95 81'(5+22' $,5 &2035(6625 ,167$//$7,21...

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.

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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


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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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.


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


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


Fax: 1-250-740-3201 8

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


Fax: 1-250-740-3201 10

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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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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Fax: 1-250-740-3201 14

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


15

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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Fax: 1-250-740-3201 16

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


Fax: 1-250-740-3201 20

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


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).

!


Fax: 1-250-740-3201 22

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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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.


Fax: 1-250-740-3201 24

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


25

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


Fax: 1-250-740-3201 26

!

5.2 Installing the Tank Assembly and Hoses


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.


27

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).


Fax: 1-250-740-3201 28

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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Part 6: Installing the Control Components

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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.


31

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


Fax: 1-250-740-3201 32

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


33

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.


Fax: 1-250-740-3201 34

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


35

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


Fax: 1-250-740-3201 36

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.


37

!

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.

!


Fax: 1-250-740-3201 38

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.

!


39

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.

!


Fax: 1-250-740-3201 40

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


41

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.


Fax: 1-250-740-3201 42

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

!


43

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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