Illustrated Parts List for VMAC System V910006 FORD 6.0L POWERSTROKE DIESEL F250-F550 SUPERDUTY 2003.25-2007 WODA, W/WOAC 1. Kit Pack List... 2 2. Fastener Pack, 3800421... 4 3. Compressor Assembly, P140038... 8 4. Compressor Sub Components, P140037... 9 5. Inlet Valve Sub Components, 9210038... 11 6. Tank, VR150, 9210050... 12 7. Main Bracket Assembly, 4800432... 14 8. Remote Idler Assembly, 4800385... 15 9. Remote Idler Assembly, 4800386... 15 10. Tank Bracket Assembly Rear, 4800516... 16 11. Tank Bracket Assembly Front, 4800517... 17 12. Spigot Assembly, 4800340... 18 13. Adaptor Kit, 2003.25-2004 Model Year, A910001... 18 14. Cooler Assembly, 4800415... 19 15. Adaptor Kit, 2005-2007 Model Year, A910002... 20 16. Cooler Assembly, 4800438... 21 Document 1930116 - Changes and Revisions Revision Revised Version Details by/date Approved by/date Implemented I ECN 08-038 SL 4 Mar 2008 SH 14 May 2008 14 May 2008 J ECN 08-074 SL 24 July 2008 TG 24 Jul 2008 25 July 2008 K ECN 10-112 SAR 14 Oct 2010 NC 14 Oct 2010 18 Oct 2010 L ECN 10-118 SAR 22 Nov 2010 NC 22 Nov 2010 30 Nov 2010 M ECN 11-050 SH 4 Apr2011 SM 21 Apr 2011 27 Apr 2011 N ECN 11-061 SH 8 Jun 2011 SH 12 Sep 2011 13 Sep 2011 P ECN 15-144 CJH 22 Apr 2016 KM/GB 12 May 2016 01 Jun 2016 R ECN 17-110 CJH 18 Sep 2017 BOJ/RB/AWG 20 Sep 2017 08 Nov 2017 Fax: 1-250-740-3201 Page 1 of 23
1. Kit Pack List 1 1200299 1 CLIP, TANK MOUNT 2 1200348 1 BRACKET, GLOW-PLUG 3 1200392 1 BRACKET, ALTERNATOR, BRACE 4 1200393 1 BRACKET, BATTERY, MOUNT 5 1200407 1 BRACKET 6 1200465 1 BRACKET, FAN MOUNTING 7 1200490 1 BRACKET, VACUUM TANK 8 1620352 1 BELT, K081000 9 1700545 1 ELBOW, SILICONE, 90 DEG, 3 1/4 ID 10 1710674 1 HOSE, HEATER 3/4" X 106" (1700177) 11 1720621 1 TUBE, HEATER RETURN 12 1752053 1 HOSE, CRIMPED, 1/2" X 53" 13 1752088 1 HOSE, CRIMPED, 1/2" X 88" 14 1781050 1 HOSE, CRIMPED, 1" X 50" 15 1800184 1 PULLEY CRANK, FORD 6.0L, VR150 16 1930048 1 MANUAL, INSTALLATION, V910006 17 1930060 1 MANUAL, OWNERS GENERIC, VR70 & 150 18 1930116 1 ILLUSTRATED PARTS LIST 19 2200149 2 CLAMP, MOUNTING BRACKET 20 3550677 1 INTERFACE CABLE 21 3550723 1 CONTROL BOX, VR 22 3800421 1 FASTENER PACK 23 4800340 1 SPIGOT ASSEMBLY 24 4800385 1 ASSEMBLY, IDLER 25 4800386 1 ASSEMBLY, IDLER, BRACE 26 4800516 1 ASSEMBLY, TANK BRACKET REAR 27 4800517 1 ASSEMBLY, TANK BRACKET FRONT 28 4800483 1 SYSTEM OPERATION INSTRUCTION & ID 29 4800432 1 ASSEMBLY, MAIN BRACKET 30 4800479 1 ASSY, TUBE, INTERCOOLER 31 9210050 1 TANK, VR150 DRESSED 32 A700091 1 OIL, VR, 1L, HIGH PERFORMANCE 33 A700094 2 OIL, VR, 4L, HIGH PERFORMANCE 34 P140038 1 COMPRESSOR ASSEMBLY Page 2 of 23 Fax: 1-250-740-3201
Figure 1 - Kit Pack List (not to scale) Fax: 1-250-740-3201 Page 3 of 23
2. Fastener Pack, 3800421 1 3800369 1 FASTENER PACK, MAIN BRACKET 1.1 1520538 1 BOLT, HHCS, FLHD, M10 X 1.50 X 35 1.2 1520540 3 BOLT, HHCS, FLHD, M10 X 1.50 X 55 2 3800370 1 FASTENER PACK, FAN SHROUD &GLO PLG RELAY 2.1 1500449 4 SCREW,PAN PHILLIPS 8 X 1 SMS(18.8) 3 3800423 1 FASTENER PACK, BATTERY MOUNT 3.1 1520147 3 BOLT, HHCS G8.8,M8 X 1.25 X 20 FULL 3.2 1560407 1 NUT, NYLOCK, M8 3.3 1570067 3 WASHER, SAE, 5/16 4 3800424 1 FASTENER PACK, CRANK PULLEY 4.1 1520011 3 BOLT, HHCS G10.9, M10 X 1.5 X 90 4.2 1570044 3 WASHER, ALLOY PL SAE, 3/8 4.3 3400055 1 SPACER, FAN 5 3800425 1 FASTENER PACK, INTERCOOLER TUBE 5.1 1200399 1 BRACKET, INTERCOOLER SUPPORT 5.2 1510028 1 BOLT, HHCS NC G8 PL, 1/4 X 3/4 5.3 1550029 1 NUT, NYLOCK NC, 1/4 5.4 1570038 2 WASHER, FLAT SAE, 1/4 5.5 2200018 8 TIE, NYLON MD, 11 5.6 2200049 4 TIE, NYLON MD, 14" 5.7 2200153 2 CLAMP, 3 3/4 5.8 2200161 1 CLAMP, MODIFIED 6 3800429 1 FASTENER PACK, COOLER 6.1 2200048 4 CLAMP, HOSE HS12 6.2 5300043 1 CONNECTOR, TEE NYLON, 3/4 7 3800437 1 FASTENER PACK, REMOTE IDLER 7.1 1520013 1 BOLT, HHCS G10.9, M10 X 1.5 X 35 7.2 1570044 1 WASHER, ALLOY PL SAE, 3/8 8 3800443 1 FASTENER PACK, TRANSMISSION DIPSTICK 8.1 1510520 1 BOLT, HHCS NC FL LK, 1/4 X 1 1/4 8.2 1550221 1 NUT, HEX NC PL, 1/4, GR8 8.3 1570067 1 WASHER, SAE, 5/16 Page 4 of 23 Fax: 1-250-740-3201
Figure 2 Fastener Packs Fax: 1-250-740-3201 Page 5 of 23
Fastener Pack, 3800421 (Continued) 9 3800604 1 FASTENER PACK, ICP SENSOR 9.1 4900118 1 FITTING, BANJO, MODIFIED 9.2 5800098 1 GROMMET, RUBBER 10 3800480 1 FASTENER PACK, WATER PUMP 10.1 1540389 4 BOLT, SHCS, M8 X 1.25 X 18, LOW PRO 11 3800509 1 FASTENER PACK, COMPRESSOR 11.1 1400230 1 SPACER 11.2 1400231 1 SPACER 11.3 1520557 1 BOLT,FLAT HEAD SOCKET,M10 X 1.5 X50 11.4 1540316 1 BOLT, SHCS, M8 X 1.25 X 140 11.5 1540521 2 BOLT, SHCS, M8 X 1.25 X 110 12 3800537 1 FASTENER PACK, HEATER RETURN 12.1 1510028 1 BOLT, HHCS NC G8 PL, 1/4 X 3/4 12.2 2200002 2 CLAMP, HOSE MH-10 13 3800538 1 FASTENER PACK, FAN WIRING HARNESS 13.1 1560407 1 NUT, NYLOCK, M8 13.2 2200047 1 CLAMP, HOSE, HS16 14 3800556 1 FASTENER PACK, F450-F550 REAR TANK BRKT 14.1 1400229 1 SPACER 14.2 1400272 2 SPACER 14.3 1400273 1 SPACER 14.4 1510003 2 BOLT, HHCS NC G8 PL, 5/16 X 1 14.5 1510182 2 BOLT, HHCS NC G8 PL, 5/16 X 1 1/4 14.6 1570067 4 WASHER, SAE, 5/16 15 3800559 1 FASTENER PACK, VAC TANK 15.1 1710638 1 HOSE, VACUUM TANK 12" (1700551) 15.2 1710705 1 HOSE, VACUUM SWITCH 8" (1700551) 15.3 2200160 1 CLAMP, 3.5 ID, ACCUSEAL 16 3800678 1 FASTENER PACK HOSE 16.1 1700570 131.5 TUBE, TEFLON, PTFE,1/4"OD X 3/16"ID 16.2 1700571 103 TUBE, TEFLON,PTFE, 3/16"OD X 1/8"ID 16.3 1700581 131.5 LOOM, SPLIT PLASTIC, 1/4, HIGH TEMP 16.4 1700581 103 LOOM, SPLIT PLASTIC, 1/4, HIGH TEMP 16.5 2200039 10 TIE, NYLON MD, 7" Page 6 of 23 Fax: 1-250-740-3201
Figure 3 Fastener Packs (Continued) Fax: 1-250-740-3201 Page 7 of 23
3. Compressor Assembly, P140038 1 5830004 2 O-RING, VITON, 3 1/8 ID X 1/8 2 3200312 1 ADAPTOR, INLET VALVE 3 1540526 4 BOLT, SHCS, M8 X 1.25 X 20 4 5000020 1 ELBOW, BRASS NPT-POLY, 1/8-1/4 5 9200395 1 INLET VALVE INT. REG.SHORT MACHINED 6 4300076 1 PIPE FTG, PLUG SKT HEAD, 1/8 7 3500288 1 SENSOR, PRESSURE 8 1540550 2 BOLT,SHCS,M8 X 1.25 X 50, G12.9 PLT 9 5000112 1 ELBOW, BRASS STREET 45 DEG, 1/8 10 1540530 2 BOLT,SHCS,M8 X 1.25 X 55, G12.9 PLT 11 5000162 1 CONNECT,BRASS NPT-POLY,3/16-1/8 NPT 12 P140037 1 COMPRESSOR, ALUMINUM, 150 13 5830103 1 O-RING, VITON, 5/8 ID X 3/32 14 4900203 1 CONN, STEEL, 90, #8 MJIC - #8 MORB Page 8 of 23 Fax: 1-250-740-3201
Figure 4 Compressor Assembly 4. Compressor Sub Components, P140037 Fax: 1-250-740-3201 Page 9 of 23
1 3550682 1 TEMPERATURE PROBE 2 P200050 1 CLUTCH,REPLACEMENT,8 GROOVE,175FTLB 2.1 P200049 1 CLUTCH, COMPLETE,8 GROOVE, 175FT LB 2.2 3801129 1 FASTENER PACK, VR150 CLUTCH 2.2.1 1510064 1 BOLT, HHCS NF G8 PL, 5/16 X 1 1/4 2.2.2 1570476 1 WASHER, 5/16 ID X 3/4 OD 2.2.3 1500689 3 SCREW,BHSC,PL,M6X1X8MM 2.2.4 1570038 4 WASHER, FLAT SAE, 1/4 2.2.5 1520646 1 BOLT, HHCS G10.9, M6 X 1 X 10 FL PL Figure 5 Compressor Sub Components Page 10 of 23 Fax: 1-250-740-3201
5. Inlet Valve Sub Components, 9210038 1 1400200 1 SPACER 2 1500077 4 SCREW, BUTTON HEAD, 10-32 X 3/8 3 1500532 1 ROD, THREADED, 1/4 X 5.62" 4 1550029 1 NUT, NYLOCK NC, 1/4 5 1550514 1 NUT, FLANGE TORQ LOCK NC, 1/4-20 6 1570038 1 WASHER, FLAT SAE, 1/4 7 3200288 1 PLATE, INNER FILTER 8 3600046 1 KIT, REGULATOR 9 3600068 1 CAP, FILTER 10 3600072 1 ELEMENT, FILTER, PAPER 11 4900045 1 PLUG, STEEL HEX SAE/O-RING PORT 12 5830002 1 O-RING, VITON, 2 3/8 ID X 3/32 13 5830043 1 O-RING, VITON, 1 7/8 ID X 1/8 14 5830070 1 O-RING, VITON, 2 9/16 ID X 3/32 (4X) 2 10 1 7 14 11 5 3 9 13 4 6 12 8 Shown for reference only Figure 6 Inlet Valve Sub Components Fax: 1-250-740-3201 Page 11 of 23
6. Tank, VR150, 9210050 1 9210040 1 TANK, WELDMENT, VR150 2 4100358 1 COALESCER SPRING PLATE 3 5840068 1 SPRING, COMPRESSION, 2.187 OD X 5 4 3600071 1 ELEMENT, SEP, COALESCING 5 5830123 1 O-RING, VITON, 7 ID X 1/8 6 3600075 1 SEAL, TANK REAR CAP 7 9210028 1 CAP, BLOWDOWN VR150 7.1 3200226 1 BLOWDOWN CAP, VR150 7.2 4500104 1 MUFFLER, SINTERED EXHAUST, 1/8" 7.3 3600073 1 VALVE, SAFETY, 3/8, 200 PSI 8 5000165 1 ELBOW,90, BRASS NPT-POLY, 1/8-3/16 9 5000020 1 ELBOW, BRASS NPT-POLY, 1/8-1/4 10 1570009 6 WASHER, SPLIT LOCK, 3/8 11 1510016 6 BOLT, HHCS NC G8 PL, 3/8 X 1 1/2 12 5840069 1 SPRING, COMPRESSION, FL 1.5",OD.54 13 3600090 1 THIMBLE, SCREEN 14 4900106 1 PLUG, STEEL, #5 ORB, HEX (VITON-O) 15 4900035 1 NIPPLE, STEEL STR THRD, 3/4-16 16 9200039 1 OIL FILTER, VR 3.250 SHORT 17 4900200 1 CONN, STRAIGHT, #8 MORB X #8 MJIC 18 4900104 1 CONNECTOR, STEEL, #16 ORB - #16 JIC 19 1520646 2 BOLT, HHCS G10.9, M6 X 1 X 10 FL PL 20 5800142 1 COVER, SIGHT GLASS 21 A700061 1 PYREX WINDOW KIT Page 12 of 23 Fax: 1-250-740-3201
Figure 7 VR150 Tank Fax: 1-250-740-3201 Page 13 of 23
7. Main Bracket Assembly, 4800432 1 1100167 1 BRACKET, MAIN 2 1200391 1 BRACKET, IDLER MOUNT 3 1300010 1 IDLER, SERP 8 RIB BACK STEEL 4 1300023 1 IDLER, PULLEY 8 RIB, 3 5 1400051 2 SPACER, IDLER - BOLT 6 1510161 2 BOLT, HHCS NC G8 FL, 1/2 X 1 1/4 7 1520210 1 BOLT, HHCS G10.9, M10 X 1.5 X 80 8 1520556 3 BOLT,HHCS G10.9,M8X1.25X25 FULL,PLT 9 3300026 1 TENSIONER 1 2X 2X 6 5 4 3 3X 8 2 7 9 Figure 8 Main Bracket Assembly Page 14 of 23 Fax: 1-250-740-3201
8. Remote Idler Assembly, 4800385 1 1300023 1 IDLER, PULLEY 8 RIB, 3 2 1400215 1 SPACER, IDLER 3 1400227 1 STUB, IDLER 4 1520536 1 BOLT, HHCS G10.9, M10 X 1.5 X 135 1 3 2 4 Figure 9 Remote Idler Assembly 9. Remote Idler Assembly, 4800386 1 1200389 1 POST, IDLER ASSEMBLY 2 1300023 1 IDLER, PULLEY 8 RIB, 3 3 1400215 1 SPACER, IDLER 4 1520536 1 BOLT, HHCS G10.9, M10 X 1.5 X 135 1 2 3 4 Figure 10 Remote Idler Assembly Fax: 1-250-740-3201 Page 15 of 23
10. Tank Bracket Assembly Rear, 4800516 1 1200266 1 BRACKET, TANK MOUNT CLIP 2 1200296 1 BRACKET, TANK MOUNT 3 1200388 1 BRACKET, TANK, REAR 4 1400229 1 SPACER 5 1510349 4 BOLT, HHCS NC G8 PL, 5/16 X 1/2 6 1550066 2 NUT, HEX NC, 5/16 7 1570067 4 WASHER, SAE, 5/16 8 1570476 1 WASHER, 5/16 ID X 3/4 OD 9 2200169 1 STRAP, TANK CABLE, 17.5" 3 9 2 2X 6 4 8 1 4X 5 4X 7 Figure 11 Tank Bracket Assembly Rear Page 16 of 23 Fax: 1-250-740-3201
11. Tank Bracket Assembly Front, 4800517 1 1200266 1 BRACKET, TANK MOUNT CLIP 2 1200296 1 BRACKET, TANK MOUNT 3 1200387 1 BRACKET, TANK, FRONT 4 1400229 1 SPACER 5 1510349 4 BOLT, HHCS NC G8 PL, 5/16 X 1/2 6 1550066 2 NUT, HEX NC, 5/16 7 1570067 4 WASHER, SAE, 5/16 8 1570476 1 WASHER, 5/16 ID X 3/4 OD 9 2200169 1 STRAP, TANK CABLE, 17.5" 3 9 2 4 8 6 2X 1 4X 5 4X 7 Figure 12 Tank Bracket Assembly Front Fax: 1-250-740-3201 Page 17 of 23
12. Spigot Assembly, 4800340 1 1200352 1 PLATE, DRILLED 2 1500540 1 RING, RETAINING, EXT.875 3 3200243 1 ADAPTOR, HOSE Figure 13 Spigot Assembly 13. Adaptor Kit, 2003.25-2004 Model Year, A910001 1 3550679 1 DDC, FORD 2003-2004 2 3560087 1 THROTTLE CONTROL 3 4800415 1 ASSEMBLY, COOLER 1 2 3 Not to scale See Assembly Figure 14 Adaptor Kit, 2003.25-2004 Model Year Page 18 of 23 Fax: 1-250-740-3201
14. Cooler Assembly, 4800415 1 1200381 2 BRACKET, COOLER 2 1520011 2 BOLT, HHCS G10.9, M10 X 1.5 X 90 3 1570044 6 WASHER, ALLOY PL SAE, 3/8 4 1520129 2 BOLT, HHCS G10.9, M10 X 1.5 X 110 5 1560037 2 NUT, PL, M10 X 1.5 6 1710630 1 HOSE, RAD, MODIFIED 7 2200027 2 CLAMP, HOSE HS32 8 5000016 1 CONNECTOR, BRASS HOSE BARB, 3/4-3/4 9 9210099 1 COOLER 1 3 2 4 2X 6X 9 2X 8 6 7 2X 5 2X Figure 15 Cooler Assembly Fax: 1-250-740-3201 Page 19 of 23
15. Adaptor Kit, 2005-2007 Model Year, A910002 1 3560092 1 THROTTLE CONTROL 2 4800438 1 ASSEMBLY, COOLER 2 See Assembly 1 Figure 16 Adaptor Kit, 2005-2007 Model Year Page 20 of 23 Fax: 1-250-740-3201
16. Cooler Assembly, 4800438 1 1200451 2 BRACKET, COOLER 2 1400225 2 SPACER, 3 1520011 2 BOLT, HHCS G10.9, M10 X 1.5 X 90 4 1560037 2 NUT, PL M10 X 1.5 5 1570044 6 WASHER, ALLOY PL SAE, 3/8 6 1520129 2 BOLT, HHCS G10.9, M10 X 1.5 X 110 7 1710700 1 HOSE, MODIFIED (1700559) 8 2200027 2 CLAMP, HOSE HS32 9 5000016 1 CONNECTOR, BRASS HOSE BARB, 3/4-3/4 10 9210104 1 COOLER 9 6 2X 6X 5 10 2X 1 2X 3 2X 8 7 2 2X 4 2X Figure 17 Cooler Assembly Fax: 1-250-740-3201 Page 21 of 23
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