VMAC Manuals & Illustrated Parts Lists
DOCUMENT 1900590 Installation Manual For The System #V900064 UNDERHOOD AIR COMPRESSOR 2001 FORD SUPER DUTY F250-F550 7.3 L POWER STROKE DIESEL 1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3 TEL: 250-754-6997 FAX: 250-754-6972 TOLL FREE: 800-738-8622 Installation Manual Document 1900590 VR7000 Underhood Air Compressor System Number V900064 Application: 2001 Ford Super Duty F250-F550 7.3 L Power Stroke Diesel Publication Date: February 2000 Origination Documents: #1900590 - introduction #1900590a - General information #1900591 - Installing the compressor and oil cooler #1900592 - Installing the air tank and lines #1950593 - Installing the control components #1900594 - illustrated parts list #1900130 - warranty registration Registered Trademarks: VR7000, VMAC and Throttle Commander are registered trademarks of VMAC. Ford, Super Duty, F250-F550, Power Stroke Diesel are registered trademarks of Ford Motor Company Loctite, Prime N' Clean, 242 and PST are registered trademarks of Loctite Corporation. Nylok is a registered trademark of Nylok Fastener Corporation. Notice: Manuals and products are subject to change without notice. Copyright 2000 The contents of this manual may not be reproduced in any form without the express written permission of VMAC 2 4 DOCUMENT 1900585a Installation Notes 5. These installation instructions are intended as a general guide. In some instances, due to variations in vehicle manufacture (or if prior modifications have been made to the vehicle) it may be necessary to carry out grinding, bending or rearranging operations for correct fit. These operations must follow sound, standard shop practices. 6. Left and right definitions in this manual are determined when sitting in the driver's seat, facing forward. 7. All fasteners must be of the correct size and torqued according to the specifications shown below. Torque specifications are in foot pounds (ft-lb).Always use manufacturers torque values for OEM fasteners STANDARD GRADE 8 NATIONAL COARSE THREAD Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 Foot-pounds 9 18 35 55 80 110 170 280 STANDARD GRADE 8 NATIONAL FINE THREAD Size 3/8 7/16 1/2 5/8 3/4 Foot-pounds 40 60 90 180 320 METRIC CLASS 10.9 Size M8 M10 M12 M14 M16 Foot-pounds 19 41 69 104 174 The above fastener torque values are applicable when Loctite is used . If the threads are dry add 20% to the torque values. WARNING 6 DOCUMENT 1900585a 8 Part 1 DOCUMENT 1900591 Installing the Compressor and Oil Cooler System #V900064 2001 FORD SUPER DUTY F250-F550 7.3 L POWER STROKE DIESEL UNDERHOOD AIR COMPRESSOR 9 10 DOCUMENT 1900591 Part 1: Installing the Compressor and Oil Cooler 1.1 Preparing for installation 1. Disconnect the batteries and remove the battery from the driver's side box. 2. Drain the coolant from the radiator. 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 (Figure 1.1). 4. Loosen the clamps holding the left intercooler tube at the air intake on the engine and at the intercooler beside the radiator and remove the intercooler tube. Remove This Cover R em ove Coola nt E xp ansion Tank Figure 1.1 5. Remove and discard the plastic cover and attaching nuts from the center top area of the engine (Figure 1.1). 6. Remove the OEM belt 7. Remove the cooling fan and the fan shroud. Removing the cooling fan will provide additional clearance for removing and installing components. NOTE 11 DOCUMENT 1900591 8. Disconnect the air inlet horn from the front of the air cleaner and battery box. Leave this part in place. This is optional for ease of removal and installation. Remove the air cleaner box and the battery box from the driver's side of the vehicle (Figure 1.2). Rem ove The Air Cleaner And Battery Boxes Figure 1.2 9. Remove the alternator from its mount and lay it back on top of the engine. Keep the OEM fasteners for alternator installation. 10. Remove the power steering pump pulley (noting the position of the pulley on the shaft), then remove the power steering pump from the bracket. Keep the OEM fasteners for the power steering pump installation. You will require the correct puller to remove the power steering pump pulley. 11. Remove the power steering return hose from the power steering pump. Remove and discard the metal portion of the hose. 12. Fasten the pump out of the way or lay it on the frame. Do not allow it to hang from the pressure hose. 13. Remove and discard the OEM alternator and power steering pump mounting bracket and the OEM bracket fasteners (Figure 1.3). 14. Peen the edge of the valve cover flat against the cylinder head in the area where the compressor mounting bracket will attach. This allows the compressor mounting bracket to sit flush with the cylinder head surface (Figure 1.3). 15. Remove and discard the upper and lower radiator hoses. 12 DOCUMENT 1900591 Peen Back This Area O f The Cover FRONT LEFT SIDE OF ENG INE Cylinder H ead M ounting Area Engine Block M ount OEM F a ste n e rs OEM Alternator And Power Steering Pump M ounting Bracket Figure 1.3 16. Exchange the forward right bolt and rear left stud on the aluminum cover at the top front of the engine (Figure 1.4). Front Exchange these two fasteners Figure 1.4 13 DOCUMENT 1900591 17. Remove and discard the 12 mm bolt from lower alternator bracket (lower right side of the engine) and the 12 mm cap screw (lower left side of the engine) which retain the ground straps (Figure 1.5). 18. Remove and discard the positive battery cable locating bracket from the same area. 12 m m bolt securing lower alternator bracket to the engine and holding ground strap and transmission cooling lines 12 mm hex head cap screw holding ground strap Figure 1.5 19. Clean the front of the engine block thoroughly to ensure that there is no contamination in the areas where the cooling tank and mounting bracket will fit. If the mounting area is dirty, the bracket will not mount flush, resulting in fouling of the pulley or belt. 1.2 Installing the oil cooler 1. Install the oil cooler on the engine. Insert the supplied M12 x 30 mm hex head cap screws and 12 mm serrated washer through the ground strap fittings on the drivers side and fasten the oil cooler in place. Fit the supplied M12x 80 hex head cap screw with the 7/16 flat washer through the cooler mount strap and the ground strap on the passengers side. Fit to the lower alternator bracket where the bolt was removed from previosly, tighten both bolts. Torque the fasteners to specifications. M12 x 0 HHCS To rad iator M12 x 30 HHCS Figure 1.6 14 To engin e block DOCUMENT 1900591 2. Place hose clamps on both hoses. Connect the right side cooler hose to the bottom radiator outlet (Figure 1.7) and the left side hose to the engine block connection. Tighten all the hose clamps securely. 3. Fit two (2) 4" lengths of 1/2" rubber hose around the transmission line for protection where they pass the cooler bracket. Use ties to hold the rubber in position on the lines Lower radiator hose 1/2" oil line fittings Figure 1.7 Hose to engine block 1.3 Installing and mounting components 1. Install the crankshaft pulley using three (3) supplied M10 x 20 mm socket head cap screws. Torque them to specifications. 2. Install four (4) 3/8" flat washers on the four (4) supplied M10 x 30 mm hex head cap screws for the compressor mounting bracket. Apply Loctite to the fasteners. 3. Install the supplied VR7000 mounting bracket using the four (4) M10 x 30 mm hex head cap screws. Torque them to specifications. 4. Install the power steering pump to the compressor mounting brackets using the OEM fasteners. 5. 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. 15 DOCUMENT 1900591 Four (4) M10 x 30 Hex Head Cap Screws Installing the VR7000 components 6. Install the alternator onto the compressor mounting bracket using the OEM fasteners. The alternator must be mounted 180 degrees (upside-down) from the original mounting position. Rotate the alternator 180 degrees in a counterclockwise direction. NOTE 7. Insert the supplied hose barb into the power steering rubber return hose which is attached to the brake booster. 8. Install the supplied 3/8" x 11" power steering return hose on the other end of the hose barb. 9. Install one of the OEM hose clamps on the end which will attach to the power steering pump fitting. Install the hose on the pump. 10. Re-align the power steering hoses to clear the steering column. 16 DOCUMENT 1900591 1.4 Installing the compressor 1. Apply Loctite to the burred-ends of the three (3) 8 mm studs and thread them in the holes in the bottom of the compressor. Tighten them securely using two (2) jam nuts. 2. Install the compressor to the mounting bracket using three (3) supplied 8 mm nuts and 5/16 inch flat washers. Use Loctite on these fasteners and torque them to specifications. 3. Remove the M12 x 80 mm hex head cap screw which retains the compressor belt tensioner. Apply Loctite, install the fastener and torque it to specifications. 4. Remove the 1/2" x 1-1/4" NC hex head cap screw which retains the idler. Apply Loctite, install the fastener and torque it to specifications. 5. Install the OEM belt. Be sure to use the correct routing. A lte rn a to r Idler Air conditioning Te n s io n e r Water pump Idler Belt Idler Pulley Power steering Generator Crankshaft pulley Figure 1.9 6. Install the VR7000 belt. Be sure to use the correct routing (Figure 1.10). VR7000 Air C om pressor VR7000 Tension er VR7000 Drive Belt VR7000 Crankshaft P u lle y Figure 1.10 17 VR7000 Idler 7. Install the fan and the fan shroud. DOCUMENT 1900591 8. Install clamps on the supplied upper radiator hose and fit it on the engine and radiator fittings. 9. 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. 10. 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 on the inside of the flexible tube does not seat correctly in the groove on the intercooler tube, it is possible that the connection will come undone, allowing unfiltered NOTE air into the engine. This can result in engine damage. Installing components 18 Part 2 DOCUMENT 1900592 Installing the Air Tank, Filter and Lines System #V900064 2001 FORD SUPER DUTY F250-F550 7.3 L POWER STROKE DIESEL WITH DUAL ALTERNATORS UNDERHOOD AIR COMPRESSOR 19 20 DOCUMENT 1900592 Part 2: Installing the Air Tank, Filter and Lines 2.1 Installing the tank brackets and tank 1. The tank is mounted on the frame on the driver's side of the vehicle, positioned so that it will clear the body mounts, as shown in Figure 2.1. Figure 2.2 provides tank mount component identification. Cab Mount Ta n k S k id p la te C rossm em b er Figure 2.1 NOTE When positioning the tank brackets on the frame, make sure that they will not pinch or damage any wiring harnesses, lines or hoses. L -b ra c ke t C -c lam p m ounting cap screw s B ack ing strap S p ac e r (F250-F350 only) 5/16" nuts W ire c able Figure 2.2 2. Clean the area on the frame between the two body mounts so that the brackets will mount correctly. 3. Connect the 5/16" x 81" oil scavenge line and the 1/4" x 89" pressure control line to the fittings on the top of the tank (Figure 2.5) before installing the tank. 4. Install the two C-clamps onto the tank, inserting the pinch bolt from the top to clear the emergency brake cable. Install the washer and nut, but do not tighten. 21 DOCUMENT 1900592 5. Insert the pinch bolt from the top, then install the washer and nut, but do not tighten. 6. Thread the fittings on the 1/4 and 5/16 inch steel tubes into the matching fittings on the rear of the tank (1/4 inch in the top fitting). Tighten the fittings slightly by hand, but leave them loose enough so that the lines can move in the fittings. 7. Place the two small insulated double-tube clips over the lines with the flat side facing away from the tank and the end with the hole hanging down. Position the 1/4 inch steel tube above the 5/16 inch tube. 8. Place an L-shaped tank bracket against the one of the C-clamp on the tank with the short arm of the "L" at the top of the tank, facing away from the tank. Install a 5/16 x 1/2 inch hex head cap screw with flat washer into the bottom hole on the bracket. Do not tighten. Installing the L-brackets Attaching the L-brackets to the C-clamps 9. Fit the second hex head cap screw through one of the small insulated double-tube clips and install it through the top hole in the C-clamp and into the top hole of the L-bracket. Do not tighten. Repeat this procedure with the second L-bracket, C-clamp and double-tube clip. Insulated double tube clip Tubes in place 10. Make sure that the tubes are parallel to the tank and fit properly in the clips. The flexible lines attached to the tubes will be routed into the engine compartment when the tank is installed on the truck. 22 DOCUMENT 1900592 11. Locate the correct application in the Frame Application Diagram (on the next page) which corresponds to the model of truck on which you are install ing this system. Check the measurements to make sure that the location of the clamps and brackets on your tank match those in the diagram. Adjust the C-clamps to match your application. Make sure that when the tank is mounted, the drain plug is at the lowest location and that the tank orientation has the direction arrow pointing upward. 12. Insert the wire rope securing cables through the topholes in the backing straps, then pass the cable between the cab body and the frame from the inside, behind the transmission cross member, with the backing straps on the inside of the frame. 13. Support the tank and L-bracket assembly in place on the outside of the frame, with the short part of the L-bracket positioned over the top of the frame and pass each wire rope securing cable around the L-bracket, between the bracket and the tank. Make sure that the cable rests between the guide and the C-clamp. 14. Insert the threaded end of the securing cable through the appropriate bottom hole on the backing strap, upper hole for smaller frame locations and the lower hole for larger frame locations. Cable straps over the frame Backing staps on the inside of the frame On F250 & F350 trucks (all models) install the 1/2 x 2 inch spacer, the 1/8 inch thick 5/16 x 3/4 inch washers and the 5/16 inch nuts. NOTE On 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 c 2 inch spacer. 15. Refer to the Frame Application Diagram to ensure that the positioning dimensions are correct for your model NOTE On the F450 & F550 standard cab models (2x4 and 4x4) position the rear tank bracket so that the front edge of the bracket 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 securing 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. 23 DOCUMENT 1900592 16. When the tank is correctly positioned, tighten the securing cable retaining nuts until the cables pull tight and snug around the frame. Do not overtighten the nuts. 17. Instal a second 5/16 inch nut and tighten it securely against the first to act as a locknut. Front cab mount F250 & F350 standard cab 2x4 and 4x4 Front cab mount Front cab mount F250 & F350 super cab 2x4 and 4x4 11 .7 5 Front cab mount 16.25 1.25 Transfer case 17.25 F450 & F550 standard cab 2x4 and 4x4 19.25 16.25 17.25 F450 & F550 super cab and crew cab 2x4 and 4x4 Frame Application Diagram 24 DOCUMENT 1900592 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. Tighten the 1/4 and 5/16 inch steel fittings at the back of the tank. This alignment is extremely important. Improper installation can result in an extremely hazardous situation which could cause severe personal injury or could damage the WARNING equipment. 19. Remove each of the hex head cap screws holding the C-clamp to the L-bracket and apply Loctite. 20. Replace the cap screws and tighten to specifications. Make sure that the tank is level. Front tank mount 2.2 Connecting the air and oil lines Rear tank mount The lines must be installed in the correct locations or the system will not function properly. in addition, a hazardous situation may develop from oil spray, potential fire or explosion. WARNING NOTE If lines are grouped together, make sure that you insulate the lines from each other and from other components to prevent abrasion wear. Use the supplied plastic sleeve cut to suitable length (approximately 4 inches) and secure them in place with plastic tie wraps. Use stainless steel hose wraps to secure the hoses as necessary. 1. Connect the end of the 3/4 inch main discharge line with the straight connector to the top front tank fitting. 2. Route this line around the outside of the front body mount and install protective plastic sleeves. Fasten it to the cab floor with stainless ties using OEM holes. Route the line up to the back of the compressor. 3. Connect the 45 degree swivel fitting to the fitting on the back of the compressor. Tighten the fittingat the compressor while angling the fitting to allow the line to route outside of the steering column. Secure the line away from the steering column with ties. 25 DOCUMENT 1900592 3/4 inch main discharge line (upper) and 1/2 inch oil return line (lower) Lines installed on tank 26 DOCUMENT 1900592 4. Route the 5/16 inch scavenge line from the tank up along the frame to the compressor. 5. Connect the 5/16 inch line fitting to matching 5/16 inch 90 degree elbow fitting on the firewall side of the inlet control valve on the compressor. 6. Route the 1/4 inch pressure control line above the front cab body mount and around the outside of the steering column. Install protective plastic and tie this line to the scavenge line. You can also fasten this line to holes in the floor strenthening rib for better support. 7. Connect the end of the 1/4 inch line to the 45 degree elbow fitting on the front of the air inlet valve on the compressor. Scavenge Line Main Air Line Pressure Control Line Line connections at the compressor 8. Connect the straight end of the longest 1/2 inch oil return line to the lower tank fitting and the 90 degree end to the left (driver) side fitting on the oil cooler. Route this line over the frame rail and around the steering box. Secure it so that it clears all belts and moning parts. 9. Connect the 90 degree end of the shortest 1/2 inch oil return line 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 this line across the cooler, behind the coolant hose to the engine, across the engine block to the compressor secure it, making sure that the hose is clear of the cooling fan, pulleys and belts. 10. Make sure that you tighten all fittings. Check your routing to make sure that the lines do not contact hot areas or other moving components. Make sure that the lines do not interfere with other components. 11. Protect the lines from abrasion and damage by making sure that they are secured as required using stainless frame clamps or ties and protective plastic sleeve on contact points. 27 DOCUMENT 1900592 12. 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. 13. Install the rock guard on the front of the tank using four (4) 1/2 x 1/2 inch hex head cap screws. Lower radiator hose 1/2" x 41.5" Cooler to compressor 1/2" x 86" Cooler to tank Line connections at the cooler Hose to e n g in e b lo ck 2.3 Adding oil to the system 1. Make sure that the vehicle is level. 2. Remove the oil filler plug from the air inlet control valve. 3. Slowly pour the supplied compressor oil into the filler hole using a funnel. You must use the supplied compressor oil in this system. Failure to use this special oil will result in damage to the compressor and will void your warranty. WARNING 4. Turning the compressor clutch clockwise with a ratchet and socket using the hex head cap screw at the center of the compressor clutch and continue adding oil until the correct level is attained. 5. Observe the sight glass at the front of the tank to ensure that the correct oil level is attained. It is important not to overfill the system. 6. Insert the filler plug in the air inlet control valve and tighten it. 28 DOCUMENT 1900592 Rem ove This Plug Oil fill location 7. Fill the cooling system with the OEM recommended coolant. NOTE 8. Before operating the compressor for the first time, be sure and run the engine until it reaches operating temperature. Always check the coolant level to be sure it is correct. Check all fasteners, hose clamps and fittings to make sure that they are tight. 9. Remember to check the oil in the tank to be sure that it is at the correct level. 29 DOCUMENT 1900592 30 Part 3 DOCUMENT 1900593 Installing the Control Compontents System #V900064 2001 FORD SUPER DUTY F250-F550 7.3 L POWER STROKE DIESEL WITH DUAL ALTERNATORS UNDERHOOD AIR COMPRESSOR 31 32 DOCUMENT 1900593 Part 3: Installing the Control Unit 3.1 Installing the control unit 1. Remove the driver-side plastic door frame base panel and the plastic moulding ahead of the base panel . D river 's Se at Remove This Inside Left Kick Panel Remove This Door-frame Base Panel Removing Components 2. Mount the control unit using the supplied sheet metal screws (Figure 3.2). Mounting the control unit 33 DOCUMENT 1900593 2. 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. 3. Place the floor covering back into position. Replace the door trim piece. Cut a notch in the edge of the trim piece for the wire (Figure 4.3). Make sure that you cut a path for the wire through the saw-tooth piece just in from the edge of the trim or when you install the door trim or it will cut the wires. Cut A Notch In The Panel For The W ire approximately 16" from front 1/2" gap Rem ove jagged teeth Figure 3.2 4.2 Connecting the wiring harnesses 1. Make a slit or cut a small cross (about 1") in the steering column boot and feed the small gray harness cable with the green plug connector through the boot into the engine compartment. Route the cable clear of the steering column and pedals so that it does not make contact with any moving parts. 2. Route the wire harness from the sensor on the compressor along the engine and firewall and connect the green compressor sensor wire harness connector to the matching green connector on the harness from the control unit. 34 DOCUMENT 1900593 4.1 Installing the Throttle Commander 1. Fasten the Throttle Commander under the dash, to the right of the steering column with the adjusting screws pointing downward . The mounting bracket acts as a ground for the control unit. This bracket must be securely fastened to a metal bracket under the dash, not to a non-conductive surface. Wire connections are shown in Figure 4.1. 2. Unplug the two (2) cables from the foot pedal assembly and connect them to the matching connections at the Throttle Commander. 3. Connect the two (2) Throttle Commander cables to the matching connections at the foot pedal assembly. 4. Feed the gray, three-core cable with plug through the steering column boot into the engine compartment. Make sure that the cable is clear of all moving parts and plug it into the matching connector from the temperature sensor in the compressor. 5. Feed the pressure sensor cable from the Throttle Commander through the steering column boot into the engine compartment and plug it to the matching connector on the pressure regulator. 6. Feed the small white wire (without a connector) from the back of the Throttle Commander (complete with plastic loom) through the steering column boot. Attach the white wire to the green cam position (CMP) sensor wire (Figure 4.1). You will have to remove one of the relays to access the harness. 7. Connect the white four-cable connector at the Throttle Commander to the matching white plug on the cable from the control unitfrom the control unit. Route the cable up over the steering column clear of all moving parts and secure in place using ties. Ye llo w W hite to C M P B lac k to p ark bra ke Red to pow er Foot pedal c on n e c to r Throttle Com mander Throttle Com mander to contol unit connection C om pressor Control U n it L arg e w hite to c om p res sor clutch Foot pedal connectors C om pressor tem perature sensor connector Figure 4.1 Wiring locations 35 DOCUMENT 1900593 Green CMP Sensor Wire Cover Shown Here For Reference Purposes Only Locating the wire 4.2 Attaching the white wire 1. Cut the green wire. Strip approximately 3/8" insulation from each cut end. Cut and strip the green wire 36 DOCUMENT 1900593 2. Slip on the supplied meltable liner shrink tube (Figure 4.4). Install the shrink tube 3. Strip 1 of insulation from the end of the white wire and twist it onto the free ends of the green wire. Strip and wrap the white wire 4. Solder the connection using the supplied 60/40 rosin core solder. Apply sufficient heat to allow the solder to flow through the twisted bundle. Solder the connection 5. Slide the shrink tube over the solder joint and shrink with a heat gun until the meltable inner core extrudes slightly from each end . Do not overheat and be sure to protect the other nearby wire bundles with sheet metal or cardboard. 37 DOCUMENT 1900593 Install the shrink tube 6. Push the green wire and the splice back into the OEM plastic loom. Slide the supplied 3/16 ID loom on the white wire forward and insert the end into the slit in the OEM plastic loom. Secure the connection with the supplied nylon wire. Loom and fasten the wire 4.3 Connecting the wiring 1. Feed the large white wire with the blue bullet connector through the steering column boot, route it across the firewall and along the engine to the compressor. Connect it to the matching connector at the compressor clutch. 2. Keep the black wire and the red wire inside the operator's compartment for later internal connections. 3. Secure all wires so that they will not be damaged or interfere with vehicle operation. 4. Locate the light blue with pink stripe OEM wire under the dash. This wire may be difficult to locate. Figures 4.9 and 4.10 may assist in locating the wire. 5. Attach the red wire from the Throttle Commander to the light blue with pink stripe OEM wire using the supplied quick-connector. 38 DOCUMENT 1900593 Speed control connection to vehicle harness light Blue with Pink Stripe Wire Harness with the light blue with pink stripe wire Speed control connection OEM diagnostic connector to vehicle harness removed from under dash Light Blue with Pink Stripe for clarity Locating the connector and the wire 39 4.3.1 Standard transmission vehicles only DOCUMENT 1900593 1. Remove the OEM connector from the park brake switch on the park brake assembly. 2. Attach the black wire from the Throttle Commander with the female spade connector to the black extension wire with a male connector on one end and a piggy-back connector on the other end. 3. Route the wire to the park brake assembly and connect it to the park brake switch. 4. Attach the OEM park brake light switch wire to the piggy-back connector on the end of the black VR7000 wire at the park brake light switch. 5. The yellow wire is not used on Manual Transmission, cut off and tape over. 4.3.2 Automatic transmission vehicles only 1. Install the Drive Disable Circuit under the dash using twist ties. Figure 4.11 shows the connections at the Drive Disable Circuit. 2. Connect the black wire from the Throttle Commander with the female spade connector to the black wire with the male spade connector from the DDC. 3. Remove the OEM connector from the park brake switch on the park brake assembly. 4. Route the black wire with the piggy-back connector from the DDC to the park brake and connect the piggy-back connector to the switch. 5. Connect the OEM park brake wire to the piggy-back connector at the park brake switch. 6. Connect the yellow wire from the Compressor control panel to the yellow wire from the DDC. 7. Route the blue wire from the DDC through the firewall to the OEM wiring connectors on the driver's inner fender near the firewall. 8. Locate the forward-most connector on the inner fender liner (Figure 4.12). 9. Locate wire connection #12 on the connector (blue wire with an orange tracer). 10. Install the supplied female tap quick connector onto the blue/orange wire. Use pliers to close and latch the connection. 40 DOCUMENT 1900593 Connect to m atching connector on the yellow wire from the VR7000 Control Panel Unit Yellow Attach OEM park brake wire B la c k P ig g y -b a c k connector Connect to the OEM park brake switch B lu e B la c k Connect to quick connector on blue/orange OEM park/neutral wire at location #12 of the underhood connector Connect to black park brake wire from VR7000 Throttle Com m ander DDC wiring connections Front of v e h ic le Top o f con ne ctor 1 2 3 4 5 6 7 8 9 10 11 12 B lue /O ra ng e wire location Connector and wire location 11. Connect the blue wire from the DDC to the female tap quick connector. 4.4 Completing the installation 1. Check all under-dash and engine-compartment 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 as required. 2. Install the relay which you removed earlier to connect the CMP sensor wire. 3. Install the air cleaner and battery box. 4. Install the battery and connect the cables. 5. Install the covers and connect all hoses and tubing. 41 Testing the Drive Disable Circuit DOCUMENT 1900593 Use the following procedure to to test the operation of the DDC safety circuit: 1. Apply park brake and place transmission in park "P". 2. Turn key on but DO NOT START ENGINE. 3. Turn on compressor switch, compressor clutch should engage. 4. Place the gear selector in drive. Clutch should disengage. 5. Turn off compressor switch, place transmission in Park "P". Turn off key. 42 Part 4 DOCUMENT 1900594 Illustrated Parts List System #V900064 2001 FORD SUPER DUTY F250-F550 7.3 L POWER STROKE DIESEL UNDERHOOD AIR COMPRESSOR 45 46 DOCUMENT 1900594 ILLUSTRATED PARTS LIST SYSTEM V900064 - 2001 FORD SUPER DUTY F250 - F550 7.3 POWER STROKE DIESEL ASSY. 1.0 2.0 ITEM 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 UNIT ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea ea QTY 1 1 1 1 1 2 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 PART# 1100113 2600075 1400129 1570048 1520419 1300007 1510161 1400051 1300008 1540145 1800146 1650231 P120045 P120002 9200174 3550363 5000112 3500288 1550221 1500374 1570038 1550029 3600042 3600037 4900045 5000081 5000085 2200097 4900032 5830004 5830002 9200104 5830045 9200103 5000074 P200035 DESCRIPTION Main bracket assembly VR7000 main bracket Tensioner Idler spacer 7/16" flat washer 12mm x 80mm HHCS C/W item 1.2 C/W item 1.2 Idler, back ½" x 1 ¼" NC HHCS FL Idler bolt spacer Idler, 6 rib 10mm x 20mm SHCS VR7000 crankshaft pulley VR7000 belt Compressor assembly VR7000 compressor Inlet control valve Temperature probe 45 DEG street elbow 1/8" NPT Pressure sensor ¼" NC nut ¼" NC x 3" threaded rod ¼" SAE flat washer ¼" NC Nylok nut Filter cover Paper filter element Hollow hex plug #8 SAE Scavenge orifice 90 DEG elbow 1/8" NPT 45 DEG elbow 1/8" NPT x ¼" SAE Cable clamp, ¼" 1" Male BSPP to ¾" male 37 DEG tube O-ring 3 1/8" ID x 1/8" wide, Viton O-ring 2 3/8" ID x 3/32" wide, Viton Filter blank plate O-ring ¾" ID x 3/32" wide, Viton Filter blank plate fitting 90 DEG elbow, ½" tube ½" NPT Clutch complete 6 groove 45 DOCUMENT 1900594 ILLUSTRATED PARTS LIST SYSTEM V900064 - 2001 FORD SUPER DUTY F250 - F550 7.3 POWER STROKE DIESEL ASSY. 3.0 4.0 ITEM 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 4.1 UNIT ea ea ea ea ea ea ea ea ea ea ea ea ea in ea ea ea ea QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 4.2 ea 1 4.3 ea 1 4.4 ea 1 4.5 ea 1 5.0 5.1 ea 1 6.0 6.1 ea 2 6.2 ea 2 6.3 ea 2 6.4 ea 2 6.5 ea 2 6.6 ea 2 PART# 9203044 9200199 5000060 1200262 5830008 3200033 1500385 9200039 4900033 4900035 3600054 5830066 3200156 3600036 1500077 4800241 3600064 5840068 1710417 1710385 1710473 1710472 1710301 T510074 2200105 1200236 2200120 2200113 1400162 2200133 DESCRIPTION Tank Assembly Main tank body Brass connector ½" NPT ½" SAE Guard plate O-ring 1 15/16" ID x 3/32" wide, Viton Sight glass window Retaining ring VR7000 Oil filter Steel connector, ¾ NPT x ¾ JIC 37 deg ¾ -16 Threaded nipple 200 PSI Relief valve O-ring, 4 ¾" ID x 1/8" wide, Viton Discharge cap Coalescing filter element 10-32 x 3/8 Button head SHCS Scavenge screen assembly Tank rear cap seal Compression spring Hose Kit ½" AQP hose / 41.5" long c/w 90 DEG elbow (Cooler to Compressor) ½" AQP hose / 86.0" long c/w 90 DEG elbow (Tank to Cooler) ¼" HT hose / 99.0" long (Pressure Control Line) 5/16" HT hose / 92.0" long (Scavenge Line) ¾" AQP hose / 57.0" long c/w 45 DEG elbow (Main Discharge Line) Throttle Control Assembly VR7000 throttle control Tank Brackets Tank mounting bracket (C-clamp) Tank strap mount Tank cable strap Tank strap flat bar Cable spacer Tube clamp 46 DOCUMENT 1900594 ILLUSTRATED PARTS LIST SYSTEM V900064 -2001 FORD SUPER DUTY F250 - F550 7.3 POWER STROKE DIESEL ASSY. 7.0 8.0 9.0 ITEM 7.1 7.2 7.3 7.4 7.5 7.6 8.1 8.2 8.3 9.1 9.2 9.3 9.4 9.5 UNIT ea ea ea ea ea ea ea ea ea ea in ea ea ea QTY 1 1 4 1 1 1 1 1 1 1 11 1 2 1 PART# 4800208 9200191 1200252 2200026 1710418 1710420 2200027 3550388 3550498 3550509 1720246 1700030 5000005 2200026 1710252 DESCRIPTION Cooler Assembly VR7000 Cooler Cooler leg Hose clamp HS28 Radiator hose17030 Radiator hose17.30 Hose clamp HS 32 Electrical Assembly VR7000 control box Drive disable circuit Standard transmission park brake jumper Misc. Intercooler tube 3/8" rubber hose 3/8" hose splicer Hose clamp HS28 Upper radiator hose 47 50 Warranty Registration This form must be fully completed and returned to VMAC at the time of installation. Warranty will be void if this form is not received by VMAC within 30 days by mail or fax. Installer Information Company Name: Installer Name: City: Postal Code: Installation Date: / day month Owner Information State/Prov. Telephone: / year Owner Name: Address: City: Postal Code: Purchase Date: Purchased From: Application / day month State/Prov. Telephone: / year Vehicle Make: Year: Vehicle Identification Number (VIN#): Product Information Engine type/size: System Identification Number: 9 __ __ __ __ __ __ __ __ __ Compressor Serial Number: 12 __ __ __ __ __ __ __ __ Tank Serial Number: 30 __ __ __ __ __ __ __ __ 53 1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3 TEL: 250-754-6997 FAX: 250-754-6972 TOLL FREE: 800-738-8622Acrobat Distiller 4.0 for Windows Adobe PageMaker 6.52