Vmac V900068 Installation guide

System # V900068

INTERNATIONAL 2001 - 2003

4300, 4400 SERIES DT466

Document #1930036

2

Installation Manual – Document Number: 1930036

VR70 Underhood Air Compressor

System Number V900068

Application:

INTERNATIONAL 2001 - 2003, 4300, 4400 SERIES DT466

(Trucks with air brakes will require an adaptor kit.)

Publication Date:

Revised by S.Coker, 20th November 2003.

Registered Trademarks:

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

International is a registered trademarks 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

Printed in Canada

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CONTENTS

GENERAL INFORMATION .................................................................................................... 5

INTRODUCTION ................................................................................................................. 7

TERMS & SYMBOLS .......................................................................................................... 7

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

TORQUE SPECIFICATIONS .................................................................................................. 8

SYSTEM IDENTIFICATION NUMBER PLATE .............................................................................. 9

WARRANTY ................................................................................................................... 10

ORDERING PA RT S ........................................................................................................... 10

TOOL REQUIREMENTS ..................................................................................................... 10

SPECIAL NOTES ............................................................................................................. 11

PART 1: PREPARING FOR INSTALLATION ................................................................. 13

1.1 PREPARATION FOR INSTALLATION ....................................................................................... 15

PART 2: INSTALLING THE OIL/AIR SEPARATOR TANK AND LINES ........................ 17

2.1 INSTALLING THE OIL/AIR SEPARATOR TANK BRACKETS ......................................................... 19

2.2 ALTERNATE OIL/AIR SEPARATOR TANK MOUNTING LOCATIONS .............................................. 20

2.3 INSTALLING THE C-CLAMPS .............................................................................................. 20

2.4 ATTACHING THE LINES TO THE OIL/AIR SEPARATOR TANK ..................................................... 22

PART 3: INSTALLING THE COMPRESSOR AND OIL COOLER ................................. 23

3.1 INSTALLING THE VR70 CRANK PULLEY ............................................................................. 25

3.2 OIL COOLER INSTALLATION .............................................................................................. 26

3.3 INSTALLING THE MAIN BRACKET ........................................................................................ 28

3.4 INSTALLING THE MAIN BRACKET BRACE ............................................................................. 30

3.5 INSTALLING THE COMPRESSOR ......................................................................................... 30

3.6 ATTACHING THE LINES TO THE COMPRESSOR ...................................................................... 31

3.7 INSTALLING THE ALTERNATOR AND OEM BELT .................................................................... 32

3.8 INSTALLING THE MAIN BRACKET FRONT PLATE & VR70 BELT .............................................. 33

3.9 ADDING OIL TO THE SYSTEM ........................................................................................... 35

3.10 COMPLETING THE INSTALLATION ........................................................................................ 36

PART 4: INSTALLING THE CONTROL COMPONENTS ............................................... 37

4.1 INSTALLING THE CONTROL UNIT ........................................................................................ 39

4.2 CONNECTING THE WIRING ............................................................................................... 41

4.3 INSTALLING THE THROTTLE ............................................................................................... 43

4.4 HYDRAULIC B RAKES ....................................................................................................... 43

4.4.1 HYDRAULIC BRAKES AND STANDARD T RANSMISSION ............................................... 44

4.4.2 HYDRAULIC BRAKES AND AUTOMATIC TRANSMISSION .............................................. 44

4.5 FINAL TESTING & ASSEMBLY ............................................................................................ 45

APPENDIX A – GENERIC SOLDERING ................................................................................. 47

PART 5: ILLUSTRATED PARTS LIST ........................................................................... 49

WARRANTY REGISTRATION

4

Document #1930036

SYSTEM #V900068

INTERNATIONAL 2001 - 2003

4300, 4400 SERIES DT466

UNDERHOOD AIR COMPRESSOR

TM

GENERAL INFORMATION

Document #1930036

6

Document #1930036

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Introduction

This book provides installation instructions for the VMAC underhood air compressor installation

kit.

This symbol indicates that there is a possibility of personal

injury if the indicated warning is not followed.

This symbol indicates that there is a possibility of damage to the

equipment if the indicated warning is not followed.

This symbol indicates that there is additional information or

special emphasis on a specific procedure.

Terms and Symbols

This manual uses the following terms and symbols:

• DDC - Drive Disable Circuit

• ft-lbs - Foot Pounds (torque)

• HHCS - Hex Head Bolt (also called a hex bolt)

• N•m - Newton Meters (metric torque)

• OEM - Original Equipment Manufacturer

• SHCS - Socket Head Bolt (also called an allen head bolt)

• Hex - Hexagon (six sided)

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Installation Notes

It is important that you complete all the installation steps before operating the system.

Follow all safety precautions for underhood mechanical work.

Use Loctite 242 or equivalent on all engine-mounted fasteners.

All hoses, tubes and wires which are rerouted or shifted during installation must be secured so that

they do not contact excessively hot areas or sharp edges. Where possible, follow the routing

suggestions in this manual.

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.

Left and right definitions in this manual are determined when sitting in the driver’s seat, facing

forward.

All fasteners must be of the correct size and torqued according to specifications (Table 1). Torque

specifications are in foot pounds (ft-lb) and are only applicable when Loctite is used. If the threads

are dry, add 20% to the torque values.

Torque Specifications

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

Newton meter 12 24 47 74 108 149 230 379

STANDARD GRADE 8 NATIONAL FINE THREAD

Size 3/8 7/16 1/2 5/8 3/4

Foot-pounds 40 60 90 180 320

Newton meter 54 81 122 244 434

METRIC CLASS 10.9

Size M8 M10 M12 M14 M16

Foot-pounds 19 41 69 104 174

Newton meter 25 55 93 141 236

Table 1 – The fastener values are applicable when Loctite is applied unless otherwise specified.

Table 1 Torque Specifications

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Hose Diameter Color Coded Label

1/4 inch Yellow

5/16 inch Orange

1/2 inch Blue

5/8 inch Blue

3/4 inch Green

1 inch Green

1-1/4 inch Green

Table 2 Hose color codes

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

Check that system hoses are all tight before running the system. Refer to setup procedure in the

Owner’s Manual before attempting to run this air system.

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, for example,

A410055 is a 55 inch hose extender kit. You would receive a kit which includes a set of each size

hose 55 inches long required to relocate the tank.

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 inch

drill bit. Secure the plate in position using the supplied #6 pan head, self-tapping screws.

This plate provides information, which allows Vmac to assist in customer

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

the vehicle.

Figure 1 Identification plate mounted

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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.

Ordering Parts

To order parts, contact your nearest VMAC dealer.

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

Tool Requirements

The following tools are required for installation:

* 1/2 inch drive metric socket set

* 8 to 24 mm metric wrench set

* 1/2 inch drive SAE socket set

* 7/16 inch to 7/8 inch SAE wrench set

* Allen key sets - metric & SAE

* mechanic’s screwdriver set

* nut drivers - 5/16 to 3/8 inch

* 1/2 inch drill with assorted bits up to 1/2 inch

* hacksaw or zip wheel suitable for cutting metal

* OEM fan wrench tool

The following tools are required for throttle component installation:

* small solder gun or soldering pen

* wire cutters

* wire strippers

* crimping tool

* digital multimeter, preferably with a frequency (Hz) setting

* small jeweller’s screwdriver set for adjustment of the throttle control

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Special Installation Notes

If you intend to use an auxiliary air tank with this system you must observe the

following installation procedure. Failure to observe this procedure will result

in damage to the system.

1. The line from the VR70 tank to the auxiliary air tank must have a check valve installed to

prevent blow-back 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.

Figure 3 Auxiliary air tank piping

12

Document #1930036

SYSTEM #V900068

INTERNATIONAL 2001 - 2003

4300, 4400 SERIES DT466

UNDERHOOD AIR COMPRESSOR

TM

PART 1

PREPARING FOR

INSTALLATION

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1.1 Preparing for Installation

1. Disconnect the batteries

2. Drain the coolant

3. Remove the four OEM bolts used to secure the passenger side fender shroud and set the shroud

aside temporarily.

4. Disconnect the radiator end of the passenger side turbo/intercooler pipe and allow it to hang

loose.

5. Remove the air cleaner to turbo rubber intake duct.

6. Remove the air cleaner

7. Remove the fan. Be sure to use the factory recommended fan-removing tool.

8. Lay the fan down temporarily in the fan shroud and carefully lean it against the radiator with

cardboard protection between.

9. Remove the OEM eight-rib drive belt by releasing the OEM tensioner and allow the belt to

hang loose.

10. Remove the alternator.

11. Remove the OEM eight-rib drive belt tensioner.

12. Unplug the cam sensor wiring and remove the bolt that secures the cam sensor and set it aside

temporarily. Rotate the cam sensor clockwise to expose the M8 bolt hole underneath.

13. Remove the three M10 bolts locating the alternator-mounting bracket and remove the M8 bolt

through the timing cover and alternator bracket. Discard the alternator bracket.

14. Remove the plastic OEM heater hose clamp and bracket from the front right of the cylinder

head. Discard the plastic clamp but retain the mounting nut, bolt and bracket. Put the original

bracket-mounting bolt back into the hole and retighten it to secure it in place.

15. Remove the two OEM bolts locating the engine-lifting lug on the side of the cylinder head and

remove and discard the lifting lug. It will be necessary to zip wheel the head of the bolt after

loosening to be able to remove it.

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Document #1930036

SYSTEM #V900068

INTERNATIONAL 2001 - 2003

4300, 4400 SERIES DT466

UNDERHOOD AIR COMPRESSOR

TM

PART 2

INSTALLING THE OIL/AIR

SEPARATOR TANK AND

LINES

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2.1 Installing the oil/air separator tank brackets

1. Measure 10-1/2 inches (26 cm) back from the rear of the front spring hanger and mark the

lower edge of the driver side frame rail (Figure 2.1).

Figure 2.1 Bracket mounting -driver side Figure 2.2 Bracket tab facing the frame rail

2. Measure 23 inches (58 cm) back along the rail from the previous mark and mark the lower

edge of the driver side frame rail (Figure 2.1).

3. Pass the threaded end of the supplied tank cable strap, through the top hole in the front tank

mount bracket from the flat side of the bracket. Pull the cable right through to the stop

(Figure 2.2).

4. Hang the front tank mount bracket on the inside of the driver side frame rail at the 10-1/2 inch

mark, with the cable over the top of the frame rail. Wrap the cable around the outside of the

frame rail and pass the threaded end back through the hole in the tank mount bracket that

aligns with the under side of the frame rail. Set the notch protruding from the bracket on the

inside of the frame, locating the bracket on the top edge of the lower frame rail lip.

5. Repeat the above procedure with the rear tank mount bracket and set this bracket at the rear

marked position on the frame rail.

6. Square up the brackets and install the two 5/16 inch thick washers then the two 5/16 inch nuts

to the threaded ends of the tank cable straps. Tighten the nuts on the cables until the tank

mounting brackets are securely located. Do not over tighten the cables.

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2.2 Alternate oil/air separator tank mounting locations

The 2.2 section is for trucks with under deck exhaust system or trucks that

cannot mount the oil/air separator tank on the driver side of the vehicle.

1. Measure 20 inches (51 cm) back from the front spring hanger along the frame rail and mark

this as the position of the first bracket (Figure 2.3).

2. Measure an additional 20 inches (51 cm) back from the first mark to make a second marking

for the rear tank-mounting bracket.

3. Following these measurements, install the tank brackets in the marked positions as outlined in

figure 2.4 and steps 3, 4, 5, and 6 of section 2.1.

Figure 2.3 Bracket mounting, passenger side Figure 2.4 Tank brackets, passenger side

2.3 Installing the C-clamps

The C-clamps will need to be on the opposite side of the tank when installing

the tank on the passenger’s side.

1. During the installation, it will help to align the clamps if the tank is set on the edge of a

workbench (Figure 2.5). Remove the 1/4 × 3-1/2 inch pinch bolts and nuts from both the

supplied tank mount C-clamps. Slide both clamps over the front of the tank with the flat side

of the clamp facing the opposite side to the oil filter. Set the front clamp at 6 inches from the

front of the tank. (For a driver side tank mount) set the rear clamp position 23 inches (58

cm) back from the front bracket. (For a passenger side tank mount) set the rear clamp

position 20 inches (51 cm) back from the front bracket). Set the clamps so that the up arrow

on the front of the tank is in the vertical position and check that the clamp holes align with the

mount bracket holes. Reinstall the 1/4 × 3-1/2 clamp pinch bolts and nuts and tighten enough

just to loosely hold the tank.

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Vmac V900068 Installation guide

Vmac V900068 Installation guide

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