Vmac V900056 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.

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 Owner’s

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

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 driver’s

door. Also remove the kick panel on the

driver’s side.

2. Locate the control unit on the floor near

the back of the driver’s 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

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 driver’s 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

Vmac V900056 Installation guide

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