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- Page 1 DOCUMENT 19250 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...
- Page 2 #19254 - throttle commander installation #19255 - control unit installation #19256 - illustrated parts list #19130 - warranty registration Copyright 1998 The contents of this manual may not be reproduced in any form without the express written permission of VMAC...
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Page 3: General Information
DOCUMENT 19250a General Information System #9018 1999 NAVISTAR INTERNATIONAL Cummins ISB M11 Engine UNDERHOOD AIR COMPRESSOR... -
Page 4: Installation Steps
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:... -
Page 5: Installation Notes
Installation Notes 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. Follow all safety precautions for under-hood mechanical work. Use Loctite 242 or equivalent on all engine-mounted fasteners. 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. -
Page 6: Ordering Parts
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. -
Page 7: Installing The Compressor
DOCUMENT 19252 Part 1 Installing the Compressor System #9018 1999 NAVISTAR INTERNATIONAL Cummins ISB M11 Engine UNDERHOOD AIR COMPRESSOR... -
Page 8: Preparing For Installation
Part 1: Installing the Compressor 1.1 Preparing for installation Disconnect the batteries. Drain the coolant. Remove the tube which crosses over the top of the engine and connects the inter- cooler to the turbocharger inlet. Remove the air conditioning compressor. Lift it upward and set it on top of the engine. - Page 9 Remove the ½″ NF cap screws holding the radiator and firewall tie-rod bracket to the frame on the left-hand side. ″ NC nuts from the bracket holding the radiator tie-rod to the left-hand Remove the side of the radiator. 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.
- Page 10 Slide the second HS4 clamp into position over the cooler connection and tighten the clamp. Install the OEM lower radiator hose to the cooler inlet. Tighten all hose clamps. Install the oil filter. If you are using a new filter, fill it with clean, OEM recom- mended oil before installation.
- Page 11 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. M10 x 30 (2) M10 x 35 (4) M10 x 35 (2) Figure 3 1.4 Installing and mounting components Install the VR7000 pulley over the OEM pulley and harmonic balancer.
- Page 12 OEM Air Conditioning Compressor Mounting Holes Hole For 1/2“ NC Air Conditioning Adjuster Bolt VR7000 Mounting Bracket Mount Regulator Here VR7000 6-Rib Belt Tensioner Tensioner Mounting Bolt VR7000 Compressor Mounting Holes VR7000 Back Idler Back Idler Mounting Bolt And Spacer Figure 4 Install the OEM 8-rib drive belt as shown in Figure 5 and tension it to manufacturer’s specifications.
- Page 13 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.
- Page 14 1.5 Installing the power steering bracket Swing the tie-rod bracket away from the frame rail and insert the supplied power steering bracket underneath the tie-rod bracket. 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.
- Page 15 OEM Air Conditioning Compressor Pressure Regulator VR7000 Mounting Bracket Power Steering Reservoir VR7000 Air Compressor VR7000 Power Steering Bracket Radiator Tie-rod VR7000 Bracket Power Steering Hose Radiator Tie-rod Frame Tie-rod Bracket Figure 7 VR7000 Power Radiator Steering Tie-rod Reservoir Bracket Tie-rod Bracket OEM Cap...
- Page 16 DOCUMENT 19253 Part 2 Installing the Air Tank and Lines System #9018 1999 NAVISTAR INTERNATIONAL Cummins ISB M11 Engine UNDERHOOD AIR COMPRESSOR...
- Page 17 Part 2: Installing the Air Tank and Lines 2.1 Installing the air tank 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. Frame Tank Mount Brackets Attached with Exhaust...
- Page 18 Compressor Control Line Part #17223 Air Pressure Control Line COMPRESSOR Part #17228 REGULATOR Main Air Line Part #17229 Cooler-Compressor Line THIS OIL LEVEL Oil Scavenge Line (check cold) Part #17222 Part #17221 IMPORTANT Wire Harness Oil Return Line Part #17227 TANK OIL COOLER Figure 10...
- Page 19 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).
- Page 20 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).
- Page 21 Remove the inlet control valve. Pour six (6) litres (1.8 US Gal.) of the supplied compressor oil into the large air intake opening. You must use the supplied compressor oil in this system. Failure to use this special oil will result in damage to the compressor and will void your warranty. WARNING Turn the compressor clockwise with a ratchet and socket using the hex head cap screw at the center of the compressor clutch.
- Page 22 Pressure Regulator 5/16 x 148.5 Oil Scavenge Line Part #17221 Tank Compressor Oil Cooler Figure 17 ″ × 11″ compressor control line (part #17223) between the fitting on the Install the regulator and the top inside fitting at the compressor (Figure 18). Pressure Regulator 5/16 x 11 Compressor Control Line Part #17223...
- Page 23 Figure 19 shows the tank, mounted on the frame rail, with lines attached. Line 1 From Compressor (main air line) Hold-down Straps Part #22069 Part #17229 Tank Line 2 To Pressure Regulator (air pressure control line) Part #17228 Line 3 To Compressor (oil scavenge line) Part #17221 Line 4 To Oil Cooler (oil return line) Part #17227 Figure 19 Remember to ensure that the lines do not contact any sharp or hot objects.
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Page 24: Installing The Control Unit
DOCUMENT 19255 Part 3 Installing the Control Unit System #9018 1999 NAVISTAR INTERNATIONAL Cummins ISB M11 Engine UNDERHOOD AIR COMPRESSOR... -
Page 25: Control Unit Installation
Part 3: Installing the Control Unit 3.1 Control unit installation Remove the screws holding the plastic protector panel in place on the floor inside the driver’s door. Remove the panel. Remove the rear outer seat rail cap screw. Mount the throttle control unit to the floor on the rail using the OEM cap screw (Figure 20). - Page 26 Cut or drill a ¾″ hole in the plastic firewall connector where the air lines pass through the firewall (Figure 21). Be careful not to damage any lines or wires. Apply the spring brakes using the spring brake control on the dash of the truck. This will vent all air out of the spring brake chambers and lines.
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Page 27: Routing The Wiring
Insert the ends of the lines in the T-fitting, slide the ferrules into position against the T-fitting and tighten the nuts. Start the engine and allow the air pressure in the air brake system to build up to cut-out pressure. Release the spring brakes using the control knob on the dash. - Page 28 DOCUMENT 19254 Part 4 Installing the Throttle Commander System #9018 1999 NAVISTAR INTERNATIONAL Cummins ISB M11 Engine UNDERHOOD AIR COMPRESSOR...
- Page 29 Part 4: Installing the Throttle Commander Use the wiring diagram in Figure 22 to determine wire connections. Secure all wires so that they will not be damaged or interfere with vehicle operation. NOTE Throttle Commander Control Unit Orange To F15 On Fuse Panel Green to Fuse Holder Ground...
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Page 30: Connecting The Wiring
Throttle Commander Steering Column Fuse Panel Throttle Control Steering Shaft At Pedal With U-joints Figure 23 4.2 Connecting the wiring Remove the fuse panel cover. Connect the orange wire with the in-line fuse to the empty fuse numbered “F15” in the fuse panel (lower row, 2 from the left). - Page 31 Connect the following wires to the gang-ground on the firewall: • the green wire from the Throttle Commander • the green wire in the flat, blue harness from the control unit • the short black wire from the air pressure switch (installed in the yellow air line) In the engine compartment, feed the white wire from the control unit into the same loom as the gray wire from the Throttle Commander.
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Page 32: Illustrated Parts List
DOCUMENT 19256 Part 5 Illustrated Parts List System #9018 1999 NAVISTAR INTERNATIONAL Cummins ISB M11 Engine UNDERHOOD AIR COMPRESSOR... - Page 34 ILLUSTRATED PARTS LIST SYSTEM 9018 - 1999 NAVISTAR INTERNATIONAL MODELS 2574 & 2674 CUMMINS ISB M11 ITEM UNIT PART # DESCRIPTION 1212 SCREW COMPRESSOR 92108 INLET CONTROL VALVE 36037 PAPER FILTER ELEMENT 36045 FILTER COVER 15221 ¼” NC NUT 15374 ¼”...
- Page 35 A DIVISION OF MANGONEL CORPORATION ILLUSTRATED PARTS LIST SYSTEM 9018 - 1999 NAVISTAR INTERNATIONAL MODELS 2574 & 2674 CUMMINS ISB M11 ITEM UNIT PART # DESCRIPTION ” NPT SCAVENGE ORIFICE 90 ° ELBOW 92091 58004 VITON 3 ”...
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Page 36: Warranty Registration
Warranty Registration This form must be completed and returned to VMAC at the time of installation. Warranty will be void if this form is not received by VMAC within 30 days by mail or fax. Installer Information Company Name: Installer Name: City: State/Prov.
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