Installation Manual for VMAC System V900083

Transcription

1 Installation Manual for VMAC System V Ford Triton 5.4L V8 E250-E350 Van General Information... 3 Before You Start... 3 Part 1: Preparing for Installation Preparing for Installation... 4 Part 2: Installing the Tank Assembling the Brackets and Tank Installing the Tank Assembly... 9 Part 3: Installing the Cooler, Bracket and Compressor Installing the Oil Cooler Installing the Main Bracket and Compressor Connecting the Hoses Completing the Installation Adding Oil to the System Part 4: Installing the Control Components Installing the Components Connecting the Under-hood Wiring Connecting the In-cab Wiring Completing and Testing the Installation Part 5: Finishing the Installation Before Starting the Engine Checklist After Starting the Engine Checklist Setup, Performance Testing and Adjustments System Identification and Warnings Auxiliary Air Receiver Accessory Products from VMAC

2 Document Installation Manual for VMAC System V Ford Triton 5.4L V8 E250-E350 Van Changes and Revisions Version Revision Details Revised by/date Approved Implemented 00 Original document IB 14 Dec 2004 BC 22 Dec 2004 Jan A Model year confirmation IB 10 Apr 2006 SM 10 Apr 2006 Apr 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 vans must follow standard shop practices. These instructions are a general guide for installing this system on standard production vans and do not contain information for installation on non-standard vans. 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 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 van. 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. If you have to move the tank, the lines may be too short. Measure the hose shortfall and order a Hose Extender Kit. The following table shows the color code used by VMAC to identify hose diameters. Hose Diameter 1/2 inch 5/8 inch 3/4 inch 1 inch Colour-Coded Label Blue Blue Green Green 3

4 Part 1: Preparing for Installation Preparation for installation is very important. Missing an item can cause problems in the installation or even damage to components. Check off each item as it is completed so that you do not miss any preparation steps. 1.1 Preparing for Installation Remove the inside engine cover. Remove the plastic air intake connector and air filter assembly. Disconnect the battery. Remove all plastic shields from under the engine. Drain the coolant. Remove the upper radiator hose and lower radiator hose from between the radiator and diverter (leave the diverter in place). Keep the lower radiator hose section if you intend to return the van to OEM condition. Remove the fan and the fan shroud together. Remove the OEM drive belt from the alternator pulley but leave the belt in position on the engine. Remove the alternator and move it over to the driver s side of the engine. Replace the existing M6 bolt that secures the front right-hand fuel rail to the intake with the supplied M6 x 20mm flat head socket bolt (Figure 1.1). Remove the electrical noise suppressor from the front passenger side cylinder head and remove the studded bolt. 4

5 Low profile bolt Figure 1.1 Remove the engine-to-drip rail ground strap connection from the engine. Remove the bolts holding the plastic wire harness retainer to the drip rail so that the harness can be moved out of the way during installation. Remove the oil fill tube and plug the opening on the valve cover. Remove the bolt holding the automatic transmission dipstick tube bracket to the intake manifold and bend the bracket up toward the center of the engine about 90 degrees. Disconnect the electrical harness from the sensor on the passenger side fuel rail and move it out of the way. Remove the vent hose from the passenger side valve cover and move it out of the way. Remove the 3/4 inch heater hose and the small hose from the front right spigot on the intake manifold. Remove the heater hose barb from the manifold intake. Keep the fitting if you intend to return the vehicle to OEM condition. 5

6 Apply sealant to the supplied 90 degree hose barb and press it into the heater hose coolant port (Figure 1.2). Make sure it is pressed all the way in to the shoulder on the fitting. 90 degree hose barb Intake Manifold Figure 1.2 Connect the small coolant hose to the fitting on the hose barb. Loosen the small bolt holding the slotted air conditioning line mount bracket to the heater box, move it all the way to the passenger side and tighten the bolt. Carefully push the vertical part of the air conditioning lines toward the passenger side of the van to provide clearance for the oil fill tube. Remove the bolts holding the sway-bar bushings on the frame and install the supplied spacer blocks and hex head bolts. Torque to specifications. Clean the inside of the OEM pulley and install the VR pulley, making sure that the pulley is sitting flush. Apply Loctite, install three M10 x 70mm bolts and flat washers and torque to specifications. 6

7 Part 2: Installing the Tank 2.1 Assembling the Brackets and Tank The tank (Figure 2.1) will mount to the passenger side frame rail behind the body mount (under the side doors). Note that the upper frame clip is different for the E250 and E350. Tank strap cable Tank strap mount Upper frame clip Lower frame clip Spacer C-clamp 5/16 nuts and washer 1/4 and 3/16 tubes 3/4 hose fitting 1/2 hose fitting Oil filter Figure 2.1 Place the tank on a work bench with the front (oil filter end) of the tank to your left and remove the oil filter. Remove the two 1/4 inch clamp bolts from the C-clamps. Expand the clamps slightly and slide them over the front of the tank. Position the front clamp approximately 4 inches from the filter end of the tank and the rear clamp approximately 4 inches from the back of the tank. 7

8 Place the two L-shaped tank strap mounts under the C-clamps with the right-angle ends facing you and hanging over the edge of the work bench. Apply Loctite and thread 5/16 x 1/2 inch bolts with flat washers into the bottom hole on each bracket, but do not tighten. Install the 1/4 inch clamp bolts into the C-clamps so that the heads of the bolts face toward you, apply Loctite and install the nuts but do not tighten. Rotate the tank so that the directional arrow on the end of the tank is parallel to the work bench and faces toward you. Apply Loctite and insert 5/16 x 1/2 inch bolts through the C- clamp and thread them into the mount brackets, but do not tighten. Install a 3/4 inch fitting (not supplied) in the back of the tank. Check tank alignment then tighten the C-clamp bolts. Slide the tank all the way down on the tank mount brackets (away from you) and tighten the mounting bolts. 8

9 3/16 tube 1/4 tube Figure Installing the Tank Assembly Insert the cable straps through the tubes of the upper frame clips. Note that the E250 and E350 use different upper clips. Pass the cable strap upper frame clips over the passenger side frame from the outside. Position the front strap about 16 inches back from the body mount and the second frame clip and cable strap approximately where the back tank mount will locate. Support the tank and L-bracket assembly in place on the outside of the frame between the cab mounts, with the short part of the L-bracket over the top of the frame. Route the cable straps through the grooves on the tank mount brackets, behind the steel lines and under the frame (Figure 2.3). Adjust the rear strap as necessary to line up with the tank mount bracket. 9

10 Install the spacers and tighten the nuts just enough to hold the tank in position with the front of the tank about 12 inches back from the body mount. E250 E350 Cable must fit in the grooves Tank not shown for clarity Figure 2.3 When the tank is correctly positioned, tighten the securing cable retaining nuts until the cables pull tight and snug around the frame. Do not over-tighten. Install a second 5/16 inch nut and tighten it securely against the first to act as a locknut. 10

11 Part 3: Installing the Cooler, Bracket and Compressor 3.1 Installing the Oil Cooler Insert the supplied cooler mounting bolts through the holes in the front body support brackets under the radiator. Place the cooler in position over the bolts, with the hoses and oil fittings facing to the rear of the van (Figure 3.1). Install the nylon locking nuts and tighten them securely. Loosen the hose clamps on the cooler end of the radiator hoses so that they can be adjusted and positioned. Install the end of the driver side hose onto the OEM diverter valve (lubricate the fitting or the hose to make installation easier). Position the hose for best fit and tighten the clamps. Install the passenger side hose on the radiator fitting, position the hose for best fit and tighten the clamps. Cooler to diverter hose Cooler to radiator hose Radiator support bracket Radiator support bracket Figure

12 3.2 Installing the Main Bracket and Compressor Remove the idler and tensioner pulleys from the main bracket (Figure 3.2). Do not remove the tensioner body. Tensioner Tensioner idler Main bracket Idler Figure 3.2 Back idler Place the bracket in position on the passenger side of the engine. Apply Loctite, insert two M10 x 25 mm socket head bolts through the bracket and down into the engine block holes under the alternator, but do not tighten. Apply Loctite, insert the M10 x 100 mm socket head bolt through the main bracket and thread it into the upper front hole on the right side cylinder head, but do not tighten. Apply Loctite, insert the M8 hex head bolt (with the 5/16 flat washer) through the lower front of the bracket and thread it into the timing cover next to the OEM belt tensioner, but do not tighten. Check all OEM wiring harnesses to make sure that they are not trapped by the bracket and are clear of the mounting points. 12

13 Position the bracket securely against the engine and lightly snug down all the fasteners. Tighten the two M10 x 25 mm socket head bolts, then the M10 x 100 mm socket head bolt and finally the M8 hex bolt, then torque to specifications in the same sequence. Install the alternator and the OEM belt. Relocate the electrical noise suppressor and the ground strap from the body to one of the rear alternator bracket mount bolts. Lift the cross-body electrical harness out of the way and place the compressor in position on the mounting bracket. Make sure that no wires are trapped by the compressor. Apply Loctite, thread the three M8 double-serrated nuts onto the compressor mounting studs and tighten. Apply Loctite and install the VR pulleys. Install the VR drive belt (Figure 3.3). Compressor Tensioner Back Idler Ribbed Idler Crank Pulley Figure

14 3.3 Connecting the Hoses Route the end of the 3/4 inch hose with the straight connector up from under the van into the engine compartment and connect it to the 90 degree fitting on the back of the compressor, but do not tighten. Route the hose along the top of the frame to the tank and connect it to the matching fitting on the tank. Tighten both ends. Connect the straight end of the longest 1/2 hose to the fitting on the tank, but do not tighten. Route the end with the 90 degree fitting along the top of the frame and attach it to the passenger side fitting on the oil cooler. Tighten both ends. Connect the 90 degree end of the shorter 1/2 inch hose to the driver s side fitting on the cooler. Route the hose across the front of the van and up to the fitting in the left side of the compressor. Tighten both ends. Insert the ¼ and 3/16 inch tubes into the fittings on the back of the tank and install high temperature loom around tubes. Route the tubes up and over the frame, over the side of the engine (clear of the exhaust manifold) and out the front. Connect them to the matching fittings on the inlet control valve. Secure all hoses away from sharp or hot surfaces and protect them at contact points with plastic split loom. Tie-wrap the hoses together and securely fasten them to the chassis and body. Fit the supplied P-clip over the 1/4 and 3/16 inch tubes and secure it to the threaded hole in the back of the passenger side cylinder head with the 10 x 20 mm bolt. Bend the P-clip as necessary to clear the engine cover. Install the fuel rail sensor connector and the vent tube. 14

15 3.4 Completing the Installation Reposition the wiring harnesses near the compressor so they are above the transmission dipstick tube. Fasten the two plastic wiring connectors away from the compressor and behind the air conditioning tubes with nylon ties. Make sure that no wires or harnesses are touching the body of the compressor. Fasten them out of the way as required. Install the bolts holding the OEM wire harness trough to the rain gutter on the body. Install the supplied transmission dipstick tube bracket between the body and harness trough above the dipstick tube and tighten all the bolts. Secure the dipstick tube to the bracket with the supplied clamp. Wrap heat protector around the oil fill tube and secure it with nylon ties. Remove the valve cover plug, fit the fill tube back onto the valve cover, release the clamp and bolt the hanger back into the original position. Tie the tube to the air conditioning lines to provide clearance from the compressor body. Fit the VR oil fill tube under the wire harness, over the engine oil fill and transmission dipstick tubes and attach it to the top of the compressor. Position it as required and tighten the fitting. Install the 3 inch piece of heater hose to the hose barb on the intake manifold and to one end of the supplied 90 degree plastic fitting, with the long end of the plastic fitting pointing upward. Route the 3/4 heater hose over the compressor and connect it to the 90 degree fitting. Position the hose and fittings to provide clearance and tighten the clamps. Install the fan and shroud together. Clip the lower hoses back onto the driver side of the shroud. Install the upper radiator hose and fill the cooling system with the recommended coolant. Replace the shrouds under the engine, install the air cleaner assembly and replace any other OEM parts removed in preparation for installation. 15

16 OEM hose Manifold fitting 3 hose with clamps Plastic barb Figure Adding Oil to the System! 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. Remove the plug from the fill tube and slowly pour oil into the inlet control valve using a funnel. Turn the center of the compressor clutch clockwise to speed the fill process. 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. Install the fill plug in the inlet control valve and tighten it securely.! Do not overfill the system. Overfilling the system with oil can flood the sight glass window and make the system appear empty. 16

17 FIREWALL FIREWALL Part 4: Installing the Control Components Clutch White Inlet valve Black 3 pin connector Compressor Green 4 pin connector Connect to OEM orange wire switched 12 volts Connect to OEM white with pink stripe CTO circuit 0648 Control Box Red Connect to green/red stripe wire at the park brake switch Black Red White White To ground Green Red DDC Black To ground Throttle Controller Connect to accelerator pedal OEM Connector from accelerator pedal Red White Interface Connector Connect Red White 17

18 4.1 Installing the Components Remove the driver-side step liner, the kick panel behind the park brake pedal and the dash trim panel from under the steering wheel. Remove the screws holding the data-link connector to the dash. Remove the six screws holding the under-dash cross-brace in place and remove the cross-brace. Mount the control box in a convenient location in the cab, positioned so that the wire harness will reach the air compressor. Route the wire harness along the trough in the bottom of the step well, behind the park brake and up under the dash. Use tape to hold the wires in position. Replace the step liner and the kick panel. Keep wires away from the park brake mechanism. Route wires clear of the steering column and pedals so they do not contact moving parts. Tie-wrap the throttle control box to a suitable location under the dash, away from moving parts and heat duct openings. Apply the park brake and shift the transmission into the lowest forward gear. Apply Loctite to the set-screw and mount the magnetic actuator to the transmission arm under the dash (Figure 4.1).! Do not pinch or damage the orange shift indicator wire during installation. 18

19 Mount close to the end of the arm Set screw Do not damage or pinch the orange cable Figure 4.1 Drill a 15/64 inch hole on the support under the dash near the transmission arm (Figure 4.2). Install and remove the bracket mounting screw to tap threads in the hole. Transmission arm Drill hole for mounting Figure

20 Mount the switch bracket to the frame under the dash. Note the location of the rectangular washer; the hole in the bracket is offset for adjustment (Figure 4.3). Rectangular washer with offset hole Figure 4.3 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. Shift the transmission back into park, being careful not to hit the switch. Loosen the screw, slide the switch toward the magnet and align the two pieces so that the magnet and switch are close together but do not touch (Figure 4.4). Tighten the screw with a screwdriver.! Check the spacing between the magnet and the switch while holding the shift lever as far past the PARK position as it will go to make sure they do not touch. 20

21 Slide the switch over Transmission in park Figure 4.4 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. 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.! An improperly operating safety interconnect (DDC) can result in inadvertent van movement during operation. 4.2 Connecting the Under-hood Wiring Drill a hole in the firewall or locate a suitable plug or grommet and pass the following wires into the engine compartment: small gray harness with the green connector small gray harness with the black connector white wire with a bullet connector white wire with no connector from the throttle controller 21

22 Route the white wire with the bullet connector and the two small gray harnesses to the compressor and connect them to the matching connectors. Cover the wires with plastic loom and secure them along the front of the van with nylon ties. Solder and seal the red wire from the inline fuse holder to the orange wire (circuit 49, 12 Volt ignition switched) in the 4-wire OEM connector located at the B-pillar (Figure 4.5). Orange wire B-pillar Figure 4.5 Solder and seal the white wire to the blunt-cut white with pink stripe wire just above the air intake ducting (Figure 4.6). It may have a tag that says CTO. Locate white with pink stripe wire in the harness behind this hose Air inlet ducting 22 Figure 4.6 Brake M/C

23 4.3 Connecting the In-cab Wiring Unplug the cable from the foot pedal assembly and connect it to the throttle control box. Connect the throttle control box cable to the foot pedal assembly. Connect the white four-wire interface connector to the matching white plug on the harness from the control box. Connect the green ground wires from the throttle control box and the interface connector to a fastener under the dash that has good metal contact and will provide a good ground. An OEM ground point is a good location. Connect the red wire from the interface connector to the red wire with the matching connector from the throttle control box. Solder and seal the black wire from the DDC to the green wire with the red stripe at the park brake. The preferred method is shown in Figure 4.7. Shrink sleeve OEM wire Soldered joint VR wire Figure 4.7 Connect the remaining black wire from the DDC to the black wire from the interface connector. 23

24 4.4 Completing and Testing the Installation Check all wiring to ensure that it will not contact any hot or moving components and will not interfere with the operation of the van. Secure all wiring with nylon ties and protect with split loom as required. Install and connect the batteries Safety Test Place the transmission in Park and apply the park brake. Turn the ignition key ON but do not start the engine. Check the control box to see if there is a number showing in the hour-meter. If there is no display, there is no power to the control box. Push the ON button on the control box. The green light will illuminate and the compressor clutch will engage. Release the Park brake. The green light will flash, Park Brake will show on the display and the compressor clutch will disengage. Apply the park brake. The green light will stop flashing and the compressor time will be displayed. After 20 seconds, press the ON button. The green light will illuminate and the compressor clutch will engage. On trucks up to 2005, shift into reverse from park. The green light will flash, Park Brake will be displayed and the compressor clutch will disengage. Shift back to park, wait 20 seconds and press the ON button. The green light will illuminate and the compressor clutch will engage. Repeat this test for all transmission selector positions. Turn the ignition key OFF.! If the van 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

25 Part 5: Finishing the Installation 5.1 Before Starting the Engine Checklist Make sure that the following have been completed: Check the coolant. Check the compressor oil level at the tank sight glass. Do a final inspection to make sure that everything has been completed and tightened. Perform a final belt alignment check. Check all wiring for security and protection. Make sure nothing is touching the compressor body. 5.2 After Starting the Engine Checklist Make sure that the following have been completed: Operate the system with an air tool for at least 1/2 hour (1 hour preferred). Road test the van for approximately 14 miles (20 km). Watch the underhood operation to make sure that belts rotate properly, pulleys rotate smoothly and nothing is rubbing or contacting hot parts. Check all components, connections and fasteners once the engine is turned off and the system has cooled. Check the coolant level after the engine has been operated. Check the compressor oil level after the engine has been shut down and the oil level has had time to stabilize. 25

26 5.3 Setup, Performance Testing and Adjustments This system has been adjusted at the factory for general operation. If your operation requires different settings, refer to the owner s manual for specific instructions on how to adjust the system. You can test the system operation using the tools that will be operated by the system or you can test operations sing an orifice in the outlet to simulate tool use (Figure 5.1). Figure Install the test tool in the tank outlet fitting. If you are using the VMAC test tool, use the correct orifice fitting (small hole for VR70, large hole for VR140). 2. Make sure that the ball valve is closed. 3. Place the transmission in park and fully apply the park brake. 4. Allow the engine to run until it is at operating temperature. 5. Operate the air compressor system until the oil is warm. 6. Observe the pressure gauge. Pressure should be approximately 150 psi. 7. Open the ball valve on the test tool and observe the engine tachometer. Engine speed should increase to about 1,800 to 2,200 RPM. 8. Close the air valve slowly to allow the system pressure to rise. 9. Once the system pressure is at maximum, slowly open the ball valve on the test tool until the pressure on the gauge begins to drop. Engine speed should start to increase when air pressure drops to approximately 140 PSI. 26

27 5.4 System Identification and Warnings The System Identification Number Plate must be attached to the van 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 to the top surface of the radiator support in front of the battery, then secure the plate with selftapping screws. System ID number plate Figure 5.2 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 van operators (Figure 5.3). 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 2. Check Drive Belt 3. Check for Leaks 1. Ensure Compressor is OFF 2. Ensure discharge valve is CLOSED 3. Ensure air system is discharged 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 ( ) 1. Allow engine to idle for 1 minute 2. Turn OFF compressor 3. Wait for system to discharge for 1 minute before restarting! WARNING Always allow system pressure to discharge before restarting Figure

28 5.5 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 (part # ) to prevent blow back from the auxiliary tank and to stop moisture from entering the VMAC tank (Figure 5.4). 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 Figure

29 Accessory Products from VMAC The following accessory products for your VR compressor system are available from VMAC. For more information or to order these products, call Eliminator Aftercooler Part Number A Removes up to 80% of moisture from compressed air. Quick installation, automatic drain and compact design Filter Regulator Lubricator Part Number A Removes lubricants, water and dirt from the air stream. Adds atomized tool oil to lubricate tools. Reduces pressure for longer tool life. Hose Reel Part Number A Secure, compact, retractable hose storage in a sturdy reel. Air Receiver Tank Part Number A Thirty-five gallon capacity in a compact tank, complete with fittings and a gauge. DE-ICING HEATER De-icer Kit Part Number A Insulated rope heater prevents freezing of lines and regulator. Service Kits VR hour Part Number A VR hour Part Number A VR hour Part Number A VR hour Part Number A Using OEM service products will extend the life of your system. Includes oil, filters, seals and O- rings. 200 hour and 400 hour service interval kits are available 29

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