Vmac 9019 Installation guide

Installation Manual

For The

System #9019

UNDERHOOD AIR COMPRESSOR

1999 - 2001 INTERNATIONAL 4700, 4800, 4900, &

4700LP DT 466E

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

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

DOCUMENT 19624

Owner’s Manual

VR7000 Underhood Air Compressor

System Number 9019

Application: 1999 - 2001 International 4700, 4800, 4900 & 4700LP DT 466E

Publication Date: February 2001

Origination Documents: 19624a - Introduction

19624b - Installing the compressor

19624c - Installing the tank and lines

19624d - Installing the control unit

19624e - Installing the Throttle Commander

19625 - Illustrated parts list

19130 - Warranty registration

Registered Trademarks:

VR7000, 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.

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 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 ............................................................... 31

3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 33

3.2 CONNECTING THE WIRING ................................................................................................ 35

PART 4: INSTALLING THE THROTTLE COMMANDER ........................................... 39

4.1 MOUNTING AND CONNECTING THE THROTTLE COMMANDER ................................................. 41

ILLUSTRATED PARTS LIST .............................................................................................. 43

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

1

DOCUMENT 19624

2

General Information

System #9019

1999 - 2001 INTERNATIONAL 4700, 4800, 4900, &

4700LP DT 466E

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 19624

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:

1999- 2001 International 4700, 4800, 4900 & 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

DOCUMENT 19624

WARNING

!

NOTE

6

DOCUMENT 19624

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.

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.

7

DOCUMENT 19624

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 (Monday-Friday)

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.

8

Special installation notes

If you intend to use an auxiliary air receiver 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 VR7000 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 VR7000 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.

VR7000 Tank

Auxiliary Receiver

One-way check valve

Install the line as high as

possible, NOT on the

bottom of the tank

DOCUMENT 19624

Part 1

Installing

the Compressor

and

Oil Cooler

System #9019

1999 - 2001 INTERNATIONAL 4700, 4800, 4900, &

4700LP DT 466E

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 19624

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

DOCUMENT 19624

12

DOCUMENT 19624

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 VR7000 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

DOCUMENT 19624

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 VR7000 bracket and align the holes.

Apply Loctite and install two (2) 12 x 70 mm hex head cap screws. For vehicles without

A/C use the two 12 x 40mm hex head cap screws supplied.Use the 7/16 flat washers

supplied with the mounting bolts.

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 VR7000 crank pulley using the six (6) supplied 10 x 45 mm fasteners and flat

washers provided. 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 VR7000 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 VR7000 bracket, then connect them to the sensors.

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

of the compressor.

14. Apply Loctite to the other end of the threads, then place the compressor on the mounting

bracket.

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

14

DOCUMENT 19624

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 1.4.

19. Route the alternator electrical harness over the VR7000 compressor and connect the

harness to the alternator and air conditioning connectors.

20. Install the VR7000 belt. Figure 1.5 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

15

DOCUMENT 19624

1.3 Installing the oil cooler assembly

1. Identify the loction for the cooler mounting bracket on the inside of the passengers 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 immediatly 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.

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

DOCUMENT 19624

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

properly tightened.

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

Figure 1.7

5. Connect the 17 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 degree 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.

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

Disconnect heater return

hose and connect to front

spigot on cooler.

Cut to length 3/4 heater hose &

fit from water pump to rear spigot

on cooler

17

DOCUMENT 19624

Figure 1.8

18

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Vmac 9019 Installation guide

Vmac 9019 Installation guide

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