Vmac V910002 Installation guide

UNDERHOOD AIR COMPRESSORS

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1333 KIPP ROAD NANAIMO B.C. V9X 1R3

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UNDERHOOD AIR COMPRESSORS

TM

2001 – 2002 Ford F650 - F750

CAT 3126 W/WOAC

System # V910002

Installation Manual

Installation Manual Document Number: 1930040

VR140 Underhood Air Compressor

System Number V910002

Application

2001 - 2002 Ford F650 - F750 CAT 3126 W/WOAC

Publication Date

Original: Revised by S. Large, January 22, 2003

Notice

Manuals and products are subject to change without notice.

Registered Trademarks

VR140, Underhood, VMAC, and Throttle Commander are registered trademarks of VMAC.

Ford, Super Duty, F650-F750, 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.

The contents of this manual may not be reproduced in any form without express, written permission.

Contents

INSTALLATION MANUAL.............................................................................................................1

PART 1 GENERAL INFORMATION ............................................................................................. 3

1.1 INTRODUCTION............................................................................................................................ 4

1.2 INSTALLATION STEPS................................................................................................................... 4

1.3 TERMS AND SYMBOLS ................................................................................................................. 4

1.4 INSTALLATION NOTES.................................................................................................................. 4

1.5 SYSTEM IDENTIFICATION NUMBER PLATE .................................................................................. 5

1.6 WARRANTY................................................................................................................................. 5

1.7 ORDERING PARTS ........................................................................................................................ 6

1.8 CHANGES AND IMPROVEMENTS ................................................................................................... 6

PART 2 PREPARING FOR INSTALLATION............................................................................... 7

2.1 INSTALLATION PREPARATION...................................................................................................... 9

PART 3 INSTALLING THE AIR TANK AND LINES ............................................................... 11

3.1 INSTALLING THE TANK BRACKETS ............................................................................................. 13

3.2 INSTALLING THE C-CLAMPS ...................................................................................................... 13

3.3 ATTACHING THE LINES TO THE TANK......................................................................................... 14

3.3.1 TRUCKS USING AIR BRAKES .................................................................................................... 15

PART 4 INSTALLING THE COMPRESSOR AND OIL COOLER ......................................... 17

4.1 MODIFYING THE OIL FILL TUBE ................................................................................................. 19

4.2 INSTALLING THE REPLACEMENT FUEL LINES AND FITTINGS ..................................................... 19

4.3 INSTALLING THE MAIN BRACKET ............................................................................................... 20

4.4 BRACKET TIGHTENING PROCEDURE........................................................................................... 22

4.5 INSTALLING THE VR140 CRANK PULLEY................................................................................... 23

4.6 INSTALLING THE COOLER.......................................................................................................... 24

4.7 COMPLETING THE INSTALLATION .............................................................................................. 26

PART 5 INSTALLING THE CONTROL COMPONENTS ........................................................ 31

5.1 INSTALLING THE CONTROL COMPONENTS................................................................................. 34

5.2 CONNECTING THE WIRING ......................................................................................................... 36

5.2.1 AUTOMATIC TRANSMISSION................................................................................................... 37

5.2.2 MANUAL TRANSMISSION ................................................................................................... 39

PART 6 ILLUSTRATED PARTS LIST......................................................................................... 41

WARRANTY REGISTRATION .................................................................................................... 47

Page 1

Page 2

DOCUMENT #1930040

Part 1

General Information

System #V910002

2001 - 2002 Ford F650 - F750

CAT 3126 W/WOAC

UNDERHOOD AIR COMPRESSOR

Page 3

1.1 Introduction

This book provides installation instructions for the VMAC underhood air compressor installation kit.

1.2 Installation steps

The installation procedure in this manual has four main steps:

• Preparing for Installation

• Installing the Air Tank and Lines

• Installing the Compressor and Oil Cooler

• Installing the Control Components

1.3 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)

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.

1.4 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 system.

Refer to setup procedure in owner’s manual before attempting to run air system.

Page 4

Page 5

Table 1 – Torque values.

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.

Hose diameter Color coded label Part number prefix

1/4” Yellow 173

5/16” Orange 174

1/2” & 5/8” Blue 175 & 176

3/4” & 1” Green 177 & 178

Table 2- Hose color codes.

9. Table 2 above illustrates the color code used by VMAC to define the different hose diameters.

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.

1.5 System Identification Number Plate

The System Identification Number Plate included with the kit must be attached to the vehicle at the time

of installation. Locate the plate as shown below. Mark and drill two holes using a 7/64” drill bit. Secure

the plate in position using the supplied #6 pan head, self-tapping screws.

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

Page 6

1.6 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.

1.7 Ordering Parts

To order parts, contact your VMAC dealer.

Please quote the VMAC part number, the description and the quantity.

1.8 Changes and improvements

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

DOCUMENT #1930040

Part 2

Preparing for Installation

System #V910002

2001 - 2002 Ford F650 - F750

CAT 3126 W/WOAC

UNDERHOOD AIR COMPRESSOR

Page 7

Page 8

2.1 Installation Preparation

1. Disconnect batteries positive and ground cables.

2. Drain coolant into suitable container.

3. Disconnect the coolant hoses to the coolant expansion tank.

4. Remove the coolant expansion tank, and the crossbar support.

5. Remove the upper radiator hoses and connecting tube, discard the hoses and tube.

6. Remove the fan shroud.

7. Remove the fan, left hand thread.

8. Remove the air duct for the air cleaner intake.

9. Remove the rubber bellows from the air cleaner to the turbo inlet.

10. Remove the air cleaner and its mounting brackets from the engine.

11. Remove the longer of the steel fuel lines from the fuel filter on the upper left side of the engine to the

back of the fuel distributor pump. Discard the line.

12. Remove the shorter steel fuel line from the fuel filter on the upper left side of the engine to the front

left fitting in the side of the cylinder head. Discard the line.

13. Remove the fuel filter and its mounting bracket from the upper left side of the timing cover and

remove the filter from its OEM bracket. Discard the bracket. (Store the filter upright to prevent

spillage and air locks).

14. Remove the OEM O- ring port fittings from the side of the cylinder head and the rear of the fuel

distribution pump that the steel fuel lines were connected to. Discard the fittings.

15. Disconnect the wiring to the alternator and retaining clamps that locate the harness to the cylinder

head.

16. Remove OEM 8-rib drive belt.

17. Undo the 8 OEM bolts holding the fan pulley to the fan hub.

18. Disconnect the A/C compressor from the fan hub alternator mount casting.

19. Remove the alternator.

20. Remove the four 10mm OEM bolts that locate the OEM front engine lifting lug plate to the fan hub

alternator mount casting. Remove the cast bracket assembly with the OEM belt tensioner and the

front engine lifting lug plate. Discard the lifting lug plate.

21. Remove the OEM bolts locating the right (passenger side), angled section of the front engine mount

assembly and remove this section, (figure 1).

Page 9

22. Remove the right side OEM front engine mount bolt with the tab attached from the center section of

the front mount, (figure 1).

Figure 1, OEM engine bolt detail.

Engine mount bolt

23. Remove the oil fill tube from the front of the engine timing cover and cover the port in the timing

cover to prevent dirt or debris from getting in the timing chain.

Page 10

DOCUMENT #1930040

Part 3

Installing the Air Tank and

Lines

System #V910002

2001 - 2002 Ford F650 - F750

CAT 3126 W/WOAC

UNDERHOOD AIR COMPRESSOR

Page 11

Page 12

3.1 Installing the tank brackets

1. Measure 12 inches back from the rear of the front spring hanger and mark the lower edge of the driver

side frame rail.

2. Measure 13 inches back along the rail from the previous mark and mark the lower edge of the driver

side frame rail. Re-adjust the park brake cable-mounting clip near the battery box, inside the frame

rail to allow adequate clearance for the tank brackets. Loosen the bolt that secures the clip and rotate

it downward then re-tighten the bolt.

Figure 1, tank bracket mounting positions Figure 2, bracket tab - towards the frame rail

3. Pass the threaded end of the 1/2 x 5 1/2 inch supplied tank bracket bolt through the lower of the top

holes in the metal backing strap mount bracket from the inside of the frame rail, (figure 2).

4. Hold the backing strap in place at the twelve-inch mark on the backside of the frame rail. Pass the

threaded end of the bracket bolt with washer through the second hole from the top on the tank mount

bracket. The frame rail will become sandwiched between the backing strap and the tank mount

bracket. Make sure that the tab on the tank mount bracket is facing towards the frame rail so that it

will slot into the top edge of the lower frame rail lip.

5. Install another 1/2-inch flat washer and Nylock nut and thread until hand tight. In a similar fashion,

pass the next 1/2 x 5 1/2 inch bolt through the lowest hole on the backing strap and through the hole

just below the tab on the tank mount bracket. Install the supplied 1/2-inch flat washer and Nylock nut.

Tighten both nuts on the assembly to specification, (figure 2).

6. Repeat the above procedure with the rear tank mount bracket and set this bracket at the rear marked

position on the frame rail, (figure 4).

3.2 Installing the C-clamps

1. Remove the 3/8 x 1 1/2 inch pinch bolts and nuts from both the supplied tank mount C-clamps. Line

up the four holes in each clamp half section, with the mounting holes in the tank mount brackets.

Install the four 3/8 x 1 inch bolts with washers in each C-clamp. Install the four supplied 3/8 inch nuts

and tighten to specification, (figure 5 & 6).

Page 13

2. Lift the tank into position so that the first clamp is six inches from the front of the tank and is resting

on the curved half sections of the installed C-clamps. Set the tank so that it sits vertical with the arrow

on the front of the tank pointing up. Refit the other half of the C-clamps with the 3/8 x 1 1/2 inch

pinch bolts and Nylock nuts. tighten enough just to loosely grip the tank, (figure 5).

Figure 4, tank-mounting brackets. Figure 5, C-clamp mounting positions

13”

2 x 5 1/2 x 1/2” NC

4 x 1” NC HHCS

2 x 1 1/2” NC HHCS

Figure 6, C-clamp mounting detail

3.3 Attaching the lines to the tank

1. Insert the threaded end of the 5/16-inch scavenge line into the fitting at the bottom rear of the tank.

Route the steel pipe section down the upper inside, (frame rail side) of the tank.

2. Insert the threaded end of the 1/4-inch pressure control line into the fitting at the top rear of the tank.

Route the steel pipe section down the upper inside, (frame rail side) of the tank alongside of the

scavenge line.

3. Spring open the two small insulated “P” clips and fit them over the two steel sections of the scavenge

and pressure control lines. Ensure the flat edge of the clips are facing the tank mounting brackets.

Page 14

4. Undo the top bolt from the first C- clamp and insert it through the “P” clip that holds the steel lines.

Re-insert this assembly through the other hole on the top half of the C-clamp that is attached to the

tank bracket on the frame rail. Install the supplied Nylock nut and tighten to specifications.

5. Follow the same procedure outlined in steps three and four to install a “P” clip on the second C-clamp

located 13 inches further forward on the tank. .

6. Feed the flexible hose ends of the 1/4 and 5/16 lines up into the engine compartment

7. Fit the straight connector end of the 1-inch main air discharge hose to the top fitting on the front of

the tank. Route the flexi hose up into the engine compartment with the 1/4 and 5/16 hoses.

8. Fit the straight end connector of the longest 5/8-inch oil return hose to the lower fitting on the front of

the tank. Route the hose up into the engine compartment.

Figure 8, completed tank mount – rear view.Figure 7, completed tank mount – front view.

Detail A – Illustration of the tank

3.3.1 Trucks using air brakes

For trucks with air brakes, see the instructions supplied with accessory pack #A700054. This accessory pack

contains the pressure switch used to sense engagement of the park brake in air brake equipped vehicles.

Page 15

Page 16

DOCUMENT #1930040

Part 4

Installing the Compressor

and Oil Cooler

System #V910002

2001 - 2002 Ford F650 - F750

CAT 3126 W/WOAC

UNDERHOOD AIR COMPRESSOR

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Vmac V910002 Installation guide

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