
“Engine Stop” light will
illuminate and the alarm
buzzer will activate and
operate continuously.
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Vmac V900056 Installation guide

Type
Installation guide

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