Vmac V900036 Installation guide

Installation Manual

For The

System #V900036

UNDERHOOD AIR COMPRESSOR

2000 FREIGHTLINER

CUMMINS M11 ISM FL 112

WITH AIR BRAKES - W/WO A/C

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

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

DOCUMENT 1900627

Installation Manual

VR70 Underhood Air Compressor

System Number V900036

Application: 2000 Freightliner Cummins M11 ISM with air brakes, w/wo A/C

Publication Date: December 1999

Origination Documents: 1900370a - Introduction

1900371 - Installing the compressor

1900372 - Installing the tank and lines

1900373 - Installing the control unit

1900374 - Installing the Throttle Commander

1900375 - Illustrated parts list

1900130 - Warranty registration

Registered Trademarks:

VR70, 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.

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 ................................................................................................................ 5

ORDERING PARTS ...................................................................................................................... 6

WARRANTY ............................................................................................................................. 6

SYSTEM IDENTIFICATION NUMBER PLATE .................................................................................... 7

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

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 ............................................................................................ 16

1.4 COMPLETING THE INSTALLATION ...................................................................................... 18

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 ................................................................................ 23

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

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

PART 3: INSTALLING THE CONTROL UNIT AND THROTTLE COMMANDER .. 27

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

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

ILLUSTRATED PARTS LIST .............................................................................................. 35

WARRANTY REGISTRATION .......................................................................................... 41

1

DOCUMENT 1900627a

2

General Information

System #V900036

2000 FREIGHTLINER

CUMMINS M11 ISM

WITH AIR BRAKES - W/WO A/C

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 1900627a

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:

2000 Freightliner Cummins M11 ISM with air brakes - w/wo A/C

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 and 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)

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 1900627a

WARNING

✁

NOTE

6

DOCUMENT 1900627a

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).

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.

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.

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.

WARNING

✁

7

DOCUMENT 1900627a

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 Time

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

System Identification Number Plate

The enclosed System Identification Number Plate (S/N) must be attached to the vehicle at the time

of installation. Locate the S/N plate on the composition fan shroud on the passenger side of the

vehicle below the fan warning decal (Figure 0.1). 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

IMPORTANT

This S/N plate provides information, which allows VMAC to assist in customer inquiries and/or

ordering of parts. It is important that this S/N plate is affixed to the vehicle.

Changes and improvements

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

Mount the s

y

stem ID plate here

1. The line from the VR70 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 VR70 tank.

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.

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.

DOCUMENT 1900627a

Auxiliary Receiver

One - way 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 #V900036

2000 FREIGHTLINER

CUMMINS M11 ISM

WITH AIR BRAKES - W/WO A/C

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 1900627b

10

Part 1: Installing the Compressor and Oil Cooler

1.1 Preparing for installation

1. Disconnect the batteries (positive terminal first). Cover the battery terminals with the OEM

plastic protectors or use a battery cover to prevent the terminals from being shorted when

the steel braid air lines are installed.

2. Drain the coolant from the radiator and the engine block. Remove the upper radiator hoses

and metal tube. Remove and discard the rubber connector tube from the engine end.

3. Remove and discard the metal cross-over tube and rubber connector hose that connect

between the surge tank and the fitting on the lower radiator hose. The hose connected to the

surge tank must remain.

4. Remove the radiator support bars which run from the radiator to the firewall on the driver’s

side of the truck (Figure 1.1). Be sure to remove the hose support retainers before

attempting to remove the bars.

5. Remove the intercooler tube which runs across the top of the engine (Figure 1.1).

6. Remove the six (6) cap screws holding the fan to the clutch assembly and the fan shroud to

the radiator supports and remove both the fan and the shroud (Figure 1.1).

7. Remove OEM drive belt. Remove the cap screws and remove the OEM crank pulley.

8. Drain the air brake reservoirs on the truck.

Figure 1.1

11

DOCUMENT 1900627b

Remove the fan

and shroud together For added clearance,

remove these bars

Remove the upper rad

hose and coolant tube

Remove the intercooler

tube

12

DOCUMENT 1900627b

9. If the vehicle is equipped with air conditioning, remove the cap screws holding the

compressor to the mounting bracket. Place a protective cover on the valve cover, lift the

compressor up onto the engine valve cover and secure it in place with a piece of wire.

Do not disconnect any air conditioning lines from the compressor.

10. Remove the six (6) fasteners holding the OEM air conditioning mounting bracket to the side

of the cylinder block and remove the bracket.

11. Remove the OEM hex head cap screws holding the flat plate with the belt tensioner to the

front of the engine. Remove the OEM tensioner from the mounting bracket and discard the

bracket and cap screws.

12. Remove any additional OEM cap screws required for attaching the VR70 replacement

plate (Figure 1.2).

Figure 1.2

1.2 Installing the bracket and compressor

1. Make sure that the mounting area for the crank pulley is clean. Fit the VR70 crank pulley

to the crankshaft (Figure 1.3). Apply Loctite to the 10 mm cap screws and install them.

Torque the fasteners to specifications.

2. Place the supplied replacement tensioner plate on the front of the engine. Apply Loctite and

install the 7 (seven) 8 mm socket head cap screws. Torque them to specifications.

3. After the plate has been installed on the engine, make sure that all of the holes in the front

cover have hex head cap screws installed. Install the supplied 8 x 25 mm full thread hex

head cap screw (without a washer) in the location shown in Figure 1.2 along with the air

brake pipe securing clamp. If there are other empty holes, install the short OEM cap

screws in those locations and torque them to specifications.

The VR7000

bracket requires

these locations

for mounting

Replace this

capscrew

NOTE

13

DOCUMENT 1900627b

Figure 1.4

Figure 1.3

4. Place the compressor mounting bracket in position on the driver’s side of the engine.

5. Apply Loctite and install four (4) 10 mm hex head cap screws into the four (4) locations on

the side of the timing cover and two (2) 10 mm socket head cap screws on the side of the

cylinder block (Figure 1.4). Secure the wire harness retainer behind rear lower cap screw.

Torque the fasteners to specifications.

Socket head

cap screws

Hex head

cap screws

Hex head

cap screws

6. If the vehicle is not equipped with air conditioning, remove the two hex head cap screws

from the top of the VR70 bracket and remove the A/C mounting cradle using the 1/4” NC

jacking bolt in the threaded hole in the center of the mounting cradle (Figure 1.5).

14

DOCUMENT 1900627b

Figure 1.6

Install and ti

g

hten this line before installin

g

the compressor

7. Install the OEM tensioner on the stud located on the front mounting plate. Apply Loctite,

install the OEM retaining nut and torque to specifications (Figure 1.5).

8. Remove the 12 mm hex head cap screw from the VR70 tensioner. Apply Loctite, install

and torque to specifications. Remove the 1/2” cap screw holding the A/C back idler on the

tensioner plate, apply Loctite and torque it to specifications.

9. Install the A/C compressor in place on the VR70 bracket. Apply Loctite, install the cap

screws and torque to specifications.

10. Install the 8 rib OEM A/C drive belt and the supplied A/C drive belt (Figure 1.7).

Tensioner

Idler

Jacking hole

Bolts

Dowel pins

Figure 1.5

11. Remove the idler from the VR70 bracket. Apply Loctite to the 1/2” flange hex head cap

screw, install it and torque to specifications.

12. Install the 90 degree end of the 1/4” x 127-1/2” pressure control line to the 90 degree fitting

on the side of the air inlet valve on the compressor. Align the line so that it is parallel with

the compressor, facing to the rear and tighten the fitting (Figure 1.6).

This line must be installed before the compressor is mounted. Once the compressor is

mounted you will not be able to access this fitting.

13. Place the compressor on the mounting bracket.

14. Install flat washers on the three (3) 8 mm hex head cap screws, apply Loctite, thread them

into the compressor through the bracket and torque them to specifications.

A/C compressor VR70 compressor

VR70 idler

VR 70 tensioner

A/C tensioner

OEM A/C

drive

A/C back

idler

15

DOCUMENT 1900627b

15. Install the VR70 belt (Figure 1.7)

Oil cooler

Remove this cap screw

to mount the support bracket

Intercooler tube

NOTE

Figure 1.8

Figure 1.7

1.3 Installing the oil cooler

1. Remove the fender liner from the passenger side of the engine compartment.

2. Remove the back three (3) hex head cap screws holding the manifold to the cylinder head.

Also remove and discard the back outer cap screw from the intercooler flange mount at the

turbocharger (Figure 1.8).

3. Place the cooler assembly in position on the side of the engine and over the back of the

valve cover.

4. Apply Loctite to three (3) 10 x 55 mm hex head cap screws and install them through the

cooler mount plate and into the manifold.

5. Apply Loctite to the hex head cap screw and install it into the support bracket and into the

intercooler flange mount hole.

6. Locate the cab heater return hose where it connects to the vacuum flow control valve. Cut

the hose 19” from the heater control valve, place hose clamps over the ends, install the

supplied Y-fitting (Figure 1.9) and tighten the clamps.

7. Install hose clamps and insert the supplied 3/4” x 14” section of hose between the Y-fitting

and the forward hose fitting on the oil cooler. Tighten the clamps.

16

DOCUMENT 1900627b

Figure 1.9

Heater control valve

Coolant

overflow

tank

Heater return hose Y-fittin

g

Steel coolant line

Water pump

Intercooler tube

Oil cooler

3/4 hose

5/8 hose

3/4 hose

Transmission cooler Standard

transmission

5/8 hose

Automatic transmission

19

Protective loom

(discarded)

8. Remove the 1/2” x 16 plug from the water pump (Figure 1.10) and install the supplied

1/2” x 16 90 degree hose barb fitting.

9. Install hose clamps and insert the supplied 5/8” x 54” hose between the hose barb at the

pump and the rear fitting on the oil cooler.

10. Install plastic loom protector to the hose. Make sure that you route this hose over the

intercooler tube and away from the hot turbocharger and exhaust. Locate the plastic loom

where the hose passes over the intercooler tube.

11. Install hose clamps and insert the 46-1/2” x 1” replacement hose between the coolant

overflow container and the fitting on the lower radiator return tube. Route this hose across

the front of the engine, behind the A/C compressor and secure it so that it does not contact

the fan or other moving parts.

12. Use a nylon tie to fasten the hose from the cooler and the hose from the overflow cannister

together (Figure 1.11).

17

DOCUMENT 1900627b

Figure 1.10

Figure 1.11

Remove

this pluG

Front

1/2 x 16

Replacement hose

18

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

DOCUMENT 1900627b

3. Install the spacer and the fan on the clutch hub. There are two different fan clutches uses on

this model, Horton or Kyser.

The Horton fan clutch has an air connection at the top. Install the fan spacer with a 2-1/2”

diameter center using Loctite on the supplied 3/8” x 1” flange lock cap screws.

The Kyser fan clutch has the air connection at the bottom. Install the fan spacer with a 2”

diameter center using Loctite on the supplied 3/8” low profile nuts. Do not overtighten the

nuts.

4. Fill the cooling system with the manufacturer recommended coolant to the correct level.

5. Install the support bars back into position and attach any hose retainer clamps to the bars.

1.4 Completing the installation

1. Install the top radiator tube with the replacement hose on the engine end (with the top end

forward) and tighten the clamps (Figure 1.11).

2. Remove the nut retaining the driver’s side hood strap and install the radiator tube support

under the strap to prevent the tube from rubbing against the A/C compressor pulley (Figure

1.12).

Figure 1.12

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Vmac V900036 Installation guide

Vmac V900036 Installation guide

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