Vmac V900073 Installation guide

0

UN DERHOOD A IR CO MPRES SOR S

THE BENCHMARK IN INNOVATION

1333 KIPP ROAD NANAIMO B.C. V9X 1R3

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Installation Manual

For The

2003 FREIGHTLINER FL60-FL70

MERCEDES MBE 900, W/WOAB

System # V900073

Installation Manual Document Number: 1930024

VR70 Underhood Air Compressor

System Number V900073

Application

2003 FREIGHTLINER FL60-FL70

MERCEDES MBE 900

Publication Date: Revised by T. W. Mitchner, 26 August 2003

Notice

Manuals and products are subject to change without notice.

Registered Trademarks

VR70, VMAC and Throttle Commander are registered trademarks of VMAC.

FL60-70 and MBE 900 are registered trademarks of Freightliner and Mercedes Benz.

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

Nylok is a registered trademark of Nylok Fastener Corporation.

The contents of this manual may not be reproduced in any form without express, written permission.

Contents

PART 1 GENERAL INFORMATION ............................................................................................. 3

1.1 INTRODUCTION............................................................................................................................ 5

1.2 INSTALLATION STEPS................................................................................................................... 5

1.3 TERMS AND SYMBOLS ................................................................................................................. 5

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

1.5 SYSTEM IDENTIFICATION NUMBER PLATE.................................................................................... 6

1.6 WARRANTY................................................................................................................................. 7

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

1.8 TOOL REQUIREMENTS.................................................................................................................. 7

1.9 SPECIAL INSTALLATION NOTES.................................................................................................... 8

1.10 CHANGES AND IMPROVEMENTS ................................................................................................. 8

PART 2 PREPARING FOR INSTALLATION............................................................................... 9

2.1 PREPARATION FOR INSTALLATION............................................................................................. 11

PART 3 INSTALLING THE AIR TANK AND LINES ............................................................... 15

3.1 INSTALLING THE TANK BRACKETS............................................................................................. 17

3.2 INSTALLING THE C-CLAMPS ...................................................................................................... 17

3.3 INSTALLING THE TANK AND LINES............................................................................................. 18

3.4 ALTERNATE TANK MOUNTING FOR 2000 MODEL YEAR TRUCKS ................................................ 19

PART 4 INSTALLING THE COMPRESSOR AND OIL COOLER ......................................... 21

4.1 COOLER INSTALLATION............................................................................................................. 23

4.2 INSTALLING THE MAIN BRACKET ............................................................................................... 26

4.3 INSTALLING THE COMPRESSOR .................................................................................................. 28

4.4 INSTALLING THE VR IDLER/TENSIONER BRACKET..................................................................... 29

4.5 INSTALLING THE CRANK PULLEY AND VR BELT ........................................................................ 30

4.6 ATTACHING THE LINES TO THE COMPRESSOR ........................................................................ 31

4.7 INSTALLING THE FAN SPACER .................................................................................................... 33

4.8 COMPLETING THE INSTALLATION .............................................................................................. 34

4.9 ADDING OIL TO THE SYSTEM ..................................................................................................... 35

PART 5 INSTALLING THE CONTROL COMPONENTS ........................................................ 37

5.1 INSTALLING THE CONTROL PANEL ............................................................................................. 39

5.2 INSTALLING THE SWITCHING BOX.............................................................................................. 39

5.3 CONNECTING THE WIRING ......................................................................................................... 41

5.4 BRAKE SYSTEMS........................................................................................................................ 42

5.5 INSTALLING THE THROTTLE....................................................................................................... 44

5.6 FINAL TESTING AND ASSEMBLY................................................................................................. 47

5.7 ADJUSTING THE THROTTLE........................................................................................................ 48

PART 6 ILLUSTRATED PARTS LIST......................................................................................... 51

WARRANTY..................................................................................................................................... 57

Page 1

Page 2

DOCUMENT #1930024

Part 1

General Information

System #V900073

2003 FREIGHTLINER FL60-FL70

MERCEDES MBE 900 W/WOAB

UNDERHOOD AIR COMPRESSORS

Page 3

Page 4

1.1 Introduction

This book provides installation instructions for the VMAC underhood air compressor installation kit.

1.2 Installation steps

The installation procedure in this manual has four main steps:

• Preparing for Installation

• Installing the Air Tank and Lines

• Installing the Compressor and Oil Cooler

• Installing the Control Components

1.3 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.

1.4 Installation notes

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

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 suggestions 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 following

specifications. Torque specifications are in foot pounds (ft-lb) and are only applicable when

Loctite is used. If the threads are dry, add 20% to the torque values.

Page 5

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

Table 1 Torque Specifications

Hose diameter Color coded label Part number prefix

1/4” Yellow 173

5/16” Orange 174

1/2” & 5/8” Blue 175 & 176

3/4” & 1” Green 177 & 178

Table 2- Hose color codes

Table 2 above illustrates the color code used by VMAC to define the different hose diameters.

Check that system hoses are all tight before running the system. Refer to setup procedure in the

Owner’s Manual before attempting to run this air system.

Different frame designations will affect the tank mounting position. You may have to move the tank

rearward from the standard position on your application. If you must move the tank, the lines may be

too short. If this is the case, measure the hose shortfall and order a “Hose Extender Kit”, P/N

(A410XXX). The last three digits in the P/N indicate the length of the extension, for example,

A410055 is a 55-inch hose extender kit.

1.5 System identification number plate

The System Identification Number Plate included with the kit must be attached to the vehicle at

the time of installation. Locate the plate as shown below. Mark and drill two holes using a 7/64”

drill bit. Secure the plate in position using the supplied #6 pan head, self-tapping screws.

Page 6

1.6 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.

1.7 Ordering parts

To order parts, contact your nearest VMAC dealer.

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

You must also quote the number from the System Identification Number Plate to ensure that you

get the right parts.

1.8 Tool requirements

The following tools are required for compressor installation:

• 1/2” drive metric socket set

• 8 –24 mm metric wrench set

• 1/2” drive SAE socket set

• 7/16 – 1 1/4” SAE wrench set

• Allen key sets – metric and SAE

• mechanic’s screwdriver set

• nut drivers – 5/16”- 3/8”

• 1/2” drill with assorted bits up to 1/2”

• hacksaw or zip wheel suitable for cutting metal

Page 7

The following tools are required for throttle component installation:

• small soldering gun or soldering pen

• wire cutters

• wire strippers

• crimping tool

• digital multi-meter – preferably with a frequency (Hz) setting

• small jeweler’s screwdriver set for the adjustment of the throttle control

1.9 Special installation notes

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

the following installation procedure. Failure to observe this procedure will

result in damage to the system.

1. The line from the VR70 tank to the auxiliary air receiver must have an auxiliary check valve

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

the VR70 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.

VR70 Tank

A

uxiliary check valve

possible, NOT on the

bottom of the tank

Install the line as high as

A

uxiliary Receiver

1.10 Changes and improvements

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

Page 8

DOCUMENT #1930024

Part 2

Preparing for Installation

System #V900073

2003 FREIGHTLINER FL60-FL70

MERCEDES MBE 900 W/WOAB

UNDERHOOD AIR COMPRESSORS

Page 9

Page 10

2.1 Preparation for installation

Intercooler tube

Figure ? – Remove the intercooler tube and radiato

r

Figure ? – Disconnect the batteries

1. Disconnect the battery.

2. Disconnect all of the electrical connections running to the hood.

3. Unbolt and remove the hood.

4. Drain the coolant into a suitable container.

Figure ? – Releasing the cooler hose clamp

5. Undo the hose clamp restraining the oil hoses running to the oil cooler. Undo the 4 bolts

securing the oil cooler, and move the cooler to the side with the oil lines still attached. Give

adequate protection to the cooler.

Page 11

6. Unbolt and remove the passenger side inner fender.

7. Undo the four bolts that hold the passenger side bumper section and swing it out of the way

for easier access.

8. Unclip the two small hoses running from the coolant expansion tank at the radiator and water

pump. Leave them connected to the expansion tank and secure them out of the way

9. Undo all of the hose clamps on the air filter intake hose assembly. Remove the pipes and

hoses in separate component parts.

10. Remove all of the fasteners securing the air filter assembly. Remove the air filter.

11. Disconnect the top radiator hose at the radiator only

12. Disconnect the two hoses running into the inter cooler.

13. Undo and remove the remaining short section of intercooler tube on the passenger side.

14. Remove the large black radiator to engine intercooler tube.

15. Unclamp the bottom radiator hose at the radiator end and remove the hose completely.

Remove the passenger side radiator supporting brace bar and bracket from the frame rail.

16. Undo the six bolts securing the fan shroud. Move the fan shroud as far back towards the

engine as possible.

17. Remove the radiator and intercooler as a unit.

18. Remove the fan shroud.

19. Undo the six Nylock nuts, (four bolts for an Eaton fan) on the fan and remove the fan.

Figure ? – OEM hose removal

Remove

this hose

Figure ? – OEM hose removal

Page 12

20. Unclamp and remove the section of rubber hose running from the 90-degree tee to the cooler

expansion tank (Figure ?).

Figure ? – Remove OEM bolts

Remove brass

fitting

Remove bolts

If the brass fitting shown in Figure ? can be removed without removal of the whole

assembly proceed directly to (step 24).

21. Remove the brass 90-degree fitting from the lower section of the steel tube (Figure ?).

22. Using pipe sealant, install the supplied 3/4-inch NPT socket head plug into the port where the

90-degree fitting was removed.

23. Re-install the section of steel tube running up the side of the driver side frame rail. Tighten

all fasteners to specification.

24. Re-install the flexible hose to the water pump.

27. Undo the brass fitting on the water pump. Remove the bolt securing the road draft steel tube.

Undo the clamp on the rubber 90-degree connector (Figure ?). Remove the bracket assembly.

Replace the bolt with Loctite and torque to specification. Replace the brass fitting and tighten

to specification. Undo the retaining clamp holding the rubber section of the road draft tube.

Fully disassemble the remaining sections of the road draft tube.

Page 13

Water pump

b

olt

Figure ? – Removal of road draft steel tube

Figure ? – Loosening the intercooler tube

Loosen the

OEM clamps

Remove the

OEM bolt

Road draft tube

Brass Fitting

28. Remove the bolt securing both intercooler tubes to the support bracket mounted to the

cylinder head. Undo the clamps for the intercooler tubes enough to allow the tubes to rotate

(Figure ?).

29. Remove the tension from the OEM belt and slide the belt off the alternator pulley

30. Disconnect the electrical connections to the alternator.

31. Unbolt the alternator and its bracket. Make a special note of any spacers that are

associated with the alternator bracket and the order of how they are applied for later

re-installation.

32. Unbolt and remove the two clamps restraining the main battery cable located on the inside of

the frame rail on the driver’s side behind the fuel tank.

Figure ? – Remove the alternato

r

Figure ? – OEM battery cable clamps

Page 14

DOCUMENT #1930024

Part 3

Installing the Air Tank and

Lines

System #V900073

2003 FREIGHTLINER FL60-FL70

MERCEDES MBE 900 W/WOAB

UNDERHOOD AIR COMPRESSORS

Page 15

Page 16

Battery

cable clamp

Cable stra

p

Figure ? – Tank brackets mounte

d

Figure ? – Detail of cable routing

3.1 Installing the tank brackets

1. Place one of the tank mounting brackets on the inside of the drivers side frame rail

underneath the metal bracket used to locate the battery cable clamp. Locate the pressed lug

onto the inside of the frame rail with the 45-degree bend pointing out to the driver’s side.

Pass a tank strap through the hole at the top of the bracket and route it down the outside of

the frame rail and back through the hole close to the 45-degree bend in the bracket.

2. Loosely secure the strap in place with the supplied 5/16-inch ID x 3/4-inch OD washer and

one of the 5/16-inch nuts. Ensure the bracket is mounted vertically and the strap does not

conflict with any other installed equipment. Fully tighten the strap and use a second 5/16-

inch nut to lock the previous nut in place.

3. Take one of the previously removed battery cable support brackets and mount to the second

tank bracket using the supplied 5/16-inch x 2 1/2-inch hex head bolt in place of the OEM

bolt. Mount to the centrally placed hole. Leave the clamp slightly loose to allow for final

alignment later.

4. Mount the second tank bracket on the frame rail forward of the first tank mounting bracket

ensuring that it butts up to the OEM bracket previously used for mounting the battery cable

support clamp. Install the tank-mounting bracket following the same procedure as the first

bracket. Ensure the strap goes through the space between the fuel tank mounting structure.

5. Reinstall the battery cable into the clamp and tighten to specification.

3.2 Installing the C-clamps

1. Remove the bolts from the supplied C-clamps and slide them onto the tank. Slide one up to

the weld on the end where the oil filter is located. Measure the distance between the installed

tank mounting brackets and position the second C-clamp the same distance apart (approx

12.4 inches). Install the bolts into the clamps and hand tighten.

2. With the tank placed on a flat surface, rotate the tank until the mounting direction arrow is at

45-degrees. Tighten the C-clamp brackets.

Page 17

3.3 Installing the tank and lines

1. Use a pair of jack stands or other suitable means of support to hold the weight of the tank

during installation. Lift the tank into position on the tank mounting brackets with the filter

end pointing forward.

2. Place a supplied 5/16-inch x 1 1/4-inch bolt through one of the 5/16-inch washers and

through the bottom hole in the rear C-clamp and the mating bottom hole in the bracket.

Loosely secure the bolt with another 5/16-inch flat washer and a 5/16-inch Nylock nut.

3. Repeat this procedure for the forward bottom mounting hole on the other C-clamp. Align the

tank horizontally and tighten the installed bolt to stop the tank from moving.

4. Pass the 5/16-inch and 1/4-inch oil lines on the outside of the rear tank mounting bracket and

the inside of the forward tank mounting bracket. Pass the lines over the lower frame cross

members.

5. Loosely install the lines to the rear of the tank. Group the lines together close to the tank

mounting bracket.

1/4” Line

12.4”

5/16” Line

Figure ? – Rear line attachments

Figure ? – Positioning the C-clamps

6. Place the supplied P-clips over the 5/16-inch and 1/4-inch steel lines. The rear P-clip mounts

to the outside face of the tank bracket with the bolthole at the top. The forward P-clip mounts

to the inside face of the tank mounting bracket with the bolthole at the bottom (Figure ?).

7. Place a supplied 5/16-inch x 1 1/4-inch bolt through one of the 5/16-inch washers and

through the top hole in the rear C-clamp and the mating bottom hole in the bracket. Place the

P-clip onto the bolt and loosely secure the bolt with a 5/16-inch flat washer and a 5/16-inch

Nylock nut.

8. Place a supplied 5/16-inch x 1 1/4-inch bolt through the remaining 5/16-inch washer and pass

it through the forward P-clip and the top hole in the tank C-clamp and corresponding tank

bracket. Loosely secure the bolt with a 5/16-inch flat washer and a 5/16-inch Nylock nut.

9. Check the alignment of tank horizontally and that the direction arrow on the tank end cap is

pointing vertically. Adjust as necessary. Fully tighten to specification all tank bracket-

mounting bolts and C-clamp bolts.

Page 18

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Vmac V900073 Installation guide

Vmac V900073 Installation guide

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