Installation Manual for VMAC System V Ford L Power Stroke Diesel

Transcription

1 Installation Manual for VMAC System V Ford L Power Stroke Diesel F250-F550 Super Duty General Information... 3 Before You Start... 3 Special Installation Notes... 4 Part 1: Preparing for Installation Preparing for Installation... 6 Part 2: Installing the Tank and Hoses Installing the Tank and Frame Mounts Attaching Hoses to the Tank Part 3: Installing the Main Bracket and Compressor Oil Cooler Installation Exceptions Installing the Oil Cooler Installing the Pulley and Bracket Installing the Compressor Adding Oil to the System Part 4: Installing the Control Components Installing the Control Unit Installing the Throttle Control Connecting the Wiring Completing and Testing the Installation

2 Installation Manual - Document # Installation Manual for VMAC System V Ford L Power Stroke Diesel F250-F550 Super Duty Changes and Revisions Version Revision Details Revised by/date Approved by/date Implemented 00 Original Manual IB 27 Jan 2004 SC 14 Mar Mar 2004 A Revisions IB 18 June 2006 SM 20 June June 2006 B ECN IB 05 Nov 2007 SH 23 Nov Nov 2007 Important Information 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 underhood mechanical work. Any grinding, bending or restructuring operations for correct fit in modified trucks must follow standard shop practices. 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. 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 Copyright 2007 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 2

3 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 ¾ Foot-pounds (ft-lb) Newton meter (N m) STANDARD GRADE 8 NATIONAL FINE THREAD Size 3/8 7/16 1/2 5/8 ¾ Foot-pounds (ft-lb) Newton meter (N m) METRIC CLASS 10.9 Size M8 M10 M12 M14 M16 Foot-pounds (ft-lb) Newton meter (N m) Hose Coding 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. The following table shows the color code used by VMAC to define the different hose diameters. Hose Diameter 1/2 inch 5/8 inch 3/4 inch 1 inch Colour-Coded Label Blue Blue Green Green 3

4 Special Installation Notes trucks will require accessory kit A trucks will require accessory kit A System Identification Number Plate The enclosed System Identification Number Plate must be attached to the vehicle at the time of installation. This plate provides information which allows VMAC to assist in customer inquiries and the ordering of parts. Mark and drill two 7/64 inch holes, then secure the plate with two #6 pan head self-tapping screws. System ID number plate Left Front Safety Decal 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. This Vehicle is Equipped with a VMAC Air Compressor System OPERATING INSTRUCTIONS Daily Pre-Start Check Start Up Procedure Shutdown Procedure 1. Check Oil Level in Tank 1. Ensure Compressor is OFF 1. Allow engine to idle for 1 minute 2. Check Drive Belt 2. Ensure discharge valve is 2. Turn OFF compressor 3. Check for Leaks CLOSED 3. Wait for system to discharge 3. Ensure air system is discharged for 1 minute before restarting 4. Place vehicle in Neutral or Park and engage vehicle safety features - park brake 5. Start engine and bring up to operating temperature 6. Turn ON compressor For Technical Support/Parts contact your VMAC Dealer To locate your nearest dealer call ( )! WARNING Always allow system pressure to discharge before restarting 4

5 Auxiliary Air Receiver! If you intend to use an auxiliary air receiver with this system you must observe the following installation procedure to prevent damage to the system. The line from the VMAC tank to the auxiliary air receiver must have a one-way check valve installed to prevent blow back from the auxiliary tank to stop moisture from entering the VMAC tank. 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 entering the line. One-way check valve Auxiliary Tank VR Tank Install the line as high as possible, NOT on the bottom of the auxiliary tank 5

6 Part 1: Preparing for Installation 1.1 Preparing for Installation 1. Disconnect the battery and remove it from the vehicle. 2. Drain the coolant. 3. Remove the OEM fasteners from the coolant expansion bottle and move it out of the way. Do not disconnect the hoses from the bottle. 4. Remove the left intercooler tube from between the engine and the intercooler. 5. Remove and discard the plastic cover and attaching nuts from the center top area of the engine. 6. Remove the OEM belt, cooling fan and the fan shroud. 7. Disconnect the air inlet horn from the front of the air cleaner and battery box, but leave it in place. Remove the air cleaner box and the battery box. 8. Remove the alternator from its mount and lay it back on top of the engine. Keep the OEM fasteners. 9. Mark the position of the power steering pump pulley in relationship to the shaft and remove the pulley using an approved puller. 10. Remove the power steering pump from the bracket. Keep the OEM fasteners. Fasten the pump out of the way on the frame. 11. Remove and discard the power steering return hose from the power steering pump. 12. Remove and discard the OEM alternator and power steering pump mounting bracket. Keep the fasteners. 13. Remove the upper and lower radiator hoses. 6

7 14. Exchange the forward right bolt and rear left stud on the aluminum cover at the top front of the engine (Figure 1.1). Front Exchange these two fasteners Figure Remove and discard the 12 mm stud and nut (lower right side of the engine) and the 12 mm bolt (lower left side of the engine) which retain the ground straps (Figure 1.2). M12 stud holding ground strap and transmission cooling lines M12 hex head cap screw holding ground strap Figure Remove and discard the positive battery cable locating bracket from the same area. 7

8 17. Clean the front of the engine block to ensure that the oil cooler and mounting bracket will fit flush. 18. Clean the driver s side frame. 19. Remove the three OEM bolts from the crankshaft pulley. 8

9 Part 2: Installing the Tank and Hoses The tank will mount on the driver side frame rail behind the front cab mount. Apply Loctite to all fasteners before installing them. 2.1 Installing the Tank and Frame Mounts Upper frame clip Tank strap cable Tank strap mount Spacer for F250-F350 Lower frame clip C-clamp 1/4 and 3/16 tubes 3/4 hose fitting 1/2 hose fitting Oil filter Figure Remove the pinch bolts from the C-clamps, spread the clamps slightly and slide them over the front of the tank. 2. Rotate the C-clamps so that the flat mounting surfaces are on the right side of the tank, as viewed from the back of the tank (Figure 2.2). 9

10 3/16 tube 1/4 tube Figure Insert the pinch bolt from the top, then install the washer and nut, but do not tighten. 4. Place a tank strap mount against the one of the C-clamps on the tank with the short arm (or L ) at the top of the tank, facing away from the tank. Install a 5/16 x 1/2 inch bolt with flat washer into the bottom hole. Do not tighten. 5. Insert the second bolt through the top hole in the C-clamp and into the top hole on the tank strap mount. Do not tighten. 6. Repeat this procedure with the second strap mount bracket and C-clamp. 7. Identify the tank mounting position which matches the vehicle (Figure 2.4). These locations are suggestions only. 10

11 Front cab mount Front cab mount F250 & F350 standard cab 2x4 and 4x4 F250 & F350 super cab 2x4 and 4x4 Front cab mount Front cab mount Transfer case F450 & F550 standard cab 2x4 and 4x F450 & F550 super cab and crew cab 2x4 and 4x4 Figure Remove the nuts and washers from the threaded end of the tank strap cables, insert them through the end of each tank flat bar strap with the single hole and pull them to the stops. 11

12 9. Place the tank strap cables over the frame rail from the inside of the frame, with the tank flat bar strap on the inside of the rail and the tank strap cables hanging over the top outer edge of the frame rail (Figure 2.5). 10. Support the tank and assembly in place on the outside of the frame, with the short part of the tank mount strap positioned over the top of the frame. 11. Pass each tank strap cable around the tank mount strap, between the strap and the tank. Make sure that the tank strap cable fits between the cable guide and the C-clamp (Figure 2.5). Cable must fit in the grooves! Figure 2.5 When positioning the tank on the frame, make sure that the mounting location will not pinch or damage any wiring harnesses, lines or hoses. 12. Insert the threaded end of each cable strap through the tubes on the lower frame locating U-clips. A special clip is included for trucks with double frames. 12

13 13. Install the appropriate spacer and nut combination: F250 and F350 trucks (all models) install the 1/8 inch thick 5/16 x 3/4 inch washers, the 1/2 x 2 inch spacer and the 5/16 inch nuts. F450 & F550 trucks (all models) install the 1/8 inch thick 5/16 x 3/4 inch washers and the 5/16 inch nuts. Discard the 1/2 x 2 inch spacer 14. Thread a 5/16 inch nut on each tank strap cable and tighten the nuts enough to hold the tank in position. 15. Check the dimensions in Figure 2.4 to ensure that the positioning is correct for the appropriate model. On the F450 & F550 standard cab models (2x4 and 4x4) position the rear tank bracket assembly so that the front edge of the tank flat bar strap is approximately 1-1/4 inches back from the forward edge of the cut-out for the transfer case.! Make sure that the threaded end of the tank strap cable is not positioned next to the transfer case housing, as torque movement will cause the transfer case housing to strike the threaded end of the securing cable. 16. When the tank is correctly positioned, tighten the tank strap cable retaining nuts until the cables pull tight and snug around the frame. Do not over-tighten the nuts. 17. Install a second 5/16 inch nut and tighten it securely against the first to act as a locknut. 18. Check the alignment of the tank to make sure that the UP arrow on the end of the tank points directly upward and that the tank is aligned correctly, then tighten the C-clamp pinch bolts securely, but not so much as to distort the mounting surfaces.! Improper installation can result in an extremely hazardous situation, causing injury or equipment damage. 19. Remove each of the bolts (one at a time) holding the C-clamp to the tank strap mount, apply Loctite and replace the cap screws. 20. Make sure that the tank is level with the vehicle and tighten the bolts. 13

14 2.2 Attaching Hoses to the Tank 1. Route the straight end of the 3/4 inch hose over the cab mount and thread it into the top fitting on the tank but do not tighten. 2. Route the straight end of the longest 1/2 inch hose over the cab mount and thread it onto the lower fitting on the front of the tank but do not tighten. 3. Insert the 1/4 and 3/16 inch tubes into the fittings on the back of the tank and cover them with high temperature loom. Route the tubes through the frame up to the compressor and connect them to the matching fittings on the compressor inlet valve. 4. Bunch all hoses together and protect them where they pass over the cab mount. 5. Route all the hoses and tubes into the engine compartment. 14

15 Part 3: Installing the Main Bracket and Compressor Apply Loctite to all fasteners before installing them. 3.1 Oil Cooler Installation Exceptions Vehicles manufactured prior to Ford model year (Calendar year April 2001) must have the lower 90 deg coolant spigot (RH65) removed from the engine and replaced with the supplied straight spigot. On vehicles with dual alternators, install the supplied alternate leg before the cooler. 1. Remove the 5/16 NC bolts and nuts that fasten the passenger side cooler mounting bracket to the back of the cooler and discard the bracket. 2. Facing the front of the cooler, install the alternate leg so that the hook shape at the top faces left and the spacers on the adaptor face the cooler. 3. Use the supplied 5/16 x 1-1/4 inch NC bolts to fasten the alternate leg to the cooler with the existing washers and Nylok nuts. Torque to specifications. 3.2 Installing the Oil Cooler 1. Fit the cooler in place under the crankshaft pulley, over the two studded fasteners at the front of the engine block (Figure 3.1). 2. Attach the transmission lines to the right hand stub. This may require the bracket to be bent or modified slightly. 3. Install the ground cable, thread on two M10 Nylok nuts and tighten. 15

16 Hose to Engine Block Mounting Brackets for Attaching to the Engine Hose Fittings Hose to Radiator Figure Installing the Pulley and Bracket 1. Clean all dirt and debris from the face of the OEM pulley before installing the pulley. 2. Install the compressor pulley using three supplied M10 x 20 mm socket head bolts. Torque to specifications. 3. Remove the idler and tensioner from the main bracket. 4. Install the main compressor mount bracket using the four OEM flange lock bolts. Torque them to specifications (Figure 3.2). 5. Install the power steering pump to the main bracket using the OEM fasteners. 16

17 Main bracket OEM bolt locations Tensioner Ribbed idler Figure Align the marks and install the power steering pump pulley. The outer edge of the power steering pump pulley must be flush with the end of the pump shaft. 7. Install the alternator onto the main bracket using the OEM fasteners. The alternator must be mounted 180 degrees (upsidedown) from the original mounting position. Rotate the alternator 180 degrees counterclockwise. 8. Install the supplied 3/8 x 36 inch power steering return hose between the power steering pump and the master cylinder. 9. Align the power steering hoses to clear the steering column. 17

18 3.4 Installing the Compressor 1. Place the compressor onto the main bracket and fasten it in place using the three supplied 8 mm double serrated lock nuts. Torque to specifications. 2. Install the idler and tensioner and torque the fasteners to specifications. 3. Install the OEM (Figure 3.3) and compressor belts (Figure 3.4) Alternator Air conditioning Idler Tensioner Idler Water pump Power steering Crankshaft pulley Figure 3.3 VR70 Air Compressor VR70 Tensioner VR70 Drive Belt VR70 Crankshaft Pulley Figure 3.4 VR70 Idler 18

19 4. Connect the straight end of the 3/4 inch hose to the top front tank fitting, route it around the outside of the front body mount and up to the compressor. 5. Connect the 45 degree swivel fitting on the 3/4 inch hose to the fitting on the back of the compressor. Tighten the fitting at the compressor while angling the fitting to allow the line to route outside of the steering column. 6. Route the 3/16 inch tube from the tank to the compressor and connect it to the 90 degree elbow fitting on the firewall side of the compressor inlet control valve. 7. Route the 1/4 inch tube above the front cab body mount and around the outside of the steering column, then connect it to the 45 degree elbow fitting on the front of the compressor air inlet valve. 8. Connect the straight end of the longest 1/2 inch hose to the lower front tank fitting and the 90 degree end to the left (driver) side fitting on the oil cooler. 9. Connect the 90 degree end of the shortest 1/2 inch hose to the right (passenger) side fitting on the cooler and the straight end to the 90 degree fitting on the bottom of the compressor. Route it across the cooler, behind the coolant hose to the engine and across the engine block to the compressor. 10. Tighten all fittings. Some adjustment of the tank brackets along the frame may be necessary if the hoses are too tight or too loose and hang down under the truck. 11. Install the oil filter to the tank and, once the gasket has contacted the base, tighten an additional 3/4 turn. 12. Install all OEM parts removed in preparation for installation. 13. Install the upper radiator hose. Rotate the hose on the thermostat housing and radiator fitting until the hose clears both the compressor belt and the fan shroud. Tighten the clamps. 19

20 14. Install the intercooler tube and tighten the clamps. Be sure that the tube clears the back of the compressor and power steering pump and the bead inside the rubber OEM bellows sits in the groove properly before tightening the clamps.! If the locating rib inside of the flexible tube does not seat correctly in the intercooler tube groove, unfiltered air may enter the engine, causing engine damage. 3.5 Adding Oil to the System 1. Remove the fill plug from the air inlet control valve and pour oil into the oil fill hole on the inlet control valve using a funnel.! You must use the VMAC supplied and approved compressor oil in this system. Failure to use this special oil will result in damage to the compressor and will void your warranty. 2. Turn the compressor clutch clockwise with a ratchet and a 1/2 inch socket using the hex head bolt at the centre of the compressor clutch during the fill process. 3. Allow 5 minutes for the oil to drain into the tank, then check the level at the sight glass at the front of the tank. Continue adding oil until the level is correct.! Do not overfill the system. Overfilling the system with oil can flood the sight glass window and make the system appear empty. 4. Install the fill plug in the inlet control valve and tighten it securely. 20

21 Part 4: Installing the Control Components 4.1 Installing the Control Unit 1. Remove the driver-side plastic door frame base panel and the plastic molding ahead of the base panel. 2. Mount the control unit using the supplied sheet metal screws (Figure 4.1). 3. Route the wire harness under the floor covering, along the inside of the door where it will be covered by the trim piece and up under the dash. Driver s Seat Cut a notch for the wire in the door trim Control box Figure 4.1 Keep wires away from the park brake mechanism. 4. Place the floor covering back into position and replace the inside left kick panel. 21

22 5. Cut a notch in the edge of the trim piece through the saw-tooth section just inside the edge of the trim so that the wire is not cut when the trim is installed and replace the door trim piece. 6. Route the wire with the green connector to the compressor and connect it to the matching connector on the temperature probe. 4.2 Installing the Throttle Control 1. Bolt the throttle control under the dash, to the right of the steering column with the adjusting screws pointing downward (Figure 4.2). The mounting bracket acts as a ground for the control unit. This bracket must be fastened to a metal component under the dash, not a non-conductive part. Dashboard Frame Mounting Bracket Steering Column Throttle Control Unit Foot Pedal Assembly Figure Connecting the Wiring 22 Wiring schematic diagrams are provided in Figure and Figure Refer to the appropriate diagram when connecting the wiring. 1. Unplug the cable from the foot pedal assembly and connect it to the throttle control

23 2. Connect the throttle control cable to the foot pedal assembly. 3. Cut a short slit in the steering column boot on the right side of the column at the firewall and feed the pressure sensor cable, the large white wire with the blue bullet connector through the slit into the engine compartment. Leave the red and black wires inside the cab. Note the wire color for different model years. 4. On models, also feed the grey wire with the clear end (complete with plastic loom) into the engine compartment and route it to the green cam position (CMP) sensor wire (Figure 4.3). You will have to remove one of the relays to access the harness. 5. On models, also feed the small white wire without a connector (complete with plastic loom) into the engine compartment and route it to the green cam position (CMP) sensor wire (Figure 4.3). You will have to remove one of the relays to access the harness. 6. Connect the pressure sensor cable to the matching connector on the compressor pressure sensor. 7. Route the gray wire from the temperature sensor on the compressor along the engine and firewall and it to the matching green connector on the harness from the control unit. 8. Connect the white wire with the blue bullet connector to the matching connection at the compressor clutch.! The green CMP sensor wire is critical. The engine will not run without it connected properly. Follow this procedure carefully. 23

24 Green Wire (CMP Sensor Wire) Figure Cut and strip the green wire and slip the melting-liner shrink tube over one end of the wire. 10. Strip 1" of insulation from end of grey wire with the clear end or the small white wire and twist it together with both stripped ends of green wire. 11. Solder the joint using the supplied rosin core solder. Apply sufficient heat so that the solder fill flow through the twisted wire bundle. 12. Slide the shrink tube over the solder joint and shrink with a hot air gun until the meltable inner core extrudes slightly from each end (Figure 4.4. Do not overheat and be sure to protect the other nearby wires with a piece of cardboard or sheet metal. 24

25 13. Push the green wire and splice back into the OEM plastic loom, install loom over the connection and insert it into the slit in the OEM loom. Secure the looms with a nylon tie or electrical tape. Green wire Cardboard or metal heat protector Shrink tube over the soldered joint Grey wire with clear end or small white wire Figure Connect the white four-wire connector from the throttle control to the matching white plug on the cable from the control unit. Route the cable up over the steering column clear of all moving parts and secure it in place using nylon ties. 15. Locate the key-switched OEM power wire under the dash by following the wiring harness up from the diagnostic connector: white with a light blue stripe (Figure 4.5) blue with pink stripe (Figure 4.6) Dash Steering column White wire with a light blue stripe OEM ground OEM diagnostic connector Figure

26 Blue wire with a pink stripe Diagnostic connector Figure Attach the red wire from the throttle control to the appropriate power wire using the supplied butt connector Installing the Safety Switch! IF THE VEHICLE HAS AN AUTOMATIC TRANSMISSION, THE THROTTLE CONTROL MUST BE CONNECTED SO THAT IT WILL NOT FUNCTION UNLESS THE TRANSMISSION IS IN PARK OR NEUTRAL. FAILURE TO INSTALL AND VERIFY THE FUNCTION OF THIS SAFETY FEATURE CAN RESULT IN INJURY OR DEATH. IF YOU REQUIRE A SAFETY INTERCONNECT TO PERFORM THIS TASK, ORDER THE VMAC DRIVE DISABLE CIRCUIT. BE SURE TO PERFORM THE SAFETY TEST IN THE DDC INSTALLATION INSTRUCTIONS BEFORE PROCEEDING. 1. Apply the park brake and shift the transmission into the lowest forward gear. 2. Apply Blue Loctite 242 to the set-screw and mount the magnetic actuator to the transmission arm under the dash (Figure 4.7).! Do not pinch or damage the orange shift indicator harness during installation. 26

27 Mount close to the end of the arm Set screw Do not damage or pinch the orange cable Figure Mount the magnetic switch under the dash on the support near the transmission arm (Figure 4.8). Install and remove the screw for the magnetic switch bracket in the hole to tap threads in the hole. Transmission arm Mounting location Figure

28 4. Mount the switch bracket to the frame under the dash. Note the location of the rectangular washer, the hole is offset to provide more clearance (Figure 4.9). Rectangular washer with offset hole Figure Slide the bracket all the way to the right. Use a screwdriver to hand-tighten the screw as a socket will push the bracket to the left. 6. Shift the transmission back into park, being careful not to hit the switch. 7. Slide the switch to the magnet and align the two pieces. This alignment does not need to be perfect and the magnet and switch should not quite touch (Figure 4.10). Tighten the screw with a screwdriver. 28

29 Slide the switch over Transmission in park! Figure 4.10 To prevent damage to the switch, check the spacing between the magnet and switch while holding the shift lever as far past the PARK position as it will go. 8. Connect an Ohmmeter to the two black wires from the magnetic switch. In park, there should be less than 2 Ohms resistance. In all other gears, the resistance must be greater than 20 M-Ohms. 9. If you do not have an Ohmmeter, connect 12 volts to one wire and a test light probe to the other. The light should be on in park and off in all other gears.! Failure to properly install and verify the operation of the safety interconnect (DDC) can result in inadvertent vehicle movement during operation Automatic Transmission Vehicles 1. Connect the black DDC wire labeled Park Brake to the green with red stripe wire at the park brake (Figure 4.11). Solder and seal this connection. 2. Connect the remaining DDC wire to the black wire coming from the throttle control. 29

30 Green wire with a red stripe Figure Manual Transmission Vehicles 1. Locate the green with red stripe wire at the park brake switch. 2. Attach the black wire from the throttle control (with the female spade connector) to the black Park Brake jumper wire with a male connector on one end and a piggy-back connector on the other. Tape this connection. 3. Cut off the piggy-back connector and connect the black wire to the green with red stripe wire at the park brake switch. Solder and seal this connection Manual Transmission Vehicles 1. Locate the green with red stripe wire at the park brake switch. 2. Attach the black wire from the throttle control (with the female spade connector) to the black Park Brake jumper wire with a male connector on one end and a piggy-back connector on the other. Tape this connection. 30

31 3. Cut off the piggy-back connector and connect the black wire to the green with red stripe wire at the park brake switch. Solder and seal this connection Automatic Transmission Vehicles 1. Remove the OEM connector from the park brake switch. 2. Crimp the supplied piggy-back connector to the DDC black wire labeled Park Brake. 3. Route the wire to the vehicle park brake and connect the piggyback connector to the switch. 4. Connect the OEM connector to the piggy-back connector. 5. Connect the remaining DDC wire to the black wire coming from the throttle control Manual Transmission Vehicles 1. Remove the OEM connector from the park brake switch. 2. Attach the black wire from the throttle control (with the female spade connector) to the black Park Brake jumper wire with a male connector on one end and a piggy-back connector on the other. Tape this connection. 3. Route the wire to the vehicle park brake and connect the piggyback connector to the switch. 4. Connect the OEM connector to the piggy-back connector. 31

32 LEGEND XXXX WIRE XXXX LABEL XXXX OEM KEY SWITCHED 12 VOLTS ( WHT/LT BLU) ( BLU/PNK) IMPORTANT BOLT THROTTLE BRACKET TO TRUCK FRAME FOR GOOD GROUND 12 VOLTS RED GRY GRY W/ CLR END DDC GRY THROTTLE FIREWALL BULKHEAD PRESSURE SENSOR Control Box 4 PIN CONNECTOR (WHITE) AUTOMATIC TRANSMISSIONS ONLY BLK BLK BLACK WIRE INTERFACE CABLE OR THROTTLE DDC PARK BRAKE SEE MANUAL FOR CHANGE TRANS PARK BRAKE JUMPER IN 2003 MODEL YEAR STD. TRANS. ONLY NO DDC PARK BRAKE BLK 16GA WHT OEM PARK BRAKE WIRE ACCELERATOR PEDAL OEM HARNESS (UNPLUGGED FROM ACCELERATOR PEDAL) GREY TO DARK GREEN (CMP SENSOR) WIRE 3 PIN CONNECTOR (BLACK) TEMPERATURE PROBE 4 PIN CONNECTOR (GREEN) CLEAR END PRESSURE SENSOR INLET VALVE CLUTCH COMPRESSOR CLUTCH 16GA WHT CMP SENSOR CONNECTOR OEM GREEN WIRE CONNECTION POINT SOLDER & HEAT SHRINK HEAT SHIELD Figure to

33 LEGEND XXXX WIRE XXXX LABEL XXXX OEM KEY SWITCHED 12 VOLTS ( BLUE WITH PINK STRIPE) IMPORTANT BOLT THROTTLE BRACKET TO TRUCK FRAME FOR GOOD GROUND 12 VOLTS RED GRY WHITE DDC GRY THROTTLE 4 PIN CONNECTOR (WHITE) Control Box AUTOMATIC TRANSMISSIONS ONLY BLK BLK BLACK WIRE INTERFACE CABLE OR THROTTLE DDC PARK BRAKE TRANS PARK BRAKE JUMPER STD. TRANS. ONLY NO DDC BLK 16GA WHT OEM PARK BRAKE WIRE OEM HARNESS (UNPLUGGED FROM ACCELERATOR PEDAL) FIREWALL BULKHEAD PRESSURE SENSOR PARK BRAKE ACCELERATOR PEDAL GREY TO DARK GREEN (CMP SENSOR) WIRE 3 PIN CONNECTOR (BLACK) TEMPERATURE PROBE 4 PIN CONNECTOR (GREEN) CLEAR END PRESSURE SENSOR INLET VALVE CLUTCH COMPRESSOR CLUTCH 16GA WHT CMP SENSOR CONNECTOR OEM GREEN WIRE CONNECTION POINT SOLDER & HEAT SHRINK HEAT SHIELD Figure to

34 4.4 Completing and Testing the Installation 1. Check all wiring to ensure that it will not contact any hot or moving components and will not interfere with the operation of the vehicle. Secure all wiring with nylon ties and loom as required. 2. Install and connect the batteries Operational and Safety Test 1. Install a test tool into the tank outlet and close the ball valve. Place the automatic transmission in park or the standard transmission in neutral. Apply the park brake, start the engine and allow it to reach operating temperature. Check the compressor system for leaks and proper clearance. 2. Press the ON button on the control box. The compressor clutch will engage and engine speed will increase to 2200 RPM and then drop to 900 RPM. 3. With the wheels blocked and brake pedal firmly depressed, release the park brake. The compressor clutch will disengage and engine speed should return to base idle. The display on the control box should read Park Brake. Apply the park brake and press the ON button. Engine speed will increase to 2200 RPM and then drop to 900 RPM Automatic Transmission With the wheels blocked and brake pedal firmly depressed switch the transmission from Park to Reverse. The compressor clutch will disengage and engine speed will return to base idle. The display on the control box should read Park Brake. Place the gear selector in Park, apply the park brake and press the ON button. Engine speed will increase to 2200 RPM and then drop to 900 RPM. Repeat this test for all gear selector positions other than Park.! If the vehicle fails the test, check the wiring to make sure that all the connections are correct and secure. If you require additional assistance, contact your local VMAC dealer. Call or

35 4.4.2 Setup and Adjustments For setup instructions, see the appropriate section in the owner s manual Important Information Before starting the engine: check the compressor oil level check all installed parts to make sure that fasteners and fittings have been securely tightened make sure no parts contact hot or moving components on the vehicle check alignment of the belt with all pulleys and idlers make sure the bracket is seated correctly Read the Owner s Manual for setup procedures After starting the engine: operate the system with an air tool for at least 1/2 hour (1 hour preferred) road test the vehicle for approximately 14 miles (20 km) check all components once the engine is turned off and the system has cooled 35