Vmac V900019 Installation guide

UNDERHOOD AIR COMPRESSORS

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1333 KIPP ROAD NANAIMO B.C. V9X 1R3

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UNDERHOOD AIR COMPRESSORS

TM

1995 - 2001 INTERNATIONAL 4900,

4800, 4700, & 4700LP DT 466E

System # V900019

Installation Manual

Installation Manual Document #1930026

VR70 Underhood Air Compressor

System Number V900019

Application: 1995 - 2001 International 4900, 4800, 4700 & 4700LP DT 466E

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

Origination Documents: 1900671a - Introduction

1900671b - Installing the compressor

1900671c - Installing the tank and lines

1900671 d- Installing the control unit

1900671e - Installing the Throttle Commander

1930026- 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, Klean N’ Prime, 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

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

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

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

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

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

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

1.2 INSTALLING THE BRACKET AND COMPRESSOR ...................................................................... 12

1.3 INSTALLING THE OIL COOLER-FILTER ASSEMBLY .................................................................. 15

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

2.1 INSTALLING THE TANK MOUNTS AND THE TANK .................................................................. 21

2.2 CONNECTING THE AIR AND OIL LINES ................................................................................. 24

2.3 ADDING OIL TO THE SYSTEM ............................................................................................. 26

2.4 COMPLETING THE INSTALLATION ...................................................................................... 26

PART 3: INSTALLING THE CONTROL UNIT ............................................................... 27

3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 29

3.2 CONNECTING THE WIRING ................................................................................................ 31

PART 4: INSTALLING THE THROTTLE COMMANDER ........................................... 35

4.1 MOUNTING AND CONNECTING THE THROTTLE COMMANDER ................................................. 37

ILLUSTRATED PARTS LIST .............................................................................................. 39

WARRANTY REGISTRATION .......................................................................................... 45

1

2

General Information

System #V900019

1995 - 2001 INTERNATIONAL 4900, 4800, 4700, &

4700LP, DT 466E

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 1930026

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:

1995 - 2001 International 4900, 4800, 4700 & 4700LP, DT466E

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

WARNING

!

NOTE

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).

8. 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.

Example: A410055 is a 55-inch hose extender kit.

Table 1 - Torque values

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

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

dry add 20% to the torque values.

7

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

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.

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.

Ordering Parts

To order parts, contact your nearest VMAC dealer.

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.

Hose diamete

r

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

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 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.

Auxiliary Receiver

Auxiliary check valve

VR70 Tank

Install the line as high as

possible. NOT on the

bottom of the tank.

Part 1

Installing

the Compressor

and

Oil Cooler

System #V900019

1995 - 2001 INTERNATIONAL 4900, 4800, 4700, &

4700LP, DT 466E

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 1930026

10

Part 1: Installing the Compressor and Oil Cooler

1.1 Preparing for installation

1. Remove the protective covers from the electrical connections on the engine management

system located on the driver’s side of the engine.

2. Remove the two hex head cap screws holding the electrical connectors on the engine

management system and remove the electrical connectors from the unit.

3. Disconnect the coolant temperature sensor behind the alternator and the cam position

sensor on the timing cover and place the wires out of the way.

4. Disconnect the positive battery cable that attaches to the engine.

5. Drain the coolant from the radiator and the engine block, then remove the upper radiator

hose.

6. Disconnect the alternator wiring and air conditioning plug connector, then lift the harness up

and out of the way.

7. Remove the top alternator bolt, loosen the bottom mounts and tilt the alternator outward.

8. Remove the coolant hose, wire harness and air conditioning lines from the OEM U-shaped

bracket. Remove and discard the bracket from the top air conditioning cap screw and

replace the cap screw.

9. Disconnect the two hoses from the coolant expansion bottle and remove the bottle.

10. Remove OEM drive belt and the air conditioning drive belt.

11. Remove the OEM belt tensioner and the air conditioning belt tensioner.

12. Remove the bolts holding the air conditioning compressor to the OEM mounting bracket, lift

it and lay it on the two radiator cross-rail supports above the engine. Do not disconnect any

air conditioning lines from the compressor.

13. Remove the OEM hex head cap screws holding the air conditioning compressor mounting

bracket to the cylinder head and remove the bracket.

14. Remove the 3/4” heater hose and the coolant expansion tank overflow hoses from the

thremostat housing fittings on the cylinder head, then remove the fittings from the thermostat

housing and cylinder head.

15. Remove the fan and the fan shroud.

16. Remove and discard the engine lifting bracket from the passenger side of the cylinder head.

The rear bolt will not clear the ridge on the exhaust manifold. Cut the head off of the bolt

for removal. Figure 1.1 shows the two bolt locations with the bracket removed.

11

12

1.2 Installing the bracket and compressor

1. Remove the OEM 3/8“ x 1/8“ NPT hose barb straight connector from the OEM 45 degree

1/8“ NPT elbow and screw the straight connector back into the cylinder head without the 45

degree elbow.

2. Reinstall the 3/4“ 45 degree OEM heater hose elbow to the cylinder head and angle it 15

degrees down from the horizontal position (Figure 1.2).

3. Peen back the lip of the thermostat housing flush with the cylinder head.

4. Clean all dirt and debris from the right side of the engine and fit the VR70 compressor

mount bracket to the passenger side of the cylinder head (Figure 1.2 & 1.3).

Check the fit against the exhaust manifold gasket and trip away excess gasket if

necessary.

Figure 1.1

12mm x 40 machined head SHCS

Figure 1.2

OEM 3/8 x 1/8 NPT hose barb with

45 degree elbow removed

3/4” 45 degree elbow hose barb

angled down 15 degrees

Two upper bolt

locations for VR

bracket & OEM

A/C bracket

Peen back this

edge

13

Figure 1.3

5. Apply Loctite and install the machined-head 12 x 40 mm socket head cap screw into the

rear lifting bracket hole and a 12 x 40 mm hex head cap screw into the front lifting bracket

hole. See figure 1.2.

Install the side engine mounting cap screws first, then the remaining caps screws.

6. Place the OEM air conditioning bracket on top of the VR70 bracket and align the holes.

Apply Loctite and install two (2) 12 x 60 mm hex head cap screws. For vehicles without

A/C use the two 12 x 40mm hex head cap screws supplied.

7. Install the OEM air conditioning belt tensioner on the air conditioning bracket using the

OEM fastener.

8. Clean all dirt and residue from the inside of the harmonic balancer.

9. Install the VR70 crank pulley using the six (6) supplied 10 x 45 mm fasteners. Use Loctite

on the threads and torque the fasteners to specifications.

10. Install the OEM drive belt.

11. Install the rib and back idlers on the VR70 bracket. Use Loctite and torque to

specifications.

12. Feed the OEM harness for the coolant temperature sensor and cam position sensor down

through the provided opening in the VR70 bracket. Feed the large connector through first,

then connect them to the sensors.

13. Apply loctite to one end of the three (3) 8 mm studs and install them in the bottom of the

compressor.

14. Place the compressor on the mounting bracket.

15. Install the 8 mm nuts and torque them to specifications.

14

Figure 1.5

16. Install the OEM air conditioning compressor to the OEM bracket using the OEM cap

screws.

17. Install the supplied belt on the air conditioning compressor.

18. Bend the air conditioning line from the cab very slightly so that it is not in contact with the air

compressor. See figure 1.3.5.

19. Route the alternator electrical harness over the VR70 compressor and connect the harness

to the alternator and air conditioning connectors.

20. Install the VR70 belt. Figure 1.4 shows all of the belts, tensioners and idlers in place.

21. Refit the 3/4 OEM heater supply hose to the 45 degree elbow angled down 15 degrees on

the thermostat housing and tighten the clamp.

Figure 1.4

1.3 Installing the oil cooler assembly

Indentify the location for the cooler mounting bracket on the inside of the passenger side

frame rail. The rear locating hole for the cooler bracket is the rear of the three (3) 1/2 inch

holes in the frame rail immediately in front of the cab support mount and behind the front

shock absorber (See figure 1.6)

Figure 1.6

1. Clean the frame area around the fuel filter mounting bracket.

2. Remove the lower 12 mm nut and bolt securing the fuel filter bracket to the passenger side

frame rail.

3. Remove the cooler from the cooler mounting bracket, then install the bracket to the inside of

the passenger side frame rail. Fit one of the 1/2 inch x 1 3/4 flange bolts supplied to the rear

hole in the chassis rail then through the rear cooler bracket hole.

4. Install the OEM 12 mm bolt (previously removed) through the front hole on the cooler

bracket, through the frame under the brake hose bracket (Figure 1.6) Install nuts on the

two bolts and torque them to specifications.

15

22. Fit the supplied fan spacer (left hand thread), then refit fan and fan shroud.

23. Refit the coolant expansion bottle and hoses. Refit the 3/8 coolant expansion syphon hose

to the hose barb on the thermostat housing. Route the hose away from the alternator pulley

and secure.

24. Refit top rad hose and tighten clips.

16

When operating the engine for the first time following installation, be sure to allow the

engine to reach full operating temperature and ensure that the cooling system level is

correct. Failure to do so could result in an overheat condition and possible engine damage.

NOTE

9. Fill the cooling system with OEM recommended coolant to the correct level.

Figure 1.7

5. Connect the 24 inch long 3/4” heater hose provided to the rear cooler 3/4 hose spigot then

connect to the OEM fitting at the back of the engine water pump. (See figure 1.7)

6. Cut the removed OEM 3/4 “ hose to fit (approximately 29 inches long) between the cab

heater return outlet and the cooler inlet hose barb front connector. Route the hose back

through OEM fixing clips clear of hood closing.

7. Connect the 1/2” x 29” cooler to compressor oil return line to the connector on the front of

the cooler then route the 90 degree fitting end of the oil return hose to the engine side of the

compressor and connect to the fitting. Loosen the 90 eegree elbow jam nut on the side of

the compressor and rotate the fitting forward to lift the hose clear of the compressor to

prevent hose chafing. Tighten the jam nut, then tighten both ends of the oil return hose.

8. Check all hose clamps and fasteners installed up to this point to make sure that they are

properly tightened.

Figures 1.8 shows additional views of the bracket in place on the engine

Cut to length 3/4 heater hose &

fit from water pump to rear spigot

on cooler

Disconnect heater return

hose and connect to front

spigot on cooler.

17

Figure 1.8

18

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Vmac V900019 Installation guide

Vmac V900019 Installation guide

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