Vmac V900088 Installation guide

V900088

2007 FREIGHTLINER M2

7.2L Caterpillar C7 ACERT Diesel

www.vmacair.com

VR70 UNDERHOOD

AIR COMPRESSOR

INSTALLATION MANUAL

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 1

Installation Manual for VMAC

Systems V900088

2007 Freightliner M2 7.2L Caterpillar C7

ACERT Inter-cooled Diesel

with Allison Automatic Transmission

General Information..................................................................... 3

Before You Start..................................................................... 3

Part 1: Installing the Control Components .............................. 4

1.1 Locating the Modules and Wires.................................... 5

1.2 Installing Components..................................................... 8

1.3 Connecting the Wiring..................................................... 9

Part 2: Preparing for Installation............................................... 12

Part 3: Installing the Bracket, Compressor and Cooler......... 14

3.1 Installing the Main Bracket and Compressor................ 14

3.2 Installing the Cooler......................................................... 16

Part 4: Installing the Tank and Hoses....................................... 20

4.1 Installing the Tank............................................................ 20

4.2 Connecting the Steel Lines and Hoses.......................... 21

4.3 Completing the Installation............................................. 22

4.4 Adding Oil to the System................................................. 23

Part 5: Finishing and Testing..................................................... 24

5.1 Before Starting the Engine Checklist............................. 24

5.2 After Starting the Engine Checklist................................ 24

5.3 Testing Operation............................................................. 25

5.4 Setup, Performance Testing and Adjustments............. 26

5.5 System Identification and Warnings .............................. 27

5.6 Auxiliary Air Receiver ...................................................... 28

Accessory Products from VMAC............................................... 29

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Document #1930123

Installation Manual for VMAC Systems V900088

2007 Freightliner M2 7.2L Caterpillar C7 ACERT Inter-cooled Diesel

with Allison Automatic Transmission

Changes and Revisions

Version Revision Details Revised by/date Approved by/date Implemented

000 Draft creation IB 22 June 2006 BC 17 Jul 2006 21 Jul 2006

Important Information

The information in this manual is intended for certified VMAC

installers who have been trained in installation procedures and for

people with mechanical trade certification who have the tools and

equipment to properly and safely perform the installation. Do not

attempt this installation if you do not have the appropriate

mechanical training, knowledge and experience.

Follow all safety precautions for underhood mechanical work. Any

grinding, bending or restructuring operations for correct fit in modified

trucks must follow standard shop practices.

These instructions are a general guide for installing this system on

standard production trucks and do not contain information for

installation on non-standard trucks. This system may not fit special

order models or those which have had other changes without

additional modifications. If you have difficulty with the installation,

contact VMAC.

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.

To order parts, contact your VMAC dealer. Your dealer will ask for

the VMAC serial number, part number, description and quantity. To

locate your nearest dealer, call 1-800-738-8622.

All trademarks used in this manual are the property of the respective copyright holder.

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

written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3.

Printed in Canada

VMAC – Vehicle Mounted Air Compressors

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Fax: 1-250-740-3201 3

General Information

Before You Start

Read this manual before attempting installation so that you can

familiarize yourself with the components and how they fit on the

truck. This manual should be read completely before attempting

installation. Open the package, unpack the components and identify

them.

All fasteners must be torqued to specifications. Use manufacturers

torque values for OEM fasteners. Apply Loctite 242 or equivalent on

all engine-mounted fasteners. Torque values are with Loctite applied

unless otherwise specified.

STANDARD GRADE 8 NATIONAL COARSE THREAD

Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 ¾

Foot-pounds (ft-lb) 9 18 35 55 80 110 170 280

Newton meter (N•m) 12 24 47 74 108 149 230 379

STANDARD GRADE 8 NATIONAL FINE THREAD

Size 3/8 7/16 1/2 5/8 ¾

Foot-pounds (ft-lb) 40 60 90 180 320

Newton meter (N•m) 54 81 122 244 434

METRIC CLASS 10.9

Size M8 M10 M12 M14 M16

Foot-pounds (ft-lb) 19 41 69 104 174

Newton meter (N•m) 25 55 93 141 236

Hose Coding

Different frame designations will affect the tank mounting position. If

you have to move the tank, the lines may be too short. Measure the

hose shortfall and order a Hose Extender Kit. The following table

shows the color code used by VMAC to identify hose diameters.

Hose Diameter Colour-Coded Label

1/4 inch

5/16 inch

1/2 inch

5/8 inch

3/4 inch

1 inch

Yellow

Orange

Blue

Green

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Part 1: Installing the Control

Components

White

Interface

Connector

Green4pin

connector

White

Red

R

e

d

Red

White

Compressor

Inlet valve

Clutch

Green

Black 3 pin

connector

Throttle

Controller

T

o

g

r

o

u

n

d

Blue

Throttle

Controller

Blue

Connect the blue wires

MANUAL TRANSMISSION

Throttle

Controller

Blue

Control Box

Black

Purple

White

Orange

Chassis module

see appropriate

section for details

Engine control module

see appropriate section for details

Transmission control

module see appropriate

section for details

Do not use short

blue wire with

crimp connector

12 Volts

30

85

87

86

Relay Bulkhead module

see appropriate

section for details

10 A

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The VMAC throttle control uses the dedicated PTO

function which must be programmed by an OEM

qualified technician.

The PTO configuration must be set to:

• remote throttle

• PTO shut down time = 0 (default)

• PTO top engine limit = 2750 (default)

If the engine is programmed before the VMAC throttle is installed,

the system will check for a signal when the ignition is on in PTO

mode. The check engine light will illuminate but will shut off once the

throttle is installed.

1.1 Locating the Modules and Wires

Locate the bulkhead, engine control, transmission and chassis

modules (Figure 1.1).

1.1.1 Bulkhead Module

The bulkhead module is located on the driver’s side of the engine

compartment, mounted on the firewall, with connectors on the engine

side and the cab side of the module. Remove the kick plate from

under the dash on the driver’s side to access the connectors.

Locate the wire at location “G” on the top connector inside the cab of

the truck (Figure 1.2). Test the wire with a voltmeter to ensure that

there is 12 Volts with the ignition switch in the ON position and no

Volts with the switch in the OFF position.

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B

u

lkh

ead

M

odu

l

e

C

h

ass

i

s

Co

ntr

o

l M

odu

l

e

Transmission

C

ontrol ModuleEngine

C

ontrol Module

Figure 1.1

Engine Compartment Cab Under Dash

Firewall

To p Con n e c t o r

B5 Dash Harness

A

B

C

D

H

G

F

E

Figure 1.2

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1.1.2 Chassis Module

The chassis module is located on the driver’s side frame rail under

the cab.

Locate the wire at pin “F” on connector C3 (Figure 1.3) Check

continuity between the pin and ground. There should be continuity

when the park brake is applied and an open circuit when the park

brake is released.

H

G

F

E

D

C

B

A

J

K

L

M

N

P

R

S

Bl

ac

k

w

i

re

Figure 1.3

1.1.3 Transmission Module

The transmission module is located on the driver’s side frame rail

under the cab.

For THIRD generation controls on 3000 series Allison automatic

transmissions (Figure 1.4) locate pin 2 of the gray connector.

For FOURTH generation controls on Allison 1000/2000 product

families, 3000 product families and 4000 product family automatic

transmissions, remove the harness tape and locate wire 145.

With the engine running, check for continuity to ground in both Park

and Neutral and an open circuit in all other gears.

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16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

THIRD GENERATION CONTROLS

Figure 1.4

1.1.4 Engine Control Module

The engine control module is located on the driver’s side rear of the

engine.

1.2 Installing Components

□ Disconnect the battery ground cable.

□ Install the throttle controller inside the cab under the dash next to

the driver’s door. Attach it to the main wire harness with tie

straps.

□ If the truck has a manual transmission, cut the long blue wire

from the throttle control to about six inches and connect it to the

short blue wire with the crimp connector.

□ Install the control box in a suitable location for easy access. You

can mount it to the floor between the driver’s seat and the door

so that it can be accessed from inside or outside the cab and

route the wiring under the side door trim and under the dash.

□ Connect the white interface connector to the matching connector

from the control box.

□ Connect the two red wires from the interface connector to the red

wires with the matching connectors from the throttle controller.

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□ Route the following wires through an available access port just

above the throttle pedal:

• black wire from the interface connector

• black, orange and white wires from the throttle controller

• long red wire with the female spade connector

• if the truck has an automatic transmission, the long blue wire

from the throttle controller

• purple wire with female spade connector

• the cable with the black three pin connector from the throttle

controller

• cable with the green four pin connector from the control box

• white wire with the bullet connector from the interface

connector

□ Fasten the green throttle wire and the green interface cable wire

to an existing chassis ground.

□ Leave the cables with the three and four pin connectors and the

white wire with the bullet connector for connection to the

compressor once it is installed.

1.3 Connecting the Wiring

1.3.1 Bulkhead Module

□ Install a relay in the engine compartment next to the bulkhead

module.

□ Connect the long red wire with the female spade connector from

the interface connector to pin 30 on the relay.

□ Connect pin 85 to a good chassis ground.

□ Connect pin 87 to a 12 Volt source.

□ Connect pin 86 on the relay to connector B5 wire “G” at the

bulkhead connector using the purple wire (Figure 1.2).

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1.3.2 Engine Control Module

□ Cut the tie wraps holding the ECM cover and remove the plastic

cover.

□ Remove the rear connector (J1/P1) on the engine control module

(Figure 1.5).

1 2 3 4 5 6 7 8 9 10 11 12 13

58 59 60 61 62 63 64 65 66 67 68 69 70

14 23

24 31

32 39

40 47

48 57

Shown from wire side of connector

Black wire Orange wire

White wire

Connector

P1-J1

Figure 1.5

□ Push out the small white pin protectors at pins 3, 56 and 68 with

a small pin punch.

□ Install the ECM connector and torque the Allen head screw to 55

inch-pounds (6 Nm).

□ Insert the connectors as follows:

• black wire into pin socket 3

• orange wire into pin socket 56

• white wire into pin socket 68

□ Check each wire to make sure pins have locked in the sockets.

□ Secure all wiring away from hot or moving parts, install the

plastic ECM cover and tie-wrap all wires

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1.3.3 Transmission Control Module

□ On THIRD generation controls on 3000 series Allison automatic

transmissions, connect the long blue wire to at pin 2 of the gray

connector (Figure 1.4). Solder and seal the connection (if there is

a wire at this location) or install the supplied wire.

□ On FOURTH generation controls on Allison 1000/2000 product

families, 3000 product families and 4000 product family

automatic transmissions, solder and seal long blue wire to

transmission wire 145. Strain relief and loom the long blue wire

along the chassis wiring.

1.3.4 Chassis Module

□ Connect the black wire from the interface connector to the wire

at pin “F” on connector C3 of the chassis module (Figure 1.3).

Solder and seal the connection.

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Part 2: Preparing for Installation

□

Drain the cooling system.

□

Remove the outer bolts from the bumper extensions, loosen the

inner bolts and swing the bumper extensions forward to gain

access to the engine compartment.

□

Remove the four bolts holding the passenger side hood hinge to

the frame. Insert the 3/4 inch spacer block between the hood

hinge and the frame and insert the replacement 3/8 x 2 inch bolts

and tighten securelyly. Repeat this procedure on the driver side

hinge.

Check headlight alignment before releasing the truck

into service as the addition of the 3/4 inch spacers will

deflect the hood and the headlights upward.

□

Remove the power steering reservoir but do not disconnect the

hoses.

□

Remove the upper radiator hose and the intercooler tube on the

driver side; disconnect the radiator overflow hose from the

passenger side of the radiator.

□

Disconnect the brace bars from both sides of the top of the

radiator and move them outward slightly to make removal of the

fan and shroud easier.

□

Remove the OEM belt, then remove the fasteners from the fan

shroud and remove the fan, clutch assembly and shroud

together.

□

Remove the bolts and steel ring from the front of the crankshaft

pulley. Thoroughly clean the inside of the OEM crank pulley to

ensure a good fit for the VMAC pulley.

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□

Place the VMAC crankshaft pulley adapter and crankshaft pulley

in position over the OEM pulley, place the steel ring over the

VMAC pulley, align the holes, insert the M10 x 100 mm bolts and

torque to specifications.

□

Remove the fan from the fan clutch assembly.

□

Install the five studs into the fan spacer.

□

The fan and fan shroud must be installed together. To do this

you can attach the fan to the fan clutch assembly and install the

assembly and shroud together or install the fan clutch assembly

first; then install the shroud and the fan. Use the supplied 3/8

nuts to secure the fan onto the studs and tighten all fasteners.

□

Install the OEM belt.

□

Install the brace bars.

□

Install the radiator overflow hose on the passenger side of the

radiator.

□

Disconnect the steel lines from the fuel filter, remove the three

bolts holding the fuel filter to the engine block and remove the

filter assembly.

□

Remove and discard the small bracket attached to the engine lift

bracket, then remove the steel fuel lines from the engine fittings.

□

Install the 90 degree swivel fitting to the fuel fitting on the front of

the cylinder head.

□

Connect the 45 degree end of one of the fuel hoses to the swivel

fitting. Adjust it to clear the head and bracket, then tighten the

fittings.

□

Connect the 90 degree end of the other fuel hose to the fitting on

the back of the fuel pump.

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Part 3: Installing the

Bracket, Compressor and Cooler

3.1 Installing the Main Bracket and Compressor

□

Remove the idler pulleys and the belt tensioner from the main

bracket.

□

Place the compressor bracket in position on the driver’s side

front of the engine block. Apply Loctite and install two M10 x 60

mm bolts, one M10 x 55 mm bolt and one M10 x 35 mm bolt

(Figure 3.1). Make sure that the bracket sits flush against the

mounting points and tighten the bolts.

M10 x 60 mm

M10 x 35 mm

M10 x 55 mm

OEM 10 mm fue

l

filter mount bolts

M10 x 35 mm bolt

with flat washer

Mount fuel filter here

Figure 3.1

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During tightening, make sure that alignment is correct

and there are no gaps. Do not use the bolts to force

gaps to close, check and correct the reason for the gap.

□ Install the idler pulleys and the belt tensioner onto the main

bracket. Use Loctite on the fasteners and torque to

specifications.

□ Mount the filter housing to the front of the compressor bracket

using two of the OEM bolts and one supplied M10 x 35 mm hex

head bolt with flat washer.

□ Rotate the front fuel line fitting 90 degrees clockwise so that the

fitting points upward. Rotate the top fitting a few degrees

counterclockwise to provide clearance for the hose.

□ Connect the new fuel line hoses to the fittings on the fuel filter.

□ Prime the fuel system with the pump on the filter assembly.

If you do not clear the air in the hose between the

injector pump and the filter, air will enter the fuel

system and the engine will not start.

□ Install the power steering reservoir using the three spacers, the

supplied 3/8 x 2 inch bolts and the OEM nuts.

□ Install the intercooler tube.

□ Place the compressor in position on the bracket and fasten it in

place using the supplied bolts.

□ Install the VR compressor drive belt (Figure 3.2).

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Figure 3.2

3.2 Installing the Cooler

□

Remove the steel heater return line standoff bracket from the

engine block on the passenger side, just behind the engine oil

filter.

□

Fasten the cooler mounting plate to the passenger side of the

engine block with two M14 x 30 mm bolts into threaded holes

near the front of the block. Place the standoff bracket over the

rear hole in the mounting plate and insert an M10 x 55 mm bolt

(Figure 3.3). Tighten all fasteners.

□

Attach the cooler to the mounting plate using the supplied nuts

and washers.

□

Remove the lower radiator hose from between the radiator and

the transmission cooler. Rotate it 90 degrees so that the radiator

end of the hose faces backward.

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□

Attach the long end of the U-shaped hose to the rear spigot on

the cooler. Install the long steel coolant tube between the OEM

radiator hose and the U-shaped hose on the rear spigot of the

cooler with the longest section of the steel tube at the cooler end.

Cooler

Mounting plate

To OEM lower coolant hose

Coolant bypass hose

Line from

compressor

Line from

tank

Figure 3.3

□

Install the shorter steel coolant tube between the hose on the

front spigot of the cooler and the lower radiator hose connection,

using the supplied section of hose between the tube and the

radiator. Adjust all tubes and hoses for best fit and tighten the

clamps.

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□

Remove the plug from the fitting on the back of the thermostat

housing, inboard of the steel heater line.

□

Install the supplied ORB fitting into the head, then the spigot

fitting and connect the supplied 3/4 inch hose between the fitting

on the thermostat housing and the fitting on the steel tube at the

cooler. Tighten the clamps and secure the hose to the steel

heater return line with a nylon tie to prevent it from rubbing.

□

Connect the 90 degree end of the shortest 1/2 inch hose to the

rear fitting on the cooler, route it between the engine oil pan and

the transmission cooler and up to the compressor. Connect it to

the matching fitting on the compressor.

□

Install the supplied hose to the top radiator spigot and insert the

supplied steel coolant tube (Figure 3.4) into the other end.

Supplied steel tube

Insulated P-clip

Supplied hos

e

OEM hose

Figure 3.4

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Vmac V900088 Installation guide

Vmac V900088 Installation guide

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