Vmac 9049 Installation guide

Installation Manual

For The

System #9049

UNDERHOOD AIR COMPRESSOR

1998-2000 FREIGHTLINER FL50, FL60, FL70, FL80

5.9 CUMMINS ISB W/WOAC

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

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

DOCUMENT 19629

Installation Manual

VR7000 Underhood Air Compressor

System Number 9049

Application: 1998-2000 Freightliner FL 50, FL60, FL70, FL80 5.9 Cummins ISB

Publication Date: February 2001

Origination Documents: 19629a- Introduction

19629b - Installing the compressor

19629c - Installing the tank and lines

19629d - Installing the control unit and Throttle Commander

19629e - Installing the Throttle Commander

19630 - 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 ............................................................................................................... 6

WARRANTY ............................................................................................................................. 7

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

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

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

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

1.2 INSTALLING THE CRANK SHAFT PULLEY .............................................................................. 12

1.3 INSTALLING THE COMPRESSOR BRACKET ............................................................................. 12

1.4 INSTALLING THE COMPRESSOR ........................................................................................... 14

1.5 INSTALLING THE OIL COOLER ............................................................................................ 15

1.6 INSTALLING THE COOLANT HOSES ...................................................................................... 15

PART 2: INSTALLING THE AIR TANK AND LINES.................................................... 17

2.1 INSTALLING THE TANK BRACKETS ...................................................................................... 19

2.2 INSTALLING THE TANK ..................................................................................................... 19

2.3 ATTACHING THE REMAINING LINES .................................................................................... 21

2.4 COMPLETING THE INSTALLATION ...................................................................................... 22

PART 3: INSTALLING THE CONTROL COMPONENTS ............................................ 23

3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 25

3.2 INSTALLING THE AIR PRESSURE SWITCH .............................................................................. 26

3.3 CONNECTING THE WIRING ................................................................................................. 27

3.4 CONNECTING THE THROTTLE COMMANDER AND PARK BRAKE WIRE ..................................... 27

ILLUSTRATED PARTS LIST.............................................................................................. 31

WARRANTY REGISTRATION .......................................................................................... 37

1

DOCUMENT 19629

2

General Information

System #9049

1998-2000 FREIGHTLINER FL50, FL60, FL70, FL80

5.9 CUMMINS ISB

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 19629

4

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.

General Information

Introduction

This book provides installation instructions for:

VMAC underhood air compressor installation kit

VMAC Throttle Commander

This kit has been designed for:

1998-2000 FREIGHTLINER FL50, FL60, FL70, FL80 5.9 CUMMINS ISB

NOTE: The installation shown in the photographs in this manual was performed

on a 09/99 FL70 equipped with ABS hydraulic service brakes, air-operated

driveline park brakes and a custom frame-mounted box.

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)

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DOCUMENT 19629

WARNING

!

NOTE

6

DOCUMENT 19629

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

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

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

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DOCUMENT 19629

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.

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

of installation. This plate provides information, which allows VMAC to assist in customer inquiries

and ordering of parts. It is important that this plate is affixed to the vehicle.

Instructions

Locate the S/N plate on the front of the windshield wiper/rain channel on the driver’s side of the

vehicle (Figure 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

Changes and improvements

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

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.

VR7000 Tank

Auxiliary Receiver

One-way check valve

Install the line as high as

possible, NOT on the

bottom of the tank

DOCUMENT 19629

Part 1

Installing

the Compressor

and

Oil Cooler

System #9049

1998-2000 FREIGHTLINER FL50, FL60, FL70, FL80

5.9 CUMMINS ISB

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 19629

10

Part 1: Installing the Compressor and Oil Cooler

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DOCUMENT 19629

1.1 Preparing for installation

1. Drain the coolant from the radiator and

the engine block.

2. Remove the intercooler discharge tube

from the intercooler and the intake

manifold.

3. If the vehicle is equipped with air

conditioning, loosen the adjuster and

remover the drive belt from the AC

compressor pulley.

4. Remove the AC compressor mounting

bolt and the adjuster pivot bolt and

remove the compressor from the

engine. Position the compressor along

the frame and support it so that it does

not hang by the hoses.

Some applications may require

adjustment of the AC lines at the

compressor to clear the VR7000

compressor. If adjustment is

necessary, crack the fitting nuts

only enough to allow the lines to

move, then immediately tighten

them once they have been

repositioned..

5. Remove the three (3) OEM hex head

cap screws holding the air conditioning

compressor mounting bracket to the

cylinder head and remove the bracket.

Air conditioning compressor and intercooler tube

AC compressor and intercooler tube removed

Engine mount webs

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DOCUMENT 19629

1.2 Installing the crankshaft pulley

3. Remove the OEM crankshaft pulley and

clean the paint from the face of the

pulley where the VR7000 pulley will

seat.

4. Fit the VR7000 crank pulley to the

crankshaft and mark the front engine

mount webs where the pulley touches

them.

5. Grind sufficient material from the front

engine mount webs so that the VR7000

pulley has adequate clearance and will

not touch the webs. Make sure that

there is enough clearance between the

webs and the pulley so that the OEM

belt can be installed.

6. Install the VR7000 crank pulley on the

crankshaft over the OEM pulley using

the OEM fasteners. Use Loctite on the

threads and torque the fasteners to

specifications.

1.3 Installing the compressor bracket

1. Remove the crankcase vent tube from

the front of the engine.

2. Cut two (2) inches from the end of the

vent tube, then reinstall the tube.

3. Loosen the fasteners on the dipstick

tube bracket so that it can be adjusted.

If the vehicle does not have a bracket,

make sure that the dipstick is adequately

secured.

4. Tap or push the frame rail clamp holding

the dipstick tube support toward the

cab, approximately the same distance as

the width of the clip.

Grinding the webs for clearance

VR7000 pulley installed

Location of the crankcase vent tube

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DOCUMENT 19629

5. Adjust the dipstick and tighten the

fasteners.

6. Thoroughly clean the area on the

cylinder head and lower block where

the bracket will fit to make sure that

nothing will interfere with correct

alignment of the bracket.

7. Clean the two empty threaded holes on

the lower left side of the cylinder block.

If necessary, use a thread chaser to

make sure the threads are clean.

8. Place the VR7000 bracket in place on

the engine, aligning the three top holes

with the AC mount holes and the two

lower holes with the holes in the block.

9. If the vehicle is equipped with AC,

place the AC mounting bracket over

the VR7000 bracket and align the

holes.

Fit all the cap screws loosely in the

mounting bracket until all are

installed, then tighten them.

10. Apply Loctite and install the three (3)

10 x 45 mm supplied hex head cap

screws through the OEM air

conditioning mounting bracket, the

VR7000 bracket and into the cylinder

head.

12. If the truck is not equipped with air

conditioning, apply Loctite and install

three (3) 10 x 30mm supplied hex head

cap screws through the top of the

bracket into the cylinder head.

Top three mounting holes

Two lower mounting holes

2”

Cutting the end off the crankcase vent tube

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DOCUMENT 19629

Belt tensioner and idler

VR7000 belt under the tensioner

Compressor Pulley

Back

Idler

Tensioner

Crankshaft

Pulley

VR7000 and OEM AC brackets in place

13. Apply Loctite to two (2) 12 x 35mm

supplied socket head cap screws and

install them in the two bottom holes on

the bracket and into the engine block.

14. Torque all fasteners to specifications.

15. Install the air conditioning compressor

in place on the OEM mount.

13. Install the air conditioning belt and

adjust the tension to OEM

specifications.

14. Remove the tensioner and back idler

from the VR7000 bracket. Apply

Loctite to the fasteners, install the

tensioner and back idler and torque

them to specifications.

15. Install the OEM serpentine drive belt.

1.4 Installing the compressor

Before installing the compressor,

record the serial number on the

warranty sheet.

1. Apply Loctite to the burred end of the

three (3) 8 mm studs and install them in

the bottom of the VR7000 compressor.

2. Apply Loctite to the other end of the

studs, install the compressor on the

mounting bracket and fasten it in place

using three (3) 8 mm nuts and 5/16 inch

flat washers. Tighten them to

specifications.

3. Place the VR7000 drive belt over the

crankshaft pulley and route it behind the

tensioner to the compressor.

4. Place the belt over the compressor

pulley and locate it on top of the back

idler.

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DOCUMENT 19629

3/4 x 52 coolant hose from Y piece

5. Using a wrench or socket assembly,

swing the tensioner up until the belt can

be placed under the tensioner pulley.

1.5 Installing the oil cooler

1. Insert the two (2) 1/2 x 1-1/2 flanged

hex head cap screws into the two holes

in the front crossmember under the

radiator (behind the bumper). These

cap screws must be slid in between the

radiator and crossmember and then

tilted into the holes.

2. Place the cooler in place under the

crossmember, guiding the two cap

screws through the mounting holes.

3. Install lock washers and 1/2 inch nuts.

4. Push the cooler sideways to jam the

cap screws and tighten the nuts

securely.

1.6 Connecting the coolant hoses

1. Remove the threaded plug from the side

of the cylinder block just behind the

water pump. Apply pipe sealant and

install the supplied 3/4 NC x 3/4 NPT

hose fitting into the cylinder block.

Tighten the fitting securely.

Cooler installed,

3/4 x 81 inch coolant hose from block

2. Place hose clamps on the 3/4 x 81 inch

heater hose and install one end on the

block fitting.

3. Route the hose along the frame rail to the

bumper mount, then under the radiator

support to the driver side fitting on the

cooler. Fasten the hose in place as

required with nylon ties.

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DOCUMENT 19629

4. Place a hose clamp on the 3/4 x 7-1/2

inch heater hose with the Y-fitting and

install it onto the 90 degree return line

fitting on the bottom of the water pump.

Swivel the Y-piece around to fit inside

the frame rail andTighten the clamp.

5. Cut 9 inches from the end of the OEM

heater return hose. Install the OEM

hose onto the straight end of the Y-

fitting and tighten the clamp.

6. Place hose clamps on the 3/4 x 52 inch

heater hose and connect one end to the

Y-fitting

7. Route this hose along the frame and front

crossmember to the passenger side

fitting on the cooler. Install the end on

the passenger side fitting of the cooler

and tighten both clamps.

8. Route all the cooler hoses away from any

sharp edges or hot surfaces and cover

hoses with the supplied plastic loom if

necessary.

Fitting installed in the block

To cooler

(driver side)

To cooler

(passenger side)

Block fitting

Water pump fitting

OEM heater hose

Cooling hose routing

Heater return fitting on water pump

Part 2

Installing the

Air Tank and Lines

System #9049

1998-2000 FREIGHTLINER FL50, FL60, FL70, FL80

5.9 CUMMINS ISB

UNDERHOOD AIR COMPRESSOR

17

DOCUMENT 19629

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Vmac 9049 Installation guide

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