V-Tec Installation Manual IN0078 - r0

V-TEC SPEED CONTROLLER SYSTEM
INSTALLATION MANUAL
NOTE NOTE NOTE

Making unauthorized modifications to This manual covers the installation of
the system components WILL VOID THE the Vanair V-TEC Speed Control System,
WARRANTY! for the purpose of controlling a PTO-
Always inform Vanair Manufacturing, driven air compressor system already
Inc., before beginning any changes to installed on the vehicle.
the V-TEC Speed Control system. For information on a PTO-driven air
Read this manual before installing,
operating or servicing this compressor system, consult Vanair.
equipment. Failure to comply with
Vanair Manufacturing, Inc.
the operation and maintenance
instructions in this manual WILL 10896 West 300 North
VOID THE EQUIPMENT WARRANTY. Michigan City, IN 46360
Phone: (219) 879-5100
(800) 526-8817
PART NUMBER:
KEEP THE MANUAL Service Fax: (219) 879-5335 IN0078_r0
Parts Fax: (219) 879-5340
WITH THE VEHICLE Effective Date: 7-11
Sales Fax: (219) 879-5800
©2011
www.vanair.com All rights reserved
WARRANTY: V-TEC Speed Control System
Subject to the terms and conditions below, Vanair® Manufacturing Inc. warrants to the original end user that the V-TEC Speed
Control System equipment sold after the effective date of this limited warranty is free of defects in material and workmanship, at
the time it was shipped from Vanair.
This statement of warranty is expressly in lieu of, and disclaims all other express warranties, Implied warranties of
merchantability and fitness for a particular purchase, and all other implied warranties, which extend beyond the
description on the face hereof. The warranty does not include incidental or consequential damages.
Within the warranty periods and conditions listed below, Vanair will repair or replace any warranted parts or components that fail
due to defects in material or workmanship:
FACTORY INSTALLED SYSTEM
The V-TEC Speed Control System consisting of: an I/O Module, a Display Module, an Inclusive Connecting Harness System
and Sensors, is warranted, when installed at the Vanair factory, by the manufacturer for one (1) year against defects in
materials and workmanship. Factory installed units will include warranty on the installation for one (1) year.
NON-FACTORY INSTALLED SYSTEM
For V-TEC Speed Control System not installed at the Vanair factory, system components including an I/O Module, a Display
Module, an Inclusive Connecting Harness System and Sensors, are warranted by the manufacturer for one (1) year against
defects in materials and workmanship.
Splicing in to the V-TEC Connecting Harness System, including any of its peripheral wire cables, with the exception of the
underhood wire cable, will VOID the warranty. The underhood wire cable's engine controller wiring and/or transmission
controller wiring may be altered to connect to the vehicle without voiding the warranty.
Warranty is limited to the supply of replacement parts failing within the warranty period.
Warranty will commence upon receipt of the Warranty Registration Card. If the Warranty Registration Card is not received
within six (6) months, then warranty commencement date shall be thirty (30) days from the date of shipment from Vanair.
Records of warranty adherence are the responsibility of end user.
Any disassembly of major components must be approved by Vanair to preclude voiding of warranty. Any and all such claims for
warranty consideration must be coordinated through the Warranty-Service Department at the address below. DO NOT return
parts without prior authorization.
Warranty claims must be pre-approved, and are limited to, the supply of replacement parts falling within the warranty period.
Credit for labor required to refit replacement parts is NOT included. All warranted parts are to be shipped PREPAID to Vanair.
Replacement parts will be shipped back to the customer by Vanair via ground shipment. Cost to expedite delivery of
replacement parts will be incurred by customer.
This warranty shall be void and Vanair shall have no responsibility to repair, replace or repay the purchase price of defective or
damaged parts resulting from the use of or repair of replacement parts not of Vanair's manufacture or from buyer's failure to
store, install, maintain and operate the equipment according to the recommendations contained in the manual.
All claims under the Warranty shall be made by contacting Vanair Warranty-Service Department.
Register Your Warranty Online at www.vanair.com under the Support Tab!

Or Call: (800) 526-8817 • Fax: (219) 879-5800
Mail to: 10896 W 300 North • Michigan City, IN 46360
Effective November 2011
V-TEC® SPEED CONTROLLER SYSTEM TABLE OF CONTENTS
TABLE OF CONTENTS
WARRANTY .............................................. BEHIND COVER
TABLE OF CONTENTS......................................................I
WARRANTY CLAIMS PROCEDURE.................................V
WARRANTY CLAIMS FOR WARRANTED VANAIR PARTS ...................................................................V
INTRODUCTION.................................................................VII
EXPERIENCE THE VANAIR® ADVANTAGE! ........................................................................................VII
A NOTE ON MANUAL LAYOUT NAVIGATION........................................................................................VIII
PART I: PRE-INSTALLATION .................................. 1

1.1 GENERAL SAFETY .......................................................................................................................1
1.1.1 SAFETY WARNINGS -ELECTRICAL SHOCK CAN KILL ................................................................................. 2
1.2 GENERAL INTRODUCTION..........................................................................................................3
1.3 PRE-ASSEMBLY PROCEDURE....................................................................................................4
1.4 OVERVIEW ....................................................................................................................................4
1.5 CONNECTION LOCATIONS FROM I/O MODULE........................................................................4
1.6 RECOMMENDED ITEMS AND TOOLS NEEDED FOR ASSEMBLY ............................................5
1.7 TYPICAL COMPONENT LAYOUT - FORD SUPER DUTY (F-350, F-450 AND F-550) ................6
1.8 TYPICAL COMPONENT LAYOUT - FREIGHTLINER M2 SERIES,
FORD SUPER DUTY (F-650 AND F-750) .....................................................................................8
1.9 TYPICAL COMPONENT LAYOUT - FREIGHTLINER MT SERIES AND
WORKHORSE CUSTOM CHASSIS ..............................................................................................10
1.10 TYPICAL COMPONENT LAYOUT - INTERNATIONAL CAB CHASSIS SERIES..........................12
1.11 HARNESS WIRE CONNECTORS .................................................................................................14
PART II: MOUNTING THE I/O MODULE ................ 15

2.1 MOUNTING THE I/O MODULE .....................................................................................................15
2.1.1 INITIAL CONSIDERATIONS WHEN DETERMINING MOUNTING LOCATION................................................. 15
2.1.2 SUGGESTED MOUNTING LOCATIONS ........................................................................................................... 16
Continued on next page...
IN0078_r0 PAGE - I
TABLE OF CONTENTS V-TEC® SPEED CONTROLLER SYSTEM
PART II: MOUNTING THE I/O MODULE (CONT.)

2.1.2.1 FORD SUPER DUTY F-350, F-450 AND F-550 SERIES............................................16
2.1.2.2 FREIGHTLINER M2 SERIES AND WCC ....................................................................16
2.1.2.3 FREIGHTLINER MT SERIES AND WORKHORSE CUSTOM CHASIS ......................16
2.1.2.4 INTERNATIONAL CAB CHASSIS SERIES .................................................................16
2.1.3 MOUNTING INSTRUCTIONS ..............................................................................................................................16
2.1.3.1 UNDERHOOD MOUNT ...............................................................................................16
2.1.3.2 CAB FLOOR MOUNT (FORD SUPER DUTY) ............................................................18
PART III: MOUNTING THE DISPLAY MODULE.....21

3.1 GENERAL SAFETY....................................................................................................................... 21
3.2 GENERAL INTRODUCTION ......................................................................................................... 21
3.3 MOUNTING THE DISPLAY BRACKET ......................................................................................... 22
3.3.1 SEAT FRAME MOUNTING..................................................................................................................................24
3.3.2 CONVENTIONAL LOCATION MOUNTING.........................................................................................................25
3.3.3 TRANSMISSION HUMP MOUNTING..................................................................................................................26
PART IV: ROUTING AND CONNECTING THE MAIN

HARNESS ................................................29
4.1 GENERAL SAFETY....................................................................................................................... 29
4.2 GENERAL INTRODUCTION ......................................................................................................... 29
4.3 LAYING OUT THE MAIN TRUNK HARNESS ............................................................................... 30
4.4 CONNECTING THE MODULE COMPONENTS ........................................................................... 31
4.4.1 I/O MODULE ........................................................................................................................................................31
4.4.2 DISPLAY MODULE..............................................................................................................................................32
4.5 INSTALLING THE SENSOR CONNECTIONS .............................................................................. 33
4.5.1 TEMPERATURE THERMISTOR CONNECTION.................................................................................................34
4.5.2 SECURING THE THERMISTOR CONNECTION ................................................................................................34
4.5.3 SECURING THE PRESSURE TRANSDUCER CONNECTION ..........................................................................36
4.6 COMPONENT CONNECTIONS .................................................................................................... 37
4.6.1 GROUND TERMINAL CONNECTION.................................................................................................................37
4.6.2 PTO SOLENOID CONNECTION .........................................................................................................................37
4.6.3 POWER CONNECTION.......................................................................................................................................38
4.6.4 UNDER DASHBOARD/UNDER HOOD CONNECTION......................................................................................38
4.6.5 COOLER FAN CONNECTION.............................................................................................................................40
PAGE - II IN0078_r0
V-TEC® SPEED CONTROLLER SYSTEM TABLE OF CONTENTS
PART IV: ROUTING AND CONNECTING THE MAIN

HARNESS (CONT.)
4.6.6 (OPTIONAL) GENAIR PANEL CONNECTION................................................................................................... 40
4.6.7 (OPTIONAL) DUAL PRESSURE SWITCH......................................................................................................... 41
4.6.8 J1939 VEHICLE BUS CONNECTION ................................................................................................................ 41
4.6.8.1 J1939 RESISTOR........................................................................................................ 41
PART V: SYSTEM CHECK TEST............................ 43

5.1 PRE-TEST REVIEW ......................................................................................................................43
TABLE 5A: INITIAL POST-INSTALLATION/PRE-INITIAL START UP CHECKLIST
FOR COMPRESSOR SYSTEM...................................................................................................................... 45
TABLE 5B: INITIAL POST-INSTALLATION/PRE-INITIAL START UP CHECKLIST
FOR VEHICLE ................................................................................................................................................ 46
TABLE 5C: INITIAL POST-INSTALLATION/PRE-INITIAL START UP CHECKLIST
FOR FOR V-TEC SYSTEM ............................................................................................................................. 47
5.2 V-TEC TEST PROCEDURE...........................................................................................................49
5.2.1 KEY ON / ENGINE OFF...................................................................................................................................... 49
5.2.2 KEY ON / ENGINE ON........................................................................................................................................ 50
PART VI: TROUBLESHOOTING............................. 53

6.1 GENERAL INFORMATION ............................................................................................................53
6.2 TROUBLESHOOTING GUIDE - ERROR MESSAGES .................................................................54
APPENDIX A: ADDITIONAL INFORMATION ......... 57

A.1 VISUAL HARNESS-TO-COMPONENT CONNECTION LAYOUT .................................................57
A.2 WIRING LAYOUT GUIDE ..............................................................................................................58
A.3 CUMMINS/PACCAR ECM 60-PIN CONNECTOR (TYPICAL).......................................................59
A.4 EPA 2010 ECM 60-PIN CONNECTOR ..........................................................................................60
APPENDIX B: WIRE ASSEMBLY ........................... 61

B.1 WIRE ASSEMBLY INTRODUCTION .............................................................................................61
B.2 WIRE ASSEMBLY - CONDUCTOR PREPARATION .....................................................................62
B.3 WIRE ASSEMBLY - SOLDERED SPLICES: MESHED .................................................................63
B.4 WIRE ASSEMBLY - SOLDERED SPLICES: LAPPED ..................................................................64
IN0078_r0 PAGE - III

TABLE OF CONTENTS V-TEC® SPEED CONTROLLER SYSTEM
APPENDIX B: WIRE ASSEMBLY (CONT.)

B.5 WIRE ASSEMBLY - SLEEVING FOR SOLDERED SPLICES....................................................... 65
B.6 WIRE ASSEMBLY - CRIMPED BARREL SPLICES ...................................................................... 66
B.7 WIRE ASSEMBLY - CRIMPED DOUBLE-SIDED SPLICES ......................................................... 67
B.8 WIRE ASSEMBLY - HEAT SHRINK CONNECTOR (1:1 WIRES) ................................................. 68
B.9 WIRE ASSEMBLY - HEAT SHRINK CONNECTOR (2:1 WIRES) ................................................. 69
PAGE - IV IN0078_r0
V-TEC® SPEED CONTROLLER SYSTEM WARRANTY PROCEDURE
WARRANTY CLAIMS
PROCEDURE
CLAIMS PROCESS FOR WARRANTED
VANAIR PARTS
This process must be used by owners of Vanair®
equipment in situations where a warranted item needs
repair or replacement under the terms of the purchase
warranty. Do not return items to Vanair without prior
authorization from the Vanair Warranty Administrator.
PROCEDURE: NOTE
When a customer needs assistance in troubleshooting a The unit’s serial number is important to
system and/or returning parts, follow the steps below. determine the proper configuration of the
machine.
1. Locate the machine’s serial number:
For machine serial plate identification and location refer
to Figure W-1.
IMPORTANT
2. Have a list of the symptoms/condition/malfunctions
along with any applicable temperature and pressure Customers have 30 days after the RMA
readings, and also the number of operational hours number is issued to return the item. If the
available: part is not returned within this period, the
RMA is void and any claims will be
3. Contact the Vanair Service Department by phone (1- denied.
219-879-5100) to speak with a Service Technician.
4. Vanair Service will troubleshoot the problem based
on the information provided by the customer.
5. If the unit cannot be returned to service, and Vanair
800-526-8817
determines this matter may be a warranty issue, the www.vanair.com
Service Technician may assign an RMA (Return MODEL NUMBER
Material Authorization) number that will provide for SERIAL NUMBER
the return of the item to Vanair for analysis and a final PSIG
MAXIMUM PRESSURE
determination as to the item’s warranty status.
COMPRESSOR INPUT RPM
260940
6. Vanair will need a P.O. or credit card number to cover
the cost of the part and shipping before sending a The serial tag is typically located in the
part to a customer for warranty consideration. driver’s side door jamb, or on the visor.
7. If the returned item, which in Vanair’s judgment is

proven to be defective as warranted, than Vanair will Figure W-1: Serial Tag and Number
issue a credit for the cost of that item to the Identifciation/Location
customer.
IN0078_r0 PAGE - V
WARRANTY PROCEDURE V-TEC® SPEED CONTROLLER SYSTEM
8. Returned parts eligible for warranty must have the

NOTE RMA number on the packing slip.
The RMA number must be placed on the
No items can be returned “freight collect”. The customer
outside of the package being returned.
pays any additional costs for warranty parts delivered
through expedited services (i.e., Next Day, Second Day).
Vanair® Manufacturing strives to continuously improve its

customer service. Please forward any questions,
NOTE comments, or suggestions to Vanair Service (219-879-
All labor claims or invoices must be 5100, ext. 400) or e-mail us (www.vanair.com).
approved by the Vanair Warranty
Administrator prior to starting repair work
along with the cost of the repair. All paper
work associated with the returned item
and warranty repair cost must reference
the RMA number issued against the part,
and be forwarded to Vanair within 30 days
of the completion of work.
PAGE - VI IN0078_r0
V-TEC® SPEED CONTROLLER SYSTEM INTRODUCTION
EXPERIENCE THE VANAIR® NOTE

ADVANTAGE!
Since 1972, Vanair has grown from a small subsidiary of
Sullair® Corporation to what is today the world’s largest
manufacturer of vehicle-mounted compressor systems.
Vanair pioneered the use of transmission Power Take-Off
(PTO) to power rotary screw air compressors, and
continues to be the driving innovative force in this
segment of the industry. Read this manual before installing,
operating or servicing this equipment.
Vanair offers compressor products with output capacities Failure to comply with the operation and
ranging from 20 cfm to 1000 cfm. This wide product maintenance instructions in this manual
range allows for various drive method applications, which WILL VOID THE EQUIPMENT WARRANTY.
can be installed on most vehicles.
Vanair’s strength consists of its highly-qualified and
skilled workforce. Its experienced service personnel
provide customers with prompt and comprehensive
support. A professional engineering staff uses advanced NOTE
design tools to develop custom solutions to complex and Making unauthorized modifications to the
highly specific customer requirements. compressor or system components WILL
VOID THE WARRANTY!
IN0078_r0 PAGE - VII

INTRODUCTION V-TEC® SPEED CONTROLLER SYSTEM
Questions or problems pertaining to the operation or

Vanair Manufacturing, Inc. maintenance of this equipment should be addressed to
10896 West 300 North the Vanair® Warranty-Service Department.
Michigan City, IN 46360
This publication contains the latest information available
TEL: (219) 879-5100 at the time of preparation. Every effort has been made to
(800) 526-8817 ensure accuracy. However, Vanair Manufacturing, Inc.
takes no responsibility for errors or consequential
SERVICE (219) 879-5335 damages caused by reliance on the information
FAX: contained herein.
PARTS (219) 879-5340 Vanair Manufacturing, Inc. reserves the right to make
FAX: design change modifications or improvements without
prior notification.
WEB SITE: www.vanair.com
A NOTE ON MANUAL
LAYOUT NAVIGATION
Refer to Figure M-1. This manual is presented in a two-
column per page sequence. As shown in the figure, the
inner columns represent the machine application data in
a continuous page-by-page flow. The outer columns are
reserved for auxiliary information relating to the specific
data put forth in the inner column. This auxiliary data can,
for example, be a relative warning or note detail. It will
support the concept which is listed nearby in the inner
column.
Sometimes, if an illustration is too large to fit in the outer
column, or if a large table matrix is present, it may occupy
the two-column space of a page. In such cases the inner
column will always be continued on the next available
page after the illustration.
B A A B
KEY DESCRIPTION
A INNER PAGE COLUMNS:
Main text flow of information layout represents the main
body of machine applications divided into sections and
sub-sections.
B OUTER PAGE COLUMNS:
Contain auxiliary information such as notes, warnings,
and small illustrations. This information is related, and
will be located in proximity, to the main, inner page col-
umn application.
Figure M-1: Manual Layout Navigation
PAGE - VIII IN0078_r0

V-TEC® SPEED CONTROLLER SYSTEM PART I: PRE-INSTALLATION
PART I:
PRE-INSTALLATION
1.1 GENERAL SAFETY
IMPORTANT
WARNING
Vanair recommends that the compressor
Before beginning any installation or system be completely installed on the
maintenance procedure, the person or vehicle before beginning the V-TEC
persons responsible should always be Speed Controller system installation.
familiar with the safety guidelines
provided with the vehicle’s user manual,
compressor operation manual, and also
any pertinent local, state and Federal
safety regulations that may apply. NOTE
IMPORTANT
It is highly recommended that Vanair®
products be installed by Vanair
technicians, or technicians who have The V-TEC Speed Control System
been trained and certified by Vanair. operator must read the V-TEC Operation
Training classes are held on a regular Manual, which came with the V-TEC
basis and customers may contact the package, before operating or servicing
company for further information. this equipment. Failure to comply with the
operation and maintenance instructions
If installation is not to be performed in the operation manual WILL VOID THE
by a Vanair, or Vanair-trained, EQUIPMENT WARRANTY.
technician Installer should have a This manual must be read in conjunction
fundamental understanding of electricity
with other appropriate supplied manuals,
and electrical application before
such as the vehicle operation manual,
performing an installation of the V-TEC
engine operation manual, etc.
system.
The products provided by Vanair Manufacturing, Inc., are

designed and manufactured for safe operation and
maintenance. But it is ultimately the responsibility of the
installers, users and maintainers for safe operation and
use of this equipment. Part of this responsibility is to read
and be familiar with the contents of this manual before
beginning installation, operation or performing
maintenance actions.
IN0078_r0 PAGE - 1
PART I: PRE-INSTALLATION V-TEC® SPEED CONTROLLER SYSTEM
1.1.1 SAFETY WARNINGS - ELECTRICAL SHOCK

CAN KILL
Touching live electrical parts can cause
fatal shocks or severe burns. The installer
must read through and become familiar
with the possible hazards that may occur
when installing electrical application equipment, as
presented in this section. In addition the electrical
application must be installed properly; incorrectly
installed or improperly grounded equipment is a hazard.
• Do not touch live electrical parts.
• Wear dry, hole-free insulating gloves and body
protection when working on a high voltage system.
• Insulate yourself from work and ground using dry
insulating mats or covers big enough to prevent
any physical contact with the work or ground.
• Do not use AC output in damp areas, if movement
is confined, or if there is a danger of falling.
• Additional safety precautions are required when
working in electrically hazardous conditions such
as in damp locations or while wearing wet clothing;
on metal structures such as floors, gratings, or
scaffolds; when in cramped positions such as
sitting, kneeling, or lying; or when there is a high
risk of unavoidable or accidental contact with the
work piece or ground.
• Do not work alone!
• Disconnect input power or stop engine before
installing or servicing this equipment.
• Properly install this equipment according to its
Owner’s Manual and national, state, and local
codes.
• Frequently inspect wiring for damage or bare wiring;
replace cord immediately if damaged—bare wiring
can kill.
• Turn off all equipment when not in use.
• Do not use worn, damaged, undersized, or poorly
spliced cables.
• Do not drape cables over your body.
• If earth grounding of the work piece is required,
ground it directly with a separate cable.
PAGE - 2 IN0078_r0
• Use only well-maintained equipment. Repair or

replace damaged parts immediately. Maintain unit
according to manual.
• Wear a safety harness if working above floor level.
• Keep all panels and covers securely in place.
1.2 GENERAL INTRODUCTION

The Vanair Manufacturing, Inc. V-TEC Speed Controller
provides control and monitoring functions for vehicle-
mounted equipment, such as PTO-driven compressors
and generators, from a user interface console. It consists
of a Display Module, an I/O Module, wiring harnesses,
mounting brackets and mounting hardware. When
performing anything from a system diagnostic run to
checking for upcoming maintenance indications, the V-
TEC Speed Controller offers a thorough and methodical
solution to controlling your system’s operation, all from a
convenient, simple interface panel.
TABLE 1A: V-TEC SPEED CONTROL PACKAGE CONTENTS

ITEMI PART NUMBER QTY
I/O Module 267364 1
Display Module 6060001 1
Temperature Thermistor 266844 1
Pressure Transducer 267363 1
Main Trunk Harness Per order specification 1
Wiring Harness Extension Cables
Dual PSI (optional) 269022 / 270471 1

Power 269023 1
Ground 269024 1
Temperature 269025 1
PSI 269026 1
Fan 269027 1
Generator (optional) 269028 1
Display 269029 1
PTO Per order specification 1
Underhood Per order specification 1
Display Bracket Per order specification 1
I/O Bracket Per order specification 1
Wiring Diagram Per order specification 1
I
For help in visually identifying many of these components, refer to Appendix A, Section A.1.
IN0078_r0 PAGE - 3
This portion of the V-TEC Installation Instruction Manual

NOTE concerns the initial installation procedure of the V-TEC
Speed Controller and system parts. Parts included with
The V-TEC Speed Controller system is an
integrated part of the entire vehicle
the V-TEC Speed Controller package are listed in
system. When dealing with a malfunction, TABLE 1A: V-TEC Speed Control Package Contents.
be aware that its solution may fall
beyond the scope of the V-TEC’s 1.3 PRE-ASSEMBLY PROCEDURE
capabilities to precisely diagnose and Upon receipt of the package, use Table 1A as a guide to
pinpoint the problem specifically. reassure that all parts are included before beginning
Although the V-TEC message indication assembly. Contact Vanair® Manufacturing, Inc., if the
may help to identify a particular problem, package contents do not match this list.
the best approach to take when
diagnosing a malfunction is to consult all 1.4 OVERVIEW
literature pertinent to the vehicle, Although Vanair has arrived at a basic installation
including the compressor and/or approach in terms of integrating the V-TEC package’s
generator operation manuals, and the components with the vehicle, exact locations of
vehicle operation manual. For additional
components may need to vary in accordance with the
assistance with problem diagnostics,
consult the Vanair Service Department.
end user’s needs or space requirements. These
installation instructions should therefore be utilized as a
guideline rather than an exact specification.
The procedural approach used in this instruction guide,
NOTE for the purpose of installing the V-TEC speed control
Sensors are pre-installed at the factory,
module, consists of mounting the two modular units (the
with the exception of updating a system I/O and Display modules), and then routing the wiring
via retro-assembly. In cases where harness to the components of the system that are to be
sensors are not installed, consult Section controlled and/or monitored. For a general idea of the
4.5, Installing the Sensor Connections of components to be covered and their mounting locations,
this manual. consult Section 1.7 through Section 1.10, depending on
vehicle make.
1.5 CONNECTION LOCATIONS

FROM I/O MODULE
NOTE Before beginning the installation procedure the installer
The connection point locations shown in should have a general knowledge of where the various
Section 1.7 through Section 1.10 are components of the speed control system are, or will be,
given as suggestions to afford the located. This will help to visualize the most optimal
installer a general idea of a typical system routing path when laying out the harness wire and its
component layout. However, the final extension connections. Section 1.7 through Section
layout determined for a particular vehicle 1.10 illustrate general regional component locations, in
installation may vary in regard to the regard to the vehicle, needed to determine the V-TEC
components shown. control layout. These sections are divided into vehicle
model types as shown in the following table.
PAGE - 4 IN0078_r0
VEHICLE MODEL TYPE SECTION LOCATION

(Typical Component Layout)
FORD SUPER DUTY (F-350, 1.7 page 6
F-450 and F-550 Series) Diesel
and Gas
FREIGHTLINER M2 Series, 1.8 page 8
FORD (F-650 and F-750)
FREIGHTLINER MT Series and 1.9 page 10
Workhorse Custom Chassis
INTERNATIONAL Cab Chassis 1.10 page 12
Series
Harness Wire Connectors 1.11 page 14
1.6 RECOMMENDED ITEMS AND

TOOLS NEEDED FOR
ASSEMBLY
Table 1B: Recommended Tools and Assembly Items
TABLE 1B: RECOMMENDED TOOLS
for V-TEC Speed Control installation, which contains a AND ASSEMBLY ITEMS
list of items and tools recommended by Vanair to perform
7/16 WRENCH
a complete V-TEC installation assembly.
5/32 ALLEN WRENCH
SCREW DRIVERS
WARNING (various sizes, Philips and standard
slotted)
Always be aware of the proper and safe
application for using any tool. For safety DRILL (with various sized drill bits)
measures, consult Section 1.1, Section TAPE MEASURE (twelve feet or greater
1.1.1, and the vehicle operation manual. in length)
WIRE STRIPPER
WIRE CUTTER
CRIMPER; CRIMPING TOOL
SPLICERS - ASSORTED
HEAT SOURCE (heat gun, micro-torch,
et. al.)
HEAT SHRINK TUBING
SOLDERING TOOLS: soldering iron,
flux
ELECTRICAL TAPE
ZIP TIES (where required)
DIALECTIC GREASE
CLEAN CLOTH (for wiping/drying)
IN0078_r0 PAGE - 5
1.7 TYPICAL COMPONENT LAYOUT - FORD SUPER DUTY

(F-350, F-450 AND F-550)
MAIN HARNESS
1 2
7 11
5 4
10
6 3
8 9
KEY LEGEND Vehicle DETAIL AA
- MAIN HARNESS
- EXTENSION CABLE
Driveshaft
1
- ALTERNATE LOCATION
- CONNECTOR PLUG
Chasis
Support Rail
10 11
2A
2B
1
6
4
3
7 5 8 SEE DETAIL AA FOR
ALTERNATE ROUTE CONNECTION
9
PAGE - 6 IN0078_r0
1.7 TYPICAL COMPONENT LAYOUT - FORD SUPER DUTY (350,

450 AND 550) DIESEL AND GAS
LOCATION
CONNECTION POINT INSTRUCTION LOCATION IN THIS GUIDELINE
NUMBER
I/O Module – NOTE: this is the PART II – MOUNTING THE I/O PANEL
1
MODULES
wiring harness hub location
Display ModuleI PART III – MOUNTING THE DISPLAY MODULE

2
Temperature Transducer 4.5.1 Temperature Thermistor Connection

3
SENSORS
4.5.2 Securing the Thermistor Connection

Pressure Transducer 4.5.3 Pressure Transducer Connection
4
Ground Terminal 4.6.1 Ground Terminal Connection

5
PTO Solenoid 4.6.2 PTO Solenoid Connection

COMPONENT CONNECTIONS
Power 4.6.3 Power Connection

7
Under Hood / 4.6.4 Under Dashboard / Under Hood Connection

8
ECM / TCM / Connector
Cooler Fan 4.6.5 Cooler Fan Connection
9
Genair Panel 4.6.6 (Optional) Genair Panel Connection

10
Dual Pressure Switch 4.6.7 (Optional) Dual Pressure Switch

11
(optional)
I
The two most common mounting locations for the display module are: [2A] on the door-side of the
passenger seat, facing the door, and [2B], centered on the transmission hump on the floor of the
cab.
NOTE NOTE
Ground wire must be connected directly Generator panel, dual psi and/or fan may
to battery (negative post), or approved be mounted in various locations.
vehicle grounding post.
IN0078_r0 PAGE - 7
1.8 TYPICAL COMPONENT LAYOUT - FREIGHTLINER M2

SERIES, FORD SUPER DUTY (F-650 AND F-750)
MAIN HARNESS
8 11 7 12 5 3 4 9 10
1
6
KEY LEGEND
- MAIN HARNESS
- EXTENSION CABLE
- CONNECTOR PLUG
10
2 9
11
6
4
1 3
8 7 5
12
PAGE - 8 IN0078_r0
1.8 TYPICAL COMPONENT LAYOUT - FREIGHTLINER M2

SERIES, FORD SUPER DUTY (F-650 AND F-750)
LOCATION
NUMBER
1
MODULES
Display Module PART III – MOUNTING THE DISPLAY MODULE

2

3
SENSORS

4

5

6

7

8
9

10

11
(optional)
J1939 4.6.8 J1939 Vehicle Bus Connection
12
NOTE
Ground wire must be connected directly
to battery (negative post), or approved
IN0078_r0 PAGE - 9
1.9 TYPICAL COMPONENT LAYOUT - FREIGHTLINER MT

SERIES AND WORKHORSE CUSTOM CHASSIS
MAIN HARNESS
3
4
7 11 8 5 2 10 9
1
268753_r3
7
6
5 11 8 1
9
2
5
11
8
KEY LEGEND
1 - MAIN HARNESS
- UNDERHOOD HARNESS
7
4 - EXTENSION CABLE
3
- CONNECTOR PLUG
6 12
10
PAGE - 10 IN0078_r0
1.9 TYPICAL COMPONENT LAYOUT - FREIGHTLINER MT

SERIES AND CUSTOM WORKHORSE CHASSIS
LOCATION
NUMBER
1
MODULES
Display Module PART III – MOUNTING THE DISPLAY MODULE

2

3
SENSORS

4
Ground TerminalI 4.6.1 Ground Terminal Connection

5

6

7

8 II
9

10

11
(optional)
12
I
Ground Connection to ground stud on firewall.
II For typical engine ECM connector location, refer to Appendix A, Section A.3 or Section A.4 (for Freightliner MT).
NOTE
IN0078_r0 PAGE - 11
1.10 TYPICAL COMPONENT LAYOUT - INTERNATIONAL CAB

CHASSIS SERIES
MAIN HARNESS
8 11 7 12 5 3 4 9 10
1 6
268877_r3
KEY LEGEND
- MAIN HARNESS
- EXTENSION CABLE
- CONNECTOR PLUG
10
9
2
11
6
4
3
1
8 7
12 5
PAGE - 12 IN0078_r0
1.10 TYPICAL COMPONENT LAYOUT - INTERNATIONAL CAB

CHASIS SERIES
LOCATION
NUMBER
I/O Module – NOTE: this is the PART 2 – MOUNTING THE I/O PANEL
1
MODULES
Display Module PART 3 – MOUNTING THE DISPLAY MODULE

2

3
SENSORS

4

5

6

7

8
ECM / TCM / ConnectorI
9

10

11
(optional)
12
I
For typical engine ECM connector location, refer to Appendix A, Section A.3 or Section A.4 (for Freightliner MT).
NOTE
IN0078_r0 PAGE - 13
NOTE 1.11 HARNESS WIRE CONNECTORS

For harness connections using male to female connector
Never force connection plugs to connect.
Although some connections may be tight, plugs, there are two types associated with the harness
be aware that the pins and connection connection wires (Figure 1-1). The two-pin type
holes must align correctly. If the plug ends (Packard) configuration is used with the PTO solenoid
are having difficulty connecting, check to and the fan connection points. Various types of Deutsch
confirm that the pin-to-pin hole connecting plugs are used on almost everything else.
arrangements match before using The one exception is the program access port connector
excessive force, which may damage the plug, which is located near the Display Module, and is
pins. used to program the software via computer access.
A KEY DESCRIPTION
A PACKARD TWO-PIN
CONNECTOR DETAIL
BI DEUTSCH CONNECTOR
DETAIL
C PROGRAM ACCESS PORT
CONNECTION PLUG
B D
LOCATION
NOTE: DO NOT Over
tighten thumb srews. If one
should break, order
replacement harness.
I
Deutsch connectors fit very
snugly: apply enough pressure to
make sure that teh connector
ends are fully engaged.
C D
Figure 4-9: PTO - Built-in Solenoid Connection
PAGE - 14 IN0078_r0
V-TEC® SPEED CONTROLLER SYSTEM PART II: MOUNTING THE I/O MODULE
PART II: MOUNTING THE I/O

MODULE
2.1 MOUNTING THE I/O MODULE NOTE
• The longer harness part number will
2.1.1 INITIAL CONSIDERATIONS WHEN begin with the same number. The
DETERMINING MOUNTING LOCATION dash number represents the length.
Examples:
The I/O module (Figure 2-1) is the first component to be * 269029-025 is a 2.5’ display harness.
mounted, as the main trunk harness layout will originate
* 269029-075 is a 7.5’ display harness.
from this unit as its starting point. The mounting location
of the I/O module is subject to the vehicle layout, which • “Underhood” harnesses are only
may include more than one area that is advantageous to available in one length.
the installer; in addition, basic vehicle layout differs by • Call Vanair Parts Department to check
manufacturer. With this in mind, the following the availability of lengths.
observations should be included when determining a
proper mounting location:
A
NOTE
The I/O module should be mounted where
it will not be subjected to excessive heat
as with temperatures greater than 185°F.
Although the module is weather resistant,
C
care should be observed when selecting a
location to minimize exposure to extreme
moisture, harsh climate or other B
situations that could damage or
compromise its operation.
KEY DESCRIPTION
• Make sure the main trunk harness will not be strained A I/O MODULE MOUNTING
by excessive tight bending when selecting location.
BRACKET
Consult Section A.2 and Section A.3 in Appendix
Section for an idea of how hoses and wiring should be B I/O MODULE UNIT (may be pre-
assembled to bracket at factory)
laid out for installation connections.
C CONNECTION-SIDE VIEW OF I/O
• Plan where main trunk breakouts will land under the MODULE
vehicle to ensure that the extension harnesses will
reach. Longer extension harnesses may be ordered
Figure 2-1: I/O Module & Mounting Bracket
from the Vanair® Parts Department: 1 (800) 526-8817
(ext. 300). Call to check availability of lengths.
IN0078_r0 PAGE - 15
PART II: MOUNTING THE I/O MODULE V-TEC® SPEED CONTROLLER SYSTEM
NOTE 2.1.2 SUGGESTED MOUNTING LOCATIONS

The I/O module and mounting bracket are
Consult the following subsection that best fits the type of
designed to be located within two (2) feet vehicle model in which the V-TEC package is to be
of the designated area, in order to be installed.
within range of the wiring harness
connection’s maximum extended length;
2.1.2.1 FORD SUPER DUTY F-350, F-450 AND
Do not strain cable tension in order to F-550 SERIES
make a connection—for acceptable cable
A typical location for mounting the I/O module in the Ford
running and connecting procedure,
consult Appendix A.2, Wiring Layout Super Duty F-350, F-450 and F-550 Series includes:
Guide. • Behind the seat, on the floor near to the transmission
hump (center of cab). For mounting instructions
consult Section 2.1.3.2.
NOTE 2.1.2.2 FREIGHTLINER M2 SERIES AND WCC

A typical location for mounting the I/O module in the Ford
Do not mount the I/O module too close to
areas that will generate excessive heat,
Super Duty F-650 and F-750 Series, as well as the
such as with a close proximity to the Freightliner M2 Series, includes:
engine. • Under the hood near the power distribution/fuse panel,
mounted to an auxiliary bracket anchored at a spot
that meets the requirements listed in Section 2.1.1.
For mounting instructions consult Section 2.1.3.1.
2.1.2.3 FREIGHTLINER MT SERIES AND

WORKHORSE CUSTOM CHASSIS
A typical location for mounting the I/O module in the
Freightliner MT Series includes:
• Under the hood mounted to an auxiliary bracket
anchored at a spot along the top edge of the vehicle
wall separating the engine compartment from the cab.
For mounting instructions consult Section 2.1.3.1.
2.1.2.4 INTERNATIONAL CAB CHASSIS SERIES

A typical location for mounting the I/O module in the
International Series includes:
• Under the hood near the power distribution/fuse panel,
mounted to an auxiliary bracket anchored at a spot
that meets the requirements listed in Section 2.1.1.
The module may also be direct-mounted to the engine-
side of the wheel’s fender. For mounting instructions
consult Section 2.1.3.1.
2.1.3 MOUNTING INSTRUCTIONS

2.1.3.1 UNDERHOOD MOUNT
There may be several viable options as to where the I/O
module may be mounted under the vehicle’s hood,
PAGE - 16 IN0078_r0
depending upon the make, model and age of the vehicle.

The best approach should always consider the factors
listed in Section 2.1.1, as well as being within reach of
the trunk harness wire once it is laid out for connection.
Depending on vehicle layout, one should always consider
utilizing existing bracket structures and hole alignments,
which may serve to minimize any additional auxiliary hole
drilling.
The final location of the I/O module mounting bracket
should use, at minimum, two bolts to allow for a solidly
anchored mounting of the module. Figure 2-2 and
Figure 2-3 show typical auxiliary bracket-mount types
incorporated into existing underhood component
mounting structures.
1. After the mounting bracket has been installed,
if the I/O module is not pre-fastened to the
bracket, affix the I/O module to the bracket
using the four (4) mounting screws and lock
washers..
2. Connect the harness to the module, using a
5/32” Allen wrench.
3. On the underside of the vehicle run and
connect the harness leads to the various
component harnesses, as labeled in Figure
4-1. For specific information on extension
B A
KEY DESCRIPTION
A I/O MODULE (Connected)
B MOUNTING BRACKET -
Typical example
Inset I/O MODULE -
Connection pin-side shown
Figure 2-2: I/O Module - Mounting Location for Freightliner M2
IN0078_r0 PAGE - 17
C
A
B
KEY DESCRIPTION KEY DESCRIPTION

A I/O MODULE (Connected) C STEERING COLUMN
B MOUNTING BRACKET - Typical Inset A I/O MODULE - Connection pin-side shown
example
Figure 2-3: I/O Module - Mounting Location for International Cab Chassis (Bracket-mount)
cable connection points, consult Part IV:

Routing and Connecting the Main
Harness.
2.1.3.2 CAB FLOOR MOUNT (FORD SUPER DUTY)

Refer to Figure 2-4.
1. Drill a 1-3/4” hole in the floor bed indentation to run the

harness cable for the I/O module. The hole should be
situated in the depression on the floor behind the driver’s
side of the seat (or close proximity), next to the driver’s
side edge of the transmission hump, within the extension
harness’s reach of the mounting bracket location (Figure
4-3).
2. Fasten the I/O module bracket box [A] to the floor using
four (4) #14 x 1” self-tapping screws. The I/O module
bracket contains the I/O, circuit breaker and relay, as well
as the I/O harness wire.
3. Run the I/O harness through the provided grommet [C],
and then into the access hole.
4. Affix the grommet [B] to circumference rim of hole as
shown.
PAGE - 18 IN0078_r0
E
B
A
B
D C
F
G D

A I/O MODULE MOUNTING BRACKET E DRIVER’S SIDE DOOR
(INTERIOR - FLOOR)
B GROMMET F HARNESS CABLE
C FLOOR INDENTATION (MOUNTING SURFACE) (MAIN I/O CONNECTOR)
D BACK OF SEAT G PASSENGER CAB FLOOR
Figure 2-4: I/O Module - Floor-mount Location (Ford F-350, F-450 & F-550 / International Cab Chassis)
5. On the underside of the vehicle connect the I/O wire to

the various component wires as labeled in Section 1.7
through Section 1.10 (depending upon the vehicle—
also consult the provided package wiring diagram). For
specific information on extension wire connection points,
consult Part IV: Routing and Connecting the Main
Harness.
IN0078_r0 PAGE - 19
BLANK PAGE
PAGE - 20 IN0078_r0
V-TEC® SPEED CONTROLLER SYSTEM PART III: MOUNTING THE DISPLAY MODULE
PART III:
MOUNTING THE DISPLAY MODULE
3.1 GENERAL SAFETY NOTE

WARNING
Before beginning any installation or
maintenance procedure, the person or
persons responsible should always be
The V-TEC Speed Control System
operator must read the V-TEC Operation
Manual, which came with the V-TEC
package, before operating or servicing
this equipment. Failure to comply with the
safety regulations that may apply.
operation and maintenance instructions
in the operation manual WILL VOID THE
The products provided by Vanair® Manufacturing, Inc., EQUIPMENT WARRANTY.
are designed and manufactured for safe operation and
maintenance. But it is ultimately the responsibility of the This manual should be read in
conjunction with other appropriate
installers, users and maintainers for safe operation and
supplied manuals, such as the vehicle
use of this equipment. Part of this responsibility is to read operation manual, engine operation
and be familiar with the contents of this manual before manual, etc.
beginning installation, operation or performing
maintenance actions.
NOTE
3.2 GENERAL INTRODUCTION The V-TEC Speed Controller system is an
The Display Module may be mounted anywhere within integrated part of the entire vehicle
system. When dealing with a malfunction,
the reach of the harness wire extension cable that
be aware that its solution may fall
connects it to the main trunk harness from the I/O beyond the scope of the V-TEC’s
module. However, there are several factors that must be capabilities to precisely diagnose and
taken into consideration before choosing the permanent pinpoint the problem specifically.
location for the Display Module, including:
Although the V-TEC message indication
• Protection from weather and extreme ambient may help to identify a particular problem,
conditions (water, heat and cold). the best approach to take when
diagnosing a malfunction is to consult all
literature pertinent to the vehicle,
NOTE including the compressor and/or
Display Module is rated to -4°F. generator operation manuals, and the
vehicle operation manual. For additional
• Ease of access for the operator to view and control assistance with problem diagnostics,
the various functions of the V-TEC system. consult the Vanair Service Department.
• Secured position, free of radio interferences and

excess machine vibration.
IN0078_r0 PAGE - 21
PART III: MOUNTING THE DISPLAY MODULE V-TEC® SPEED CONTROL SYSTEM
• Adequate bottom clearance for harness to plug in

A B (at least three [3] inches).
To get an idea of possible locations where the Display
Module may be mounted, consult Diagram 1.6 through
Diagram 1.9 in Part I - Pre-Installation.
C System Operation Group Manual Location

Section
D General Introduction 3.2 page 19

Mounting the Display Bracket 3.3 page 20
Seat Frame Mounting 3.3.1 page 21
Conventional Location Mounting 3.3.2 page 23
Transmission Hump Mounting 3.3.3 page 24
3.3 MOUNTING THE DISPLAY

A
BRACKET
KEY DESCRIPTION To assist with the task of choosing the best location for
the Display Module, Vanair has provided a versatile
A DISPLAY MOUNTING mounting bracket (Figure 3-1). This sturdy light-weight
BRACKET bracket contains a variety of mounting hole arrangement
B BRACKET MOUNTING HOLES possibilities. Utilizing any two of the five holes configured
on the bracket to the vehicle’s mounting surface allows
C DISPLAY MODULE MOUNT- for adaptability to location anchor points, and a solid
ING HOLES mounting contact position of the Display Module. Once
D PROFILE: DISPLAY MODULE the bracket is mounted, the Display Module can be
SHOWING PIVOT ANGLE pivoted and set at varying degrees about the bracket’s
RANGES mounting points for additional preferred angle
adjustments.
Figure 3-1: Display Mounting Bracket
IMPORTANT
Use only 1/4”-20 x 3/8” bolts with lock
washers to mount Display Module to
bracket. DO NOT use mounting bolts that
are longer than 3/8” to attach the Display
Module to its mounting bracket—this may
damage the circuit board inside.
System Operation Group Manual Location

Section
Mounting the Display Bracket 3.3 page 20
Seat Frame Mounting 3.3.1 page 21
Conventional Location Mounting 3.3.2 page 23
Transmission Hump Mounting 3.3.3 page 24
PAGE - 22 IN0078_r0
V-TEC® SPEED CONTROL SYSTEM PART III: MOUNTING THE DISPLAY MODULE
Common locations for mounting the Display Module

include:
• Directly to the passenger seat frame on the door- A
side of the seat.
• The transmission floor hump to the right of the
driver’s seat.
• The dashboard.
• An interior surface of the truck body’s wall.
The determined location may vary in accordance with the
vehicle manufacturer, model, age and/or the vehicle
owner’s needs and preferences.
Before beginning installation, make note that the
connection wires must be stationary once the Display
Module is mounted. Refer to Appendix A, Section A.2 B
for information on laying out and connecting harness
wires.
Although there are several types of seat and seat frame
designs that will serve well for the Display Module’s
mounting location, the final position must allow for:
• A stationary mounting surface or mounting surface
anchor points (as in the case of using seat frame
cross members)
• Display mount area needs to be interference-free
(a.k.a., the seat cushion does not overlap the C
module, or the seat adjustment does not interfere,
etc.).
• Enough room—at least three inches of clearance
from the module connection port to the cable
connector allow for the cable connection without
too much stress on the cable.
• Free movement of the door (opening and closing) KEY DESCRIPTION
without contact of the module.
A BRACKET MOUNTED TO HIGH
Figure 3-2 shows a few possible variations for a seat SEAT FRAME STRUT
frame or other general mounting location. However, for
explanatory purposes, this installation guide will detail B BRACKET-MOUNTED TO PLATE
version [C] of Figure 3-2, which utilizes the V-TEC ON HIGH SEAT FRAME STRUTS
display pivot bracket (Figure 3-1). The basic procedural C PIVOT BRACKET MOUNTED FOR
approach to mounting with this bracket can be readily LOW FRAME MOUNTING
adaptable to most any type of seat design or mounting
surface location that allows for the criteria previously Figure 3-2: Seat Frame Mounting
listed. Variations for Display Module
IN0078_r0 PAGE - 23
3.3.1 SEAT FRAME MOUNTING

Refer to Figure 3-1, Figure 3-3, Figure 3-4 and the
following procedure to install the pivot bracket for a seat-
A mount Display Module.
NOTE
Check the seat type before determining
position to mount the Display Module. Some
seat models, such as those with a bucket-type
design, use a seat frame whose outer rail
(mountable surface) moves as the seat is
B C adjusted. Such action will cause connection
wire distress.
If the seat frame’s mounting surface moves
KEY DESCRIPTION
from its position during adjustment of seat
A PASSENGER SIDE SEAT position, use the non-seat method (Section
3.3.2), or the transmission hump method
B STATIONARY SEAT FRAME (Section 3.3.3) to mount the Display Module.
C BRACKET-MOUNTING HOLES 1. Make sure the seat is adjusted to maximum

FOR DISPLAY MODULE forward position.
2. Using the pivot bracket’s holes ([B] in Figure
Figure 3-3: Seat-Mounting Location 3-1) as a template, position the bracket onto
the seat frame so that the Display Module
can be mounted in a location that is not
obstructive to the seat cushion padding, and
allows for seat adjustment.
A 3. Figure 3-3: Hold the bracket into place and
mark the drill holes [C] (x two [2] holes) on
the seat frame’s surface using a marking tool
to indicate the drill hole positions. Remove
the bracket.
4. Verify that, when mounted, the display panel
is clear of the seat cushion. This can be
B C verified by measuring the dimensions of the
seat frame’s surface against the dimensions
of the Display Module box, or by placing the
KEY DESCRIPTION
display box into the desired position on the
seat frame aligned to the hole indications
A PASSENGER-SIDE SEAT (from Step #3) for visual verification. Adjust
as needed to allow for fit.
B DISPLAY MODULE PIVOT
BRACKET 5. Drill the holes where indicated using a 1/4”
drill bit (to accommodate the 1/4-20 x 3/4”
C BRACKET MOUNTING BOLTS mounting bolts).
(1/4-20 X 3/4”) WITH LOCK NUTS
6. Use two 1/4”-20 x 3/4” bolts with lock nuts to
secure the Display Module mounting bracket
Figure 3-4: Mounting the Pivot Bracket to the exposed, stationary seat frame
(Figure 3-4).
7. Refer to Figure 3-5. If an additional access
hole is needed to run the Display Module
cable from the harness to the Display
PAGE - 24 IN0078_r0
Module’s connection port, take the following

issues into account before drilling the 1-3/8” A
diameter hole:
• Do not drill too close to the floor board/

crease; leave at least an inch or so in
order for the grommet to obtain a
complete purchase around the hole’s
rim. Locating the access hole too
close to the floorboard may also
expose the cable to being kicked or
jarred by personnel using the B
passenger-side seat.
• Do not drill too close to where the

Display Module will eventually be
located. Leave enough room to allow
for the least amount of bending for the
Display Module’s cable when it
connects to the module’s port.
8. Before drilling the access hole:
• Check the underside of the cab to

confirm that the hole can be drilled
without any interference. C
• Ensure that the module does not
interfere with door closing/closed door.
9. Drill the 1-3/8” diameter hole at the indication

point determined in Step #7.
10. Mount the Display Module to the bracket
using two (2) 1/4”-20 x 3/8” bolts with lock
washers.
IMPORTANT KEY DESCRIPTION
DO NOT use mounting bolts that are A Access hole drilled too close to
longer than 3/8” to attach the Display Display Module mounting loca-
Module to its mounting bracket—this may tion - Allows for too much stress on
damage the circuit board inside. connection cable after it is con-
nected
Once the bracket is mounted, it is recommended to run B Access hole drilled too close to
the main trunk harness before routing and connecting the floor seam - Grommet cannot get a
extension cables. Consult Part IV - Routing and full purchase around the hole; may
Connecting the Main Trunk Harness. interfere with door and/or passen-
ger entrance (cable may be kicked)
3.3.2 CONVENTIONAL LOCATION MOUNTING C Access hole shows adequate
location
There exists a large scope of possible locations for
mounting the Display Module. In addition to seat-frame
mounting, other areas may include the dashboard or on Figure 3-5: Mounting Display Module to
Pivot Bracket
IN0078_r0 PAGE - 25
the vehicle’s transmission hump on the cab floor. Consult

Figure 3-6 to see a few of these possibilities.
For explanatory purposes, this installation guide will
detail example [C] of Figure 3-6, which focuses on
transmission hump mounting. This procedure also
utilizes the V-TEC display pivot bracket (see Figure 3-1).
This bracket allows for versatility when choosing a
mounting location, and the basic procedural approach to
mounting with this bracket can be readily adaptable to
A most any type of seat design, or mounting surface
location, that allows for the criteria previously listed in
Section 3.3.
B NOTE
When positioning the mounting bracket for the
Display Module, be sure to allow for enough
room between the access hole and the
dimensions of the modular unit (when
mounted). Also keep in mind that the area
should also allow for enough room to lessen
an extreme bending angle of the harness
connect wire from the access hole location to
the module’s port connection.
3.3.3 TRANSMISSION HUMP MOUNTING

When mounting the Display Module on the transmission
hump confirm that the access hole location, as well as
the module designated placement area, do not interfere
with any seat movement or auxiliary dashboard items,
such as the pull-down cup holder, etc. Figure 3-7 shows
the Display Module mounted in a neutral position
between the driver’s and passenger’s seats, where it is
C accessible from either side. However, the module may be
situated at an angle to afford more direct access from
either the driver’s or passenger’s side. As long as the
access wire confides to the guideline practices of this
installation manual in that it is mounted for efficiency and
KEY DESCRIPTION care, the exact mounting position can be determined by
the customer at installation.
A PASSENGER SIDE OF DASH-
BOARD IN CAB 1. Measuring from the edge of the center
console as shown in Figure 3-7, determine
B REAR CAB: PIVOT BRACKET the location to drill the 1-3/8” access hole for
MOUNTED TO AVAILABLE FRAME the Display Module harness wire. Note that
the hole will be off-center of the hump due to
C TRANSMISSION HUMP FLOOR-
MOUNTED better alignment with the access port on the
module, which is located at the lower right
corner of the modular unit.
Figure 3-6: Seat Frame-Mounting
Variations for Display Module
PAGE - 26 IN0078_r0
A
B
A MEASUREMENT: Approximately 10 inches as mea- D MEASUREMENT: 1-3/8” diameter

sured from edge of console access hole
B MEASUREMENT: Approximately three inches as E FRONT EDGE OF CENTER CONSOLE

measured from edge of console
C DISPLAY MODULE MOUNTING HOLES FOR

BRACKET
Figure 3-7: Mounting Display Module - Transmission Hump Location
2. Refer to Figure 3-8. Place bracket on hump

at desired position, making sure that it will
not interfere with the dashboard or
dashboard function, and that the harness
cable will not be hampered or compromised
(a.k.a., overly bent, forced, etc.) when
connected. Once bracket is in place secure
with two (2) #14 x 1” self-tapping set screws
[A].
3. Figure 3-9: Attach the Display Module to the
bracket with two (2) ¼”-20 x 3/8” mounting
IMPORTANT
bolts and lock washers [E]. Use only 1/4”-20 x 3/8” bolts with lock
4. Refer to Figure 3-10: Connect the harness washers to mount Display Module to
wire plug to the module connection port [B]: bracket. DO NOT use mounting bolts that
Once the bracket is mounted, it is are longer than 3/8” to attach the Display
Module to its mounting bracket—this may
recommended to run the main trunk harness
damage the circuit board inside.
before routing the extension cables. Consult
Part IV - Laying Out the Main Trunk
Harness.
IN0078_r0 PAGE - 27
KEY DESCRIPTION
A A SELF-TAPPING SET SCREW (x 2)
B 1-3/8” ACCESS HOLE FOR HARNESS WIRE
(with grommet)
C DISPLAY MODULE MOUNTING BRACKET
Figure 3-8: Display Module Bracket - Transmission Hump Location
A
B A
B
C
C
D
E
D
KEY DESCRIPTION
A DISPLAY MODULE
KEY DESCRIPTION B DISPLAY MODULE CONNECTION PORT (9-Pin
Female Connector)
A DISPLAY MODULE
C PROGRAM ACCESS CONNECTION PLUG (9-Pin
B PROGRAM ACCESS PORT CON- Female Connector) - Program access connector plug
NECTOR CABLE END will not pair with Display Module
C ACCESS HOLE GROMMET D DISPLAY MODULE CONNECTION PLUG (9-Pin Male
Connector)
D HARNESS CONNECTION PORT
NOTE
E DISPLAY MODULE MOUNTING Never force the connection plug into the Display Module port.
BOLT AND LOCK NUT After plug is seated, secure and stabilize the connection by
tightening the two mounting screws on either side of the plug.
Figure 3-9: Mounting Display Module Hand-tighten for a snug fit—DO NOT overtighten.
Bracket - Transmission Hump
Location Figure 3-10: Display Module Connection
PAGE - 28 IN0078_r0
V-TEC® SPEED CONTROLLER SYSTEM PART IV: ROUTING AND CONNECTING THE MAIN HARNESS
PART IV:
ROUTING AND CONNECTING
THE MAIN HARNESS
4.1 GENERAL SAFETY WARNING

The products provided by Vanair® Manufacturing, Inc.,
are designed and manufactured for safe operation and maintenance procedure, the person or
maintenance. But it is ultimately the responsibility of the persons responsible should always be
installers, users and maintainers for safe operation and familiar with the safety guidelines
use of this equipment. Part of this responsibility is to read provided with the vehicle’s user manual,
and be familiar with the contents of this manual before compressor operation manual, and also
beginning installation, operation or performing any pertinent local, state and Federal
maintenance actions. safety regulations that may apply.
4.2 GENERAL INTRODUCTION

Before routing harnesses throughout the vehicle to
connect to the various system components, there are
several issues that the installer should be aware of. Keep
these issues in mind to perform a successful harness
installation with minimum connection wire routing (refer
to Appendix A, Section A.2):
• Follow compressor hose lines whenever possible.
• Follow factory harnesses layouts whenever
possible.
• DO NOT route against any sharp edges or hot
surfaces.
• Stay inside chassis frame.
• Wrap, clip or clamp all loose excess wire.
• Secure all wiring away from any moving or rotating
components.
• Be consistent when going over, under or around
cross members of the vehicle.
• Ensure all connectors are locked in securely.
• Ensure all connections are properly tightened.
The following table gives the layout and locations for

specifics on routing and connecting the main harness:
IN0078_r0 PAGE - 29
PART IV: ROUTING AND CONNECTING THE MAIN HARNESS V-TEC® SPEED CONTROLLER SYSTEM

Section
Genereal Introduction 4.2 page 27

Laying Out the Main Trunk Harness 4.3 page 28
Connecting the Module Components 4.4 page 29
I/O Module 4.4.1 page 29
Display Module 4.4.2 page 30
Installing the Sensor Connections 4.5 page 31
Temperature Thermistor Connection 4.5.1 page 32
Securing Thermistor Connection 4.5.2 page 33
Pressure Transducer Connection 4.5.3 page 34
Component Connections 4.6 page 35
Ground Terminal Connection 4.6.1 page 35
PTO Solenoid Connection 4.6.2 page 36
Power Connection 4.6.3 page 36
Under Dashboard Connecction 4.6.4 page 36
Cooler Fan Connection 4.6.5 page 38
(Optional) Genair Panel Connection 4.6.6 page 38
(Optional) Dual Pressure Switch 4.6.7 page 39
J1939 Vehicle Bus Connection 4.6.8 page 39
J1939 Resistor 4.6.8.1 page 39
4.3 LAYING OUT THE MAIN TRUNK

HARNESS
NOTE
To get an idea of the general locations of the key
Before connecting the harness plugs to installation features that will connect to the main trunk
their corresponding connection points, harness, consult Diagram 1.7 through Diagram 1.10
consult Appendix A, Section A.2 , which (depending upon the vehicle of installation) in Part I -
shows the proper way to secure Pre-Installation. In addition, consult the wiring diagram
connection wires. provided with the assembly package, and Appendix A,
Section A.1.
1. Using the diagram from Part I that best
matches the vehicle receiving the V-TEC
installation, locate, and temporarily connect,
the I/O connection wire on the harness to the
I/O module.
2. While adhering to the guideline points given in
Section 4.2, begin laying the various
PAGE - 30 IN0078_r0
harness cable wires toward their connection

points, following the vehicle’s cross-
members and structure, and keeping the
lines in parallel with prevously-run wires,
hoses and cables whenever possible. Do not
stretch or otherwise add strain on the wires.
A
NOTE
When laying out the preliminary routes of
the main trunk harness wires, do not
fasten with any permanent fasteners such B
as tie-down zips. Keep in mind that this
initial run may need to be adjusted in
order to accommodate all of the
connection points.
3. Once the main harness’s connection wires

are routed as far as they can go toward their
destination connection points, connect the
extension cables to the ends of the main
trunk harness connectors, and then continue
laying out the extension cables toward their
destination points.
4.4 CONNECTING THE MODULE

COMPONENTS
After the main trunk harness has been tentatively laid out
and routed throughout the vehicle, the main modules (I/O
Module and Display Module) can be connected. KEY DESCRIPTION
A LED LAMP
Section B ORIENTATION KEY
Connecting the Module Components 4.4 page 29
Figure 4-1: I/O Module Connection Pin
I/O Module 4.4.1 page 29 Array (50-pin)
Display Module 4.4.2 page 30
4.4.1 I/O MODULE

Refer to Figure 4-1. The main trunk harness connects
directly into I/O Module without any extension wire. This
module serves as the communication hub for the speed
control system. The pin connection configuration of the I/
O connector contains two, twenty-five pin clusters. Use a
5/32” Allen wrench to fasten the connector.
The I/O Module should be installed at its location per
instructions given in Part II: Mounting the I/O Module,
before it is connected to the trunk harness.
IN0078_r0 PAGE - 31
4.4.2 DISPLAY MODULE

Refer to Figure 4-2 (seat frame mounted display module)
or Figure 4-3 (hump-mounted Display Module). The
Display Module is connected to the main trunk harness
via an extension harness cable. The 6-pin connector
plugs into the main harness; the 9-pin connector plugs
into the Display Module.
Before the Display Module is connected, it should be
installed at its location, per instructions given in Part III:
Mounting the Display Module.
1. From above, thread the display module
harness connector wire and program access
port cable through the grommet and then
through the access hole toward the vehicle’s
under side.
2. Affix grommet to rim of access hole to prevent
the cables from wear along the access hole’s
edge.
3. Coil and secure the program access port
cable so that it is unobtrusive, yet available
A D B C
C B D
E
H
F G

A PASSENGER-SIDE SEAT E DISPLAY MODULE
B LOCK WASHER F ACCESS HOLE FOR DISPLAY MODULE
CONNECTION WIRE
C DISPLAY MODULE MOUNTING BOLT 1/4-20 x 7/8 G HARNESS PLUG FOR DISPLAY MODULE
D DISPLAY MODULE MOUNTING BRACKET (END) H PROGRAM ACCESS PORT CABLE
Figure 4-2: Display Module - Seat Mounted Wire Connection
PAGE - 32 IN0078_r0
KEY DESCRIPTION
A DISPLAY MODULE
B PROGRAM ACCESS PORT CONNECTOR
A CABLE PLUG
C 1-3/8” ACCESS HOLE PROTECTED BY
GROMMET
B D HARNESS CONNECTION PLUG
E DISPLAY MODULE MOUNTING BOLT
C
E
Figure 4-3: Display Module - Transmission Hump Mounted Wire Connection
to be uncoiled for programming the V-TEC

software via computer interfacing.
4. Run the Display Module wire under the
chassis, keeping in mind the strategy given
in Section 4.2, and Appendix A, Section
A.2, to its junction with the I/O harness wire.
5. Connect the Display Module wire plug to the
trunk harness wire’s Deutsch connector for
the Display Module wire.
6. Once connected, secure the Display Module
wire as shown in Figure 4-4 (also refer to
Section 4.2).
4.5 INSTALLING THE SENSOR

CONNECTIONS
Section
Installing the Sensor Connections 4.5 page 31
Temperature Thermistor Connection 4.5.1 page 32
Securing the Thermistor Connection 4.5.2 page 33

Pressure Transducer Connection 4.5.3 page 34
IN0078_r0 PAGE - 33
KEY DESCRIPTION
A DISPLAY MODULE
B DISPLAY MODULE CONNECTION
PORT (9-Pin Female Connector)
C PROGRAM ACCESS CONNECTION
A PLUG (9-Pin Female Connector) -
B Program access connector plug will
not pair with Display Module
D DISPLAY MODULE CONNECTION
C PLUG (9-Pin Male Connector)
D NOTE
Never force the connection plug into the dis-
play module port.
After plug is seated, secure and stabilize the
connection by tightening the two mounting
screws on either side of the plug. Hand-tighten
for a snug fit—Do not overtighten.
Figure 4-4: Display Module Connection
4.5.1 TEMPERATURE THERMISTOR CONNECTION

NOTE
Refer to Figure 4-5. The 3-pin connector plugs into the
The thermistor and transducer sensors main trunk. The black connector with the blue seal plugs
usually come pre-installed at the factory.
into the thermistor in the tee of the tank [E].
If the vehicle does not have the thermistor
installed where shown in Figure 4-4 (as • Use Loctite® 567 or equivalent pipe sealant on the
will be the case with a retro-installation) threads to prevent leaking at the connection port.
consult Section 4.5.
4.5.2 SECURING THE THERMISTOR CONNECTION
To secure the thermistor connector, refer to Figure 4-6
and the following procedure.
1. Coat the inside cavity of the thermistor base
[C3] with a dielectic grease.
2. Fasten the thermistor plug [C2] to the base
[C1], and carefully loop the cable length
around to allow for anchoring it to the
thermistor body (refer to inset B for proper
cable layout).
3. Fasten the cable to the thermistor body with a
zip- or securing-tie [B1] as shown in [B]. DO
NOT fasten the cable to itself—it should be
secured to a non-flexible anchor point only to
lessen movement of the cable wire.
PAGE - 34 IN0078_r0
KEY DESCRIPTION
A THERMISTOR (shown con-
nected at 1/2” port on tee)
B SEPARATOR SUMPTANK
FOR COMPRESSOR
C SIGHT GLASS
D LINE FROM COMPRESSOR
E TEE: 1-1/2” x 1/2” x 1-1/2”
C D E A B
Figure 4-5: Temperature Thermistor Connection
A B
B1
A1
C
C1 C3 C2
A VIEW (reference): Tee off of the receiver tank C VIEW: Thermistor Plug and Base Components
A1 RECEIVER TANK (Horizontal) C1 THERMISTOR BASE
B VIEW (reference - detail): Properly secured C2 THERMISTOR PLUG

thermistor connection
B1 Tie secures cable to a stable anchor point to C3 APPLICATION: Apply dielectric grease coating
minimize stress on connection wires to inside of base port cavity before inserting
thermistor plug
Figure 4-6: Thermistor Assembly and Mounting
IN0078_r0 PAGE - 35
NOTE 4.5.3 SECURING PRESSURE TRANSDUCER

The thermistor and transducer sensors
CONNECTION
usually come pre-installed at the factory. The 4-pin connector plugs into the main trunk. The 3-pin
If the vehicle does not have the thermistor connector with the purple seal connects to the pressure
installed where shown in Figure 4-5 (as
transducer, which is usually mounted either in the 1/4”
will be the case with a retro-installation)
consult Section 4.5.
port on the lid of the receiver tank (single pressure) as
shown in Figure 4-7, or at the dry side separator tank
pressure port on the tee opposite the blowdown valve as
shown in Figure 4-8, for dual pressure option.
A B
NOTE
The pressure sensor must be mounted
vertically (perpendicular to the ground),
so that any residual fluid remaining in the
sensor will drain.
NOTE
The pressure transducer must be able to
sense system pressure at all times.
1. Locate the access port where the transducer

is to be mounted, per single (Figure 4-7) or
KEY DESCRIPTION
dual (Figure 4-8) package design.
A RECEIVER SEPARATOR TANK LID
2. Remove any plugs (if present) from the
B PRESSURE SENSOR TRANS- access hole. For single pressure-designed
DUCER (plumbed directly to lid) packages, a 1/4” elbow may need to be
provided in order to mount the sensor in the
Figure 4-7: Pressure Transducer vertical position. If this is the case, use
- Single Connection
Loctite® 567 or equivalent pipe sealant on
the threads when plumbing the elbow to the
tank lid.
3. Install the transducer to the access hole; use
Loctite 567 or equivalent pipe sealant on the
threads ([B] in Figure 4-9) to prevent leaking
at the connection port.
NOTE
DO NOT use excessive amounts of pipe
sealant, and apply only to the threads.
Excessive pipe sealant application may
plug the transducer and cause faulty
readings.
4. Once the transducer base is set, unplug ([A]

in Figure 4-9) and fill the connector base
cavity [C] with dielectric grease to prevent
water from filling connection.
PAGE - 36 IN0078_r0
C KEY DESCRIPTION
A PRESSURE SENSOR TRANS-
DUCER
B DRY-SIDE TEE
C RECEIVER SEPARATOR TANK
D MINIMUM PRESSURE VALVE
A
D
B
Figure 4-8 Pressure Transducer - Dual Option Connection
4.6 COMPONENT CONNECTIONS

Section
Component Connections 4.6 page 35
Ground Terminal Connection 4.6.1 page 35

A
PTO Solenoid Connection 4.6.2 page 35
Power Connection 4.6.3 page 36
Under Dashboard Connecction 4.6.4 page 36 C

Cooler Fan Connection 4.6.5 page 36
(Optional) Genair Panel Connection 4.6.6 page 36
B
(Optional) Dual Pressure Switch 4.6.7 page 39
J1939 Vehicle Bus Connection 4.6.8 page 39
J1939 Resistor 4.6.8.1 page 39

KEY DESCRIPTION
4.6.1 GROUND TERMINAL CONNECTION A TRANSDUCER CONNECTOR
Refer to Figure 4-10. The ground wire from the harness B TRANSDUCER CONNECTOR
is extended beneath the chassis and connects to the BASE (apply Loctite 567 or
ground post of the vehicle’s battery. equivalent to threads only)
C Apply dielectric grease within

4.6.2 PTO SOLENOID CONNECTION connector base cavity
The PTO solenoid may be one of two design-types,
whereby the solenoid is either built into the PTO unit Figure 4-9: Transducer
(Figure 4-11, typical depiction), or the solenoid is remote- Connection Notes
IN0078_r0 PAGE - 37
KEY DESCRIPTION
A GROUND CABLE TO
BATTERY
Figure 4-10: Ground Terminal Connection
mounted (Figure 4-12, typical depiction). These two

figures show the solenoid connection to harness
extension cable connection end. The PTO solenoid
connector utilizes the 2-pin Packard design.
A
4.6.3 POWER CONNECTION
The power harness connection routes to circuit breaker,
then from circuit breaker to battery. Installer may need to
C
provide wire from circuit breaker to battery (+). The
B battery connection attaches at the battery’s positive post
(Figure 4-13). Remove the protective cover from the
post, secure to post terminal, and replace cover.
4.6.4 UNDER DASHBOARD / UNDER HOOD

CONNECTION
D
Refer to Figure 4-14 for general approach to under
dashboard wire routing. The under dashboard extension
KEY DESCRIPTION cable connects to this 12-pin connector. This cable is
A V-TEC HARNESS CONNECTOR used to interface the V-TEC system to the vehicle’s ECM
and TCM. This is also where the keyed ignition power is
B PTO SOLENOID CONNECTOR
interfaced.
C PTO UNIT
Run the harness wire up through the engine-side of the
D PTO SOLENOID
cab to the pre-drilled access hole (covered by grommet
patch) located on the wall that separates the engine
Figure 4-11: PTO - Built-in compartment from the passenger cab. Penetrate the
Solenoid Connection grommet patch, and run the cable through to the driver’s
PAGE - 38 IN0078_r0
A
A B C
KEY DESCRIPTION
KEY DESCRIPTION
A BATTERY
A GROUND CABLE TO BATTERY
B REMOVABLE DUST PROTECTOR
B PTO SOLENOID CONNECTOR
COVER
C PTO SOLENOID
C CONNECT POWER WIRE TO POSITIVE
D PACKARD 2-PIN CONNECTOR DETAIL POST ON BATTERY
Figure 4-12: PTO - Remote Solenoid Connection Figure 4-13: Battery Connection
A
B
C
KEY DESCRIPTION
A PRE-DRILLED ACCESS HOLE (Engine compartment-side view)
B PRE-DRILLED ACCESS HOLE (Cab-side view)
C SEIC WIRES
Figure 4-14: Under Dashboard Connection Wire Routing (Ford Super Duty F-350, F-450 & F-550)
IN0078_r0 PAGE - 39
side. Splice the needed connections to the Ford SEIC

A
wires.
4.6.5 COOLER FAN CONNECTION

Refer to Figure 4-15. The fan connection runs from the
main harness to the fan connector. Follow the hose
layout and cooler structure when running and securing
the harness line to the fan connector. The fan connection
utilizes the 2-pin Packard connector.
B The 12V weather proof NO/NC relay (the high current
switch for the fan) is connected at the main trunk
harness. This relay will be near the I/O Module.
4.6.6 (OPTIONAL) GENAIR PANEL CONNECTION

KEY DESCRIPTION
Refer to Figure 4-16. The mounting destination of the
A COOLER FAN Genair Panel (if included with the purchaser’s option) is
B FAN TO HARNESS located schematically at the discretion of the customer’s
CONNECTION needs. The generator extension harness is ten feet long
to accommodate the desired position. One end of this
Figure 4-15: Cooler Fan Connection harness is plugged into the trunk harness; the other end
plugs directly into the generator panel. If one harness is
not long enough, additional extensions may be ordered
(P/N 269028). These harnesses are designed to plug
NOTE daisy-chain style into each other to accumulate the
Daisy chain generator harness. desired overall length needed.
Figure 4-16: (Optional) Genair Panel Connection
PAGE - 40 IN0078_r0
Before attempting to mount the generator panel, be sure

to pre-measure the harness wire to make sure that the A
connection will reach the panel when mounted. If new
access holes are needed for the wires to reach optional
components, be sure to use grommets to alleviate sharp
edges that can damage the wires.
4.6.7 (OPTIONAL) DUAL PRESSURE SWITCH

Refer to Figure 4-17. The mounting destination of the
Dual Pressure Switch (if included with the purchaser’s
option) is located schematically at the discretion of the
customer’s needs. Before attempting to mount the dual
KEY DESCRIPTION
pressure switch, be sure to pre-measure the harness
wire to make sure that the connection will reach the panel A Harness connects to this switchI
when mounted. I Consult wiring diagram.
NOTE Figure 4-16: (Optional) Dual Pressure

Mount dual pressure assembly in a warm, Connection
dry area.
4.6.8 J1939 VEHICLE BUS CONNECTION NOTE

If cap is not left in place on the harness
Refer to Figure 4-18. The J1939 harness connects to the
connector for non-J1939 supported
3-socket plug near the end of the display harness. The vehicles, the V-TEC will show an “IO
other end plugs into the J1939 diagnostic port on the Comm Error”
vehicle near the driver’s feet. If it is not connected to the
vehicle, the V-TEC will show an “IO Com Error”.
The J1939 data link connector is usually located at the C
lower right of the driver’s cab, below and to the left of the
steering wheel. The J1939 vehicle bus connector serves
as the communication and diagnostic network hub link. A
This connection allows the V-TEC to data link directly to B
the vehicle. For specific information on the J1939
connector, consult the Vehicle Operation and/or
Diagnostics Manuals.
4.6.8.1 J1939 RESISTOR

KEY DESCRIPTION
Refer to Figures 4-18 and 4-19. On certain vehicle
models (Ford Super Duty and GM), the J1939 vehicle A J1939 ACCESS CONNECTOR
bus connection is not available. The J1939 connection PLUG (for non-bus)
for non-bus vehicles is found on the harness near to ON DISPLAY HARNESS WIRE
where the Display Module cable ends are located. Refer B CONNECTION CAP - Leave on if
to Figure 4-19, [A] and [D] for Display Module plugs; and vehicle does not possess a
the J1939 access wire’s connector [C]. J1939 vehicle bus.
For cases where the vehicle does not possess a J1939 C (x 2) CONNECTION PINS
DETAIL: Verify that connection
vehicle bus, leave the cap [B] in place on the harness
cap contains two pins as shown.
connector to operate (do not remove).
Figure 4-18: J1939 - Harness
Connection Cap
IN0078_r0 PAGE - 41
The cap should be checked in order to verify that it

contains two pins (Figure 4-18, [C]), which need to be
present for proper functioning. If these pins are missing,
contact the Vanair® Service Department.
A B
D
KEY DESCRIPTION
A DISPLAY MODULE PLUG
B MAIN HARNESS
C J1939 HARNESS CONNECTOR PLUG (for non-bus)
D DISPLAY MODULE PROGRAM ACCESS PLUG
Figure 4-19: J1939 Non-Bus Connection Location
PAGE - 42 IN0078_r0
V-TEC® SPEED CONTROLLER SYSTEM PART V: SYSTEM CHECK TEST
PART V:
SYSTEM CHECK TEST
5.1 PRE-TEST REVIEW
WARNING
maintenance procedure, the person or
persons responsible should always be
safety regulations that may apply.
Once the V-TEC Speed Controller has been installed a

start-up test is in order to verify that the system operates
correctly. But before commencing with the check start-up,
an overall review should be performed to confirm that all
steps have been completed in the assembly process.
Refer to TABLE 5A through TABLE 5C, which cover
post-installation/initial pre-start tasks that should be
checked before starting and testing the system.
NOTE
All V-TEC programming is factory-preset
for specific machine application. There is
no need to alter any software parameters
at installation.
The pre-test check run should not only include a review

of the V-TEC Speed Controller installation, but also all of
the comporessor system’s critical components, which will
be controlled either directly or indirectly, through the V-
TEC system. For this purpose it is beneficial to consult
the compressor (and/or generator, where applicable)
system operation manual. Vanair recommends
performing a compressor system routine maintenance
review, as given by the compressor system manufacturer
in the operation manual. The compressor system
IN0078_r0 PAGE - 43
PART V: SYSTEM CHECK TEST V-TEC® SPEED CONTROLLER SYSTEM
operation manual will assist to verify that the compressor

system components are in order and functioning
properly.
The pre-test check should also include an overall vehicle
inspection, as given by the vehicle manufacturer in the
vehicle’s operation manual. A vehicle inspection will
assist to verify that the vehicle operation components are
in order and functioning properly.
Use Table 5A, Table 5B and Table 5C as guides while
performing the pre-test review. If any problems are found
during the pre-test check, remedy the discretion and
continue on until all components of all systems are ready.
Should a problem or discretion be discovered during the
pre-test inspection that has to do with either the vehicle’s
compressor system or the vehicle itself, consult the
recommended actions given in the respective operation
manual(s) maintenance and/or troubleshooting sections.
If necessary contact the Vanair Service Department, or
the vehicle manufacturer service department, to remedy
any discretion found that is not covered or solved through
the operation manuals’ procedures.
Once the post-installation/pre-initial start-up checks have
been performed and the system is ready to start, follow
the prodecure given in Section 5.2, Test Procedure.
PAGE - 44 IN0078_r0
TABLE 5A: INITIAL POST-INSTALLATION/PRE-INITIAL START UP CHECKLIST  - Check () to verify
FOR COMPRESSOR SYSTEM
CRITICAL POSITION /ALIGNMENT INTERCONNECTIONS NOTES
COMPONENT • Item positioned and secured • All harnesses and lines are laid out correctly:
correctly. * No kinks or severe bends, no exposure
• Item’s interconnections with to sharp corners or edges
other system components are * All harnesses and lines are tied/secured
correctly aligned and secured at reasonable intervals (no loose hanging
lengths)
where needed
• Hoses and lines secured and properly connected
V-TEC® SPEED CONTROLLER SYSTEM
to components
• All valves and ports closed (where applicable)
PTO Gear Box

 
Driveline: Driveshaft and U-joints are in phase
Joints  
Compressor Unit Check oil level (vehicle on
IN0078_r0
  level surface) before testing:
add if necessary
Compressor Sump
 
Compressor Control
Lines  
Cooler
 
Generator (if present)
 
PAGE - 45
PART V: SYSTEM CHECK TEST
TABLE 5B: INITIAL POST-INSTALLATION/PRE-INITIAL START UP CHECKLIST  - Check () to verify
PAGE - 46
FOR VEHICLE
CRITICAL POSITION /ALIGNMENT INTERCONNECTIONS NOTES

COMPONENT
• Item positioned and • All hoses, harnesses and lines are laid out
secured correctly. correctly:
• Item’s interconnections with * No kinks or severe bends, no expo-

other system components sure to sharp corners or edges.
are correctly aligned and
* Verify that all harnesses are tied/
secured where needed
secured
• Hoses and lines secured and properly con-
nected to components
• All valves and ports closed (where applica-
ble)
ENGINE
IN0078_r0
(J1939 ACCESS)  
TRANSMISSION (PTO)
 
VEHICLE’S ACCESS TO V-TEC components do not
V-TEC COMPONENTS   interfere with any vehicle func-
tions.
V-TEC components shielded
from extreme temperatures
(too near engine), weather
(water exposure)
TABLE 5C: INITIAL POST-INSTALLATION/PRE-INITIAL START UP CHECK-  - Check () to verify
LIST FOR FOR V-TEC SYSTEM
CRITICAL COMPONENT Location will not hinder or be Item’s interconnections with other NOTES
affected by any other vehicle system components are correctly
operation aligned and secured properly where
they are needed
V-TEC SPEED
CONTROLLER  
DISPLAY MODULE
 
I/O MODULE
 
TEMPERATURE
THERMISTOR  
PRESSURE TRANSDUCER
IN0078_r0
 
MAIN TRUNK HARNESS
 
Power
 
Ground
 
Temperature
 
PSI
 
Fan (cooler)
 
Continued on next page
PAGE - 47
TABLE 5C: INITIAL POST-INSTALLATION/PRE-INITIAL START UP CHECK-  - Check () to verify
PAGE - 48
LIST FOR FOR V-TEC SYSTEM (CONTINUED)
CRITICAL COMPONENT Location will not hinder or be Item’s interconnections with other NOTES
affected by any other vehicle system components are correctly
operation aligned and secured properly where
they are needed
PTO
 
Display
 
Underhood
 
Display Programming
 
Generator (optional)
IN0078_r0
 
Dual PSI (optional)
 
ACCESS TO V-TEC V-TEC components do not
COMPONENTS   interfere with any vehicle func-
tions.
5.2 V-TEC TEST PROCEDURE

Vanair
Air Power To Go
IMPORTANT A D 001.060 I 001.060
Copyright 2007-8
DO NOT proceed with the test procedure
until all systems pass the pre-test review
as described in Section 5.1, Pre-test Service Intervals
Review 4 OK
B 0 Below 25%
0 Need service
5.2.1 KEY ON / ENGINE OFF
Refer to Figure 5-1 and the following procedure:
Hour Meters
Compress 0: 0: 2
1. Turn the vehicle key to the accessory position, so that the C Generator
High PSI
0: 0: 0
0: 0: 0
V-TEC powers up, but the truck engine is not running.
Observe the following:
• The red LED is illuminated on the I/O Module. Rpm 0 PSI 110
Compressor PSI 1
• The Display Module will display the Splash D Compressor °F 56
Screen [A], the hour meter page [C] and then
go to sleep.
2. Press the up or down arrows to scroll through the menus. Push ON/OFF key to
Become familiar with the order of the screens, and Activate PTO
functionality of the buttons. Refer to navigation map in E PSI Setting
Generator
110
On
operation manual.
3. Note that the hour meter page [C] displays the run time of KEY DESCRIPTION
the system.
A SPLASH SCREEN
4. Scroll to the status screen [D].
B SERVICE PAGE
• Engine RPM may show inaccurate data C HOUR METER PAGE
because the engine is not running.
D STATUS PAGE
• If applicable, turn generator switch on the E INTERLOCK PAGE
breaker panel on. The letters “GEN” will appear
on the top line of the V-TEC display screen to
Figure 5-1: V-TEC Top Level Screens
indicate that the generator is active. Turn the
generator switch off.
• The temperature reading should display

ambient temperature.
NOTE
If ambient temperature is less than 32ºF,
the temperature reading may be
inaccurate or read 0ºF.
IN0078_r0 PAGE - 49
• Pressure should read 0 PSI.
NOTE
It is normal for the pressure reading to
fluctuate between 0 and 1 PSI when the
compressor system is not running.
5.2.2 KEY ON / ENGINE ON

Refer to Figure 5-1 for top level T-VEC screen
identification.
1. Turn the ingition key to full position to start the engine.

Notice the following:
• V-TEC Display Module starts up, then goes to

sleep (Press any key to “wake up “ [re-
establish] the display).
2. Pressing the on/off button on the display will request

engagement of the PTO and the V-TEC will switch to the
interlock screen [E].
• If a safety interlock is present, remedy the

faulting condition (set the park brake, shift to
neutral, etc) before attempting to start
compressor.
3. If no faulting interlocks are present, press the On/Off key

to engage the PTO.
4. The PTO will engage, a message will appear “Engaging
PTO”, and a timer will begin counting. Once the V-TEC
begins sensing system pressure (ensuring that the PTO
is engaged), it will switch back to the status screen [D]
and ramp up the engine RPM.
NOTE
If the Engaging PTO timer reaches 25,
the PTO will disengage.
5. Once the system running, closely monitor the pressure

and the temperature.
• The Compressor PSI must read 5 PSI higher

NOTE than the PSI setting in the upper right corner.
Refer to compressor operator manual for For example, if the PSI setting is 110, adjust
regulator adjustment procedure. the regulator so that the Compressor PSI
reading is 115 (see Figure 5-2).
6. Check that the cooler fan turns on and off as it should.
PAGE - 50 IN0078_r0
7. On two speed systems, open and close the service valve

to check that the engine speed will fluctuate as it should. A
Ensure that when the service valve is closed that the
engine is at low idle. When the service valve is open, the
truck should be at full load speed (high idle). Rpm 1312 PSI 110
Compressor PSI 115
Compressor °F 190
B
KEY DESCRIPTION
A Top pressure reading is 5 PSI
lower than Compressor PSI
reading.
B Compressor PSI reading is 5 PSI
higher than top pressure
reading.
Figure 5-1: V-TEC Top Level Screens -

Example
IN0078_r0 PAGE - 51
BLANK PAGE
PAGE - 52 IN0078_r0
PART VI: TROUBLESHOOTING V-TEC® SPEED CONTROLLER SYSTEM
PART VI:
TROUBLESHOOTING
6.1 GENERAL INFORMATION
The information contained in this section has been
compiled from years’ worth of information gathered
from the field. It contains symptoms and usual
causes for the most common types of problems that
may occur. All available data concerning the trouble
should be systematically analyzed before undertak-
ing any repairs or component replacement.
A visual inspection is worth performing for almost all
problems and may avoid unnecessary additional
damage to the machine. The procedures which can
be performed in the least amount of time and with the
least amount of removal or disassembly of parts,
should be performed first. Adherence to a routine
maintenance regimen will minimize the occurrence of
many common problems. Refer to the V-TEC opera-
tion manual, the compressor system operation man-
ual, the engine operation manual, and the vehicle
operation manual to get an idea of a typical mainte-
nance regimen program.
Although Vanair® strives to anticipate situations that

may occur during the operation life of a machine
package, the Troubleshooting Guide may not cover
all possible situations. Be aware that additional trou-
bleshooting information may be found in other
sources such as the various operation manuals listed
above. Should the situation remain unresolved after
exhausting available sources, contact the Vanair Ser-
vice Department at:
800-526-8817
Phone: 800-526-8817 (toll free) www.vanair.com
MODEL NUMBER
Phone: 219-879-5100, ext. 400
SERIAL NUMBER
Fax: 219-879-5335 PSIG
MAXIMUM PRESSURE
COMPRESSOR INPUT RPM

NOTE 260940
When contacting the Vanair Service The serial tag is typically located in the
Department, please have machine serial driver’s side door jamb, or on the visor.
number on hand to quickly expedite
service. See Figure 6-1 for serial tag
Figure 6-1: Serial Tag and Number
identification and number location.
Identifciation/Location
IN0078_r0 PAGE - 53
6.2 TROUBLESHOOTING GUIDE - ERROR MESSAGES

DISPLAY SCREEN INDICATION CAUSE CORRECTIVE ACTION
ERROR MESSAGE
IO Module Com Error Display Module cannot Faulty J1939 channel wir- Confirm that it is connected to
communicate with the I/O ing the vehicle.
Click key to restart module
Check wiring. Replace if faulty
or damaged.
Power wiring to the I/O Check wiring. Replace if faulty

Module faulty or damaged
I/O Module is faulty Reprogram or replace I/O

Module
Setup Check Error Display Module memory Display Module is faulty Replace or replace both the
Setting to Defaults corrupted (most likely to Display Module and the I/O
occur when unit is first Module with the same software
Click key to restart powered up out of the version.
box.)
Display Module and Upon power up the Dis- I/O Module is faulty or out Reprogram or replace both the
I/O module mismatch. play Module confirms that of version. BOTH MOD- Display Module and the I/O
For Example: the I/O Module’s version ULES MUST HAVE THE Module with the same software
of the software does not SAME SOFTWARE VER- version.
D 001.061 match the Display’s ver- SION.
I 001.060 sion. This message
should only appear if a
(Display version shows module was replaced with
001.061, and I/O ver- an incompatible version.
sion 001060)
Display Module cannot
communicate with the I/O
NOTE:
Module.
If mismatched module
versions display after ini-
tial set up, then display
and/or I/O module may
be faulty.
Shift to Park Vehicle out of gear. Vehicle is not running. Start vehicle; put gear in Park or
or Neutral.
Shift to Neutral Faulty J1939 channel wir- Check wiring. Replace if faulty
ing or damaged.
NOTE: Restart system, or press ENTER key once error has been
resolved to reset speed controller system.
Set Parking Brake Vehicle in park or station- Safety interlock requires Set Parking Brake.
ary, but Parking Brake not that the Parking Brake is
set. set. Check wiring, and/or consult
vehicle operation manual.
Continued on next page
PAGE - 54 IN0078_r0
V-TEC® SPEED CONTROLLER SYSTEM PART VI: TROUBLESHOOTING
6.2 TROUBLESHOOTING GUIDE - ERROR MESSAGES

DISPLAY SCREEN INDICATION CAUSE CORRECTIVE ACTION
ERROR MESSAGE
Stop vehicle motion I/O Module senses vehi- Vehicle is moving. Stop vehicle. Put gear in Park or
cle not in gear. Neutral.
Consult vehicle operation

manual for vehicle issue.
Alarms must be clear Triggered alarm Speed controller will not be Check corresponding error mes-
condition is not resolved. accessible until alarm con- sage and remove faulty condition.
dition is cleared.
Sump PSI too high Sump pressure becomes Regulating valve out of Readjust valve setting.
higher than regulation set adjustment.
point
PTO Engage Fail Possible transducer loca- PTO did not engage. Make sure vehicle is stationary. Set
tion issue. in either Park or Neutral.
System does not begin
building pressure after the
25 second interval.
Disch. temp Cooling system Discharge temperature Check cooler fan or shut down sys-
problem over set point. tem to cool down.
Consult compressor system opera-
tion manual.
Faulty thermistor
Temp sender error Cooling system Thermistor unplugged for- Check that thermistor is plugged
problem more than 15 in.
seconds. Replace bad thermistor.
Faulty thermistor Consult compressor system opera-
tion manual.
IN0078_r0 PAGE - 55
BLANK PAGE
PAGE - 56 IN0078_r0
V-TEC® SPEED CONTROLLER SYSTEM APPENDIX A: ADDITIONAL INFORMATION
APPENDIX A: ADDITIONAL INFORMATION
A.1 VISUAL HARNESS-TO-COMPONENT CONNECTION

LAYOUT
C NO NC
269899_r0
IN0078_r0 PAGE - 57
APPENDIX A: ADDITIONAL INFORMATION V-TEC® SPEED CONTROLLER SYSTEM
A.2 WIRING LAYOUT GUIDE
wrong
right
wrong
1. Wire cables are weakened when installed in

twisted position. Lay cable wires as straight
to form as possible. right
2. Wire cable layouts should avoid sharp angles that

may add additional stress to wires (See # 3)
3. Avoid or buffer any possibility

of cable wires contacting any
sharp edges, which may
distress the wires.
4. Avoid any possibility of cable 5. Avoid routing cable wires parallel

wires coming within close to high power wires or other
contact of a hot surface. communication wires.
wrong
wrong right
right
wrong
right
6. When cable wires are installed

in a flexing application, remem- 7. Loop and zip-tie wire cable
ber that plug connectors are not endings near to the plug 8. Secure wire cables at intervals to
part of the flexible portion. Allow base to alleviate excess prevent any additional movement,
ample free length for flexling. flexing at the plug ends. which may cause undo stress.
PAGE - 58 IN0078_r0
V-TEC® SPEED CONTROLLER SYSTEM APPENDIX A: ADDITIONAL INFORMATION
A.3 CUMMINS/PACCAR ECM 60-PIN CONNECTOR (TYPICAL)
ORIENTATION
A A
B B
E
58 59 60
50
40
30
20
10
54 55>PA6T 66-GF33<56 57
89
6 7
ENGINE D
52 53
C C
4 5
51
41
2 3
31
21
11
1
KEY DESCRIPTION G
A B H
A RECEPTACLE - ENGINE / MALE
20
30
40
50
10
60
B CONNECTOR - PLUG / FEMALE

58 59
89
C ENGINE RECEPTACLE SLOT

C
54 55>PA6T/66-GF33<5657
(Use for orientation reference)

6 7
D SQUARE HOLE PIN #3 E

F
4 5
E SQUARE HOLE PIN #8

23
52 53
F PIN #28
51
D
1
21
31
41
11
G PIN #29
H PIN #38
IN0078_r0 PAGE - 59
APPENDIX A: ADDITIONAL INFORMATION V-TEC® SPEED CONTROLLER SYSTEM
A.4 EPA 2010 ECM 60-PIN CONNECTOR
ORIENTATION
A A
B B
E
60
50
40
58 59
30
ECM CONNECTED
20
10
<5657
8 9
TO ENGINE BLOCK
54 55 > PA6T 66-GF33

7
6
RECEPTACLE
52 53
C
5
4
51
2 3
41
31
21
11
1
ENGINE
BLOCK
RECEPTACLE
KEY DESCRIPTION
A RECEPTACLE - ENGINE / MALE A G H
B
B CONNECTOR - PLUG / FEMALE
20
30
40
50
10
60
58 59
C ENGINE RECEPTACLE SLOT

89

C
54 55>PA6T/66-GF33<56 57
7
D SQUARE HOLE PIN #3

6
(Use for orientation reference) E

E SQUARE HOLE PIN #8
4 5
(Use for orientation reference) F
F PIN #28
2 3
52 53
G PIN #29
51
D
1
31
41
21
11
H PIN #38
PAGE - 60 IN0078_r0
V-TEC® SPEED CONTROLLER SYSTEM APPENDIX B: WIRE ASSEMBLY
APPENDIX B:
WIRE ASSEMBLY
B.1 WIRE ASSEMBLY
INTRODUCTION
This appendix section describes good practice measures
to take when performing wire connecting tasks. Tasks WARNING
covered include splicing, soldering and sleeving. Many
troubleshooting issues that directly affect system perfor- Whenever performing any assembly or
mance as well as safety problems, can be avoided by maintenance work, always proceed with
using proper wire connecting techniques when installing stick adherence to the safety guidelines
any electrical component. found in the Safety Section, as well as
the vehicle manufacturer’s operator’s
Table B1 gives an overview of recommended tools and and/or service manual.
assembly items needed for wire assembly. The chart
below shows the breakdown of wire assembly tasks for
Appendix Section B:
TABLE B1: RECOMMENDED TOOLS
SECTION TITLE SECTION LOCATION AND ASSEMBLY ITEMS
KEY WIRE STRIPPER
Wire Assembly Introduction B.1 57 WIRE CUTTER
Wire Assembly - Conductor Preparation B.2 58 CRIMPER; CRIMPING TOOL
Wire Assembly - Soldered Splices: Meshed B.3 59 SPLICERS - ASSORTED
Wire Assembly - Soldered Splices: Lapped B.4 60
ELECTRICAL TAPE
Wire Assembly - Sleeving for Soldered B.5 61
HEAT SOURCE (heat gun, micro-torch,
Splices
et. al.)
Wire Assembly - Crimped Barrel Splices B.6 62
HEAT SHRINK TUBING
Wire Assembly - Crimped Splices: Double- B.7 63
Sided SOLDERING TOOLS: soldering iron,
flux
Wire Assembly - Heat Shrink Connector B.8 64
(1:1 Wires) ZIP TIES (where required)
Wire Assembly - Heat Shrink Connector B.9 65 ELECTRICAL TAPE

(2:1 Wires) ZIP TIES (where required)
CLEAN CLOTH (for wiping/drying)
IN0078_r0 PAGE - 61
APPENDIX B: WIRE ASSEMBLY V-TEC® SPEED CONTROLLER SYSTEM
B.2 WIRE ASSEMBLY - CONDUCTOR PREPARATION
B A
D
KEY DESCRIPTION
A Wire ends are cut flush at 90° so that each conductor wire is about the same length
B Insulation is cut/stripped flush and even around the conductor wires without damaging to wires’
integrity
C Exposed wire lengths should be long enough to allow for adequate conduction, but over long as
to allow for wire exposure beyond connecting points (refer to the other sections in Appendix B for
required lengths where applicable)
D Exposed wires should be smooth and snug without any separate strands being kinked or bent
when splicing or attaching
NOTES:
Whenever possible while running wires to be connected, try to avoid sharp angles - lessen the angles at which wires
are to be attached to avoid undue stress, which could break the wire or tear it loose from its fitting.
Whenever possible while running wires to be connected, avoid sharp edges. Contact with sharp edges will stress and
possible break the wire insulation or the wire itself.
PAGE - 62 IN0078_r0
B.3 WIRE ASSEMBLY - SOLDERED SPLICES: MESHED
A
A2
A1
B
B2
B1 B1
C B2
KEY DESCRIPTION
A VIEW - MESHING CONDUCTOR WIRES: Wire strands interlock smoothly (no kinks or bends) for an overlap of
minimum three (3) wire bundle diameter widths, but no more than five (5).
A1 Wire Bundle Diameter Width - The diameter of the complete wire bundle, including insulation covering.
A2 Meshing Overlap Length - The length of meshing overlap shown in [A] is at the acceptable minimum of three
wire bundle diameter widths.
B VIEW - SOLDER EDGE: The solder must be as flush as possible to the wire insulation on both sides of the sol-
dering; See [B1].
B1 Solder edge follows wire insulation edge as flush as possible.
B2 Sleeve Integrity - Uniform surface is not punctured by any conductor strands. Sleeving is wetted to both wires
with lead contour discernible. Appearance should be slightly discolored, but not burned or charred.
C VIEW - SLEEVING SURFACE CHARACTERISTICS: See [B2]
IN0078_r0 PAGE - 63
B.4 WIRE ASSEMBLY - SOLDERED SPLICES: LAPPED

A A2
A3
A1
A4
B A4
KEY DESCRIPTION
A VIEW - TWO CONDUCTOR LAPPING
A2 Wire Overlap Length of Meshing
A3 Three Wire Bundle Diameters - Meshing meets and exceeds the minimum of three wire bundle diameter
lengths
A4 Solder Form - Solder is wetted and forms a solid fillet along the entire length of the wires’ lapped edges
B VIEW - MULTIPLE CONDUCTOR LAPPING
C VIEW - TWO CONDUCTOR WIRE-BOUND ENFORCED LAPPING
D VIEW - MULTIPLE CONDUCTOR WIRE-BOUND ENFORCED LAPPING
NOTE: Lapped wires are always parallel and smoothly joined (no kinked or bent wires); all wire bundles are cut flush so
that each individual conductor within the bundle is of the same length.
PAGE - 64 IN0078_r0
B.5 WIRE ASSEMBLY - SLEEVING FOR SOLDERED SPLICES
A2
A2
A3
A3
A1
B
A2
A2
A3
A3
KEY DESCRIPTION
A VIEW - SLEEVING FOR TWO OVERLAPPED CONDUCTORS
A2 One Wire Bundle Diameter Width - The minimum amount of overlap for the sleeving to cover the wires
A3 Example - Meshing meets and exceeds the minimum one wire bundle diameter length
B VIEW - SLEEVING FOR MORE THAN TWO OVERLAPPED CONDUCTORS: Note that the wires running in
the same direction run parallel to each other and to the connecting conductor wire
NOTE: Lapped wires are always parallel and smoothly joined (no kinked or bent wires); all wire bundles are cut flush so
that each individual conductor within the bundle is of the same length.
IN0078_r0 PAGE - 65
B.6 WIRE ASSEMBLY - CRIMPED BARREL SPLICES
IDEAL
D1
A B C E
C
A F
E
D
ACCEP TABLE
D2
A F
A Barrel Splice D1 Ideal - Bare wires are as flush as possible

with the barrel edges for each end of barrel
B Crimp Location - Centered on barrel, all splice
wires are completely included within
crimp formation
C Barrel Ends - Bellmouth formation are D2 Acceptable - Minimal amount of wire showing
evident at both ends of barrel for com- between wire insulation edge and edge of
plete splice NOTE: Barrel should not be barrel splice
cracked or split
D SPLICE GAP RANGE E Wire Conductors to be Crimped
All wire bundles are cut flush so that each individual conductor within the bundle is of the same length.
PAGE - 66 IN0078_r0
B.7 WIRE ASSEMBLY - CRIMPED DOUBLE-SIDED SPLICES
B A B
D D
KEY DESCRIPTION
A Ends of wires are visible through the inspection windows
B Crimps are centered over barrels
C Bellmouth is evident
D Wire exposure is minimized by having wire insulation as flush to the crimp edge as possible (at
both ends of the splicer)
IN0078_r0 PAGE - 67
B.8 WIRE ASSEMBLY - HEAT SHRINK CONNECTOR (1:1 WIRES)
D D
A A
B C E E
F F
A Prepared Wires - Insulation stripped off uni- D Wire insulation edge is close to being flush
formly without damage to exposed wires with inner crimp edge
B Heat-shrink connector: one-to-one wire con- E Crimp to center of each exposed wire
nection ratio length
C Inner crimp F Shrink wrap extends/covers a minimum of

three (3) wire diameter widths on each side
NOTES
Apply heat source to entire outer surface of heat shrink connector, but DO NOT burn the wires: Sleeve may be dis-
colored but not burned or charred.
Contours of heat shrink are apparent, burt not sharp, nor are they pierced by any wire strands.
PAGE - 68 IN0078_r0
B.9 WIRE ASSEMBLY - HEAT SHRINK CONNECTOR (2:1 WIRES)
E E
B
A C D F F
A1
A2
G G
A Prepared Wires (for double-wire side) - Insula- C Heat-shrink connector: two-to-one wire con-
tion is stripped off of each wire uniformly, to nection ratio
approximately equal lengths, and without dam-
age to exposed wires
A1 For doubled-wire side, strip both insulation D Inner crimp

ends to equal lengths
A2 If possible, twist exposed wire ends together to E Wire insulation edge is close to being flush
maximize wire exposure contact between with inner crimp edge
wires
F Crimp to center of each exposed wire
(NOTE: keep wires as parallel as possible to length
minimize fraying)
B Single Prepared Wire - Insulation stripped off G Shrink wrap extends/covers a minimum of
uniformly without damage to exposed wires three (3) wire diameter widths on each side
NOTES
Apply heat source to entire outer surface of heat shrink connector, but DO NOT burn the wires: Sleeve may be dis-
colored but not burned or charred.
Contours of heat shrink are apparent, burt not sharp, nor are they pierced by any wire strands.
IN0078_r0 PAGE - 69
BLANK PAGE
PAGE - 70 IN0078_r0
BLANK PAGE
10896 West 300 North
Michigan City, IN 46360
Phone: (219) 879-5100
(800) 526-8817
Service Fax: (219) 879-5335
Parts Fax: (219) 879-5340
Sales Fax: (219) 879-5800
www.vanair.com
Printed in the U.S.A.

Specifications Subject to Change
Without Prior Notice

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V-TEC SPEED CONTROLLER SYSTEM

NOTE NOTE NOTE

FACTORY INSTALLED SYSTEM

NON-FACTORY INSTALLED SYSTEM

Register Your Warranty Online at www.vanair.com under the Support Tab!

PART I: PRE-INSTALLATION .................................. 1

PART II: MOUNTING THE I/O MODULE ................ 15

Continued on next page...

PART II: MOUNTING THE I/O MODULE (CONT.)

PART III: MOUNTING THE DISPLAY MODULE.....21

PART IV: ROUTING AND CONNECTING THE MAIN

Continued on next page...

PART IV: ROUTING AND CONNECTING THE MAIN

PART V: SYSTEM CHECK TEST............................ 43

PART VI: TROUBLESHOOTING............................. 53

APPENDIX A: ADDITIONAL INFORMATION ......... 57

APPENDIX B: WIRE ASSEMBLY ........................... 61

Continued on next page...

IN0078_r0 PAGE - III

APPENDIX B: WIRE ASSEMBLY (CONT.)

7. If the returned item, which in Vanair’s judgment is

8. Returned parts eligible for warranty must have the

Vanair® Manufacturing strives to continuously improve its

EXPERIENCE THE VANAIR® NOTE

IN0078_r0 PAGE - VII

Questions or problems pertaining to the operation or

Figure M-1: Manual Layout Navigation

PAGE - VIII IN0078_r0

The products provided by Vanair Manufacturing, Inc., are

1.1.1 SAFETY WARNINGS - ELECTRICAL SHOCK

• Use only well-maintained equipment. Repair or

1.2 GENERAL INTRODUCTION

TABLE 1A: V-TEC SPEED CONTROL PACKAGE CONTENTS

Dual PSI (optional) 269022 / 270471 1

This portion of the V-TEC Installation Instruction Manual

1.5 CONNECTION LOCATIONS

VEHICLE MODEL TYPE SECTION LOCATION

1.6 RECOMMENDED ITEMS AND

1.7 TYPICAL COMPONENT LAYOUT - FORD SUPER DUTY

KEY LEGEND Vehicle DETAIL AA

1.7 TYPICAL COMPONENT LAYOUT - FORD SUPER DUTY (350,

wiring harness hub location

Display ModuleI PART III – MOUNTING THE DISPLAY MODULE

Temperature Transducer 4.5.1 Temperature Thermistor Connection

4.5.2 Securing the Thermistor Connection

Ground Terminal 4.6.1 Ground Terminal Connection

PTO Solenoid 4.6.2 PTO Solenoid Connection

Power 4.6.3 Power Connection

Under Hood / 4.6.4 Under Dashboard / Under Hood Connection

Genair Panel 4.6.6 (Optional) Genair Panel Connection

Dual Pressure Switch 4.6.7 (Optional) Dual Pressure Switch

1.8 TYPICAL COMPONENT LAYOUT - FREIGHTLINER M2

1.8 TYPICAL COMPONENT LAYOUT - FREIGHTLINER M2

wiring harness hub location

Display Module PART III – MOUNTING THE DISPLAY MODULE

Temperature Transducer 4.5.1 Temperature Thermistor Connection

4.5.2 Securing the Thermistor Connection

Ground Terminal 4.6.1 Ground Terminal Connection

PTO Solenoid 4.6.2 PTO Solenoid Connection

Power 4.6.3 Power Connection

Under Hood / 4.6.4 Under Dashboard / Under Hood Connection

Genair Panel 4.6.6 (Optional) Genair Panel Connection

Dual Pressure Switch 4.6.7 (Optional) Dual Pressure Switch