Vmac 9018 Installation guide

Brand: Vmac

Model: 9018

Type: Installation guide

Vmac 9018 is an underhood air compressor that is designed to be installed on a 1999 Navistar International truck equipped with a Cummins ISB M11 engine. It comes with a variety of features that can be used for a variety of purposes. Some of the key features and possible use cases for the Vmac 9018 include:

Air Compressor: The Vmac 9018 comes with a powerful air compressor that can be used to power a variety of air tools and equipment. This can be useful for a variety of tasks, such as inflating tires, powering pneumatic tools, and cleaning equipment.
Air Tank and Lines: The Vmac 9018 also comes with an air tank and lines that allow you to store compressed air for later use. This can be useful for tasks that require a lot of compressed air, such as sandblasting or painting.

Air Compressor: The Vmac 9018 comes with a powerful air compressor that can be used to power a variety of air tools and equipment. This can be useful for a variety of tasks, such as inflating tires, powering pneumatic tools, and cleaning equipment.
Air Tank and Lines: The Vmac 9018 also comes with an air tank and lines that allow you to store compressed air for later use. This can be useful for tasks that require a lot of compressed air, such as sandblasting or painting.

Installation Manual

For The

System #9018

UNDERHOOD AIR COMPRESSOR

1999 NAVISTAR INTERNATIONAL

Cummins ISB M11 Engine

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

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

DOCUMENT 19250

Installation Manual

VR7000 Underhood Air Compressor

System Number 9018

Application: 1999 Navistar International equipped with the Cummins ISB

M11 Engine

Publication Date: January 1, 1999

Origination Documents: #19250a - introduction

#19252 - compressor installation

#19253 - tank and line installation

#19254 - throttle commander installation

#19255 - control unit installation

#19256 - illustrated parts list

#19130 - warranty registration

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

written permission of VMAC

General Information

System #9018

1999 NAVISTAR INTERNATIONAL

Cummins ISB M11 Engine

UNDERHOOD AIR COMPRESSOR

DOCUMENT 19250a

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 Navistar International equipped with a Cummins M11 engine.

Installation steps

The installation procedure in this manual has four main steps:

Part 1: Installing the Compressor

Part 2: Installing the 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)

NOTE

WARNING

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.

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 under-hood 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. The possibility exists that the primary installer may be color-blind. Always ensure

that another person confirms the color codes on the wires.

Type Grade 8 plated Class 10.9 unplated

Size In Cast or

Steel

Aluminum

In Cast or

Steel

Aluminum

3/8 48 45

7/16 77 70

1/2 117 95

M8 25 20

M10 45 40

M12 80 70

M14 145 130

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.

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.

Part 1

Installing

the Compressor

System #9018

1999 NAVISTAR INTERNATIONAL

Cummins ISB M11 Engine

UNDERHOOD AIR COMPRESSOR

DOCUMENT 19252

Part 1: Installing the Compressor

1.1 Preparing for installation

1. Disconnect the batteries.

2. Drain the coolant.

3. Remove the tube which crosses over the top of the engine and connects the inter-

cooler to the turbocharger inlet.

4. Remove the air conditioning compressor. Lift it upward and set it on top of the

engine.

WARNING

5. Remove and discard the air conditioning compressor mounting bracket.

6. Remove the OEM serpentine belt.

7. Remove the five (5) OEM fasteners which retain the crankshaft pulley and harmonic

balancer and discard them. Remove and discard the 8

3″ thick spacer washer from

behind the fasteners.

8. Remove the lower radiator hose and clamps. Keep them for later installation.

9. Remove and discard the cast aluminum lower radiator hose-to-engine block inlet and

support bracket on the right side of the engine. Discard the two (2) M10 hex head cap

screws, the M8 hex head cap screw and the bracket.

10. Remove the engine oil filter. Cover the filter to prevent contamination if you will be

reinstalling the same filter.

11. Remove and discard the four (4) OEM hex head cap screws which secure the engine

dipstick tube support plate to the right-hand side of the engine.

12. Remove the power steering reservoir from the support bracket. Keep the OEM

fasteners.

13. Drain the oil from the power steering reservoir.

14. Remove and discard the ½″ oil hose from the reservoir to the steering box. Remove

the ¾″ hose from the reservoir, but do not discard this hose.

Do not disconnect the air conditioning lines.

15. Remove the ½″ NF cap screws holding the radiator and firewall tie-rod bracket to the

frame on the left-hand side.

16. Remove the 16

5″ NC nuts from the bracket holding the radiator tie-rod to the left-hand

side of the radiator.

17. Swing the tie-rod bracket away from the frame, remove and discard the power

steering reservoir mounting bracket and support plate from behind the tie-bar mount-

ing plate on the frame rail.

1.2 Installing the compressor oil cooler

1. Apply Loctite to the four (4) M10 × 30 mm hex head cap screws supplied with the

installation kit.

2. Attach the VR7000 cooler to the engine block over the dipstick tube support plate

using these hex head cap screws. Torque them to 45 ft-lb.

3. Push the supplied 2½″ × 6″ long coolant hose onto the 90° elbow. Place an HS4 hose

clamp over this connection and tighten the clamp. Slip the second HS4 clamp over

the hose, but leave it loose at this time.

4. Push the other end of the 2½″ × 6″ long coolant hose on the rear fitting of the oil

cooler.

5. Attach the supplied 90° flange elbow to the engine where OEM aluminum housing

for the lower radiator hose was originally mounted. The 90° elbow must point to the

rear (Figure 1). Use the supplied gasket, a suitable gasket sealant and two (2)

supplied M10 × 25 mm socket head cap screws. Torque the fasteners to 45 ft-lb.

Figure 1

Oil Cooler

Line Fittings

Lower Radiator

Hose Fitting

Gasket

Replacement Fitting

For OEM Aluminum

Must Point Rearward

Connecting Hose

HS44 Clamps

6. Slide the second HS4 clamp into position over the cooler connection and tighten the

clamp.

7. Install the OEM lower radiator hose to the cooler inlet. Tighten all hose clamps.

8. Install the oil filter. If you are using a new filter, fill it with clean, OEM recom-

mended oil before installation.

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

check for leaks.

1.3 Installing the compressor

NOTE

1. Install the main mounting bracket for the VR7000 to the side of the timing cover

using the eight (8) threaded holes shown in Figure 2.

Make sure that the surfaces that the main mounting bracket will contact are clean and

free of contaminants or debris. If the mounting bracket does not seat correctly

against the timing cover or engine block, the compressor and crankshaft pulleys will

not align correctly.

2. Thread the two (2) M10 × 35 mm hex head cap screws into the two holes on the side

of the engine block (Figure 3). Use 8

3″ flat washers behind the cap screws.

3. Thread four (4) M10 × 35 mm hex head cap screws in the four (4) threaded holes

originally used to mount the OEM air conditioning compressor mounting bracket

(Figure 3). Use 8

3″ flat washers behind the cap screws.

4. Thread two (2) M10 × 35 mm hex head cap screws into the two holes on the rear of

the timing cover (Figure 3). Use 8

3″ flat washers behind the cap screws.

Figure 2

OEM Air Conditioning

Compressor Mounting

Bracket Holes (4)

Timing Cover

Threaded Holes

(

)

Cylinder Block

Threaded Holes

(

)

5. Torque the cap screws which thread into the cast engine block to 45 ft-lb. Torque the

cap screws which thread into the aluminum timing cover to 35 ft-lb.

Figure 3

1.4 Installing and mounting components

1. Install the VR7000 pulley over the OEM pulley and harmonic balancer. Align the

mounting holes.

2. Apply Loctite and install five (5) M14 1.5 × 80 mm hex head cap screws. Torque

them to 145 ft-lb.

3. Install the VR7000 pressure regulator to the mounting bracket using the supplied

fasteners (Figure 4). Tighten the fasteners.

4. Fit the VR7000 belt tensioner to the front of the mounting bracket using the M12 × 80

mm hex head cap screw (Figure 4). Apply Loctite and torque it to 80 ft-lb.

NOTE

5. Remove the ½″ × 1¼″ UNC flange lock bolt securing the back idler to the bottom of

the mounting bracket. Apply Loctite and torque to 117 ft-lb. Be careful not to lose

the aluminum spacer that fits over the lock bolt and into the center of the idler.

If the VR7000 belt tensioner is already fitted on the mounting bracket, remove it,

apply Loctite to the M12 × 80 mm hex head cap screw and torque it to 80 ft-lb.

M10 x 35 (4)

M10 x 35 (2)

M10 x 30 (2)

Figure 4

6. Install the OEM 8-rib drive belt as shown in Figure 5 and tension it to manufacturer’s

specifications.

Figure 5

OEM Air Conditionin

Compressor

Mounting Holes

VR7000 Compressor

Mounting Holes

VR7000 Mountin

Bracket

Hole For 1/2“ NC Air Conditionin

uster Bolt

VR7000 6-Rib Belt Tensioner

Tensioner Mounting Bolt

Mount Regulator Here

VR7000 Back Idler

Back Idler Mountin

Bolt And Spacer

Harmonic Balancer

Fan Pulley

OEM Tensioner

OEM Crankshaft

Pulley

7. Install the OEM air conditioning compressor to the top of the VR7000 bracket using

the OEM fasteners. Thread two fasteners into the front slots in the bracket on the

engine side of the air conditioning compressor and two fasteners into the slots on the

outside of the bracket.

NOTE

8. Install the supplied V-belt on the air conditioning and engine drive pulleys.

9. Install the OEM ½″ NC adjuster bolt and locking nut to the under-side of the air

conditioning compressor base-plate and adjust the drive belt to OEM specifications.

10. Torque all air conditioning fasteners to OEM specifications.

WARNING

11. Fit the VR7000 compressor to the mounting bracket. Apply Loctite to three (3)

M8 × 25 mm hex head cap screws, install them and torque them to 25 ft-lb.

12. Install the supplied 6-rib VR7000 drive belt over the crankshaft pulley, VR7000

compressor pulley and the VR7000 tensioner (Figure 6). Check alignment of the

pulleys and belt using a straight edge.

NOTE

Do not tighten these fasteners at this time.

These fasteners are threaded into aluminum. Over-tightening will damage the

aluminum threads.

If the pulleys and belt do not line up correctly, check the installation of the mount-

ing bracket. If the fasteners have not been tightened properly or if the bracket has

not been installed flat against the timing cover, the pulleys will not align correctly.

Figure 6

Harmonic Balancer

VR7000 Compressor Pulley

VR7000 Tensioner

VR7000 Back Idler

VR7000 Crankshaft

Pulley

1.5 Installing the power steering bracket

1. Swing the tie-rod bracket away from the frame rail and insert the supplied power

steering bracket underneath the tie-rod bracket.

2. Swing the tie-rod bracket back into place, align the holes and install the ½″ NF cap

screws back into the frame, through both brackets.

3. Align the radiator tie-rod bracket with the holes in the radiator frame and install the

5″ NC nuts.

4. Torque all fasteners to OEM specifications.

1.6 Installing the power steering reservoir

1. Attach the power steering reservoir to the VR7000 bracket so that the OEM

clamp-style mounting bracket sandwiches the VR7000 bracket.

2. Secure the reservoir with the OEM fasteners and torque them to specifications.

3. Install the supplied ½″ hose and clamps between the reservoir and the steering box.

Tighten the clamps.

4. Remove 3/4" power steering hose from the steering box and reservoir.

5. Install the 3/4" replacement hose with elbow.

6. Tighten all hose clamps.

7. Refill the reservoir with the OEM recommended fluid.

8. Install the tube which connects the intercooler to the turbocharger inlet.

9. Make sure that the tube clears the air conditioning compressor and all other items

before tightening the clamps.

Figure 7 shows the general assembly. Figure 8 shows a close-up view of the new power

steering bracket installation behind the tie-rod bracket on the frame.

Figure 7

Figure 8

Pressure Regulator

Power

Steering

Reservoir

VR7000

Power

Steering

Bracket

VR7000

Power

Steering

Hose

Frame Tie-rod Bracket

Radiator

Tie-rod

Radiator

Tie-rod

Bracket

VR7000 Air

Compressor

VR7000

Mounting

Bracket

OEM Air Conditioning Compressor

Radiator

Tie-rod

OEM

Tie-rod

Bracket

Frame

VR7000

Power

Steering

Reservoir

Bracket

OEM Cap

Screws

Part 2

Installing the

Air Tank and Lines

System #9018

1999 NAVISTAR INTERNATIONAL

Cummins ISB M11 Engine

UNDERHOOD AIR COMPRESSOR

DOCUMENT 19253

Part 2: Installing the Air Tank and Lines

2.1 Installing the air tank

1. Install the tank brackets to the frame rail using the rear exhaust hanger support bolts

(Figure 9). The front bracket is part #12173 and the rear bracket is part #12174.

2. Attach the tank assembly to the brackets with the oil level window facing forward and

with the drain plug at the bottom. Make sure that the tank is installed in the correct

position by checking the “THIS WAY UP” arrow at the oil level window. Tighten the

straps.

2.2 Connecting preliminary air and oil lines

NOTE

1. Install the oil and air lines between the components shown in Figure 10 according to

the following steps. Route all air and oil lines along chassis rail so that they are clear

of all moving parts, heat sources and sharp objects. Retain the lines using the

supplied stainless steel tie wraps and chassis clips.

For information about the location of the lines on the components, refer to the

diagrams within this section.

Figure 9

The lines from the tank to the other components have been designed with extra length

to accommodate different situations and applications. Excess line can be stored

under the cab, along the top of the transmission.

Tank Mount Brackets

Attached with Exhaust

Supports

Frame

Front Bracket

Part #12173

Rear Bracket

Part #12174

Figure 10

2. Connect the end of the ¾″ × 136″ main air line (part #17229) with the ¾″ JIC 45°

swaged fitting to the matching top fitting on the air tank at location 1 (see Figure 16).

Route the line along the frame, under the cab and connect the other end to the match-

ing fitting on the back of the compressor (Figure 11).

Figure 11

Main Air Line

Part #17229

Air Pressure Control Line

Part #17228

Oil Scavenge Line

Part #17221

Oil Return Line

Part #17227

Cooler-Compressor Line

Part #17222

Compressor Control Line

Part #17223

OIL COOLER

TANK

REGULATOR

COMPRESSOR

Wire Harness

OIL LEVEL

(

ch eck cold

)

MAX

ADD

THIS

WAY

IMPORTANT

Tank

Compressor

3/4” x 136” Main Air Line

Part # 17229

4. Connect the ½″ SAE 90° swaged fitting on the ½″ × 43″ cooler-compressor line

(part #17222) to the matching fitting on the bottom of the compressor at location 5

(see Figure 16). This line can be secured to the cross-member in front of the engine

and then attached to the front fitting on the oil cooler (Figure 12).

Figure 12

5. Connect one end of the ½″ × 151″ oil return line (part #17227) to the matching lower

fitting on the air tank at location 4 (see Figure 16). This line can be routed under the

engine, behind the sump and then attached to the rear fitting on the oil cooler (Figure

13).

Figure 13

Oil Cooler

Tank

Compressor

5½ x 43 Cooler-Compressor Line

Part #17222

Oil Cooler

Tank

Compressor

4½ x 151 Oil Return Line

Part #17227

6. Connect one end of the ¼″ × 151″ air pressure control line (Part #17228) to the upper

outside fitting on the tank at location 2 (see Figure 16). Route the line along the

frame, under the cab and attach the other end to the matching fitting on the regulator

(Figure 14).

Figure 14

2.3 Adding oil to the system

1. Make sure that the vehicle is level.

2. Remove the four (4) M8 socket head cap screws which retain the air inlet control

valve (Figure 15).

Figure 15

Oil Cooler

Tank

Pressure Regulator

Compressor

¼ x 151 Air Pressure Control Line

Part #17228

M8 Socket Head Cap Screws

Air Inlet Control Valve

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Vmac 9018 Installation guide

Brand: Vmac

Model: 9018

Type: Installation guide

Air Compressor: The Vmac 9018 comes with a powerful air compressor that can be used to power a variety of air tools and equipment. This can be useful for a variety of tasks, such as inflating tires, powering pneumatic tools, and cleaning equipment.
Air Tank and Lines: The Vmac 9018 also comes with an air tank and lines that allow you to store compressed air for later use. This can be useful for tasks that require a lot of compressed air, such as sandblasting or painting.

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Vmac 9018 Installation guide

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