Installation Manual for VMAC Throttle Commander

Transcription

1 Installation Manual for VMAC Throttle Commander T Ford 6.7 L Diesel Power Stroke and L / 6.8 L Gas F-250 F-550 Super Duty (SEIC)

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3 Installation Manual for VMAC Throttle Commander T Safety... 3 Warranty... 4 General Information... 5 Connecting the wiring... 6 Wiring Diagrams... 7 Installation Auxiliary Equipment Connection Adjusting the Throttle Commander Operating the Pendant Controls Troubleshooting Warranty Registration

4 Document: Changes and Revisions Revision Revision Details Revised by Checked by Eng. Tech. Mech. Elec. Additional Application Information Ford Super Duty F-250 F-550 (SEIC), 6.7 L Diesel Power Stroke Ford Super Duty F-250 F-550 (SEIC), 6.2 L and 6.8 L Gas. Implemented D ECN SAR MH N/A N/A N/A 5 Nov 2010 E ECN AH N/A SM RD N/A 4 Oct 2013 F ECN Include MY 2017 MSP N/A AJH GB AMG 6 Mar 2017 Registered Trademarks All trademarks mentioned in this manual are the property of their respective owners. Their use by VMAC is for identification of the manufacturers products only and does not imply any affiliation to, or endorsement of said companies. Ford, Power Stroke and Super Duty are registered trademarks of Ford Motor Company. 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 mechanical work. Any grinding, bending or restructuring operations for correct fit in modified vehicles must follow standard shop practices. Qual. Notice Copyright 2017 VMAC Global Technology Inc. All Rights Reserved. These materials are provided by VMAC for informational purposes only, without representation or warranty of any kind, and VMAC shall not be liable for errors or omissions with respect to the materials. The only warranties for VMAC products and services are those set forth in the express warranty statements accompanying such products and services, if any, and nothing herein shall be construed as constituting an additional warranty. You may print or copy for your personal use any whole page or pages in this document. All other use, copying or reproduction in both print and electronic form of any part of this document without the written consent of VMAC is prohibited. The information contained herein may be changed without prior notice. Printed in Canada 2

5 Safety Important Safety Notice The information contained in this manual is based on sound engineering principles, research, extensive field experience and technical information. Information is constantly changing with the addition of new models, assemblies and service techniques. If a discrepancy is noted in this manual, contact VMAC prior to initiating or proceeding with installation, service or repair. Current information may clarify the issue. Any person with knowledge of such discrepancies who performs any work-- assumes all risks. Only proven service procedures are recommended. Anyone who departs from the specific instructions provided in this manual must first assure that their safety and that of others is not being compromised and that there will be no adverse effects on performance or the operational safety of the equipment. VMAC will not be held responsible for any liability, consequential damages, injuries, loss or damage to individuals or to equipment as a result of the failure of any person to properly adhere to the procedures set out in this manual or standard safety practices. Safety should be your first consideration in performing service operations. If you have any questions concerning the procedures in this manual or require any more information on details that are not included in this manual, please contact VMAC before beginning repairs. Safety Messages This manual contains various warnings, cautions and notices that must be observed to reduce the risk of personal injury during installation, service or repair and the possibility that improper installation, service or repair may damage the equipment or render it unsafe. This symbol is used to call your attention to instructions concerning your personal safety. Watch for this symbol; it points out important safety precautions, it means, Attention, become alert! Your personal safety is involved. Read the message that follows and be alert to the possibility of personal injury or death. Be alert; your safety is involved. As it is impossible to warn about every conceivable hazard, let good common sense be your guide. This symbol is used to call your attention to instructions on a specific procedure that if not followed may damage or reduce the useful life of the compressor or other equipment. This symbol is used to call your attention to additional instructions or special emphasis on a specific procedure. 3

6 Warranty Limited Lifetime Warranty Effective 1 October The VMAC Compressor Assembly (excluding Inlet and Clutch, where applicable) is warranted against manufacturer defects in materials and workmanship for the lifetime of the Compressor Assembly. Restrictions apply refer to VMAC Warranty Policy and VMAC Limited Lifetime Warranty for full details. Standard Product Warranty For complete warranty information, including both our standard Product Warranty and Limited Lifetime Warranty requirements, please refer to our current published warranty located at: If you do not have access to a computer, please contact us and we will be happy to send you our warranty. VMAC s warranty policy is subject to change without notice. Warranty Registration The VMAC warranty form is located at the back of this manual. This warranty form must be completed and sent to VMAC at the time of installation for any subsequent warranty claim to be considered valid. There are 4 ways warranty forms can be submitted to VMAC: Online tech@vmacair.com Fax (250) Mail VMAC - Vehicle Mounted Air Compressors 1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3 4

7 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 vehicle. Identify variations for different engine models and different situations that are listed in the manual. Open the package, unpack the components and identify them. Ordering Parts 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 or online at 5

8 Connecting the wiring VMAC suggests not cutting OEM wires whenever practical. The preferred method is to remove the pin from the connector using an appropriate tool and slide the shrink tube onto the wire. Strip the wire at the desired location and solder the VMAC wire into place. Slide the shrink tube up to the soldered joint and seal it. Finally, replace the pin in the connector taking special care to ensure the pin is fully inserted and the locking tabs are engaged (Figure 1). If this is not practical, cut the OEM wire and solder and seal using shrink tube. Figure 1 - Splice onto OEM wire Keep wires away from the park brake mechanism. Route wires clear of the steering column and pedals so they do not contact moving parts. Before drilling holes, ensure that there are no OEM wires, hoses, or components in the way. Ensure all wires are protected and routed so that they do not contact hot, sharp or moving components. 6

9 Wiring Diagrams Figure 2 Stationary mode: Fixed Speed (1 or 2 speeds) 7

10 8 Figure 3 Stationary mode: Remote Pendant

11 Figure 4 Live Drive PTO mode 9

12 Figure 5 Split shaft mode: 1 or 2 speeds See bulletin Q-180R4 or Q-256 at for split-shaft mode operation and engagement procedure. 10

13 Figure 6 Split shaft mode: Remote Pendant See bulletin Q-180R4 or Q-256 at for split-shaft mode operation and engagement procedure. 11

14 Installation Preparation for installation is very important. Missing a step or an item can cause problems in the installation or damage to components. Check off each item as it is completed so that you do not miss any steps. Do not use a test light to probe for power on vehicle circuits, the increased current draw of the test light may damage components. Complete the warranty form. The VMAC warranty form is located at the back of this manual, as well as online at: The VMAC warranty form must be completed and returned to VMAC at the time of installation for any subsequent warranty claim to be considered valid. Disconnect the vehicle battery(ies). Determine which wiring diagram is applicable. Installing the Throttle Commander Module 2017+: Remove the kick panel in the passenger side foot well and using cable ties, secure the Throttle Commander module behind the kick panel or under the passenger side dashboard. The SEIC interface connector can be disconnected for ease of access when making the connections : Remove the dashboard panel below the steering column and using cable ties secure the Throttle Commander module under the dashboard. Connecting the Wiring Connect the wires as per the applicable wiring diagram. Note the differences in connections between Diesel and Gas vehicles. Note the pin numbers of each wire. There are multiple instances of yellow/green wires on the connector. Ensure the correct one is selected by verifying pin numbers. PTO REF LE424 (Pin 18) 18 7 PTO REQ CE912 (Pin 7) 12 Figure SEIC interface connector

15 On early builds the PTO REQUEST 2 may be a blue wire with grey stripe. There will be 2 wires with this colour. Measure the resistance to ground in all gears. The Park-Only wire will show low resistance in PARK and high resistance in all other positions. The other blue wire with grey stripe is PTO REQUEST 2. Locate the SEIC blunt cut wire bundle (Figure 8). SEIC blunt cut wires Figure SEIC blunt cut wire bundle location Verify that circuit CDC64 (yellow wire with orange stripe or white wire with blue stripe on earlier builds) is used for the key switched +12 V by measuring the voltage. Voltage should be + 12 V with the ignition switched on and 0 V with the ignition switched off. Connect the wires as indicated in the applicable wiring diagram. Remote Pendant Connections Route the remote pendant cable into the cab through a suitable opening. Connect the 5 coloured wires on the pendant cable to the matching coloured wires in the heavy cable from the Throttle Commander module. Ensure the bullet connectors are pushed together securely to make a good connection. 13

16 Completing and Testing the Installation The Throttle Commander has 2 speed settings. Engine speed is determined by providing battery power to the red or purple wires. The default settings are: Speed Selection Red wire Purple wire Factory setting Off 0 Volts 0 Volts 0 rpm Speed 1 12 Volts 0 Volts 1,250 rpm Speed 2 0 Volts 12 Volts 1,800 rpm Table 1 Factory rpm settings Confirm all wiring is clear of any hot, sharp or moving components and that it will not interfere with the operation of the vehicle. Secure all wiring with cable ties and protective loom as required. Connect the battery(ies). Place the vehicle in a safe operating position and block the wheels. Ensure there are no people near the vehicle before beginning the test. Temporarily route an 18 AWG test wire from the positive battery terminal into the cab; this wire will be used for the operational and safety tests. Place the transmission in PARK and engage the park brake. Start the vehicle engine and wait for the engine speed to stabilize and for the engine temperature to reach its normal operating range. Momentarily activate the throttle by connecting the temporary wire from the positive battery post to either the red SPEED 1 or the purple SPEED 2 wire (located in the same bundle as the yellow power wire); the engine speed should increase. Firmly depress the service brake and hold it down. Release the park brake and momentarily activate the throttle as before; the engine speed should not increase. Disconnect the test wire. Apply the park brake and with the service brake firmly depressed, shift the transmission into REVERSE. Momentarily activate the throttle as before; the engine speed should not increase. Disconnect the test wire. Shift the transmission back to PARK. Repeat the test in all gears. Shift the transmission into PARK and shut down the engine. If the vehicle fails this test, check the wiring connections. If additional assistance is required, contact a local VMAC dealer or VMAC technical support at or Local VMAC dealers can be found via our online dealer locator: 14

17 Auxiliary Equipment Connection The methods for connecting single or two speed configurations are shown in Figure 9 (switched) and Figure 10 (relayed). Single Speed Control Connect the red wire from the Throttle Commander module to a suitable ignition activated switch capable of supplying 12 V. VMAC recommends that the power supply wire to the switch is a minimum 18 AWG. Install a 1 A inline fuse between the switch and the red wire. Terminate the purple wire and coil it neatly out of the way to ensure that it cannot cause a short. Multiple Speed Control Connect the red wire as described in the single speed control instructions above. Connect the purple wire from the Throttle Commander module to a separate suitable ignition activated switch capable of supplying 12 V. VMAC recommends that the power supply wire to the switch is a minimum 18 AWG. Install a 1 A inline fuse between the switch and the wire. Figure 9 Auxiliary equipment connection (switched) 15

18 Figure 10 Auxiliary equipment connection (relayed) 16

19 Adjusting the Throttle Commander Ensure the switches or equipment supplying power to the Throttle Commander are turned off. Start the vehicle engine and allow it to reach normal operating temperature. Engine speed is adjusted by turning the screws on the Throttle Commander module. To increase engine speed, turn the screw clockwise, to decrease the engine speed turn the screw counterclockwise. To adjust SPEED 1, activate the Throttle Commander using the switch that is connected to the red wire. Adjust the rpm by turning the RPM 1 screw. To adjust SPEED2, activate the Throttle Commander using the switch that is connected to the purple wire. Adjust the rpm by turning the RPM 2 screw. Do not use the park brake or the transmission as an ON / OFF switch. The Throttle Commander must be turned OFF when the engine is not running. Do not reactivate the Throttle Commander until the engine has been started and the vehicle rpm has stabilized. 17

20 Operating the Pendant Controls Turning the Throttle On Ensure the RPM knob is rotated all of the way counterclockwise before switching the Throttle Commander ON. With the park brake fully engaged, the engine running and the vehicle in PARK, turn the Throttle Commander switch on the remote pendant to ON. Slowly rotate the RPM knob clockwise until the engine is at the desired speed. Turning the Throttle Off Rotate the RPM knob all of the way counterclockwise. Turn the switch on the remote pendant to OFF. Shut down the engine. 18

21 Troubleshooting Enable/Disable Conditions for SEIC Operation Conditions that disable Conditions that enable SEIC SEIC (all required) (any one required) SEI C Live Drive Park brake applied Park brake released Yes No Foot off of service brake Service brake depressed Yes No Vehicle in park Vehicle taken out of park Yes No Foot off of accelerator pedal Yes No Vehicle is stationary (0 mph) Yes No Engine at a stable base idle speed Yes No Transmission oil temperature above 20 F Engine coolant temperature 140 F min. (If built before 11/05/10) or 120 F (if built after 11/05/10) Transmission Oil Temperature Limit exceeds 240 F Engine Coolant Temperature exceeds 234 F Yes Yes Yes Yes Catalyst Temperature Limit Yes Yes Refer to Ford s latest revision of SVE Bulletin Q-180 or Q-256 at for further SEIC / PTO operation details. If additional assistance is required, contact a local VMAC dealer or VMAC technical support at or Local VMAC dealers can be found via our online dealer locator: 19

22 Warranty Registration This form must be fully completed and returned to VMAC at the time of installation. Warranty may be void if this form is not received by VMAC within 30 days of installation. VMAC s Warranty policy and registration can be viewed online at: VMAC Dealer Information Company Name: City: Installer Information State / Province: Company Name: City: State / Province: Installation Date: / / Day Month Year Owner Information Company Name: Address: City: State / Province: Zip/Postal: Phone #: ( ) - Address: Vehicle Information Year: Make: Vehicle Identification Number: Unit #: Product Information Throttle Commander Serial Number: T 20

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