Vmac VR70 Installation Manual
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Vmac VR70 Installation Manual

Underhood air compressor
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Download this manual See also: Owner's Manual, Installation Manual
V R 7 0 U N D E R H O O D
A I R C O MP R E S S O R
I N S T A L L A T I O N MA N U A L
S y s t e m V 9 0 0 1 0 9
2 0 1 4 - 2 0 1 1 I n t e r n a t i o n a l T e r r a S t a r Ma x x F o r c e 7
6 . 4 L D I E S E L
w w w . v ma c a i r . c o m

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Summary of Contents for Vmac VR70

  • Page 1 V R 7 0 U N D E R H O O D A I R C O MP R E S S O R I N S T A L L A T I O N MA N U A L S y s t e m V 9 0 0 1 0 9 2 0 1 4 - 2 0 1 1 I n t e r n a t i o n a l T e r r a S t a r Ma x x F o r c e 7 6 .

  • Page 3: Table Of Contents

    7.7 A ............ 39 FTER TARTING THE NGINE HECKLIST 7.8 S ........40 ETUP ERFORMANCE ESTING AND DJUSTMENTS 7.9 A ................. 42 UXILIARY ECEIVER ACCESSORY PRODUCTS FROM VMAC ..........43 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 4: Installation Manual For Vmac

    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.
  • Page 5 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.

  • Page 6: General Information

    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 VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 7: 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.
  • Page 8 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 VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 9 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 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 10: Part 2: Preparing For Installation

    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)
  • Page 11 Figure 2.1 Figure 2.2 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 12: Preparing For Installation - Mechanical

    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 VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 13 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 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 14: Part 3: Installing Main Bracket, Compressor And Cooler

    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. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 15 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). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 16: Installing The Oil Cooler

    3.2 Installing the Oil Cooler The cooler will mount to the driver side radiator support/overflow bottle mount (Figure 3. 4). Front Overflow Bottle Cooler Figure 3.4 VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 17 Do not use razor knifes as this can result in damaging the hoses. To Overflow Bottle From Radiator Overflow Bottle To Engine Upper Radiator Hose. Cut Heat Shrunk Plastic Clamps Figure 3.6 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 18 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). VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 19 Secure the loom in place with the supplied nylon tie. Supplied Fitting Figure 3.9– Fitting Orientation □ Check the overflow bottle and supplied cooler mount are mounted as follows; (from front of truck to rear) VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 20 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. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 21: Part 4: Installing The Tank - 4X4

    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. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 22 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). VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 23: Installing The Air Oil Separator Tank Hoses

    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). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 24 Route them along the frame rail following the previously installed ¾” hose and up to the compressor securing with the supplied tie-wraps. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 25 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. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 26: Part 5: Installing The Tank - 4X2

    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.
  • Page 27 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. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 28: Installing The Tank Assembly And Hoses

    Loosely mount with supplied M8 fasteners. □ Position the tank so the arrow and “UP” marking on the back of the tank are facing up. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 29 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). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 30 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. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 31: Part 6: Installing The Control Components

    Part 6: Installing the Control Components Figure 6.1 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 32: Installing The Components

    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.
  • Page 33 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). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 34: Park/Neutral Signal

    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 VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 35 □ Connect the 8 pin shell connector with blue wire to the body builder connector of the Allison 1000/2000 transmission. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 36: Part 7: Finishing The Installation

    □ 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). VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 37 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. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 38: Connecting To Switched Power

    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. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 39: Adding Oil To The System

    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.

  • Page 40: Before Starting The Engine Checklist

    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: □...

  • Page 41: After Starting The Engine Checklist

    □ Check the coolant after the engine reaches operating temperature. □ Check all components once the engine is turned off and the system has cooled. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 42: Setup, Performance Testing And Adjustments

    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 VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 43 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. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 44: Auxiliary Air Receiver

    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).

  • Page 45: Accessory Products From Vmac

    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.
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  • Page 47 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...
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  • Page 52 Ma n u f a c t u r e d b y P H 2 5 0 - 7 4 0 - 3 2 0 0 F X 2 5 0 - 7 4 0 - 3 2 0 1 T F 1 - 8 0 0 - 7 3 8 - 8 6 2 2 1 3 3 3 K i p p R o a d , N a n a i mo , B C , V 9 X 1 R 3 C a n a d a w w w .

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