Vmac V900057 Installation guide

Installation Manual

For The

System #V900057

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 1900527

Installation Manual

VR70 Underhood Air Compressor

System Number V900057

Application: 2000 FORD SUPER DUTY F650-F750

5.9 CUMMINS ISB WITH AIR BRAKES

Publication Date: May 2000

Origination Documents: 1900527a - Introduction

1900528 - Installing the control components

1900529 - Installing the air tank and lines

1900530 - Installing the compressor

1900531- 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 PA RTS ...................................................................................................................... 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 #V900057

2000 FORD SUPER DUTY F650-F750

with 5.9 CUMMINS and AIR BRAKES

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 1900527a

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 1900527a

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 1900527a

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 1900527a

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 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.

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 1900528

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 tche 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 1900528

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 VR70 Shrink sleeve

Light blue wire with an orange tracer

Wire

WARNING

VENT ALL AIR FROM

THE AIR BRAKE

SYSTEM BEFORE

CUTTING THE PARK

BRAKE LINE

15

DOCUMENT 1900528

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 VR70 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 1900528

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 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.

Locating the connector

Locating pins 9, 10 and 45

9

10

45

Connector removed

B

A

17

DOCUMENT 1900528

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 VR70 kit

you must reverse the

enabling process or the

“Engine Stop” light will

illuminate and the alarm

buzzer will activate and

operate continuously.

DOCUMENT 1900528

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 V900057 Installation guide

Vmac V900057 Installation guide

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