Vmac VR70 Manuel utilisateur
V900088
2007 FREIGHTLINER M2
7.2L Caterpillar C7 ACERT 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
Systems V900088
2007 Freightliner M2 7.2L Caterpillar C7
ACERT Inter-cooled Diesel
with Allison Automatic Transmission
General Information..................................................................... 3
Before You Start..................................................................... 3
Part 1: Installing the Control Components .............................. 4
1.1 Locating the Modules and Wires.................................... 5
1.2 Installing Components..................................................... 8
1.3 Connecting the Wiring..................................................... 9
Part 2: Preparing for Installation............................................... 12
Part 3: Installing the Bracket, Compressor and Cooler......... 14
3.1 Installing the Main Bracket and Compressor................ 14
3.2 Installing the Cooler......................................................... 16
Part 4: Installing the Tank and Hoses....................................... 20
4.1 Installing the Tank............................................................ 20
4.2 Connecting the Steel Lines and Hoses.......................... 21
4.3 Completing the Installation............................................. 22
4.4 Adding Oil to the System................................................. 23
Part 5: Finishing and Testing..................................................... 24
5.1 Before Starting the Engine Checklist............................. 24
5.2 After Starting the Engine Checklist................................ 24
5.3 Testing Operation............................................................. 25
5.4 Setup, Performance Testing and Adjustments............. 26
5.5 System Identification and Warnings .............................. 27
5.6 Auxiliary Air Receiver ...................................................... 28
Accessory Products from VMAC............................................... 29
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
2
Document #1930123
Installation Manual for VMAC Systems V900088
2007 Freightliner M2 7.2L Caterpillar C7 ACERT Inter-cooled Diesel
with Allison Automatic Transmission
Changes and Revisions
Version Revision Details Revised by/date Approved by/date Implemented
000 Draft creation IB 22 June 2006 BC 17 Jul 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
trucks 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.
Copyright 2006
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
truck. This manual should be read completely before attempting
installation. 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
Blue
Green
Green
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
4
Part 1: Installing the Control
Components
White
Interface
Connector
Green4pin
connector
White
Red
R
R
e
e
d
d
Red
White
Compressor
Inlet valve
Clutch
Green
Black 3 pin
connector
Throttle
Controller
T
T
T
o
o
o
g
g
g
r
r
r
o
o
o
u
u
u
n
n
n
d
d
d
Blue
Blue
Throttle
Controller
Blue
Blue
Connect the blue wires
MANUAL TRANSMISSION
Throttle
Controller
Blue
Blue
Control Box
Black
Black
Purple
White
Orange
Chassis module
see appropriate
section for details
Engine control module
see appropriate section for details
Transmission control
module see appropriate
section for details
Do not use short
blue wire with
crimp connector
12 Volts
30
85
87
86
Relay Bulkhead module
see appropriate
section for details
10 A
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201 5
The VMAC throttle control uses the dedicated PTO
function which must be programmed by an OEM
qualified technician.
The PTO configuration must be set to:
•remote throttle
•PTO shut down time = 0 (default)
•PTO top engine limit = 2750 (default)
If the engine is programmed before the VMAC throttle is installed,
the system will check for a signal when the ignition is on in PTO
mode. The check engine light will illuminate but will shut off once the
throttle is installed.
1.1 Locating the Modules and Wires
Locate the bulkhead, engine control, transmission and chassis
modules (Figure 1.1).
1.1.1 Bulkhead Module
The bulkhead module is located on the driver’s side of the engine
compartment, mounted on the firewall, with connectors on the engine
side and the cab side of the module. Remove the kick plate from
under the dash on the driver’s side to access the connectors.
Locate the wire at location “G” on the top connector inside the cab of
the truck (Figure 1.2). Test the wire with a voltmeter to ensure that
there is 12 Volts with the ignition switch in the ON position and no
Volts with the switch in the OFF position.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
6
B
u
lkh
ead
M
odu
l
e
C
h
ass
i
s
Co
ntr
o
l M
odu
l
e
Transmission
C
ontrol ModuleEngine
C
ontrol Module
Figure 1.1
Engine Compartment Cab Under Dash
Firewall
To p C o n n e c to r
B5 Dash Harness
A
B
C
D
H
G
F
E
Figure 1.2
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201 7
1.1.2 Chassis Module
The chassis module is located on the driver’s side frame rail under
the cab.
Locate the wire at pin “F” on connector C3 (Figure 1.3) Check
continuity between the pin and ground. There should be continuity
when the park brake is applied and an open circuit when the park
brake is released.
H
G
F
E
D
C
B
A
J
K
L
M
N
P
R
S
Bl
ac
k
w
i
re
Figure 1.3
1.1.3 Transmission Module
The transmission module is located on the driver’s side frame rail
under the cab.
For THIRD generation controls on 3000 series Allison automatic
transmissions (Figure 1.4) locate pin 2 of the gray connector.
For FOURTH generation controls on Allison 1000/2000 product
families, 3000 product families and 4000 product family automatic
transmissions, remove the harness tape and locate wire 145.
With the engine running, check for continuity to ground in both Park
and Neutral and an open circuit in all other gears.
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
8
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
THIRD GENERATION CONTROLS
Figure 1.4
1.1.4 Engine Control Module
The engine control module is located on the driver’s side rear of the
engine.
1.2 Installing Components
□Disconnect the battery ground cable.
□Install the throttle controller inside the cab under the dash next to
the driver’s door. Attach it to the main wire harness with tie
straps.
□If the truck has a manual transmission, cut the long blue wire
from the throttle control to about six inches and connect it to the
short blue wire with the crimp connector.
□Install the control box in a suitable location for easy access. You
can mount it to the floor between the driver’s seat and the door
so that it can be accessed from inside or outside the cab and
route the wiring under the side door trim and under the dash.
□Connect the white interface connector to the matching connector
from the control box.
□Connect the two red wires from the interface connector to the red
wires with the matching connectors from the throttle controller.
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