Vmac 9022 Installation guide

Installation Manual

For The

System #9022

UNDERHOOD AIR COMPRESSOR

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

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

DOCUMENT 19632

1998-1999 FREIGHTLINER FL50, FL60, FL70, FL80

CATERPILLAR 3126 W/WOAC

Installation Manual Document 19632

VR7000 Underhood Air Compressor

System Number 9022

Application: 1998-1999 FREIGHTLINER FL50, FL60, FL70, FL80

CATERPILLAR 3126 W/WOAC

Publication Date: February 2001

Publication Number: 19632

Origination Documents: #19632 - introduction

#19632a - compressor and oil cooler installation

#19632b - air tank and line installation

#19632c- throttle controller installation

#19632d - control unit installation

#19633 - illustrated parts list

#19130 - warranty registration

Registered Trademarks:

VR7000 and Throttle Commander are registered trademarks of VMAC.

Freightliner is a registered trademark of Freightliner Corporation.

Caterpillar 3126 is a registered trademark of Caterpillar Inc.

Loctite, Prime N’ Clean, 242 and PST are registered trademarks of Loctite Corporation.

Nylok is a registered trademark of Nylok Fastener Corporation.

The contents of this manual may not be reproduced in any form without the express writ-

ten permission of VMAC

Contents

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

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

INSTALLATION N OTES ............................................................................................................... 6

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

WARRANTY ............................................................................................................................. 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 ..................................................................... 11

1.3 INSTALLING THE OIL COOLER/THROTTLE CONTROLLER ASSEMBLY .......................................... 15

1.4 CONNECTING THE COOLING LINES ..................................................................................... 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 ................................................................................ 23

2.3 ADDING OIL TO THE SYSTEM ............................................................................................. 27

2.4 COMPLETING THE INSTALLATION ....................................................................................... 28

PART 3: INSTALLING THE CONTROL UNIT............................................................. 29

3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 31

3.2 CONNECTING THE WIRING ................................................................................................. 32

PART 4: CONNECTING THE THROTTLE CONTROLLER ..................................... 35

4.1 CONNECTING THE CABLE .................................................................................................. 37

4.3 ADJUSTING THE CABLE .................................................................................................... 39

ILLUSTRATED PARTS LIST ............................................................................................ 41

WARRANTY REGISTRATION ........................................................................................ 47

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DOCUMENT 19632

2

General Information

System #9022

1998-1999 FREIGHTLINER FL50, FL60, FL70, FL80

CATERPILLAR 3126 W/WOAC

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 19632

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

VMAC Pneumatic Throttle Control connection and adjustment

This kit has been designed for:

1998-1999 FREIGHTLINER FL50, FL60, FL70, FL80

CATERPILLAR 3126 W/WOAC

Installation steps

The installation procedure in this manual has four main steps:

Part 1: Installing the Compressor and Oil Cooler

Part 2: Installing the Air Tank and Lines

Part 3: Installing the Control Unit

Part 4: Connecting the Pneumatic Throttle Control

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

✁

5

DOCUMENT 19632

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DOCUMENT 19632

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

WARNING

✁

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

If the threads are dry add 20% to the torque values.

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.

Ordering Parts

To order parts, contact VMAC at:

Telephone 250-754-6997

Facsimile 250-754-6972

Customer Service 1-800-736-8622

Office Hours 8:00 AM to 4:30 PM Pacific 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. The form has been designed as a convenient mailer,

just fold along the lines, tape the edge and apply sufficient postage.

System Identification Number Plate

The enclosed System Identification Number Plate must be attached to the vehicle at the time

of installation. This plate provides information, which allows VMAC to assist in customer

inquiries and ordering of parts. Locate the plate on the front body support on the passenger

side of the in front of the hood stop (Figure 1) . Drill the two hole locations using a 7/64”

drill bit. Place the plate in position and fix in place with the two #6 pan head self tapping

screws provided.

Figure 1

Changes and improvements

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

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DOCUMENT 19632

Mount the system ID plate here

8

Part 1

Installing

the Compressor

and

Oil Cooler

System #9022

1998-1999 FREIGHTLINER FL50, FL60, FL70, FL80

CATERPILLAR 3126 W/WOAC

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 19632

10

Part 1: Installing the Compressor and Oil Cooler

1.1 Preparing for installation

1. Disconnect the battery negative terminal.

2. Drain the coolant through the draincock into a suitably sized container.

3. Remove the top radiator hose.

4. Remove the driver’s side rubber intercooler tube.

5. Remove cooling fan and the fan shroud.

6. Remove OEM serpentine drive belt.

7. Remove the harmonic balancer.

8. Remove the securing bracket holding the heater hose to the valve cover.

9. Remove both fender inserts.

10. Remove the two top cap screws and loosen the two lower cap screws retaining the fan

pulley assembly and remove the fan pulley assembly from the engine. The fan pulley

assembly is slotted on the bottom and the assembly can be lifted up off the lower

bolts. Remove the OEM studs from the pulley.

11. Clean the front of the engine to remove any contamination that will interfere with

mounting the VR7000 bracket and other components. Blow out all internal threads

with compressed air.

1.2 Installing the bracket

1. Remove the idler pulley and the tensioner from the VR7000 mounting bracket. Fit the

compressor mounting bracket into position on top of the driver’s side timing cover

casting using the four supplied (4) 10 x 30mm hex head cap screws and 3/8” flat

washers. Tighten the caps screws just enough to hold the bracket in place against the

engine (Figure 1.1).

2. Mark the location of the fifth hole on the bracket mounting tab where it fits over the

engine lifting plate (Figure 1.1). Make sure that it is centered properly, or the hole

will not align with the threaded hole in the block.

3. Remove the VR7000 mounting bracket from the engine.

4. Remove the four (4) OEM cap screws from the alternator/air conditioning support

bracket at the center of the engine. These cap screws also retain the engine lifting

plate (Figure 1.1).

5. Slide the lifting plate out from behind the alternator/air conditioning bracket.

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DOCUMENT 19632

6. Center-punch the marked hole, drill a 3/16” pilot hole and then drill the plate out to 1/2".

7. Slide the lifting plate back into place behind the alternator/air conditioning bracket,

apply Loctite 242 and loosely install the OEM cap screws.

8. Install the VR7000 mounting bracket using all five (5) cap screws with Loctite 242.

9. Refit the VR7000 belt tensioner and idler (make sure the bolt spacer is installed in the

idler) using Loctite 242 (Figure 1.1).

Figure 1.1

10. Torque all fasteners to specifications.

11. Install the VR7000 crank pulley on the OEM crank pulley and align 8 holes. Place

harmonic balancer in front of both crank pulleys and fit eight (8) 10 x 70mm supplied

hex head cap screws with Loctite 242 applied to the threads. Torque them to

specifications.

12. Apply Loctite 242 to one end of each of the three (3) supplied 8mm studs and install

the studs into the bottom of the VR7000 compressor.

13. Apply Loctite to the other end of the studs, place the compressor onto the bracket and

install the supplied 8mm nuts and 5/16” flat washers on each of the studs. Torque the

nuts to specifications.

Mark and drill this hole

2 of 5 mountin

g

locations

2 of 5 mountin

g

locations

Id ler m ou n tin g lo ca tio n

Tensioner mountin

g

location

Remove 8 pulley bolts

Remove OEM belt and

fan pulley

Remove 4 bolts holding

this bracket and the engine

lifting bracket to the fron t o f

the engine

Mount the top of the

remote idler block in these

holes

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DOCUMENT 19632

14. Check the alignment between the crank pulley and the compressor pulley. If they are

out of alignment, the mounting bracket is not sitting flush on the engine. Make sure

that nothing has interfered between the engine and the mounting bracket.

15. Install the remote idler to the cylinder head above the fan pulley using four (4) 8 x

30mm socket head cap screws with 5/16” flat washers. Use loctite 242 on the cap

screws and install the top screws in the second row of threaded holes (Figure 1.1).

Torque the cap screws to specifications.

Figure 1.2 shows the bracket installed with the idler and tensioner in place. Also note

the remote idler mount on the front of the engine.

Figure 1.2

16. When all of the fasteners are torqued, fit the VR7000 serpentine belt. Route as shown

in Figure 1.3.

17. Install the top radiator hose and tighten the clamps. Ensure that the heater hose is

routed and secured away from the drive belt and over the top hose (Figure 1.5).

18. Apply Loctite 242 and install the supplied 2-1/4” long 3/8” studs with the notched

end into the fan pulley, which was removed earlier.

19. Select the correct fan spacer (4 or 6 holes) and install it over the studs.

Remote

idler

mount

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DOCUMENT 19632

VR

CRANK

TENSIONER

REMOTE

IDLER

BACK IDLER

VR BELT

(P/N 16246)

Figure 1.3

Figure 1.4

Heater hose clear of belt

Hood spring guard

20. Attach the fan using the OEM washers and nuts, then install the fan shroud at the

same time as you install the fan and pulley assembly . The fan and pulley assembly

can be lowered down until the lower slotted holes slide over the previously loosened

lower bolts that were left in place on the front of the engine.

15

1.3 Installing the oil cooler/throttle controller assembly

1. Clean the center part of the cylinder head on the passenger side of the engine.

2. Locate and clean the six (6) threaded holes in the head (Figure 1.5).

Figure 1.5

3. Bend the edges of the exhaust manifold gasket down and out of the way

4. Remove the cooler/throttle controller assembly from the mounting plate.

5. Locate the mounting plate against the cylinder head and install six (6) 10 x 35 mm

hex head cap screws with 3/8” flat washers. Torque the cap screws to specifications.

6. Locate the cooler/throttle controller assembly on the mounting plate (Figure 1.6) and

reattach the assembly. Refit OEM hose supporting clips to the two longer bolts with

nuts supplied on the cooler plate.

Four M ou nting Locations Two Locations Behind Here

DOCUMENT 19632

1.4 Connecting the cooling lines

1.4.1 Air brake equipped

1. Remove the OEM brake compressor pressure regulator from the back of the

compressor to provide access to the fittings (Figure 1.7).

2. Remove the 16-3/4” long OEM coolant line (with the swaged ends) which connects

between the air brake compressor cylinder head and the engine block.

3. Remove the 45 degree elbow from the air brake compressor cylinder head and replace

it with the supplied 1/2” NPT x 5/8” hose barb (Figure 1.7).

Figure 1.7

4. Remove the #8 O-ring to #10 JIC 45 degree fitting from the cylinder block.

5. Install the supplied replacement O-ring fitting and then the 1/2” NPT x 5/8” hose barb.

6. Slip the supplied hose clamps onto the 5/8” x 34” rubber hose and install it between

the lower rear hose barb on the cooler and the hose barb on the air brake compressor

cylinder block (Figure 1.8).

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DOCUMENT 19632

Figure 1.6

Remove 45 degree elbow Remove OEM brake Remove #8 O-ring Install 1/2” NPT x 5/8” hose barb

compressor regulator 45 degree fitting

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DOCUMENT 19632

Figure 1.8

7. Slip the supplied hose clamps onto the 5/8” x 36” rubber hose and install it between

the lower front hose barb on the cooler and the hose barb on the engine block.

8. Tighten the hose clamps and reinstall the OEM regulator.

5/8” x 36” heater hose

1.4.2 Hydraulic brake equipped

NOTE: Some hydraulic brake vehicles have an air pump. If equipped, follow Procedure

1.4.1.

1. Remove the blank plug from the engine block on the drivers side (Figure 1.9) and fit

the same fittings as in section 1.5.1 numbers 5 and 6. If for some reason this coolant

port is unavailable, locate another coolant port suitable on the upper engine block or

cylinder head.

2. Fit the 5/8” x 34” heater hose supplied between the lower rear hose barb on the cooler

and the engine block 5/8 hose barb just fitted. Add hose clamps and tighten.

3. Remove the 3/4” NPT blanking plug from the bottom rad hose housing on the engine

and fit the supplied 3/4” NPT x 5/8” hose barb.

4. Fit the supplied heater hose (longest one) 60” to the hose barb and the other end to the

front lower hose barb on the cooler. Cut to required length.

5. Install the supplied O-ring fitting and 3/4” NPT x 5/8” hose barb.

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

6. Slip the supplied hose clamps on the 5/8” x 34” rubber hose and install it between the

lower front hose barb on the cooler and the hose barb at the engine block.

7. Tighten the hose clamps.

8. Fill the cooling system with the recommended coolant to the correct level.

Remove this

plug

Figure 1.9

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DOCUMENT 19632

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Vmac 9022 Installation guide

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