Vmac 9036 Installation guide

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3

DOCUMENT 19627

Installation Manual

For The

System #9036

UNDERHOOD AIR COMPRESSOR

2000 FREIGHTLINER

CUMMINS M11 ISM FL 112

WITH AIR BRAKES - W/WO A/C

Installation Manual

VR7000 Underhood Air Compressor

System Number 9036

Application: 2000 Freightliner Cummins M11 ISM with air brakes, w/wo A/C

Publication Date: February 2001

Origination Documents: 19627a - Introduction

19627b - Installing the compressor

19627c - Installing the tank and lines

19627d - Installing the control unit &Throttle Commander

19628 - Illustrated parts list

19130 - Warranty registration

Registered Trademarks:

VR7000, VMAC and Throttle Commander are registered trademarks of VMAC.

Freightliner is a registered trademark of Freightliner Corporation.

Cummins is a registered trademark of Cummins Motor Company.

Loctite, Prime N’ Clean, 242 and PST are registered trademarks of Loctite Corporation.

Nylok is a registered trademark of Nylok Fastener Corporation.

Notice:

Manuals and products are subject to change without notice.

The contents of this manual may not be reproduced in any form without the express

written permission of VMAC

Contents

GENERAL INFORMATION ................................................................................................. 3

INTRODUCTION ........................................................................................................................ 5

INSTALLATION NOTES ................................................................................................................ 5

WARRANTY ............................................................................................................................. 6

ORDERING PARTS ...................................................................................................................... 7

SYSTEM IDENTIFICATION NUMBER PLATE .................................................................................... 7

CHANGES AND IMPROVEMENTS ................................................................................................... 7

PART 1: INSTALLING THE COMPRESSOR AND OIL COOLER ................................ 9

1.1 PREPARING FOR INSTALLATION .......................................................................................... 11

1.2 INSTALLING THE BRACKET AND COMPRESSOR ...................................................................... 12

1.3 INSTALLING THE OIL COOLER ............................................................................................ 16

1.4 COMPLETING THE INSTALLATION ...................................................................................... 18

PART 2: INSTALLING THE AIR TANK AND LINES ................................................... 19

2.1 INSTALLING THE TANK MOUNTS AND THE TANK .................................................................. 21

2.2 CONNECTING THE AIR AND OIL LINES ................................................................................ 23

2.3 ADDING OIL TO THE SYSTEM ............................................................................................ 26

2.4 COMPLETING THE INSTALLATION ...................................................................................... 26

PART 3: INSTALLING THE CONTROL UNIT AND THROTTLE COMMANDER .. 27

3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 29

3.2 CONNECTING THE WIRING ................................................................................................ 31

ILLUSTRATED PARTS LIST.............................................................................................. 35

WARRANTY REGISTRATION .......................................................................................... 41

1

DOCUMENT 19627

2

General Information

System #9036

2000 FREIGHTLINER

CUMMINS M11 ISM

WITH AIR BRAKES - W/WO A/C

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 19627

4

5

DOCUMENT 19627

General Information

Introduction

This book provides installation instructions for:

VMAC underhood air compressor installation kit

VMAC Throttle Commander

This kit has been designed for:

2000 Freightliner Cummins M11 ISM with air brakes - w/wo A/C

Installation steps

The installation procedure in this manual has four main steps:

Part 1: Installing the Compressor

Part 2: Installing the Oil Cooler, Air Tank and Lines

Part 3: Installing the Control Unit

Part 4: Installing the Throttle Commander

Terms and symbols

This manual uses the following terms and symbols:

•OEM - Original Equipment Manufacturer

•HHCS - Hex Head Cap Screw (also called a hex bolt)

•SHCS - Socket Head Cap Screw (also called an Allen head bolt)

This symbol indicates that there is additional information or special emphasis on a

specific procedure.

This symbol indicates that there is a possibility of personal injury or damage to the

equipment if the indicated warning is not followed.

WARNING

✁

NOTE

6

DOCUMENT 19627

Installation Notes

1. It is important that you complete all the installation steps before operating the system.

Refer to the Owner’s Manual before operating the system for the first time.

2. Follow all safety precautions for underhood mechanical work.

3. Use Loctite 242 or equivalent on all engine-mounted fasteners.

4. All hoses, tubes and wires which are re-routed or shifted during installation must be secured

so that they do not contact excessively hot areas or sharp edges. Where possible, follow

the routing instructions in this manual.

5. These installation instructions are intended as a general guide. In some instances, due to

variations in vehicle manufacture or if prior modifications have been made to the vehicle, it

may be necessary to carry out grinding, bending or rearranging operations for correct fit.

These operations must follow sound, standard shop practices.

6. Left and right definitions in this manual are determined when sitting in the driver’s seat,

facing forward.

7. All fasteners must be of the correct size and torqued according to the specifications shown

below. Torque specifications are in foot pounds (ft-lb).

DANGER

Never operate the system unless the vehicle transmission is in neutral (standard

transmission) or park (automatic transmission) with the park brake fully applied. A

sudden increase in engine RPM when the system is engaged will cause the vehicle to

move suddenly if the transmission is left in drive.

STANDARD GRADE 8 NATIONAL COARSE THREAD

Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4

Foot-pounds 9 18 35 55 80 110 170 280

STANDARD GRADE 8 NATIONAL FINE THREAD

Size 3/8 7/16 1/2 5/8 3/4

Foot-pounds 40 60 90 180 320

METRIC CLASS 10.9

Size M8 M10 M12 M14 M16

Foot-pounds 19 41 69 104 174

WARNING

✁

The above fastener torque values are applicable when Loctite is used .

If the threads are dry add 20% to the torque values.

Warranty

The VMAC warranty form is located at the back of this manual. This warranty form must be

completed and mailed or faxed to VMAC at the time of installation for any subsequent warranty

claim to be considered valid.

7

DOCUMENT 19627

System Identification Number Plate

The enclosed System Identification Number Plate (S/N) must be attached to the vehicle at the time

of installation. Locate the S/N plate on the composition fan shroud on the passenger side of the

vehicle below the fan warning decal (Figure 0.1). Drill the two hole locations using a 7/64” drill bit.

Place the S/N plate in position and fix in place with the two #6 pan head self tapping screws

provided.

Figure 1

IMPORTANT

This S/N plate provides information, which allows VMAC to assist in customer inquiries and/or

ordering of parts. It is important that this S/N plate is affixed to the vehicle.

Changes and improvements

These products and documents are subject to changes or improvements without notice.

Mount the s

y

stem ID plate here

Ordering Parts

To order parts, contact VMAC at:

Telephone 250-754-6997

Facsimile 250-754-6972

Office Hours 8:00 AM to 4:30 PM Pacific Time

Please quote the VMAC part number, the description and the quantity.

8

Special installation notes

If you intend to use an auxiliary air receiver with this system you must observe the following

installation procedure (Figure 2) . Failure to observe this procedure will result in damage to the

system.

1. The line from the VR7000 tank to the auxiliary air receiver must have a one-way check

valve installed to prevent blowback from the auxiliary tank and to prevent moisture from

entering the VR7000 tank.

2. The line to the auxiliary tank must not be installed in the bottom of the tank, but must be

installed as high as possible to prevent water from clogging the line.

DOCUMENT 19627

VR7000 Tank

Auxiliary Receiver

One-way check valve

Install the line as high as

possible, NOT on the

bottom of the tank

Figure 2

Part 1

Installing

the Compressor

and

Oil Cooler

System #9036

2000 FREIGHTLINER

CUMMINS M11 ISM

WITH AIR BRAKES - W/WO A/C

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 19627

10

11

Remove the fan

and shroud together For added clearance,

remove these bars

Remove the upper rad

hose and coolant tube

Remove the intercooler

tube

Part 1: Installing the Compressor and Oil Cooler

1.1 Preparing for installation

1. Disconnect the batteries (positive terminal first). Cover the battery terminals with the

OEM plastic protectors or use a battery cover to prevent the terminals from being

shorted when the steel braid air lines are installed.

2. Drain the coolant from the radiator and the engine block. Remove the upper radiator

hoses and metal tube. Remove and discard the rubber connector tube from the engine

end.

3. Remove and discard the metal cross-over tube and rubber connector hose that connect

between the surge tank and the fitting on the lower radiator hose. The hose connected

to the surge tank must remain.

4. Remove the radiator support bars which run from the radiator to the firewall on the

driver’s side of the truck (Figure 1.1). Be sure to remove the hose support retainers

before attempting to remove the bars.

5. Remove the intercooler tube which runs across the top of the engine (Figure 1.1).

6. Remove the six (6) cap screws holding the fan to the clutch assembly and the fan

shroud to the radiator supports and remove both the fan and the shroud (Figure 1.1).

7. Remove OEM drive belt. Remove the cap screws and remove the OEM crank pulley.

8. Drain the air brake reservoirs on the truck.

Figure 1.1

DOCUMENT 19627

9. If the vehicle is equipped with air conditioning, remove the cap screws holding the

compressor to the mounting bracket. Place a protective cover on the valve cover, lift

the compressor up onto the engine valve cover and secure it in place with a piece of

wire.

Do not disconnect any air conditioning lines from the compressor.

10. Remove the six (6) fasteners holding the OEM air conditioning mounting bracket to

the side of the cylinder block and remove the bracket.

11. Remove the OEM hex head cap screws holding the flat plate with the belt tensioner to

the front of the engine. Remove the OEM tensioner from the mounting bracket and

discard the bracket and cap screws.

12. Remove any additional OEM cap screws required for attaching the VR7000

replacement plate (Figure 1.2).

Figure 1.2

12

The VR 7000

bracket requires

these locations

fo r mou nting

Replace this

capscrew

NOTE

1. Make sure that the mounting area for the crank pulley is clean. Fit the VR7000 crank

pulley to the crankshaft (Figure 1.3). Apply Loctite to the 10 mm cap screws and

install them. Torque the fasteners to specifications.

2. Place the supplied replacement tensioner plate on the front of the engine. Apply

Loctite and install the 7 (seven) 8 mm socket head cap screws. Torque them to

specifications.

3. After the plate has been installed on the engine, make sure that all of the holes in the

front cover have hex head cap screws installed. Install the supplied 8 x 25 mm full

thread hex head cap screw (without a washer) in the location shown in Figure 1.2

along with the air brake pipe securing clamp. If there are other empty holes, install

the short OEM cap screws in those locations and torque them to specifications.

1.2 Installing the bracket and compressor

DOCUMENT 19627

13

Socket head

cap screws

Hex head

cap screws

Hex head

cap screws

4. Place the compressor mounting bracket in position on the driver’s side of the engine.

5. Apply Loctite and install four (4) 10 mm hex head cap screws into the four (4)

locations on the side of the timing cover and two (2) 10 mm socket head cap screws

on the side of the cylinder block (Figure 1.4). Secure the wire harness retainer behind

rear lower cap screw. Torque the fasteners to specifications.

6. If the vehicle is not equipped with air conditioning, remove the two hex head cap

screws from the top of the VR7000 bracket and remove the A/C mounting cradle

using the 1/4” NC jacking bolt in the threaded hole in the center of the mounting

cradle (Figure 1.5).

Figure 1.3

Figure 1.4

DOCUMENT 19627

14

Tensioner

Idler

Jacking hole

Bolts

Dowel pins

7. Install the OEM tensioner on the stud located on the front mounting plate. Apply

Loctite, install the OEM retaining nut and torque to specifications (Figure 1.5).

8. Remove the 12 mm hex head cap screw from the VR7000 tensioner. Apply Loctite,

install and torque to specifications. Remove the 1/2” cap screw holding the A/C back

idler on the tensioner plate, apply Loctite and torque it to specifications.

9. Install the A/C compressor in place on the VR7000 bracket. Apply Loctite, install the

cap screws and torque to specifications.

10. Install the 8 rib OEM drive belt and the supplied A/C drive belt (Figure 1.7).

Figure 1.5

Figure 1.6

Install this hose before installing compressor (1/4 pressure control line)

DOCUMENT 19627

11. Remove the idler from the VR7000 bracket. Apply Loctite to the 1/2” flange hex

head cap screw, re- install it and torque to specifications.

12. Install the 90 degree end of the 1/4” x 127-1/2” pressure control line to the 90 degree

fitting on the side of the air inlet valve on the compressor. Align the line so that it is

parallel with the compressor, facing to the rear and tighten the fitting (Figure 1.6).

This line must be installed before the compressor is mounted. Once the

compressor is mounted you will not be able to access this fitting.

13. Place the compressor on the mounting bracket.

14. Install flat washers on the three (3) 8 mm hex head cap screws, apply Loctite, thread

them into the compressor through the bracket and torque them to specifications.

A/C compressor VR7000 com pressor

VR7000 idler

VR7000 tensioner

A/C tensioner

OEM A/C

drive

A/C back

id le r

15

Oil cooler

Remove this cap screw

to mount the support bracket

Intercooler tube

NOTE

Figure 1.7

Figure 1.8

DOCUMENT 19627

1.3 Installing the oil cooler

1. Remove the fender liner from the passenger side of the engine compartment.

2. Remove the back three (3) hex head cap screws holding the manifold to the cylinder

head. Also remove and discard the back outer cap screw from the intercooler flange

mount at the turbocharger (Figure 1.8).

3. Place the cooler assembly in position on the side of the engine and over the back of

the valve cover.

4. Apply Loctite to three (3) 10 x 55 mm hex head cap screws and install them through

the cooler mount plate and into the manifold.

5. Apply Loctite to the hex head cap screw and install it into the support bracket and into

the intercooler flange mount hole.

6. Locate the cab heater return hose where it connects to the vacuum flow control valve.

Cut the hose 19” from the heater control valve, place hose clamps over the ends,

install the supplied Y-fitting (Figure 1.9) and tighten the clamps.

7. Install hose clamps and insert the supplied 3/4” x 14” section of hose between the Y-

fitting and the forward hose fitting on the oil cooler. Tighten the clamps.

16

Heater control valve

Coolant

overflow

ta nk

Heater return hose Y-fitting

Steel coolant line

Water pump

Intercooler tube

Oil cooler

3/4 hose

5/8 hose

3/4 hose

Transmission cooler Standard

transmission

5/8 hose

Automatic transmission

19

Protective loom

(discarded)

Figure 1.9

DOCUMENT 19627

17

Remove

this pluG

Front

1/2 x 16

Replacement hose

8. Remove the 1/2” x 16 plug from the water pump (Figure 1.10) and install the supplied

1/2” x 16 90 degree hose barb fitting.

9. Install hose clamps and insert the supplied 5/8” x 54” hose between the hose barb at

the pump and the rear fitting on the oil cooler.

10. Install plastic loom protector to the hose. Make sure that you route this hose over the

intercooler tube and away from the hot turbocharger and exhaust. Locate the plastic

loom where the hose passes over the intercooler tube.

11. Install hose clamps and insert the 46-1/2” x 1” replacement hose between the coolant

overflow container and the fitting on the lower radiator return tube. Route this hose

across the front of the engine, behind the A/C compressor and secure it so that it does

not contact the fan or other moving parts.

12. Use a nylon tie to fasten the hose from the cooler and the hose from the overflow

cannister together (Figure 1.11).

Figure 1.10

Figure 1.11

DOCUMENT 19627

18

NOTE

1.4 Completing the installation

1. Install the top radiator tube with the replacement hose on the engine end (with the top

end forward) and tighten the clamps (Figure 1.11).

2. Remove the nut retaining the driver’s side hood strap and install the radiator tube

support under the strap to prevent the tube from rubbing against the A/C compressor

pulley (Figure 1.12).

3. Install the spacer and the fan on the clutch hub. There are two different fan clutches

uses on this model, Horton or Kyser.

The Horton fan clutch has an air connection at the top. Install the fan spacer with a 2-

1/2” diameter center using Loctite on the supplied 3/8” x 1” flange lock cap screws.

The Kyser fan clutch has the air connection at the bottom. Install the fan spacer with

a 2” diameter center using Loctite on the supplied 3/8” low profile nuts. Do not

overtighten the nuts.

4. Fill the cooling system with the manufacturer recommended coolant to the correct

level.

5. Install the support bars back into position and attach any hose retainer clamps to the

bars.

When operating the engine for the first time following installation, be sure to allow

the engine to reach full operating temperature and ensure that the cooling system

level is correct. Failure to do so could result in an overheat condition and possible

engine damage.

Figure 1.12

DOCUMENT 19627

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Vmac 9036 Installation guide

Vmac 9036 Installation guide

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