Vmac V900053 Installation guide

Brand: Vmac

Model: V900053

Type: Installation guide

Installation Manual

For The

System #V900053

UNDERHOOD AIR COMPRESSOR

1995.5-1997 FORD F250-F350

7.3 Power Stroke Diesel

TEL: 250-740-3200

FAX: 250-740-3201

TOLL FREE: 800-738-8622

1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3

DOCUMENT 1900682

Installation Manual

VR70 Underhood Air Compressor

System Number V900053

Application: 1995.5-1997 Ford F250-F350 with the 7.3 Power Stroke Diesel

Publication Date: Revised by S. Large, August / 2001

Publication Number: 1900682

Origination Documents: #1900682a - General Information

#1900682b - Installing the air tank and lines

#1900682c - bracket, compressor and cooler installation

#1900682d -Control component installation

#1900682e - Illustrated parts list

#1900130 - Warranty registration

Registered Trademarks:

VR70, VMAC and Throttle Commander are registered trademarks of VMAC.

Ford, Super Duty, F250-F350, Power Stroke Diesel are registered trademarks of Ford 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 AIR TANK AND LINES ..................................................... 9

1.1 INSTALLING THE BRACKETS AND TANK ............................................................................... 11

1.2 INSTALLING THE TANK ..................................................................................................... 12

1.3 CONNECTING AND ROUTING THE LINES ............................................................................. 12

2.1 PREPARING FOR INSTALLATION .......................................................................................... 17

2.2 INSTALLING THE COMPONENTS ......................................................................................... 19

2.3 INSTALLING THE OIL COOLER .............................................................................................21

2.4 CONNECTING THE LINES .................................................................................................. 22

2.5 FILLING THE SYSTEM WITH OIL ....................................................................................... 23

PART 3: INSTALLING THE CONTROL UNIT ............................................................... 25

3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 27

3.2 INSTALLING THE SWITCHING BOX ....................................................................................... 27

3.3 INSTALLING THE THROTTLE CONTROLLER ......................................................................... 28

3.4 CONNECTING THE PARK BRAKE WIRE .............................................................................. 30

ILLUSTRATED PARTS LIST.............................................................................................. 33

WARRANTY REGISTRATION.......................................................................................... 39

PART 2: INSTALLING THE COMPRESSOR, OIL COOLER AND OIL FILTER.......15

2.6 COMPLETING THE INSTALLATION ...................................................................................... 23

General Information

System #V900053

1995.5-1997 FORD F250-F350

7.3 POWER STROKE DIESEL

UNDERHOOD AIR COMPRESSOR

DOCUMENT 1900682

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 Controller

This kit has been designed for:

1995.5-1997 Ford F250-F350 equipped with a 7.3 Power Stroke Diesel

Installation steps

The installation procedure in this manual has four main steps:

Part 1: Installing the Compressor

Part 2: Installing the Oil Cooler, Air Tank and Lines

Part 3: Installing the Control Unit

Part 4: Installing the Throttle Control

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

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 instructions 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).

WARNING

BEFORE OPERATING THE VR70 UNDERHOOD AIR COMPRESSOR

SYSTEM ALWAYS MAKE SURE THAT THE

VEHICLE IS IN PARK (AUTOMATIC TRANSMISSION) OR

NEUTRAL (MANUAL TRANSMISSION) AND THAT THE PARK

BRAKE IS FIRMLY ENGAGED.

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

The above fastener torque values are applicable when Loctite is used .

If the threads are dry add 20% to the torque values.

WARNING

Ordering parts

To order parts, contact your nearest VMAC dealer.

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 (S/N) must be attached to the vehicle at the time

of installation. This S/N plate provides information, which allows VMAC to assist in customer

inquiries and/or ordering of parts. It is important that this S/N plate is affixed to the vehicle.

Locate the S/N plate on the front body support on the driver’s side of the vehicle near the hood

stop (Figure 1) . Drill the two hole locations using a 7/64” drill bit. Place the S/N plate in position

and fix in place with the two #6 pan head self tapping screws provided.

Figure 1 Location of System Identification Number Plate

Changes and improvements

These products and documents are subject to changes or improvements without notice.

Special installation notes

If you intend to use an auxiliary air receiver with this system you must observe the following

installation procedure (Figure 2) . Failure to observe this procedure will result in damage to the

system.

1. The line from the VR70 tank to the auxiliary air receiver must have a one-way check valve

installed to prevent blowback from the auxiliary tank and to prevent moisture from entering

the VR70 tank.

2. The line to the auxiliary tank must not be installed in the bottom of the tank, but must be

installed as high as possible to prevent water from clogging the line.

VR70 Tank

Auxiliary Receiver

One-way check valve

Install the line as high as

possible, NOT on the

bottom of the tank

Figure 2

Part 1

Installing the

Air Tank and Lines

System #V900053

1995.5-1997 FORD F250-F350

7.3 POWER STROKE DIESEL

UNDERHOOD AIR COMPRESSOR

DOCUMENT 1900682

1.1 Installing the brackets

1. Enlarge the four tank mounting holes on

the frame using a 13/32 drill bit.

2. Place the forward tank bracket (the one

with the wide two-hole spacing) on the

outside of the passenger frame rail

under the cab, just in front of the

transmission cross-member.

3. Install flat washers on two (2) 3/8 NC x

1-1/4 inch hex head cap screws and

insert them through the bracket and the

two existing holes in the frame.

4. Place flat washers on each of the cap

screws on the inside of the frame and

thread 3/8 inch NC Nylok nuts on the

cap screws.

5. Place the rear tank bracket (the one

with the narrow three-hole spacing) on

the outside of the passenger frame rail

under the cab, in the middle of the

upward bend area behind the cross-

member.

6. Install flat washers on two (2) 3/8 NC x

1-1/4 inch hex head cap screws and

insert them through the lower holes on

the bracket and the two drilled holes in

the frame.

7. Place flat washers on each of the cap

screws on the inside of the frame and

thread 3/8 inch NC Nylok nuts on the

cap screws.

8. Torque the fasteners to specifications.

9. Cut the plastic tie-wraps from the tank

mount brackets and remove the two

retaining straps.

Part 1: Installing the Air Tank and Lines

Forward tank mounting location

Rear tank mounting location

Brackets mounted in position

1.2 Installing the tank

1. Insert the four (4) 5/16 NC x 1-1/4 hex

head cap screws through the holes in

the tank brackets.

2. Place the tank in position in the tank

brackets on the frame. Use suitable

supports to hold tank temporarily in

place.

3. Place the forward and rear tank

overstraps on the tank and over the

5/16 inch hex head cap screws on the

front and rear brackets.

4. Install 5/16 inch washers and 5/16

inch NC hex nuts on the cap screws.

5. Align the tank so that the direction

arrow on the rear of the tank points

upward.

Tank alignment is extremely

important. Improper installation

can result in personal injury,

death or damage to the

equipment. Ensure the tank sits

horizontally

6. Move the tank as necessary so that the

distance between the front of the tank

and the center of the front cab mount is

approximately 11-1/2 inches. This may

vary on different cab configurations.

7. Torque the overstrap fasteners to

specifications.

1.3 Connecting and routing the lines

1. Feed the flexihose section of the 1/4

inch pressure control line inside the

front and rear tank brackets on the

frame rail side of the tank. Route hose

WARNING

Line attaching points and tank alignment

Tank installed in position

1/4 and 5/16 lines over mount

up and over the cab mount. Thread the

fitting on the steel tube attached to the

end of the 1/4 inch pressure control

line into the upper threaded fitting,in the

rear of the tank.

2. Routethe flexihose section of the 5/16

inch scavenge hose alongside the 1/4

inch pressure control line and up and

over the cab mount. Thread the fitting

on the steel tube attached to the 5/16

inch hose into the lower threaded fitting

in the rear of the tank.

3. Fit the two (2) supplied tube clamps

over the 1/4 inch and 5/16 inch steel

tubes and bolt into the threaded holes in

the front and rear tank brackets using

the two (2) supplied 5/16x 1/2 inch

Hex Head Cap Screw bolts and two

(2) 5/16 flat washers.

4. Connect the straight end of the 1/2 x 76

inch tank to cooler oil return line to the

matching lower fitting on the front of

the tank. Hand-tighten the fitting. Route

the hose over the cab mount and up

along the chassis rail towards the front

of the engine

5. Route the 45 Degree end of the 3/4

inch main air discharge hose up

towards the front of the engine up over

the cab mount. Connect the straight end

to the fitting on the front of the tank.

6. Tie wrap all hoses to the frame and

protect any areas of the lines which may

be exposed to sharp or hot objects with

plastic loom.

Cooler and discharge line connections

1/2 and 3/4 lines installed over mount

Protective loom on lines

7. Remove the oil filter from the front of the

tank and apply a small amount of oil to

the rubber gasket and refit oil filter.

Tighten by hand

Part 2

Installing the

Compressor and Cooler

System #V900053

1995.5-1997 FORD F250-F350

7.3 POWER STROKE DIESEL

UNDERHOOD AIR COMPRESSOR

DOCUMENT 1900682

2.1 Preparing for installation

1. Disconnect the batteries.

2. Drain the coolant from the radiator.

3. Remove the fan from the water pump.

4. Disconnect the top radiator hose from

the radiator.

5. Disconnect the expansion tube and

remove the lower radiator hose.

6. Remove the fasteners from the fan

shroud, then remove the fan and shroud

from the vehicle.

7. Remove the OEM belt.

8. Remove the OEM fasteners securing

the alternator and move it out of the

way.

9. Remove the OEM tensioners and idlers

from the alternator bracket.

10. Remove the OEM alternator bracket.

11. Remove the plastic cover from the air

inlet on top of the engine.

12. Remove the heater hose and the fitting

from the inside of the right cylinder.

Part 2: Installing the Compressor and Cooler

Engine prior to installation

OEM mounting bracket before removal

Mounting location on the cylinder head

13. Remove and discard the plastic battery

cable holder from the radiator bulk-

head.

14. Remove the radiator from the vehicle.

15. Remove the hose from the bottom of

the pressure tank, cut 1 inch from the

hose and install it back on the fitting.

16. Remove the small top hose from the

pressure tank, cut 3/4 inch from the

spigot and install the hose back on the

fitting.

17. Cut 6 inches from the hose that runs

from the block to the heater.

18. Remove the speed clips from the

radiator bulkhead flange.

19. Remove the radiator supports.

20. Peen the edge of the valve cover flat

against the cylinder head in the area

where the compressor mounting

bracket will attach. This allows the

compressor mounting bracket to sit

flush with the cylinder head surface.

This is important for belt alignment

21. Remove the OEM fasteners holding the

OEM crankshaft pulley in place.

22. Clean the inside of the crankshaft pulley

where the VR70 pulley will fit.

Cut 3/4” from the end

of the spigot

Cut 1” from the end of

this hose

Coolant

expansion

bottle

Peen this area

Mounting locations

Cut the spigot and the hose

Peen the valve cover flat

Clean the inside of the pulley

NOTE

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Vmac V900053 Installation guide

Brand: Vmac

Model: V900053

Type: Installation guide

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Vmac V900053 Installation guide

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