Vmac A70G120 Installation guide

Brand: Vmac

Model: A70G120

Type: Installation guide

Installation Manual for VMAC

System A70G120

2013-2011 Ford F250-F550 6.7L Diesel

General Information..................................................................... 4

Before You Start ....................................................................... 4

Additional Requirements .......................................................... 5

Part 1: Warranty and System ID ................................................. 6

Part 2: Preparing for Installation ............................................... 8

Part 3: Installing the Compressor Components ...................... 9

Part 4: Installing the Discharge Check Valve .......................... 11

4.1 Installing the Discharge Check Valve ................................. 11

Part 5: Installing the Control Components .............................. 12

5.1 Removing the Control Components ................................... 13

5.2 Routing the Wiring .............................................................. 13

5.3 Installing the components ................................................... 14

5.4 Connecting the In-cab Wiring ............................................. 19

5.5 Completing and Testing the Installation ............................. 22

Part 6: Finishing the Installation ................................................ 26

6.1 Before Starting the Engine Checklist.................................. 26

6.2 Safety Test ......................................................................... 26

6.3 Setup, Performance Testing and Adjustments ................... 29

6.4 Auxiliary Air Receiver ......................................................... 30

Accessory Products from VMAC ............................................... 31

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Document #1930203

Installation Manual for VMAC System A70G120

2013-2011 Ford F250-F550 6.7L Diesel

Changes and Revisions

Version

Revision Details

Revised by/date

Approved

Implemented

ECN 13-021 Eng. Release

SDM 15Feb2013

RD/SM 15 Feb 2013

15 Feb 2013

Important Information

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 additional

instructions or special emphasis on a specific procedure.

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 under hood mechanical work. Any

grinding, bending or restructuring operations for correct fit in modified

trucks must follow standard shop practices.

All hoses, tubes, and wires that are rerouted or shifted

during installation must be secure so that they do not

contact excessively hot areas or sharp edges. Where

possible, use rubber coated P-clips. Follow the routing

suggestions in this manual and cover all hoses with the

supplied plastic loom.

These instructions are a general guide for installing this system on

standard production trucks and do not contain information for

installation on non-standard trucks. This system may not fit special

order models or those which have had other changes without

additional modifications. If you have difficulty with the installation,

contact VMAC.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

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.

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 1-888-241-2289.

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

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

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

truck. Identify variations for different model years and different

situations that are listed in the manual. Open the package, unpack

the components and identify them.

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

Foot-pounds (ft-lb)

110

170

280

Newton meter (N•m)

108

149

230

379

STANDARD GRADE 8 NATIONAL FINE THREAD

Size

3/8

7/16

1/2

5/8

Foot-pounds (ft-lb)

180

320

Newton meter (N•m)

122

244

434

METRIC CLASS 10.9

Size

M10

M12

M14

M16

Foot-pounds (ft-lb)

104

174

Newton meter (N•m)

141

236

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Additional Requirements

Special Tools

None required for this kit.

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

Part 1: Warranty and System ID

□ Complete the warranty form. 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.

System Identification and Operating Instructions

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 customer inquiries and the ordering of

parts.

□ Locate the original V900120 system id plate. It should be in the

top of the cross member in front of the OEM air filter box. Mark

and drill two 7/64-inch holes as close to this plate as possible.

Secure the A70G120 plate with supplied self- tapping screws

□ If not already attached, clean cross member beside the number

plate and stick the VMAC belt routing diagram to the cross

member.

□ Apply battery warning label to driver side of primary cooling

reservoir.

□ 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 1.1).

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Figure 1.1

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Part 2: Preparing for Installation

Preparation for installation is very important. Missing an item can

cause problems in the installation or even damage to components.

Check off each item as it is completed so that you do not miss any

preparation steps.

Ensure that you have filled out the VMAC Warranty

Registration. Install the System Identification Number

Plate and Operational Instruction Decal. (Please see

Part 1 for details).

Always discharge all air from the system before

servicing the compressor or its components.

□ Disconnect the batteries, (both driver and the one relocated from

the passenger side).

□ Loosen the hose clamps on the engine intake tube at the

silicone elbow and the bellows on the engine. Remove the

intake tube. Cover both openings.

It is very important to tape or cover the openings in the

engine to ensure that nothing can enter the engine as this

may cause severe damage to the internal parts or failure

of the engine.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Part 3: Installing the

Compressor Components

□ Thoroughly clean the inlet valve and top of the compressor.

□ Disconnect the 3/16” & 1/4" tubes from the inlet valve fittings.

□ Locate the pressure sensor on the passenger side firewall.

□ Remove the bolt retaining the P-clip and remove the assembly.

Replace the bolt.

□ Remove the two bolts, washers and nylock nuts joining the two

brace brackets between the inlet valve and the engine block.

Retain the fasteners for later use.

□ Remove the four bolts and the upper brace bracket holding the

inlet to the compressor. Retain the fasteners and bracket and

make note of the location of the different lengths as removed.

(Figure 3.1)

□ Remove the inlet valve.

□ Immediately cover the opening in the compressor to prevent any

contaminates from entering the rotor housing.

It is very important to tape or cover the opening in the top

of the compressor to ensure that nothing can enter the

compressor housing as this may cause severe damage to

the internal parts or failure of the compressor.

□ Clean and inspect the O-ring for damage, replace if necessary.

□ With O-ring in place, install the new inlet valve, upper brace

bracket and the four bolts in the same locations as removed

from. Finger tight only.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

□ Before torquing inlet valve bolts, install and snug bolts holding

inlet brace together while holding bracket down tight on inlet

valve. Then torque the four inlet bolts to specifications, followed

by tightening the brace bolts.

Longest Bolts

Shortest Bolt

Figure 3.1 (Inlet not exactly as shown)

Never use an impact wrench to install inlet bolts.

The torque spec for inlet bolts is 19 ft. lbs.

□ Reconnect the 3/16” and 1/4” lines onto the inlet valve.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Part 4: Installing the Discharge

Check Valve

4.1 Installing the Discharge Check Valve

Discharge all air from any reservoir tanks installed in

the system.

□ Clean the discharge hose and fitting at the back of the tank on

the passenger side frame rail.

□ Disconnect the discharge hose.

□ Remove the discharge fitting from the back end of the tank.

□ If a check valve is installed between the VR tank and any

reservoir tanks, remove it from the system.

□ Install the discharge check valve assembly supplied. Ensure

that the pressure sensor is at the top.

□ Install the discharge fitting into the end of the check valve

assembly.

□ Reconnect the discharge hose to the check valve assembly

fitting.

It is strongly recommended that a reservoir tank of a

minimum of 5 gal. is installed to best take advantage of the

start/stop features of the VR70G system.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Part 5: Installing the Control

Components

Figure 5.1

CONTROL BOX

RELAYS

START

HOT

12V

STOP

PARK ONLY, BLU

To OEM SEIC blue wire w/

grey stripe CLS05

DISPLAY

BOX

RED +

BLK -

3 Amp

Fuse

Cut OEM wire

Inside steering column

Splice/solder joints

YEL

BLU

ORG

BLU

GRN-RED or BLU-RED

BLU-WHT

Both go to OEM Ignition Switch Harness

To Hood Sw. 2 Pin

Conn – GRY & BLK

To Clutch Bullet Conn - WHT

DIGITAL GND,

GRN-YEL To pin 3

Purple w/ green stripe

To AOST 3 pin BLK

pressure connector

To Beacon 2 Pin

Conn - GRY & RED

To Buzzer Ring

Conn - BLK & RED

To Inlet 2 Pin

Conn - BRN & RED

To Temp. Sensor

4 pin GRN Conn

OEM Connector

to accelerator

pedal

REMOTE ON,

YEL

Connect to

accelerator

pedal

GROUND, GRN-YEL

TACH, WHT

To OEM SEIC blue wire CE913

THROTTLE

CONTROLLER

PARK BRAKE, BRN

To OEM SEIC white wire w/ purple stripe

CMC25

ORG

IGN SW 12V, RED

To OEM SEIC yellow wire w/ orange stripe on early

builds or white wire w/ blue stripe on later builds

CDC64

Firewall

Diode

IGNITION CONNECTOR

IN STEERING WHEEL

4 7

YEL

BLU

ORG

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

5.1 Removing the Control Components

□ Disconnect the White four-wire interface connector from the

control box.

□ Disconnect the Green 4-pin connector going to the compressor

from the control box.

□ Remove the control box.

□ Disconnect the following from the throttle controller:

Red wire bullet connector.

Green wire ring connector.

Two accelerator pedal connectors.

Black 3 pin connector going to the inlet valve.

Cut the blue park-only & white CTO wires (mark both for

later use).

□ Disconnect the white wire bullet connector from the clutch.

□ Disconnect the interface cable’s green wire ring connector.

□ Remove the interface cable by cutting its red (IGN SW 12V) and

black (Park Brake) wires. (mark both for later use).

5.2 Routing the Wiring

□ Determine suitable installation locations for the Buzzer and

Beacon modules.

The Buzzer should be located such that it is audible to

individuals around the vehicle.

The Beacon should be located such that it is visible to

individuals around the vehicle.

□ Estimate the length to be added to both the Buzzer and Beacon

wires.

□ Extend the blunt-cut red and black BUZZER wiring on the control

box harness with 18AWG wiring. Solder and seal.

□ Extend the blunt-cut grey and red BEACON wiring on the control

box harness with 18AWG wiring. Solder and seal.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

□ Cut an opening in the firewall plug or use an existing opening,

and route harness wires from the cab to the engine bay for the

following:

Hood switch

Inlet valve solenoid

Pressure sensor

Compressor temperature sensor

Clutch

Buzzer

Beacon

□ Route these wires to their destinations. One suitable way is:

Route the Beacon and Buzzer wires to their installation

locations.

Route the remaining wires along the perimeter of the engine

bay to the front of the truck.

The hood switch connector rests near the driver’s side

headlight

The remaining wiring follows the radiator cooling lines across

the radiator towards the compressor

The inlet valve solenoid, clutch, and compressor

temperature connectors rest near the compressor.

The remaining pressure sensor cable can go down along

with the pressure line until it reaches the chassis. Then run

along the chassis towards the rear of the truck to the location

of the Discharge Check Valve at the back of the tank.

□ Crimp the ring terminals provided to the end of the Buzzer wires.

□ Solder and seal the pigtail provided in the AUS Electrical Pack to

the end of the Beacon wires placed through firewall.

5.3 Installing the components

5.3.1 Control Box Mount

□ Fasten the control box to the control mount bracket using screws

provided in its fastener pack.

□ Fasten the relay sockets onto the mount bracket using remaining

screws in the fastener pack.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

□ Install relays into the relay-sockets.

Verify the terminals in the relay-sockets did not get

pushed loose from the relay-sockets during relay

installation.

□ Install the control box wiring harness’ three rectangular

connectors into their respective mates on the control box.

□ Fasten the heat-shrunk diode with a nylon-tie to either the fuse

holder or the back side of the narrow column on the control

mount. The diode assembly can be identified by its short orange

and long red wires coming out of heat-shrunk tubing.

□ Find the two unused M8 vertical studs (2-3/4” apart) located

inside the cab above the firewall plug.

□ Install control box mounting bracket as shown in Figure 5.2.

Figure 5.2

HOT 12V

RELAY

EXISTING FORD

STUDS ABOVE

KICKER PANEL

STOP

RELAY

START

RELAY

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Figure 5.3

5.3.2 VR Throttle Controller

□ Install the Throttle Controller underneath the dash with nylon-

ties.

□ Route both of its two 6-pin connectors to the foot pedal.

□ Connect the 4-pin connector with the mating connector on the

wiring harness coming from the Control Box.

Ensure wiring and in-cab installed electronics keep away

from, and do not interfere with, the operation of the park

brake mechanism, brake & accelerator pedals, and

steering column.

5.3.3 Hood Switch

Blue w/Pink

OEM Wire

Grey - VMAC Wire To Be Added

Shrink Sleeve

Soldered Joint

Figure 5.4

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

□ If the vehicle comes equipped with a hood switch, splice and

seal the OEM blue w/pink hood switch wire with VMAC’s grey

hood-switch wire, See Figure 5.4. Ensure VMAC’s black hood-

switch connector wire is left unexposed, as it is at 12V. Skip to

section 5.3.4

□ If the vehicle doesn’t come equipped with hood switch, using the

provided screw, install hood switch in a pre-existing hole in the

engine bay, near the driver’s headlight. See Figure 5.5

Figure 5.5

□ Visually verify the switch is suitably installed such that it’s

actuated when the hood is closed.

□ Connect the hood switch’s connector to its mating connector on

the main wiring harness in the engine bay.

5.3.4 Compressor Connections

□ Connect the Inlet Valve Solenoid on the VR70 Compressor

Assembly to its mating connector with red and brown wires on

the wiring harness.

HOOD SWITCH

FWD

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

□ Connect the Clutch on the VR70 Compressor Assembly to the

mating bullet connector with white wire on the wiring harness.

□ Connect the Compressor Temperature Sensor on the VR70

Compressor Assembly to its mating 7 pin (4 wires) connector on

the wiring harness.

5.3.5 Pressure Sensor

□ Connect the Pressure Sensor on the Discharge Check Valve to

the mating connector on the wiring harness.

5.3.6 Beacon and Buzzer Modules

Verify the Beacon and Buzzer installation locations make

them visible and audible to individuals around the vehicle.

□ Install the Beacon and Buzzer in suitable locations.

□ Connect the Beacon with the mating connector on wiring

harness.

□ Connect the Buzzer wires (with ring terminals) routed earlier.

The red wire goes to positive on Buzzer, and black wire goes to

negative on Buzzer.

5.3.7 Display Box

□ Connect the Display Box to the 4-wire connector coming from

the control box.

□ Install the Display Box in a suitable location with provided

screws.

Mount the Display Box inside the cab or a cabinet

protected from extreme weather. The Display Box is

splash-proof, but not fully sealed. Ensure that it will not

get kicked or hit by tools and equipment.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

5.4 Connecting the In-cab Wiring

□ Unplug the OEM foot pedal connector from the foot pedal

assembly.

□ Find the purple-green wire attached to pin 3 on the truck

harness. If needed, pull back any cover on the cable going into

the dash to expose the wires.

Verify with a multi-meter that the resistance between pin 3

on truck harness and truck ground is close to 0 Ohms.

□ Remove insulation on the wire and solder it to the 60” long

green-yellow “DIGITAL GROUND” wire coming from Control

Box. Trim the green-yellow wire’s length as needed before

soldering and sealing.

□ Connect the Throttle Controller’s connector to the foot pedal

assembly.

□ Connect the Throttle Controller’s remaining connector to the

OEM harness for the foot pedal assembly.

□ Locate the blunt-cut OEM SEIC wire harness, on the driver’s

side just below the OBDII port (Figure 5.6). You will need to find

the following wires:

ignition-switched 12V OEM SEIC circuit CDC64 –

 yellow wire with orange stripe on early builds

 white wire with blue stripe on later builds

tachometer signal OEM SEIC circuit CE913 – blue wire

transmission park signal OEM SEIC circuit CLS05 – blue

with grey stripe (marked previously)

park brake switch OEM SEIC CMC25 – white wire with

purple stripe

These were all marked during the removal of the original

electrical components.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

HOOD

SEIC blunt-cut wires

bundle

Figure 5.6

□ Solder and seal the long red ‘KEY SWITCHED 12V’ wire

(coming from the shrink-wrapped diode) to the OEM SEIC circuit

CDC64 yellow with orange stripe wire on early builds, white with

blue stripe wire on later builds, at the blunt-cut harness.

□ Connect the ring terminal on the green-yellow ground wire

coming from the control box to any grounded bolt underneath the

dash.

□ Solder and seal the white ‘TACH’ wire coming from the control

box to the OEM SEIC circuit CE913 blue wire at the blunt-cut

harness.

□ Solder and seal the black ‘PARK BRAKE’ wire from the control

box to the OEM SIEC circuit CMC25 white wire with a purple

stripe at the blunt-cut harness

□ Solder and seal the long blue ‘PARK NEUTRAL’ wire coming

from the Throttle Controller to the transmission park signal found

earlier. This should be the OEM SEIC circuit CLS05 blue wire

with grey stripe in the blunt-cut bundle.

Page is loading ...

Vmac A70G120 Installation guide

Brand: Vmac

Model: A70G120

Type: Installation guide

Download PDF

report

Vmac A70G120 Installation guide

Vmac A70G120 Installation guide

Related papers

Other documents