Vmac VR70 Manuale utente

System V900075

1999 - 2003.25 Ford F-250 - F-550 Super Duty

7.3L Power Stroke Diesel

www.vmacair.com

VR70 UNDERHOOD

AIR COMPRESSOR

INSTALLATION MANUAL

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 1

Installation Manual for VMAC

System V900075

Ford 1999 – 2003.25

7.3L Power Stroke Diesel

F250-F550 Super Duty

General Information..................................................................... 3

Before You Start....................................................................... 3

Special Installation Notes......................................................... 4

Part 1: Preparing for Installation............................................... 6

1.1 Preparing for Installation .................................................... 6

Part 2: Installing the Tank and Hoses....................................... 9

2.1 Installing the Tank and Frame Mounts............................... 9

2.2 Attaching Hoses to the Tank.............................................. 14

Part 3: Installing the Main Bracket and Compressor.............. 15

3.1 Oil Cooler Installation Exceptions....................................... 15

3.2 Installing the Oil Cooler...................................................... 15

3.3 Installing the Pulley and Bracket........................................ 16

3.4 Installing the Compressor................................................... 18

3.5 Adding Oil to the System.................................................... 20

Part 4: Installing the Control Components .............................. 21

4.1 Installing the Control Unit................................................... 21

4.2 Installing the Throttle Control ............................................. 22

4.3 Connecting the Wiring........................................................ 22

4.4 Completing and Testing the Installation............................. 34

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

Installation Manual - Document #1930058

Installation Manual for VMAC System V900075

Ford 1999-2003.25 7.3 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 2004 18 Mar 2004

A Revisions IB 18 June 2006 SM 20 June 2006 22 June 2006

B ECN 07-145 IB 05 Nov 2007 SH 23 Nov 2007 26 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 1-800-738-8622.

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

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 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) 9 18 35 55 80 110 170 280

Newton meter (N•m) 12 24 47 74 108 149 230 379

STANDARD GRADE 8 NATIONAL FINE THREAD

Size 3/8 7/16 1/2 5/8 ¾

Foot-pounds (ft-lb) 40 60 90 180 320

Newton meter (N•m) 54 81 122 244 434

METRIC CLASS 10.9

Size M8 M10 M12 M14 M16

Foot-pounds (ft-lb) 19 41 69 104 174

Newton meter (N•m) 25 55 93 141 236

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 Colour-Coded Label

1/2 inch

5/8 inch

3/4 inch

1 inch

Blue

Green

Special Installation Notes

2001-2003.25 trucks will require accessory kit A700121

1999-2001.25 trucks will require accessory kit A700120

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.

SystemIDnumberplate

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.

Daily Pre-Start Check Start Up Procedure Shutdown Procedure

This Vehicle is Equipped with a VMAC Air Compressor System

1. Check Oil Level in Tank

2. Check Drive Belt

3. Check for Leaks

1. Allow engine to idle for 1 minute

2. Turn OFF compressor

3. Wait for system to discharge

for 1 minute before restarting

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 1-800-738-8622 (250-740-3200)

OPERATING INSTRUCTIONS

Always allow system pressure to discharge before restarting

WARNING

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

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.

Install the line as high as

possible, NOT on the

bottom of the auxiliar

tank

VR Tank

One-way check valve

uxiliary Tank

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 5

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

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.

14. Exchange the forward right bolt and rear left stud on the

aluminum cover at the top front of the engine (Figure 1.1).

Exchange these two fasteners

Front

Figure 1.1

15. 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 scre

holding ground strap

Figure 1.2

16. Remove and discard the positive battery cable locating bracket

from the same area.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 7

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

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.

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