Vmac VR70 User manual

System V900109
2014-2011 International TerraStar MaxxForce 7
6.4L DIESEL
www.vmacair.com
VR70 UNDERHOOD
AIR COMPRESSOR
INSTALLATION MANUAL

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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

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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

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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.

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□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

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□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

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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

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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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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).
Cooler
Overflow Bottle Front
Figure 3.4
Crank Pulley
Compressor
Tensioner
Idler
Idler
Install Here Last
Figure 3.3

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□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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□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.