Vmac VR70 User manual

System V900086

2005 - 2007 International 4300 - 4400

DT466 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

System V900086

International 2005 – 20074300-4400

DT466 Diesel

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

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

Part 1: Preparing for Installation............................................... 4

1.1 Preparing for Installation .................................................... 4

Part 2: Installing the Tank.......................................................... 7

2.1 Installing the Tank .............................................................. 7

2.2 Connecting the Hoses ........................................................ 9

Part 3: Installing the Cooler, Bracket and Compressor.......... 10

3.1 Installing the Cooler and Coolant Hoses............................ 10

3.2 Installing the Bracket and Compressor .............................. 12

3.3 Connecting the Hoses ........................................................ 15

3.4 Adding Oil to the System.................................................... 15

3.5 Completing the Installation ................................................. 16

Part 4: Installing the Control Components .............................. 17

4.1 Installing Components........................................................ 17

4.2 Connecting the Wiring ........................................................ 20

4.3 Completing the Wiring ........................................................ 24

Part 5: Finishing the Installation................................................ 25

5.1 Before Starting the Engine Checklist ................................. 25

5.2 After Starting the Engine Checklist..................................... 25

5.3 Setup, Performance Testing and Adjustments................... 28

5.4 System Identification and Warnings................................... 29

5.5 Auxiliary Air Receiver ......................................................... 30

Accessory Products from VMAC............................................... 31

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

Installation Manual - Document #1930087

Installation Manual for VMAC System V900086

International 2005 – 2006 4300-4400 DT466 Diesel

Changes and Revisions

Version Revision Details Revised by/date Approved Implemented

00 New format IB 16 Mar 2005 BC/SM 31 Mar 2005 1 Apr 2005

a Coolant tube change IB 22 Apr 2005 BC/SM 25 Apr 2005 28 Apr 2005

b bracket mounting spacers IB 16 Jun 2005 BC/SM 20 Jun 2005 22 Jun 2005

c ECN 06-122 IB 27 May 2006 SM 29 May 2006 01-Jun 2006

d ECN 06-151 IB 12 July 2006 SC 18 July 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

vehicles 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

Toll Free: 1-800-738-8622

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

vehicle. 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

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

This system will fit a 215 hp engine with a Borg Warner

fan clutch. If your truck has a 245 hp engine and a

Horton fan clutch order adaptor pack # A900005.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

Part 1: Preparing for Installation

1.1 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.

□Disconnect the batteries.

□Drain the coolant.

□Remove the front wheel mud shields from the frame and the

hood.

□Cut off the molded plastic locking rings securing the lower

radiator hose to the radiator and the engine on the passenger

side, remove and discard the lower hose.

□Cut off the molded plastic locking ring securing the upper coolant

hose on the driver side of the radiator. Disconnect the hose from

the radiator.

□Remove the fasteners securing the coolant tube to the timing

cover. Remove the coolant tube with the hose attached. Cut off

the plastic molded locking ring securing the hose to the tube and

remove the hose.

□Cut the OEM hose as shown in Figure 1.1

□Remove the two bolts from upper coolant tube thermostat flange

and discard the fasteners. Remove the coolant tube and hose

from the timing cover. Replace the OEM bolts.

□Remove the fan (left hand thread).

□If the truck has a fan shroud mounted to the engine, remove it

along with all mounting brackets.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 5

Use between cooler

and driver’s side

radiator spigot Use on passenger

side radiator spigot

Cut

Discard this section

”

12”

10-3/4”

3-1/2”

Figure 1.1

□Remove the following four OEM 8 mm bolts from the left side of

the timing cover (Figure 1.2):

•one with a small L-bracket for the coolant fill hose

•one directly above

•two below and inboard

Remove bolts

from these

locations

Figure 1.2

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

There may be a heat shield installed over the timing

cover fastened with the highest inboard fastener at the

bottom of the cover.

□Drain the power steering reservoir, disconnect the hoses,

remove it from the frame and remove the OEM mount bracket.

□Remove the coolant expansion tank from the radiator.

□Remove the small coolant fill hose L-bracket from the cross-

beam under the engine.

□Remove the air intake tube between the Intercooler and the

engine.

□Remove and discard the six OEM bolts from the crank pulley.

Clean the front surface of the pulley and install the compressor

pulley in front of the OEM pulley using the M10 x 40 bolts and

washers

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 7

Part 2: Installing the Tank

The tank can be mounted using existing locations on

the frame or by using the backing strap and bolt

method. Depending on your mounting location

requirements, you may need a hose extender kit.

2.1 Installing the Tank

2.1.1 Existing Location Method

□Remove the two 1/2 inch bolts on the drivers side that fasten the

front of the brake relay valve to the inside of the frame and

mount the bracket stamped “FRONT” in this position with the

M12 x 45 bolts, washers and nuts (Figure 2.1).

□Measure back 11-1/2 inches from the front bracket bolts and

mount the rear tank mount bracket in the two holes in the frame

using the M10 x 35 bolts, washers and nuts.

Driver’s side frame rail

Mount brackets

C-clam

P-clips and 5/16” bolt

Figure 2.1

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

2.1.2 Frame Clamp Method

□Place the mount bracket stamped “Front” in the same

approximate position as for the “Existing Location” method.

□Place an inner frame backing strap in position inside the frame,

Insert a bolt through the top hole in the bracket, through the

backing strap and install washers and a nut (Figure 2.2).

□Install another bolt, nut and washer through the lower holes and

tighten securely.

□Repeat this procedure for the rear mount, locating it

approximately 11-1/2 inches back from the front mount.

Tank mount bracket

Inner frame backing strap

Figure 2.2

□Remove the pinch bolts from the two C-clamps, spread them

slightly and slide them over the tank. Install the pinch bolts but

do not tighten.

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