1333 KIPP ROAD NANAIMO B.C. V9X 1R3

Transcription

1 UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS Installation Manual UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS System # V Ford F650 - F750 CAT 3126 W/WOAC UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS TM UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS 1333 KIPP ROAD NANAIMO B.C. V9X 1R3 TEL: (250) FAX: (250) Visit us at... underhoodair THE BENCHMARK IN INNOVATION TOLL FREE:

2 Installation Manual Document Number: VR140 Underhood Air Compressor System Number V Application 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. Copyright 2003 The contents of this manual may not be reproduced in any form without express, written permission.

3 Contents INSTALLATION MANUAL...1 PART 1 GENERAL INFORMATION INTRODUCTION INSTALLATION STEPS TERMS AND SYMBOLS INSTALLATION NOTES SYSTEM IDENTIFICATION NUMBER PLATE WARRANTY ORDERING PARTS CHANGES AND IMPROVEMENTS... 6 PART 2 PREPARING FOR INSTALLATION INSTALLATION PREPARATION... 9 PART 3 INSTALLING THE AIR TANK AND LINES INSTALLING THE TANK BRACKETS INSTALLING THE C-CLAMPS ATTACHING THE LINES TO THE TANK TRUCKS USING AIR BRAKES PART 4 INSTALLING THE COMPRESSOR AND OIL COOLER MODIFYING THE OIL FILL TUBE INSTALLING THE REPLACEMENT FUEL LINES AND FITTINGS INSTALLING THE MAIN BRACKET BRACKET TIGHTENING PROCEDURE INSTALLING THE VR140 CRANK PULLEY INSTALLING THE COOLER COMPLETING THE INSTALLATION PART 5 INSTALLING THE CONTROL COMPONENTS INSTALLING THE CONTROL COMPONENTS CONNECTING THE WIRING AUTOMATIC TRANSMISSION MANUAL TRANSMISSION PART 6 ILLUSTRATED PARTS LIST WARRANTY REGISTRATION Page 1

4 Page 2

5 DOCUMENT # Part 1 General Information System #V Ford F650 - F750 CAT 3126 W/WOAC UNDERHOOD AIR COMPRESSOR Page 3

6 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

7 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 STANDARD GRADE 8 NATIONAL FINE THREAD Size 3/8 7/16 1/2 5/8 3/4 Foot-pounds METRIC CLASS 10.9 Size M8 M10 M12 M14 M16 Foot-pounds 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: A 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. Page 5

8 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. Page 6

9 DOCUMENT # Part 2 Preparing for Installation System #V Ford F650 - F750 CAT 3126 W/WOAC UNDERHOOD AIR COMPRESSOR Page 7

10 Page 8

11 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

12 22. Remove the right side OEM front engine mount bolt with the tab attached from the center section of the front mount, (figure 1). Engine mount bolt Figure 1, OEM engine bolt detail. 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

13 DOCUMENT # Part 3 Installing the Air Tank and Lines System #V Ford F650 - F750 CAT 3126 W/WOAC UNDERHOOD AIR COMPRESSOR Page 11

14 Page 12

15 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

16 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). 13 Figure 4, tank-mounting brackets. Figure 5, C-clamp mounting positions 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

17 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 7, completed tank mount front view. Figure 8, completed tank mount rear view Trucks using air brakes Detail A Illustration of the tank For trucks with air brakes, see the instructions supplied with accessory pack #A This accessory pack contains the pressure switch used to sense engagement of the park brake in air brake equipped vehicles. Page 15

18 Page 16

19 DOCUMENT # Part 4 Installing the Compressor and Oil Cooler System #V Ford F650 - F750 CAT 3126 W/WOAC UNDERHOOD AIR COMPRESSOR Page 17

20 Page 18

21 4.1 Modifying the oil fill tube 1. Cut the oil fill tube at the first bend as shown in the photograph below. Be sure to de-bur and clean the oil fill tube before reinstallation. Reinstall the oil fill tube and install the oil fill cap bolt retainer chain. Bolt the retainer chain in the timing chain cover where shown. Refit the cap to the tube. Cut here Figure 1, oil fill tube cut detail. Figure 2, retainer chain bolt location. 4.2 Installing the Replacement Fuel Lines and Fittings 1. Thread the supplied #6(9/16-18) straight O-ring port to 1/2 JIC fitting into the front left cylinder head where the OEM steel fuel line was removed, (figure 3). Thread the 1/2 JIC 45 degree elbow onto the cylinder head fitting. Point the fitting upwards and tighten, (figure 4). Figure 3, O-ring port to 1/2 inch JIC fitting. Figure 4, 45-degree elbow, 90-degree hose end. 2. Connect the 90-degree end of the 23-inch long fuel 1/2 flexi hose to the 45-degree elbow fitting just fitted to the cylinder head. Route the hose back around the fuel accumulator, then back towards the front of the engine, (figure 5). 3. Thread the supplied #6(9/16-18) 90-degree elbow O-ring port fitting to the connection at the rear of the injection pump where the fuel filter steel line was removed from earlier. Angle this fitting upwards and tighten, (figure 6). Page 19

22 Figure 5, hose connection shown from above. Figure 6, Hose routing behind accumulator. 4. Connect the straight end of the 17-inch long fuel 1/2-inch flexi hose to the 90-degree port elbow just fitted to the pump and tighten. Both of these hoses will be fitted to the fuel filter later, (figure 6). 5. Remove the OEM belt tensioner from the OEM cast fan hub and alternator bracket, removed earlier. Mark the bracket at the top corner of the fan hub mounting, next to the grease nipple. Cut or grind out a section of the casting approximately 1 3/8 inches long by 3/8 inches in depth to allow clearance for the threaded hole in the cylinder head behind, (figure 7 and figure 8). Cut out Figure 7, OEM belt tensioner detail. Figure 8, close up of cut out notch. 6. Insert the supplied spacer plate in behind the fan hub on the cylinder head with the large hole sitting around the shouldered bolt behind the fan hub. Locate the OEM cast fan hub and alternator bracket in position using the OEM bolts. Use Loctite on the threads, (figure 9). 7. Refit the alternator back in place on the bracket and torque to specifications. Reconnect the alternator wiring. 8. Reconnect the air conditioning compressor in place to the cast bracket and torque to specifications. 4.3 Installing the main bracket 1. Fit the foot attachment for the main VR140 mounting bracket so the three holes on the long side of the attachment fit to the holes in the cylinder head immediately behind the thermostat housing on the front right side of the cylinder head. Use three M10 x 25mm HHCS with three flat washers. Only hand tighten at this time. Use Loctite on the threads, (figure 10). Page 20

23 Fan hub spacer Plate Side foot mounting bolt locations Figure 9, Spacer plate. Figure 10, Bracket foot mounting. 2 x M10 x 40 1 x M10 x 25 Figure 11, bolt fitted through notch. Figure 12, main bracket bolt mounting positions. 2. Remove the idlers from the supplied VR140 bracket prior to installation. Install the VR140 mounting bracket in position on the front upper left of the engine. Locate the machined section on the bottom of the mounting bracket in behind the fan hub and align the hole with the cylinder head hole just above the cut out section of the fan hub bracket, (figure11). 3. Align the remaining bolt holes in the mounting bracket with the holes in the aluminum casting that held the fuel filter bracket previously. Fit the two M10 x 40 hex head cap screws with flat washers to the left side upper and lower holes in the bracket to the aluminum casting. Only hand tighten at this time and apply Loctite to the threads, (figure 12). 4. Fit one M10 x 25 hex head cap screws with flat washer to the front of the machined section of the VR140 mounting bracket (fits in the cut away section of the fan hub) hand tighten only, (figure 11). Fit the remaining two M10 x 25 HHCS to mount the main bracket to the foot attachment, (figure 10). Hand tighten only and apply Loctite to the threads. 5. Fit the remote idler mount to the bracket using the two M10 x 45 bolts into the aluminum casting through the main bracket and the M10 x 30 bolt into the cylinder head. Page 21

24 2 x M10 x 25 1 x M10 x 30 2 x M10 x 50 Figure 13, remote idler bracket bolt locations. Figure 14, VR belt tensioner mounted. 4.4 Bracket tightening procedure 1. Tighten the front two M10 hex head cap screws on the front fastening to the cylinder head first. Tighten the four remaining M10 hex head cap screws fastening the front of the main bracket and remote idler mount to the aluminum casting on the top of the timing cover. Tighten the two M10 x 25 hex head cap screws locating the main bracket to the foot attachment. Finally. Tighten the three M10 hex head cap screws that locate the foot attachment to the cylinder head. Torque all bolts to the specifications shown in the chart at the front of the manual. 2. Refit the two back idlers to the two stubs on the VR140 bracket with the idler bolt spacers and 1/2- inch bolts using Loctite. Fit the back idler to the upper remote mount idler stub, fit the 8 rib idler to the lower stub on the remote mount idler bracket and install the 1/2 inch bolts and bolt spacers. Apply Loctite to the threads then torque to specifications. 3. Locate and fit the VR140 belt tensioner in position on the large boss on the front of the VR140 mounting bracket. Use the supplied M10 x 80 hex head cap screw and flat washer, (figure 14). 4. Fit the OEM fuel filter to the left side plate of the VR140 mounting bracket using the two OEM 8mm bolts. 5. Remove the T fitting and the 90 degree elbow fitting in the top of the fuel filter. Install the two supplied #6(9/16-18) O-ring port 90-degree elbow fittings in their place. Point the front fitting downwards and the rear fitting pointing rearwards, (figure 15). 6. Connect the fuel flexi hose from the cylinder head to the fitting on the front of the fuel filter. Route the hose around the rear of the VR140 bracket and tighten the connection, (figure 15). 7. Connect the 45-degree end of the fuel flexi hose from the rear of the fuel pump to the fitting on the rear of the fuel filter. Tighten the connection, (figure 15). 8. Lift the compressor into position on the VR140 main bracket. Be sure to line up the four mounting holes on the compressor with the four threaded mounts on the main bracket. Apply Loctite to the threaded ends of the supplied M8 x 110 socket head cap screws and install them by inserting them through the bolt holes in the compressor and threading them into the mounts on the main bracket horizontal deck. Page 22

25 Cut Cylinder head fuel hose Rear of fuel pump hose Figure 15, hose connections on the fuel filter. Figure 16, Bracket cut details. 9. Refit the OEM belt tensioner to its location on the cast alternator bracket. 10. Install the OEM eight-rib belt. 11. Install the supplied machined head 5/8 x 4 inch long bolt to the right side of the front center engine mount. Refit the OEM nut with Loctite and torque to specifications. 4.5 Installing the VR140 crank pulley 1. Clean off the paint from the inside lip of the OEM crank pulley to allow a good fit for the VR pulley. Install the VR140 pulley using the eight M10 x 50 hex head cap screws with flat washers and apply Loctite to the threads. Torque to specifications. 2. Install the supplied fan spacer to the front of the VR pulley. 3. Mark the right hand side engine attachment for the front center engine mount front top corner, to cut out a 90-degree section 2 1/8 inches down and 1 5/16 inches in from the front. Cut out this section and re-install the engine mount attachment. Use OEM bolts and torque to specifications, (figure 16). Remove paint from the inside lip Figure 17, OEM pulley preparation Figure 18, VR pulley mounted Page 23

26 4. Install the VR140 eight rib drive belt following the routing shown. Ensure that the belt sits correctly in the grooves and alignment looks good, (figure 19). TENSIONER BACK IDLER BACK IDLER VR140 CLUTCH BACK IDLER RIBBED IDLER CRANK PULLEY Figure 19, Belt routing detail. 4.6 Installing the Cooler 1. Locate the VR140 cooler on the right side of the cylinder head using the four threaded holes available behind the VR140 mounting bracket foot attachment. Fasten in place using four M10 x 30 hex head cap screws with flat washers. Use Loctite and torque to specifications, (figure 20). Coolant Expansion Tank Thermostat Housing Connection Cooler Plastic Tee Cut a 3 inch hose length Lower Rad Hose Connection Figure 20 - Detail of cooler- radiator hose connections. Page 24

27 Figure 21 - Lower Radiator hose connection. Figure 22 thermostat housing connection. 2. Remove the 3/4 NPT OEM plug from the passenger side of the thermostat housing and install the supplied 3/4 NPT x 3/4 hose barb 45 degree fitting using Loctite PST sealant, (figure 22). 3. Cut the hose that connects the lower radiator hose diverter to the coolant expansion tank 3 inches above the lower radiator diverter. Install the supplied 1-inch to 3/4-inch plastic tee between the coolant tank and lower radiator hose diverter. Ensure that the 3/4-inch connection is facing towards the rear of the engine. Use the supplied HS 16 hose clamps to secure the plastic tee in place. Hook the 60-inch long 3/4-inch heater hose to the 3/4-inch connection on the tee and run it back to the front connection on the cooler. Secure both ends of this hose with the supplied HS12 hose clamps. 4. Attach the end of the supplied 36-inch by 3/4-inch cooler return hose to the rear cooler hose barb with an HS12 hose clamp and tighten securely. 5. Run the other end of the 36-inch by 3/4-inch cooler return hose to the 45 degree hose fitting located on the front passenger side of the engine block in the thermostat housing. Secure this end using an HS12 hose clamp and tighten securely. 6. Connect the 5/8-inch oil return hose from the tank to the front 90-degree elbow fitting on the front of the cooler. Tighten the connection using two wrenches to prevent the hose from twisting. 7. Connect the 90-degree end of the shorter oil return hose to the rear fitting on the VR140 cooler. Route the hose around the rear and then forward to connect to the 90-degree elbow in the left side of the compressor. Route all hoses clear of sharp or hot surfaces. Tighten connections ensuring the hoses do not twist, (Figure 24). 8. Connect the 45-degree end of the 1 inch main air discharge hose to the fitting at the rear of the compressor. Tighten the connection using two wrenches to prevent the hose from twisting. 9. Route the 5/16 inch oil scavenge hose along the engine and connect it to the 5/16 inch 90 degree elbow fitting at the front of the inlet control valve. Tighten the connection securely. 10. Route the 1/4 inch pressure control hose along the engine and connect to the 1/4 inch fitting at the left rear of the inlet control valve. Tighten the fitting securely. Page 25

28 Figure 23, cooler mounted. Figure 24, cooler with hoses attached. 4.7 Completing the Installation 1. Fit the left side replacement air cleaner mounting bracket to the three threaded holes that the OEM bracket mounted just behind the compressor. Use three M8 x 35 hex head cap screws with flat washers with Loctite and torque to specification, (Figure 25). Figure 25, air cleaner mounting bracket position Figure 26, radiator tube hose and clamps 2. Locate the air cleaner assembly in position in its new mounting brackets attached to the VR140 cooler and the left side of the cylinder head. Secure the right side to the cooler using two M10 X 40 hex head cap screws and fit two flat washers and two M10 Nylok nuts. Fit two M8 x 40 hex head cap screws to secure the air cleaner to the left mount. Tighten all the fasteners. 3. Mark a line around the air cleaner to turbo rubber intake tube between the fourth and fifth ribs from the wide end and cut the tube. On both halves, cut the vertical ribs down flush with the tube body up to the next radial rib, (fourth and fifth ribs). This is to allow clamps to fit tightly around the connection, (Figure 27). Page 26

29 Cut here Figure 27, turbo intake duct cut detail. 3/4 Cut here Figure 28, air cleaner duct. cut detail. 4. Fit the small diameter end of the tube to the turbo intake with its clamp. Install the supplied connector tube into the cut end of the tube approximately 1 1/2 inches. Fit one of the HS80 hose clamps supplied and tighten. Fit the second half of the air cleaner tube to the connector tube with the second HS80 hose clamp in place. Rotate the tube and fit the large diameter end to the air cleaner. Align the tube and tighten all clamps. Turbo duct Turbo intake duct connector tube Air cleaner duct Figure 29,ducts before clamping. Air cleaner duct connector tube Figure 30,ducts after clamping. 5. Install the replacement upper radiator hose and tube supplied. Fit the bent rubber hose to the thermostat housing and then pass the tube behind the compressor. Connect the straight rubber hose to the upper radiator connection. Fit the hose clamps and tighten, (figure 26). 6. Mark a line around the plastic intake tube that fits between the front of the truck and the air cleaner intake, 3/4 inch in front of the moisture trap (towards the vehicle front) carefully cut the tube and discard the angled end. Clean up the cut edges and wipe out any debris from inside the tube, (figure 28) 7. Expand and fit the OEM rubber bellows over the aluminum connecting tube supplied. Insert over the tube approximately 1 1/4 inches. Fit one of the HS 100 clamps supplied and tighten. Fit the larger diameter end of the supplied rubber 45-degree connector elbow over the other end of the aluminum connector tube, (figure 29 & 30). Page 27

30 8. Install the assembled air cleaner intake section to the truck with the 45-degree elbow connection to the radiator end. Fit the clamps and tighten. 9. Refit the coolant tank cross bar support. 10. Reinstall the OEM fan removed earlier in the Preparation for Installation section. 11. Reinstall the OEM fan shroud removed in the Preparation for Installation section. 12. Check that all VR140 system hoses are fully tightened. Remove the oil fill plug in the top of the VR140 compressor inlet control valve, (Figure 31). Using a small funnel, pour 9 liters of the supplied certified and approved synthetic compressor oil slowly into the system. Rotate the compressor clutch using a 13mm socket as you fill the system to pump the oil to the tank. Oil fill plug Figure 31 You must use the supplied VMAC certified and approved synthetic compressor oil in this system. Failure to use this special oil will result in damage to the compressor and will void your warranty. 13. Allow a few minutes for the oil to settle then look under the vehicle at the sight glass on the front of the tank to check the level is between the FILL and MAX marks. 14. Install the coolant expansion tank using the spacers supplied, (See the illustration and table on page 28). Reconnect the coolant fill hose to the under side of the tank. Reconnect the overflow hose. Reconnect the small thermostat bypass hose to the tank 15. Check that all coolant hoses are connected and tight. Refill cooling system with the manufacturers recommended coolant. 16. Before running the engine, bleed the air from the fuel system as per manufacturers recommendations. Page 28

31 17. Cover the oil hoses with cut lengths of supplied plastic loom for protection on sharp edges and chaffing against body, engine, or other braided hoses. Tie wrap in position. 18. Conduct a tidy up of all VR140 hoses and wiring using plastic loom and tie wraps to secure components. Use the supplied nylon ties to secure a bulk of hoses together to the frame or in hot areas. 19. Allow the cooling system to bleed air thoroughly when running the engine before operating the VR140 system. OEM FASTENERS Coolant expansion tank bracket mounting detail Table A Spacers used to mount the coolant expansion tank Illustration Number Spacers Part Description 1 1 x x M6 x 70 bolts, 1 x 1/4 washers, 1 x M6 Nylock nuts 2 1 x x M6 x 70 bolts, 1 x 1/4 washers, 1 x M6 Nylock nuts 3 2 x x M6 X 40 bolts, 2 x 1/4 washers, 2 x Nylock nuts Page 29

32 Page 30

33 Part 5 Installing the Control Components DOCUMENT # System #V Ford F650 - F750 CAT 3126 W/WOAC UNDERHOOD AIR COMPRESSOR Page 31

34 Page 32

35 RED 12 VOLTS PRESSURE SENSOR FIREWALL BULKHEAD CLUTCH INLET VALVE PRESSURE SENSOR COMPRESSOR 3 PIN CONNECTOR (BLACK) CONTROL PANEL TEMPERATURE PROBE 7 PIN CONNECTOR (GREEN) CLUTCH 16GA WHT 16GA WHT BLK GROUND RED WHT GRN SOLDER CONNECTION PREFERED OR T-TAP CONNECTOR BLU YEL BLU YEL DDC TO VR70 SYSTEM YELLOW WIRE DDC BLK BLK THROTTLE COMMANDER VR70 BLACK WIRE TRANSMISSION PARK/NEUTRAL WIRE TEST FOR SELECTION (LIGHT BLUE WIRE WITH ORANGE STRIPE (OEM)) WIRE BUNDLE AUTOMATIC TRANSMISSIONS ONLY TRANS PARK BRAKE JUMPER XXXX XXXX XXXX WIRE LABEL LEGEND PARK BRAKE OEM PARK BRAKE WIRE PARKING BRAKE DDC CHASSIS GROUND STD. TRANS. ONLY NO DDC INSUL. SPADE CONN. 12 VOLTS THROTTLE OEM BREAKER PANEL IGNITION OFF: NO VOLTAGE IGNITION ON: BATTERY VOLTAGE RED GRY ACCELERATOR PEDAL OEM HARNESS (UNPLUGGED FROM ACCELERATOR PEDAL) Figure 1 Page 33

36 5.1 Installing the Control Components See Figure 1 for the wiring diagram. 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. Removing the trim panels. 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) 3/32-inch holes. 4. Mount the control unit using the four (4) supplied #8 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. Page 34

37 Cut a slot in the trim panel Remove the sharp teeth Switch box mounting position 8. Mount the throttle control under the dash to the right of the steering column. Fasten it in place on the steering column support bracket with the supplied Nylock nut. 9. Plug the white interface connector into the matching connector from the control unit. Throttle control unit in place Cut a slit in the steering boot 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 with the black pressure transducer connector from the throttle control Page 35

38 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. 5.2 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 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. OEM ground location Recommended fuse panel location 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. 8. Disconnect the connectors at the gas pedal Page 36

39 9. Connect the two mating connectors on the throttle to the two OEM connectors at the gas pedal. 10. Tie the cables up and out of the way, with the nylon ties provided. 11. Route all three wires coming from the firewall to the compressor. 12. Connect these wires to their mating connectors on the compressor. 13. Cover the wires with the loom provided and tie them in place using the supplied nylon ties. Ensure that all wires are away from hot spots and moving parts Automatic Transmission 1. Locate the light blue wire with the orange tracer in the wiring harness below the steering column in the engine compartment. WARNING FAILURE TO PROPERLY INSTALL AND VERIFY FUNCTION OF THIS SAFETY INTERCONNECT FEATURE CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH Locating the wire in the harness If the vehicle has an automatic transmission, the Throttle Commander must be connected so as to be inoperable unless the transmission is in park or neutral. If this important safety interconnect is not already provided, VMAC DDC ( Drive Disable Circuit ) P/N will accomplish this. 2. Test the wire using an Ohmmeter 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 black wire 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. Page 37

40 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. 8. Fit the wiring back into the loom and tape as necessary. Light blue wire with an orange tracer Blue VR70 wire Shrink sleeve Using the T-tap and spade connector Soldering the wires For trucks with air brakes refer to accessory kit #A manual for park brake wire connection. 9. Route the black wire with the piggyback connector under the floor mat to the park brake. 10. Remove the OEM connector from the park brake switch. 11. Connect the VR140 wire with the piggyback connector to the park brake switch, then replace the cover and screws over the parking brake lever assembly. Page 38 Connection at the park brake switch

41 5.2.2 Manual transmission For trucks with air brakes refer to accessory kit #A manual for park brake wire connection. 1. Connect the long black jumper wire with the piggyback spade connector to the black wire at the interface connector. Tape this connection. 2. Route the black wire with the piggyback connector under the floor mat to the park brake. 3. Remove the OEM connector from the park brake switch. 4. Connect the VR140 wire with the piggyback connector to the park brake switch, then replace the cover screws over the parking brake assembly. 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. Page 39

42 Page 40

43 DOCUMENT # Part 6 Illustrated Parts List System #V Ford F650 - F750 CAT 3126 W/WOAC UNDERHOOD AIR COMPRESSOR Page 41

44 Page 42

45 ILLUSTRATED PARTS LIST FOR SYSTEM V FORD F650 F750 CAT 3126 W/WOAC ASSY. ITEM UNIT QTY PART# DESCRIPTION Main Bracket Assembly 1.1 ea Main Bracket 1.2 ea Idler, Back 1.3 ea Spacer, Idler 1.4 ea Bolt, fl, G8 ½ x 1 ¼ 1.5 ea Remote Idler Mount 1.6 ea Idler, Ribbed 1.7 ea Bolt, HHCS G10.9, M10 X 1.5 X ea Washer, Alloy, pl, SAE, 3/8 1.9 ea Tensioner 1.10 ea Bracket Brace 1.11 ea Crank Pulley, VR ea /8 Alloy, pl, SAE Washer 1.13 ea Bolt, HHCS G10.9, M10 X 1.5 X ea Fan Spacer 1.15 ea VR140 Belt 2.0 P Compressor Assembly 2.1 ea 1 P VR140 Compressor 2.2 ea 1 P Clutch, complete, 8 Groove 2.3 ea Temp Probe Assembly 2.4 ea O-ring, Viton, 3 3/8 ID X 1/8 2.5 ea Elbow, Brass NPT-Tube, 1/8-5/ ea Valve. inlet control, VR ea Sensor, Pressure 2.8 ea Elbow, Brass Pipe-Tube, 1/4-1/8 2.9 ea Air Filter 2.10 ea ¼ NC Nut, Nylok 2.11 ea Rod, Threaded, 1/4 X 5.62" 2.12 ea Filter Cover 2.13 ea Washer, Flat SAE, 1/ ea /4 NC Nut, Nylock 2.15 ea Elbow, Steel JIC/O-Ring, 1/2 3/ ea O-Ring, Viton, 5/8 ID x 3/ ea Bolt, SHCS, M10 X 1.5 x ea Bolt, SHCS, M10 x 1.5 x 30 Page 43

46 ILLUSTRATED PARTS LIST FOR SYSTEM V FORD F650 F750 CAT 3126 W/WOAC ASSY. ITEM UNIT QTY PART# DESCRIPTION Tank Assembly 3.1 ea Main Tank Body 3.2 ea Plug, Hex Head Steel Allen, ea O-ring, Viton, 1 15/16 ID X 3/ ea Sight Glass Window 3.5 ea Ring retaining, 2 1/8 3.6 ea Oil filter, VR short 3.7 ea Connector, Brass NPT-SAE, 3/8-1/2 3.8 ea Connector, 1" Pipe TO 1" JIC 3.9 ea O-ring, Viton, 6 1/2 ID X 1/ ea Compression Spring 3.11 ea Coalescing Filter Element 3.12 ea Seal, tank rear cap 3.13 ea Button Head SHCS 3.14 ea Scavenge Screen Barb Assembly 3.15 ea Discharge cap 3.16 ea Valve, Safety, 3/8, 200 PSI 3.17 ea Ring, Window 3.18 ea Coalescer Spring Plate 3.19 ea O-ring, Viton 1 3/8 ID x 1/ ea O-ring, Viton 1 5/16 x 3/ ea Cover, sight glass 4.0 Hose Kit 4.1 ea Hose,crimped, 1.0" x ea Hose, crimped, 5/8 x ea Hose, crimped, 5/8 X ea Hose, crimped,. 5/16 x ea Hose, crimped, 1/4 x ea Hose, crimped, ½ x ea Hose, crimped, 1/2 x ea Elbow, ½ JIC-8-9/16 O-Ring ea Elbow, Steel Swivel 45 Deg, 1/ ea Adaptor, ½ JIC-8-9/16 O-Ring ea Hose, Coolant, 2 x ea Hose Clamp, HS ea Hose, Rad 4.14 ea Tube, Coolant 4.15 ea Hose Heater 3/4 x ea Hose Heater 3/4 x ea Clamp, Hose HS ea Elbow, Steel, 45 Deg, 3/4 -NPT-3/4 HB 4.19 ea Tube Intercooler 4.20 ea Tube Intercooler Page 44

47 ILLUSTRATED PARTS LIST FOR SYSTEM V FORD F650 F750 CAT 3126 W/WOAC ASSY. ITEM UNIT QTY PART# DESCRIPTION 4.0 Hose Kit Continued 4.21 ea Elbow Rubber 45 Degrees 4.22 ea Clamp, Hose HS ea Connector, Modified Tee 5.0 Throttle Control 5.1 ea 1 T Throttle Control 6.0 Tank Bracket Assembly 6.1 ea Strap 6.2 ea Bolt, HHCS NC G8 PL, 1/2 X 5 1/2 6.3 ea Washer, flat 1/2 6.4 ea Nut, Prevailing Torque NC, 1/2 6.5 ea Clamp, mounting bracket 6.6 ea Bracket, tank mount 7.0 Cooler Assembly 7.1 ea Cooler Assembly 7.2 ea Elbow, Steel, SAE, 1/2-1/2 7.3 ea Bracket, Air Cleaner 7.4 ea Elbow, Steel, 45 Deg, 3/4 -NPT-3/4 HB 8.0 Electrical 8.1 ea Interface Cable 8.2 ea Control Box Assembly 8.3 ea DDC Type F 9.0 Miscellaneous 9.1 ea Spacer plate Page 45