Vmac 9053 Installation guide

Installation Manual

For The

System #9053

UNDERHOOD AIR COMPRESSOR

1995.5-1997 FORD F250-F350

7.3 Power Stroke Diesel

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

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

DOCUMENT 19491

Installation Manual

VR7000 Underhood Air Compressor

System Number 9053

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

Publication Date: April 2000

Publication Number: 19491

Origination Documents: #19491a - introduction

#19492 - air tank and line installation

#19493 - bracket, compressor and cooler installation

#19494 - control component installation

#19495 - illustrated parts list

#19130 - warranty registration

Registered Trademarks:

VR7000, 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 COMPRESSOR, OIL COOLER AND OIL FILTER ........ 9

1.1 PREPARING FOR INSTALLATION .......................................................................................... 11

1.2 INSTALLING THE BRACKET ................................................................................................ 13

1.3 INSTALLING THE VR7000 COMPRESSOR AND OTHER COMPONENTS ......................................... 15

1.4 INSTALLING THE OIL COOLER AND ADAPTER ....................................................................... 16

1.4 INSTALLING THE REMOTE OIL FILTER ASSEMBLY .................................................................. 21

PART 2: INSTALLING THE AIR TANK AND LINES ................................................... 23

2.1 INSTALLING THE BRACKETS AND TANK ............................................................................... 25

2.2 CONNECTING THE AIR AND OIL LINES ................................................................................ 28

2.3 ADDING OIL TO THE SYSTEM ............................................................................................ 32

2.4 COMPLETING THE INSTALLATION ...................................................................................... 33

PART 3: INSTALLING THE CONTROL UNIT ............................................................... 35

3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 37

3.2 CONNECTING THE WIRING ................................................................................................ 38

PART 4: INSTALLING THE THROTTLE CONTROLLER ........................................... 43

4.1 INSTALLING THE THROTTLE CONTROLLER ASSEMBLY ........................................................... 45

4.2 INSTALLING AND ADJUSTING THE CABLE ............................................................................. 47

ILLUSTRATED PARTS LIST .............................................................................................. 51

WARRANTY REGISTRATION .......................................................................................... 57

1

2

General Information

System #9053

1995.5-1997 FORD F250-F350

7.3 POWER STROKE DIESEL

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 19491A

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 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

!

5

DOCUMENT 19491A

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 VR7000 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.

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 19491A

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 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 (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.

7

DOCUMENT 19491A

8

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 VR7000 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 VR7000 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.

VR7000 Tank

Auxiliary Receiver

One-way check valve

Install the line as high as

possible, NOT on the

bottom of the tank

DOCUMENT 19491A

Figure 2

Part 1

Installing the

Air Tank and Lines

System #9053

1995.5-1997 FORD F250-F350

7.3 POWER STROKE DIESEL

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 19492

10

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.

11

DOCUMENT 19492

Part 1: Installing the Air Tank and Lines

Forward tank mounting location

Rear tank mounting location

Brackets mounted in position

12

DOCUMENT 19492

1.2 Installing the tank

1. Attach one end of the 5/16 x 79-1/2

inch scavenge line to the matching fitting

on the top of the tank. Tighten the

fitting.

2. Attach one end of the 1/4 x 81 inch

pressure control line to the matching

fitting on the top of the tank. Tighten

the fitting.

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

head cap screws through the holes in

the tank brackets.

4. Place the tank in position in the tank

brackets on the frame, with the 1/4 inch

and 5/16 inch lines over the top of the

front tank bracket.

5. 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.

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

inch NC hex nuts on the cap screws.

7. Align the tank so that the direction

arrow on the front of the tank points

upward.

This alignment is extremely

important. Improper installation

can result in personal injury,

death or damage to the

equipment.

8. 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.

WARNING

!

OI L LEVE L

(check cold)

MAX

ADD

THIS

WAY

UP

IM PO RTANT

1/4” Pressure

Control Line

5/16" Scaven

g

e

Line

Alignment

Line attaching points and tank alignment

Tank installed in position

1/4 and 5/16 lines over mount

13

DOCUMENT 19492

9. Torque the overstrap fasteners to

specifications.

1.3 Connecting and routing the lines

1. Route the 1/4 inch and 5/16 inch lines

over the ground strap and the cab

mount, along the top of the frame and

into the engine compartment.

2. Pass the straight ends of the 1/2 inch

and 3/4 inch lines down from inside the

engine compartment, along the top of

the frame, over the cab mount and the

ground strap to the tank.

3. Connect the straight end of the 3/4 x 50

inch main discharge line to the matching

fitting on the tank. Hand-tighten the

fitting.

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

inch tank to cooler oil return line to the

matching fitting on the tank. Hand-

tighten the fitting.

5. Secure all of the lines to the frame as

required, using stainless clamps. Lines

can also be secured together using

stainless ties.

6. Protect any areas of the lines which

may be exposed to sharp or hot objects

with plastic loom.

OI L LEVE L

(check cold)

MAX

ADD

THIS

WAY

UP

IM PO RTANT

3/4" Main

Discharge Line

1/2" Tank to

Cooler Oil Return

Line

Alignment

Cooler and discharge line connections

1/2 and 3/4 lines installed over mount

Protective loom on lines

14

Part 2

Installing the

Compressor and Cooler

System #9053

1995.5-1997 FORD F250-F350

7.3 POWER STROKE DIESEL

UNDERHOOD AIR COMPRESSOR

15

DOCUMENT 19493

16

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.

17

DOCUMENT 19493

Part 2: Installing the Compressor and Cooler

Engine prior to installation

OEM mounting bracket before removal

Mounting location on the cylinder head

DOCUMENT 19493

18

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.

21. Remove the OEM fasteners holding the

OEM crankshaft pulley in place.

22. Clean the inside of the crankshaft pulley

where the VR7000 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

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Vmac 9053 Installation guide

Vmac 9053 Installation guide

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