Vmac 9049 Installation guide

Type
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.
Copyright 2000
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)
5
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 Owners 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 drivers 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.
7
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 drivers 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
11
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
12
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
13
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
14
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.
15
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

Type
Installation guide

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