Vmac V900018 Installation guide

Installation Manual

For The

System #V900018

ROTARY SCREW COMPRESSOR

1999 NAVISTAR INTERNATIONAL

Cummins M11 Engine

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

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

DOCUMENT 1900561

Installation Manual

VR70 Rotary Screw Compressor

System Number V900018

Application: 1999 Navistar International equipped with the Cummins M11 Engine

Publication Date: December 26, 2000

Origination Documents: #1900561a - introduction

#1900562 - compressor installation

#1900563- tank and line installation

#1900564 - control unit installation

#1900565-throttle commander installation

#1900566 - illustrated parts list

#1900130 - warranty registration

Registered Trademarks:

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

International is a trademark of Navistar International Corporation.

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

DOCUMENT 1900561

Contents

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

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

INSTALLATION NOTES ......................................................................................................6

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

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

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

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

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

1.2 INSTALLING THE COMPRESSOR OIL COOLER .....................................................................12

1.3 INSTALLING THE COMPRESSOR ....................................................................................13

1.4 INSTALLING AND MOUNTING COMPONENTS .......................................................................14

1.5 INSTALLING THE POWER STEERING BRACKET ....................................................................17

1.6 INSTALLING THE POWER STEERING RESERVOIR ..................................................................17

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

2.1 INSTALLING THE AIR TANK .........................................................................................21

2.2 CONNECTING PRELIMINARY AIR AND OIL LINES .................................................................21

2.3 ADDING OIL TO THE SYSTEM ......................................................................................24

PART 3: INSTALLING THE CONTROL UNIT........................................................25

3.1 CONTROL UNIT INSTALLATION ....................................................................................27

3.2 ROUTING THE WIRING ..............................................................................................28

PART 4: INSTALLING THE THROTTLE COMMANDER ......................................33

4.1 MOUNTING AND CONNECTING THE THROTTLE COMMANDER .................................................35

PART 5: ILLUSTRATED PARTS LIST...........................................................................37

WARRANTY REGISTRATION .................................................................................43

1

2

General Information

System #V900018

1999 NAVISTAR INTERNATIONAL





Cummins



 M11 Engine



ROTARY SCREW COMPRESSOR

3

DOCUMENT 1900561a

4

General Information

Introduction

This book provides installation instructions for:

VMAC underhood air compressor installation kit

VMAC Throttle Commander

This kit has been designed for:

1999 Navistar International equipped with a Cummins M11 engine.

Installation steps

The installation procedure in this manual has four main steps:

Part 1: Installing the Compressor

Part 2: Installing the 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)

NOTE

WARNING

✁

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.

5

DOCUMENT 1900561a

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 under-hood 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).

8. The possibility exists that the primary installer may be color-blind. Always ensure that

another person confirms the color codes on the wires.

If the threads are dry, add 20% to the torque value.

6

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

DOCUMENT 1900561a

WARNING

✁

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 Standard Time

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

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.

Changes and improvements

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

7

DOCUMENT 1900561a

8

Part 1

Installing

the Compressor

System #V900018

1999 NAVISTAR INTERNATIONAL





Cummins



 M11 Engine

ROTARY SCREW COMPRESSOR

9

DOCUMENT 1900562

10

Part 1: Installing the Compressor

1.1 Preparing for installation

1. Disconnect the batteries.

2. Drain the coolant.

3. Remove the tube which crosses over the top of the engine and connects the inter-

cooler to the turbocharger inlet.

4. Remove the air conditioning compressor. Lift it upward and set it on top of the

engine.

WARNING

✁

5. Remove and discard the air conditioning compressor mounting bracket.

6. Remove the OEM serpentine belt.

7. Remove the five (5) OEM fasteners which retain the crankshaft pulley and harmonic

balancer and discard them. Remove and discard the 8

3″ thick spacer washer from

behind the fasteners.

8. Remove the Two 10mm OEM studs and the nearest 10mm bolt, behind,the inlet tube

housing, on top of the inlet manifold. Also remove the rear right hand OEM bolt from the air

intake tube to manifold.

9. Remove the power steering reservoir from the support bracket. Keep the OEM fasteners.

10. Drain the oil from the power steering reservoir.

11. Remove and discard the ½″ oil hose from the reservoir to the steering box. Remove the

¾″ hose from the reservoir, but do not discard this hose.

12. Remove the ½″ NF cap screws holding the radiator and firewall tie-rod bracket to the

frame on the left-hand side.

13. Remove the 16

5″ NC nuts from the bracket holding the radiator tie-rod to the left-hand side

of the radiator.

14. Swing the tie-rod bracket away from the frame, remove and discard the power steering

reservoir mounting bracket and support plate from behind the tie-bar mounting plate on the

frame rail.

Do not disconnect the air conditioning lines.

11

DOCUMENT 1900562

1.2 Installing the compressor oil cooler

1. Cut the sound insulation back three inches from the front edge of the engine tunnel above

the valve cover.

2. Install the VR 70 oil cooler assembly into position on the engine just behind the intake tube

on the passengers side. Fit to the vehicle intake manifold using the three (3) supplied M10 x

55 hex head cap screws and flat washers. Fit the M10 x 40- hex head cap screw and flat

washer to the support brace and intake tube flange.

Figure 1.1

3. Identify the OEM 5/8 heater return hose to the rear of the vehicle water pump. Disconnect

the hose at the firewall and install the end onto the 5/8 hose spigot on the front of the oil

cooler. Use HS10 hose clamp supplied and tighten securely.

4. Connect one end of the supplied 5/8 heater hose to the rear hose spigot on the oil cooler

and route the hose round to the firewall heater connection. connect hose and fit two (2)

supplied HS10 hose clamps, tighten securely. A spare hose connector is supplied if required

Figure 1.2

12

Cooler Mounting

Bolts

DOCUMENT 1900562

Bracket Mount

Holes (Hidden)

Bracket Mount

Holes

1.3 Installing the compressor

NOTE

Make sure that the surfaces that the main mounting bracket will contact are clean and free

of contaminants or debris. If the mounting bracket does not seat correctly against the

timing cover or engine block, the compressor and crankshaft pulleys will not align correctly.

1. Install the main mounting bracket for the VR70 to the side of the timing cover using the

eight (8) threaded holes shown in Figure 1.3

13

Figure 1.3

2. Thread the two (2) M10 × 35 mm hex head cap screws into the two holes on the side of the

engine block (Figure 4). Use 8

3″ flat washers behind the cap screws.

3. Thread four (4) M10 × 35 mm hex head cap screws in the four (4) threaded holes

originally used to mount the OEM air conditioning compressor mounting bracket (Figure 3).

Use 8

3″ flat washers behind the cap screws.

4. Thread two (2) M10 × 35 mm hex head cap screws into the two holes on the rear of the

timing cover (Figure 4). Use 8

3″ flat washers behind the cap screws.

DOCUMENT 1900562

Bracket Mount

Holes

5. Torque the cap screws which thread into the cast engine block to 45 ft-lb. Torque the

cap screws which thread into the aluminum timing cover to 35 ft-lb.

Figure 1.4

1.4 Installing and mounting components

1. Clean all dirt and paint ridges from face of OEM pulley. Install the VR70 pulley over the

OEM pulley and harmonic balancer. Align the mounting holes.

2. Apply Loctite and install five (5) M14 1.5 × 80 mm hex head cap screws. Torque

them to 145 ft-lb.

3. Fit the VR70 belt tensioner to the front of the mounting bracket using the M12 × 80 mm

hex head cap screw (Figure 1.4). Apply Loctite and torque it to 80 ft-lb.

NOTE

4. Remove the ½″ × 1¼″ UNC flange lock bolt securing the back idler to the bottom of the

mounting bracket. Apply Loctite and torque to 117 ft-lb. Be careful not to lose the

aluminum spacer that fits over the lock bolt and into the center of the idler.

If the VR70 belt tensioner is already fitted on the mounting bracket, remove it, apply

Loctite to the M12 × 80 mm hex head cap screw and torque it to 80 ft-lb.

14

DOCUMENT 1900562

Figure 1.5

5. Install the OEM 8-rib drive belt as shown in Figure 1.6 and tension it to manufacturer’s

specifications.

Figure 1.6

15

OEM Air Conditionin

g

Compressor

Mounting Holes

VR70 Compressor

Mounting Holes

VR70 Mountin

g

Bracket

Hole For 1/2 NC Air Conditionin

g

Adjuster Bo lt

VR70 6-Rib Belt Tensioner

Tensioner Mounting Bolt

Mount Regulator Here

VR70 Back Idler

Back Idler Mountin

g

Bolt And Spacer

Harmonic Balancer

Fan Pulley

OEM Tensioner

OEM Crankshaft

Pulley

DOCUMENT 1900562

6. Install the OEM air conditioning compressor to the top of the VR70 bracket using the

OEM fasteners. Thread two fasteners into the front slots in the bracket on the engine side

of the air conditioning compressor and two fasteners into the slots on the outside of the

bracket.

NOTE

7. Install the supplied V-belt on the air conditioning and engine drive pulleys.

8. Install the OEM ½″ NC adjuster bolt and locking nut to the under-side of the air condition-

ing compressor base-plate and adjust the drive belt to OEM specifications.

9. Torque all air conditioning fasteners to OEM specifications.

WARNING

✁

10. Fit the VR70 compressor to the mounting bracket. Apply Loctite to three (3) M8 × 25

mm hex head cap screws, install them and torque them to 25 ft-lb.

11. Install the supplied 6-rib VR70 drive belt over the crankshaft pulley, VR70 compressor

pulley and the VR70 tensioner (Figure 1.7). Check alignment of the pulleys and belt using a

straight edge.

NOTE

Do not tighten these fasteners at this time.

These fasteners are threaded into aluminum. Over-tightening will damage the

aluminum threads.

If the pulleys and belt do not line up correctly, check the installation of the mount-

ing bracket. If the fasteners have not been tightened properly or if the bracket has

not been installed flat against the timing cover, the pulleys will not align correctly.

Figure 1.7

16

Harmonic Balancer

VR70 Compressor Pulley

VR70 Tensioner

VR70 Back Idler

VR70 Crankshaft

Pulley

DOCUMENT 1900562

1.5 Installing the power steering bracket

1. Swing the tie-rod bracket away from the frame rail and insert the supplied power

steering bracket underneath the tie-rod bracket.

2. Swing the tie-rod bracket back into place, align the holes and install the ½″ NF cap

screws back into the frame, through both brackets.

3. Align the radiator tie-rod bracket with the holes in the radiator frame and install the

8

5″ NC nuts.

4. Torque all fasteners to OEM specifications.

1.6 Installing the power steering reservoir

1. Attach the power steering reservoir to the VR70 bracket so that the OEM clamp-style

mounting bracket sandwiches the VR70 bracket.

2. Secure the reservoir with the OEM fasteners and torque them to specifications.

3. Install the supplied ½″ hose and clamps between the reservoir and the steering box.

Tighten the clamps.

4. Remove 3/4” power steering hose from the steering box and reservoir.

5. Install supplied 3/4” replacement hose with elbow.

6. Tighten all hose clamps.

7. Refill the reservoir with the OEM recommended fluid.

8. Install the tube which connects the intercooler to the turbocharger inlet.

9. Make sure that the tube clears the air conditioning compressor and all other items

before tightening the clamps.

Figure 1.8 shows the general assembly. Figure 1.9 shows a close-up view of the new power

steering bracket installation behind the tie-rod bracket on the frame.

17

DOCUMENT 1900562

Figure 1.8

Figure 1.9

18

Power

Steering

Reservoir

VR70

Power

Steering

Bracket

VR70

Power

Steering

Hose

Frame Tie-rod Bracket

Radiator

Tie-rod

Radiator

Tie-rod

Bracket

VR70 Air

Compressor

VR70

Mounting

Bracket

OEM Air Conditioning Com pressor

DOCUMENT 1900562

Radiator

Tie-rod

OEM

Tie-rod

Bracket

Frame

VR70

Power

Steering

Reservoir

Bracket

OEM Ca

p

Screws

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Vmac V900018 Installation guide

Vmac V900018 Installation guide

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