Vmac V900018 Installation guide

Category
Air compressors
Type
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.
Copyright 1999
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 Owners 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 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).
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 Loctiteand 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 × 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 manufacturers
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

Category
Air compressors
Type
Installation guide

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