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System V9001092014-2011 International TerraStar MaxxForce 7
6.4L DIESEL
www.vmacair.com
VR70 UNDERHOODAIR COMPRESSOR
INSTALLATION MANUAL
VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201
1
Installation Manual for VMAC System V900109
2014-2011 International TerraStar MaxxForce 7 6.4L Diesel
GENERAL INFORMATION ....................................................................... 4 BEFORE YOU START ........................................................................................ 4 ADDITIONAL REQUIREMENTS ........................................................................... 4
PART 1: WARRANTY AND SYSTEM ID .................................................. 5 PART 2: PREPARING FOR INSTALLATION ........................................... 8
2.1 PREPARING FOR INSTALLATION – ELECTRICAL................................................. 8 2.2 PREPARING FOR INSTALLATION – MECHANICAL ............................................ 10
PART 3: INSTALLING MAIN BRACKET, COMPRESSOR AND COOLER ................................................................................................................. 12
3.1 INSTALLING THE MAIN BRACKET AND COMPRESSOR ...................................... 12 3.2 INSTALLING THE OIL COOLER .................................................................... 14
PART 4: INSTALLING THE TANK – 4X4 ............................................... 19 4.1 INSTALLING THE AIR OIL SEPARATOR TANK ................................................. 19 4.2 INSTALLING THE AIR OIL SEPARATOR TANK HOSES ........................................ 21
PART 5: INSTALLING THE TANK – 4X2 ............................................... 24 5.1 INSTALLING THE TANK BRACKETS ............................................................... 24 5.2 INSTALLING THE TANK ASSEMBLY AND HOSES .............................................. 26
PART 6: INSTALLING THE CONTROL COMPONENTS ....................... 29 6.1 INSTALLING THE COMPONENTS ................................................................. 30 6.2 CONNECTING THE IN-CAB WIRING ............................................................ 30 6.3 PARK/NEUTRAL SIGNAL .......................................................................... 32
PART 7: FINISHING THE INSTALLATION ............................................. 34 7.1 COMPLETING THE INSTALLATION ............................................................... 34 7.2 CONNECTING TO SWITCHED POWER .......................................................... 36 7.3 SECURING THE WIRING ........................................................................... 36 7.4 ADDING OIL TO THE SYSTEM .................................................................... 37 7.5 SAFETY TEST ......................................................................................... 37 7.6 BEFORE STARTING THE ENGINE CHECKLIST .................................................. 38 7.7 AFTER STARTING THE ENGINE CHECKLIST .................................................... 39 7.8 SETUP, PERFORMANCE TESTING AND ADJUSTMENTS ..................................... 40 7.9 AUXILIARY AIR RECEIVER ......................................................................... 42
ACCESSORY PRODUCTS FROM VMAC .............................................. 43
VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289
Fax: 1-250-740-3201 2
Document #1930187
Installation Manual for VMAC System V900109 2014-2011 International TerraStar MaxxForce 7 6.4L Diesel
Changes and Revisions
Version Revision Details Revised by/date Approved by/date Implemented
A Engineering Release NC 26 Oct 2011 PD/BC 26 Oct 2011 26 Oct 2011
B ECN 12-146 SAR 12 OCT 2012 MH 15 Oct 2012 16 Oct 2012
C ECN 12-186, 13-013,
13-112
SH 23 Jul 2013
CJH 03 Dec 2013
MP 12 Dec 2013
RD 12 Dec 2013
17 Dec 2013
Important Information
This symbol is used to call your attention to instructions concerning your personal safety. Watch for this symbol; it points out important safety precautions, it means “attention, become alert! Your personal safety is involved. Read the message that follows and be alert to the possibility of personal injury or death. Be alert; your safety is involved. While it is impossible to warn about every conceivable hazard, let good common sense be your guide.
This symbol is used to call your attention to additional instructions or special emphasis on a specific procedure.
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 under hood mechanical work. Any grinding, bending or restructuring operations for correct fit in modified trucks must follow standard shop practices.
All hoses, tubes, and wires that are rerouted or shifted during installation must be secure so that they do not contact excessively hot areas or sharp edges. Where possible, use rubber coated P-clips. Follow the routing suggestions in this manual and cover all hoses with the supplied plastic loom.
!
!
VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201
3
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 1-888-241-2289.
Copyright 2010 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
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Fax: 1-250-740-3201 4
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. Identify variations for different model years and different situations that are listed in the manual. 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
Additional Requirements
Special Tools
Pneumatic fan wrench removal set (such as Lisle 43300) or a manual fan pulley holder (such as KD3900) OEM flywheel locking tool part number J42386.
Hose Information
Depending on other installed equipment, it might be necessary to move the air/oil separation tank from its intended location. The hoses used in VMAC compressor !
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5
systems have a specific inner liner that is compatible with our compressor oil. Use of hoses other than those supplied or recommended by VMAC may cause compressor damage and may void your warranty. Please contact VMAC for replacement hoses and further information.
Part 1: Warranty and System ID
Complete the warranty form. 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.
System Identification and Operating Instructions
The System Identification Number Plate must be attached to the vehicle at the time of installation. This plate provides information that allows VMAC to assist in customer inquiries and the ordering of parts.
Mark and drill two 7/64-inch holes in the top of the cross member in front of the OEM air filter box. Secure the plate with supplied self- tapping screws
Clean cross member beside the number plate and stick the VMAC belt routing diagram to the cross member.
Apply battery warning label to driver side of primary cooling reservoir.
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Fax: 1-250-740-3201 6
As part of the installation process, ensure that the safety and operational instruction decal is affixed in an obvious location so that it can be seen by vehicle operators. A good spot for this is usually on the inside of the door or on the panel underneath the steering wheel. (Figure 1.1)
Figure 1.1
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7
To alert any technicians that may service the vehicle, affix the servicing caution/contact label in the engine compartment near the hood latch in a visible location. Thoroughly clean the selected area before affixing the label (figure 1.2)
Figure 1.2
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Part 2: Preparing for Installation
Preparation for installation is very important. Missing an item can cause problems in the installation or even damage to components. Check off each item as it is completed so that you do not miss any preparation steps.
2.1 Preparing for Installation – Electrical 2.1.2 2014MY TerraStar
2014MY TerraStar trucks do not have a Park/Neutral output populated from the factory. The truck must be driven to an International Dealership and programmed with logic to output a Ground signal in Park and Neutral, Open Circuit in all other gears from the Body Controller (also referred to as Electrical Systems Controller or ESC). Preferred to have a blue 18AWG wire about 12inch for the Park/Neutral signal output. International dealers can contact International Diamond Logic for programming the truck logic: 1-800-336-4500 and choose PROGRAMMING SUPPORT option International Dealers capable of flashing template files can contact VMAC technical support for a template file with advanced logic. Required Signal Functions: - Low side driver (active Ground) - Ground when Transmission is in either Park or Neutral - Example implementation with pin E1 on J4 - Populate 12” blue 18AWG wire on pin E1
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Figure 2.1
Figure 2.2
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Figure 2.3
Testing the Park/Neutral signal: - Set a Multimeter to resistance setting. - With the truck running, the signal should be Ground in Park or Neutral and Open Circuit in all other gears.
2.2 Preparing for Installation – Mechanical
Disconnect the batteries.
Remove the driver’s side inner fender by unbolting both the lower brackets from the chassis.
Drain the coolant. Save the coolant, as it will be reused later. The coolant drain spigot is located on the lower driver side corner of the radiator.
Remove the coolant overflow bottle by removing the six bolts holding it to the radiator support and three radiator hoses. Save
Park/Neutral signal on pin E1 on connector J4
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11
the bolts as they will be reused later and do not damage the radiator hoses.
Remove the OEM engine oil fill tube assembly and discard the hose. Save the hose clamps, mount bolts, fill cap and housing.
Using the OEM hose clamps attach the supplied 1” oil fill hose to the engine oil fill port and oil cap housing.
Remove the OEM plug from the water pump as shown in Figure 2.4.
Install the supplied adapter fitting (4800599) in the OEM water pump.
Install the supplied heater hose on the fitting and secure with a hose clamp.
REMOVE THIS PLUG
Figure 2.4 - Plug Removal
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Part 3: Installing Main Bracket, Compressor and Cooler
3.1 Installing the Main Bracket and Compressor
Remove the steel lifting eye bracket from the front of the driver
side cylinder head.
Remove the tensioner and idlers from the compressor bracket
assembly (Figure 3.1).
M10 x 120mm (3X)
M10 x 80mm
M10 x 35mm (2X)
Idler Spacers (2X)
Figure 3.1
Install the compressor bracket onto the driver’s side cylinder
head using the 3 supplied bolts. Torque to specifications
Install the tensioner and idlers (Figure 3.1).
Temporarily remove the inlet control valve from the compressor.
Cover the opening to avoid contamination of the compressor.
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Install the compressor onto the adaptor bracket using the 3
supplied bolts.
Ensure the O-ring is in position and reinstall the inlet control
valve onto the compressor.
Note that this system uses two different length bolts in the inlet valve. Two 55mm bolts go in the two holes closest to the air filter and 50mm bolts go in the holes furthest away from the air filter (Figure 3. 2).
Long Bolts
Short Bolts
Figure 3.2
Never use an impact wrench to install inlet bolts. The torque spec for inlet bolts is 19 ft lbs.
Clean the front of the OEM crank pulley and install the supplied
crank pulley with supplied M10x30mm bolts.
Install the VR belt. For ease of installation wrap belt around
outside idler last (Figure 3.3).
!
!
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When a new belt is first installed it may touch the tensioner base. If this occurs, rotate the tensioner arm upwards to help the belt seat in the pulley grooves and provide clearance. Check clearance once system has run, there should be approximately 1/4" to 1/2" between belt and tensioner base.
3.2 Installing the Oil Cooler The cooler will mount to the driver side radiator support/overflow bottle mount (Figure 3. 4).
CoolerOverflow Bottle
Front
Figure 3.4
Crank Pulley
Compressor
Tensioner
Idler Idler
Install Here Last
Figure 3.3
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Remove the upper radiator hose heat shrunk plastic clamps and
rotate the hose until it is pointing straight up. There are two
clamps holding the hose on, one connecting to the radiator and
one connecting to the overflow bottle tee (Figure 3.5 & Figure
3.6).
The radiator hoses are connected with heat shrunk plastic clamps. To remove these clamps use the correct removal tool or a soldering iron to melt through the clamp. See special tools section. Do not use razor knifes as this can result in damaging the hoses.
From Radiator
To Engine
To Overflow Bottle
Upper Radiator Hose. Cut Heat Shrunk Plastic Clamps
Overflow Bottle
Tee
Oil Cooler
Oil Cooler Mount Brackets. (Radiator Support and Overflow Bottle Not Shown)
OEM Radiator Hose Supplied Radiator Hose
Figure 3.5
Figure 3.6
!
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Install the supplied radiator hose with the short end attaching to
the overflow bottle tee (Figure 3.5).
Install the long 1/2" hose 90° fitting to the lower port on the
cooler with the hose facing down.
Drop the cooler into place, guide the 1/2” hose between the
radiator and radiator hose and connect all radiator hoses with
supplied hose clamps (Figure 3.5)
Reinstall the coolant overflow bottle in the OEM location using
supplied bolts and four of six OEM bolts saved when removing
the overflow bottle. The supplied M8x35mm are used to mount
the side tabs of the overflow bottle and the OEM bolts will mount
the top and bottom tabs. Use Loctite on all bolts (Figure 3.7).
Using the supplied M8 nuts attach the cooler mount bracket to
the radiator support/over flow bottle mount. The previously
installed M8x35mm bolts will act as studs to hold the cooler. Use
Loctite on all bolts (Figure 3.8).
OEM Bolts
Supplied M8x35mm Bolts
OEM Bolts
Figure 3.7
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Install the supplied fitting 5000001 into the ½” NPT port in the top
of the cooler using thread sealant and orient the fitting as shown
in Figure 3.9.
Install the free end of the supplied heater hose on the brass barb
fitting on the oil cooler and secure with a hose clamp.
Install the split loom on heater hose and position to protect the
hose from rubbing on the compressors inlet valve and the OEM
lifting eye. Secure the loom in place with the supplied nylon tie.
Check the overflow bottle and supplied cooler mount are
mounted as follows; (from front of truck to rear)
Supplied Fitting
Radiator Support/Overflow Bottle Mount
Supplied Cooler Mount Bracket
Overflow Bottle Mounts This Side Using Supplied M8x35mm Bolts (Overflow Bottle Not Shown)
Figure 3.8
Figure 3.9– Fitting Orientation
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• Supplied M8x35mm bolt
• Overflow bottle
• Radiator support/overflow bottle mount
• Supplied cooler mount bracket
• Supplied M8 nuts
The nuts holding the cooler mount brackets on the
cooler are shipped lose. These nuts must be tightened
after the best position for the cooler is found.
Ensure all mounting hardware and hose clamps are tight
With the cooler and overflow bottle installed check the 1/2"
coolant hose connecting the overflow bottle to the radiator. If this
hose comes in contact with the supplied cooler bracket trim the
hose on the radiator side. Shortening the hose will pull it away
from the cooler bracket.
With the cooler installed check all radiators hoses and make sure they are not pinched or rubbing on sharp objects. If required reposition the cooler and trim radiator hoses for best fit.
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Part 4: Installing the Tank – 4x4
4.1 Installing the Air Oil Separator Tank
The tank will mount to the passenger’s side frame rail behind the cab. The mounting location and holes used will vary depending on the frame length of the truck. Two wheel drive (4x2) versions of the truck will have the tank mounted on the driver side and require the 4x2 VMAC adapter kit (A900009). Skip to Part 5 for 4x2 tank installation directions.
Figure 4.1 Locate suitable mounting holes for the air oil separator tank assembly. All frame types have holes in the same general area.
Select two holes from the passenger side frame rail that the slot in the Tank Brackets will line up with (Figure 4.1 and Figure 4.2). Measure the hole spacing.
Place the air oil separator tank on a work bench and remove the oil filter from the front of the tank.
Use existing holes in frame to mount Tank Brackets
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Remove the two 1/4” clamp bolts from the C-clamps. Expand the clamps slightly and slide them over the front of the tank.
Rotate the tank so that the up arrow is in line with the clamps mounting surface, and ensure that the C-clamps are spaced the required distance.
Tank Bracket
M8 Bolts
C-clamp
Rail Clamp
Figure 4.2
Pre-assemble the frame clamps (Figure 4.2). Note the orientation of the tank brackets.
Hand tighten the lower M8 bolts, but leave the top bolts loose.
Hang the tank assembly from the lower frame rail and line up the frame rail bolt holes with the slots in the tank bracket (Figure 4.3).
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!
Figure 4.3
Bolt the tank assembly to the frame rail using the 35mm long M10 bolts that were supplied. Push the tank up until the clamp touches the frame rail before tightening the bolts. Loctite and torque to specifications.
Loctite and torque to specifications the M8 clamping bolts.
Loctite and torque to specifications the lower M8 bolts.
4.2 Installing the Air Oil Separator tank Hoses
All hoses, tubes, and wires that are rerouted or shifted during installation must be secure so that they do not contact excessively hot areas or sharp edges. Where possible, use rubber coated P-clips. Follow the routing suggestions in this manual and cover all hoses with the supplied plastic loom.
There are brake lines mounted to the inside of the frame. If the bolts for the P-clips are installed from the outside of the frame they will come in contact with these brake lines.
Connect the 3/4" 90° fitting to the back of the compressor and
route the hose down and around the outside of the frame rail.
Using the supplied P-clip and M10 nut fasten the hose to stud in
front of the steel brake lines and behind the inner fender mount
bracket (Figure 4.4).
!
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Inner Fender Mount Bracket
Existing Stud On Frame
Figure 4.4
Route the ¾” hose across to the passenger side frame rail
following the cross member under the engine. Then follow the
passenger side frame rail back to the tank. Use the provided P-
clips to secure the hose.
Ensure that the hoses that are routed between the leaf
springs and driver side frame rail are tight to the bottom
of the frame rail to maintain clearance if the truck’s front
suspension is bottomed out.
Connect the 3/4" hose to the matching fitting on the tank
Route the 1/2" hose which was previously attached to the cooler
above the cross member and along the hard transmission cooler
lines then follow the ¾” hose routing. Connect to the matching
fitting on the tank. Secure the ½” hose to the ¾” line with the
supplied tie-wraps.
Insert the 3/16” and 1/4” tubes into the fittings on the back of the
tank and cover them with protective loom. Route them along the
frame rail following the previously installed ¾” hose and up to the
compressor securing with the supplied tie-wraps.
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23
Connect the 3/16” and 1/4” hoses to the matching fittings on the
inlet control valve.
Attached the supplied 90° fitting to the top oil port on the cooler.
This adapter should face the OEM over flow bottle (Figure 4.5).
Supplied Fitting
Oil Return Hose
Figure 4.5
Attach the 1/2" hose 90° fitting to the 90° adapter and route the
oil return line to the compressor (Figure 4.5).
Tighten all fittings.
Apply a thin coating of compressor oil to the oil filter gasket and
install the filter on the tank. Tighten the filter an additional 3/4
turn after the gasket contacts the base.
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Part 5: Installing the Tank – 4x2
5.1 Installing the Tank Brackets
The 4x2 truck requires the A900009 VMAC adapter kit. The adapter kit replaces the tank mount brackets, tank mount fasteners and ½” and ¾” compressor hoses. Discard the replaced components from the V900109 kit.
The tank will mount to the driver’s side frame rail behind the battery box.
Note there are two battery box options available on this vehicle, a two battery box or three battery box. Both battery box options will use the same tank mount straps, only the mounting location will change. (Figure 5.1)
Remove the OEM battery cable mount attached to the battery box. Discard as this will not be used again (Figure 5.2).
2 Battery Box 3 Battery Box
Tank Mounts Here Tank Mounts Here
Figure 5.1
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Remove the OEM battery cable mount attached to the frame and replace with supplied battery cable mount. Reuse all fasteners (Figure 5.2).
Loosen the negative battery cable attached to the frame. The negative battery cable will need to be repositioned when the tank is installed for best fit. (Figure 5.2).
Attached the supplied tank mount straps with M16 nuts and bolts. Note the bolts are to be installed from the inside of the frame.
There are brake lines mounted to the inside of the frame. If the bolts are installed from the outside of the frame they will come in contact with these brake lines.
Place the tank on a work bench and remove the oil filter from the front of the tank.
Remove the two 1/4” clamp bolts from the C-clamps. Expand the clamps slightly and slide them over the front of the tank.
Remove OEM Brackets
Battery Box
Negative Battery Cable
!
Figure 5.2
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!
5.2 Installing the Tank Assembly and Hoses
All hoses, tubes, and wires that are rerouted or shifted during installation must be secure so that they do not contact excessively hot areas or sharp edges. Where possible, use rubber coated P-clips. Follow the routing suggestions in this manual and cover all hoses with the supplied plastic loom.
Connect the 3/4" 45° fitting to the back of the compressor and
rout the hose down and around the outside of the frame rail.
Using the supplied P-clip and M10 nut fasten the hose to stud in
front of the steel brake lines and behind the inner fender mount
bracket (Figure 5.3).
Inner Fender Mount Bracket
Existing Stud On Frame
Figure 5.3
Route the 3/4" hose along the battery cables towards the battery
box
Place the tank and C-clamps on the tank mount straps which
have previously been mounted to the truck frame. Loosely mount
with supplied M8 fasteners.
Position the tank so the arrow and “UP” marking on the back of
the tank are facing up.
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Connect the 3/4" hose to the matching fitting on the tank
Slide the tank to its best fit position.
Tighten all tank fasteners.
Tighten the previously loosened negative battery cable.
The OEM battery cables cross over the top of the tank after installation. Ensure the cables are not touching the tank. Tie strap the cables out of the way and ensure no wires are pinched or kinked during installation
Route the 1/2" hose which was previously attached to the cooler
above the cross member and along the hard transmission cooler
lines towards the battery box. Connect to the matching fitting on
the tank.
Cut the 3/16” poly tube line from 200” to 90” (remove 110”)
Cut the 1/4” poly tube line from 185” to 75” (remove110”)
Insert the 3/16” and 1/4” tubes into the fittings on the back of the
tank and cover them with protective loom. Route them along the
frame rail wire harness and up to the compressor
Connect the 3/16” and 1/4” hoses to the matching fittings on the
inlet control valve.
Attached the supplied 90° fitting to the top oil port on the cooler.
This adapter should face the OEM over flow bottle (Figure 5.4).
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Supplied Fitting
Oil Return Hose
Figure 5.4
Attach the 1/2" hose 90° fitting to the 90° adapter and rout the oil
return line to the compressor (Figure 5.4).
Tighten all fittings.
Apply a thin coating of compressor oil to the oil filter gasket and
install the filter on the tank. Tighten the filter an additional 3/4
turn after the gasket contacts the base.
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29
Part 6: Installing the Control Components
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Fu
se
Figure 6.1
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6.1 Installing the Components
Install the control box mount bracket in a convenient location in
the cab, positioned so the wire harness will reach the
compressor located at the front driver side of the engine.
Keep wires away from the park brake mechanism. Route
wires clear of the steering column and pedals so they do
not contact moving parts. Before drilling holes make
sure that there are no OEM wire bundles or hoses where
you will be drilling.
Mount the throttle control box under the dash using plastic ties.
Select a location that will allow access to the adjusting screws.
6.2 Connecting the In-Cab Wiring
Connect the interface wire harness connector to the matching
connector from the VMAC control box.
Disconnect the multi-pin connector from the accelerator pedal
and plug it into the matching connector at the throttle control box
then plug the connector from the throttle control box into the
accelerator pedal.
Connect the wire with the ring connector from the throttle control
box and from the interface connector to a good metal ground.
There are two ground posts to the left of the accessory harness
grommets under the dash on driver’s side.
Connect the red wire from the interface connector (spliced into
white clutch wire) to the red wire from the throttle control.
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Route the following wires through the accessory harness
grommet on the firewall under the dash on driver’s side.
• Cable with the black 3 pin connector
• Cable with the green 4 pin connector
• White wire with the bullet connector
Remove the plastic cover from the park brake column. Follow the
two wires to foot pedal. Measure the resistance of both wires
with respect to ground. The correct wire will show approximately
400KΩ when the park brake is released and approximately 0Ω
when the park brake is applied. Mark this wire (Figure 6.2).
Park Brake With Plastic Cover Removed
Park Brake Sensor Switch
Park Brake Wire
Figure 6.2
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Run the black wire from the interface cable under the floor mat to
the park brake (Figure 6.2).
Solder and seal the black wire from the interface cable to the
wire of the park break signal of previous step. Splice wire as
shown in (Figure 6.3).
Error! Objects cannot be created from editing field codes.
Figure 6.3
6.3 Park/Neutral Signal 6.3.1 2014MY TerraStar
Cut and discard the connector on the Throttle Controller blue wire.
Connect the blue wire from the Throttle Controller to the International Dealer installed blue 18AWG 12inch wire under the dash from the Body Controller near the park brake. See Section 2.1 Preparing for Installation – Electrical for obtaining the Park/Neural signal from an International Dealer
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6.3.2 2013-2011MY TerraStar
Route the 8 pin shell connector with blue wire from the throttle control box.
Locate the 8 pin body builder input/output connector for the
Allison 1000/2000 transmission. This connector is located in the
engine compartment in the wire harness in front of the drivers’
side fire wall behind the master cylinder reservoir. The connector
has a terminating plug that will need to be removed and
discarded.
Connect the 8 pin shell connector with blue wire to the body
builder connector of the Allison 1000/2000 transmission.
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Part 7: Finishing the Installation
7.1 Completing the Installation
Attach the supplied oil fill bracket to the existing OEM oil fill
bracket with the wide end attached to the OEM oil fill bracket.
This bracket will be used to space the oil fill cap away from the
compressor. Use the supplied M6 bolts, nut and OEM bolts to
reattach the oil fill cap (Figure 7.1).
Install the 6” hose protector to the OEM wire harness passing
behind the compressor and compressor bracket.
Install the three 1/2" heat protective wraps to the fuel and coolant
lines around the discharge hose in the areas shown (Figure 7.2).
Supplied Oil Fill Bracket
Supplied Oil Fill Hose
Supplied M6x14mm Bolts
Supplied M6 Nuts & OEM Bolts
Figure 7.1
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Install the supplied barbed tie strap to hold fuel lines away from
the discharge hose (Figure 7.2).
Tie strap fuel and coolant lines away from the discharge hose
(Figure 7.2)
You must ensure hoses are protected from the hot
discharge fitting and hose to reduce the possibility of
overheating the fuel or causing thermal damage.
Check all fasteners, clamps, fittings and retainers to make sure
that they are tight and secure all OEM wire harnesses.
Check there is no plug in the top vent hole of the cooler
Fill the cooling system with the recommended coolant until you
can see coolant in the vent hole of the cooler.
Discharge Hose
Barbed Tie Strap 1/2”Heat Protection
Oil Fill Hose
Front
Steering Shaft
!
Figure 7.2
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Install the supplied pipe plug using thread sealant in the cooler
and finish filling cooling system
Install the inner fender.
Connect the white clutch wire with the bullet connector, the
green 4 pin temperature probe connector and the black 3 pin
pressure transducer connector to the compressor.
Reconnect the batteries
7.2 Connecting to Switched Power Locate a fuse in the fuse panel that provides power when the
ignition switch is in the “ON” position. Remove the selected fuse
from the panel and connect the fuse tap with the tap lead on the
fused side. Plug the removed fuse back into the inner (close to
the panel) empty socket and ensure the supplied 10A fuse is in
the outer socket. Use needle-nose pliers to make sure the fuses
seat properly.
7.3 Securing the Wiring
Under the hood, group all the wires and harnesses from the
compressor and secure them together with electrical tape, then
protect them from damage with plastic loom.
Cover the white wire and the blue wire with loom and make sure
that they are secured.
Route and secure the white and blue wires with loom and ensure
it does not come in contact with any moving parts.
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!
Pull all excess wire and harnesses into the cab of the truck so
that there are no loose loops under the hood.
Neatly bundle all the wiring in the cab, secure the bundles with
nylon ties or electrical tape and fasten them up under the dash,
away from the steering column, brake pedal, accelerator pedal
and park brake mechanism. Secure them with nylon ties.
Replace the dash panel and the fuse panel cover.
7.4 Adding Oil to the System
You must use the VMAC supplied and approved compressor oil in this system. Failure to use this special oil will result in damage to the compressor and will void your warranty.
Remove the fill plug from the air inlet control valve and pour about 4 US quarts (4 liters) of the supplied oil into the oil fill hole on the inlet control valve using a funnel.
Turn the compressor clutch clockwise by hand or with a ratchet and a 1/2" socket using the hex bolt at the center of the compressor during the fill process.
Allow at least 5 minutes for the oil to drain into the tank, and then check the level at the sight glass at the front of the tank. Continue adding oil until the level is correct.
Install the fill plug in the inlet control valve and tighten securely. Overfilling the system can result in oil carryover out the air discharge. The oil level will need to be rechecked after running the system for the first time as the oil will fill the cooler and hoses and may reduce the level in the tank.
7.5 Safety Test
Place the transmission in Park and apply the park brake.
!
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Turn the ignition key “ON” but do not start the engine.
Check the control box; there should be a number displayed in
the hour-meter. If there is no display, there is no power to the
control box.
Press the “ON” button. The green LED should come on and you
should hear the compressor clutch engage.
Release the park brake. The green LED should flash, “PARK
BRAKE” will show on the display and the compressor clutch
should disengage. Apply the park brake again, wait 20 seconds
and push the “ON” button. The green LED should come on and
the compressor clutch should engage.
Turn the ignition key “OFF”.
If the truck fails the test, check the wiring to make sure that all the connections are correct and secure. If you require additional assistance, contact your local VMAC dealer. Call 1-800-738-8622 or 250-740-3200.
7.6 Before Starting the Engine Checklist
Make sure that the following have been completed:
Check the engine coolant level.
Check the compressor oil level.
Do a final inspection to make sure that everything has been
completed and tightened.
Perform a final visual belt alignment check.
!
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Check belt to tensioner base clearance. See Page 10.
Check all wiring for security and protection.
Check that heat wrap has been installed where necessary.
7.7 After Starting the Engine Checklist
Place the truck in a safe operating position and block the wheels. Ensure that there are no people around the truck before beginning the test.
Make sure that the following have been completed:
Install a test fixture or air tool to the tank outlet. Close the ball valve if you are using the test tool.
Start the engine and allow it to reach operating temperature Push the “ON” button on the control box.
The green light should illuminate, the clutch should engage and the engine should rev up to 1800-2200 rpm and then idle down to 900-1000 rpm.
Release the park brake. The green light should flash, “PARK BRAKE” will be displayed and the clutch will disengage. Apply the park brake. Wait for the twenty second internal timer to reset, and then press the “ON” button.
The green light should illuminate, the clutch should engage, and the engine should rev up to 1800-2200 rpm and then idle down to 900-1000 rpm.
Watch the underhood operation to make sure that belts rotate properly and nothing is rubbing or contacting hot parts.
Check the coolant after the engine reaches operating temperature.
Check all components once the engine is turned off and the system has cooled.
!
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Once the system has cooled, briefly remove the compressor cooler vent plug to purge any air in the cooler.
Check the compressor oil level after the engine and compressor have been shut down and the oil level has had time to stabilize. Top up or drain as required.
7.7.1 Transmission Test
With the compressor operating and the engine at 900 rpm, depress the brake pedal and shift from Park to Reverse. Engine speed should drop to base idle. Shift to Park. Repeat this test for all gear selections.
Push the “OFF” button on the control box. The engine should return to base idle, the compressor should be off and the green light should be off on the control box.
Operate the system with an air tool for at least thirty minutes (1 hour preferred). Road test the truck for approximately 14 miles (20km).
7.8 Setup, Performance Testing and Adjustments
This system has been adjusted at the factory for general operation. If your tests indicate that adjustment is necessary, refer to the owner’s manual for specific instructions on how to adjust the system.
You can test the system operation using the tools that will be operated by the system or you can test operations using an orifice in the outlet to simulate tool use (Figure 7.3).
Figure 7.3
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1. Install the test tool in the tank outlet fitting.
2. Make sure that the ball valve is closed.
3. Place the manual transmission in neutral or the automatic transmission in park and fully apply the park brake.
4. Allow the truck to run until the engine is at operating temperature.
5. Operate the air compressor system until the oil is warm.
6. Observe the pressure gauge. Pressure should be approximately 150 psi.
7. Open the ball valve on the test tool and observe the engine tachometer. Engine speed should increase to about 1,800 to 2,200 RPM.
8. Close the air valve slowly to allow the system pressure to rise.
9. Once the system pressure is at maximum, slowly open the ball valve on the test tool until the pressure on the gauge begins to drop. Engine speed should start to ramp-up when air pressure drops to approximately 140 PSI.
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7.9 Auxiliary Air Receiver
If you intend to use an auxiliary air receiver with this system you must observe the following installation procedure to prevent damage to the system.
The line from the VMAC tank to the auxiliary air receiver must have a one-way check valve installed (part #3600078) to prevent blow back from the auxiliary tank and to stop moisture from entering the VMAC tank (Figure 7.4). The line to the auxiliary tank must not be installed in the bottom of the tank; It must be installed as high as possible to prevent water from entering the line.
Install the line as high as possible, NOT on the bottom of the auxiliary tank
VR Tank
One-way check valve Auxiliary Tank
Figure 7.4
!
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Accessory Products from VMAC
The following accessory products for your VR compressor system are available from VMAC. For more information or to order these products, call toll free 1-888-241-2289 or local 250-740-3200.
Eliminator Aftercooler Part Number A800070
Removes up to 80% of moisture from compressed air. Quick installation, automatic drain and compact design
Filter Regulator Lubricator Part Number A700151
Removes lubricants, water and dirt from the air stream. Adds atomized tool oil to lubricate tools. Reduces pressure for longer tool life.
Hose Reel Part Number A700007
Secure, compact, retractable hose storage in a sturdy reel.
Air Receiver Tank Part Number A300010
Thirty-five gallon capacity in a compact tank, complete with fittings and a gauge.
DE-ICING HEATER
De-icer Kit Part Number A700031
Insulated rope heater prevents freezing of lines and regulator.
Service Kits VR150 200 hour Part Number A700059 VR150 400 hour Part Number A700060 VR70 200 hour Part Number A700019 VR70 400 hour Part Number A700020
Using OEM service products will extend the life of your system. Includes oil, filters, seals and O-rings. 200 hour and 400 hour service interval kits are available
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Warranty Registration
This form must be fully completed and returned to VMAC at the time of installation. Warranty may be void if this form is not received by VMAC within 30 days of installation.
VMAC’s Warranty policy and registration can be viewed online at: www.vmacair.com/warranty
VMAC Dealer Information
Company Name: __________________________________________
City: _____________________ State / Province:_______________
Installer Information
Company Name: _____________________________________
City: _____________________ State / Province:______________
Installation Date: _____/_____/_____
Day Month Year
Owner Information
Company Name: __________________________________________
Address: ________________________________________________
City: _____________________ State / Province:_______________
Zip/Postal: ________________ Phone #: (____) ____ - _____
Email Address: ___________________________________________
Vehicle Information
Year: ____________________ Make: _________________
Vehicle Identification Number: ___________________________
Unit #: ___________________
Product Information
System Identification Number: V _ _ _ _ _ _ _ _ _ _ _ _
Compressor Serial Number: P_ _ _ _ _ _ _ _ _ _ _ _
Throttle Control Serial Number: _ _ _ _ _ _ _ _ _ _ _ _ AOST Serial Number: _ _ _ _ _ _ _ _ _ _ _ _
Submitted by
Name: ____________________ Contact: _________________
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PH 250-740-3200FX 250-740-3201TF 1-800-738-8622
1333 Kipp Road, Nanaimo, BC, V9X 1R3 Canadawww.vmacair.com