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
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Fax: [phone]
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
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2
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.
Copyright 2005
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: [phone]
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
Blue
Green
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.

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4
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.

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Use between cooler
and driver’s side
radiator spigot Use on passenger
side radiator spigot
Cut
Cut
Discard this section
18
”
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

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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

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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
ps
P-clips and 5/16” bolt
s
Figure 2.1

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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.

VMAC – Vehicle Mounted Air Compressors
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□Place the tank in position on the mount brackets and attach them
with the 5/16 inch bolts and flat washers, but do not tighten.
□Position the tank so that the front C-clamp is about 6 inches back
from the front of the tank and rotate the tank so that the “UP”
arrow points upward.
□Thread the 5/16 and 1/4 inch fittings on the combination steel
line/hose assemblies into the matching fittings on the back of the
tank, but do not tighten them.
□Place the two P-clips over the steel lines and attach them to the
C-clamps using two of the 5/16 inch mounting bolts so that they
are parallel to the tank and supported.
□Check the direction of the “UP” arrow and the position of the
tank, tighten the pinch bolts securely, then tighten the four 5/16
inch bolts.
2.2 Connecting the Hoses
□Install an outlet fitting in the back of the tank (not supplied).
□Remove the oil filter and the protective cardboard.
□Thread the straight end of the longest 1/2 inch hose to the
matching fitting on the tank and tighten.
□Thread the 45 degree end of the 3/4 inch hose to the matching
fitting on the tank. Position the fitting so the hose will clear the
edge of the battery box and tighten.
□Route all the hoses along the inside of the frame rail and into the
driver’s side of the engine compartment.
□Pour some compressor oil into the filter, lubricate the gasket and
install the filter. Tighten 1/2-3/4 turn after the gasket contacts the
base.

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10
Part 3: Installing the Cooler,
Bracket and Compressor
3.1 Installing the Cooler and Coolant Hoses
Coolant flow through the radiator will be reversed once
the compressor cooler is installed. Engine cooling will
not be affected as the truck uses a cross-flow radiator.
□Remove the horn assemblies from the cross-member under the
engine and drill the two 8 mm mounting holes to 13/32 inches.
□Bolt the cooler back plate to the front side of the cross-member
with two M10 x 30 mm bolts, washers and nuts through the horn
mounting holes.
□Install the horns into the holes at each end of the rear of cooler
back plate using the OEM bolts.
□Connect the hose on the passenger side of the cooler to the
engine water pump spigot.
□Install the short end of the 90 degree hose (cut from the lower
radiator hose) on the driver’s side fitting on the cooler and the
long end on the radiator fitting.
□At the rear of the water pump, measure 3 inches from the water
pump fitting along the 3/4 heater hose, cut the hose and install
the 3/4 inch plastic tee.
□Connect one end of the 40 x 3/4 inch hose to the tee. Route the
hose down and under the engine behind the engine cross beam
and connect the other end to the spigot on the driver side of the
cooler. Secure the hose with ties.
□Install the short piece of hose (cut from the end of the lower
radiator hose) on the passenger side radiator fitting, then insert
the steel 90 degree elbow into this hose and angle it upwards
(Figure 3.1).

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□Check the thermostat housing location to make sure that the
sealing gasket is in place. Install the dual-diameter hose onto the
steel elbow and fasten the flange to the thermostat housing with
two M8 x 30 socket head bolts.
□Place the large rubber-insulated tube clamps around the elbow
and the coolant tube above and below the reducer hose. Fasten
them to the coolant tube bracket and fasten the coolant tube
bracket in place to support them (Figure 3.1).
To thermostat
To radiator
Reducer
hose
3-1/2” piece cut
from OEM hose
Elbow
Coolant
tube
Bracket
Figure 3.1

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3.2 Installing the Bracket and Compressor
□Remove the idlers and the belt tensioner from the mounting
bracket (Figure 3.2).
□Check the mounting locations on the timing cover to make sure
that they are clean, flat and free of protrusions or rough spots.
Main bracket
Idler
Idler
Tensioner
Back idler
Support bracket
M8 x 90 mm
socket head
bolt locations
M8 x 50 mm
socket head
bolt locations
M8 x 30 mm
hex head bolts
Timing cover
Figure 3.2
□If the timing cover does not have a heat shield, install the
thickest supplied spacer onto the shorter mounting post which
matches with the upper inboard fastener position. If the timing
cover has a heat shield, insert the thinnest spacer between the
timing cover and the heat shield.

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□Place the bracket in position and install four M8 x 90 mm socket
head bolts through the bracket and into the timing cover. Apply
Loctite and thread the serrated 8mm nuts to the bolts at the rear
of the timing cover. Torque the fasteners to specifications.
□Remove and discard the two OEM 8 mm bolts holding the fuel
delivery pump to the rear timing cover.
□Install the rear compressor support bracket to this location, apply
Loctite and install two M8 x 50 mm socket head bolts through the
support bracket, delivery pump and into the timing cover, but do
not tighten (Figure 3.3).
□Align the support bracket with the two holes in the compressor
bracket base plate. Apply Loctite and insert two M8 x 30 mm hex
head bolts with washers through the base plate and into the
threaded holes in the support bracket. Hand-tighten the two bolts
and make sure that the support bracket fits properly under the
base plate (you will need a mirror to check the fit).
Rear support bracket
Delivery pump
mounting positio
n
Timing cover
Main compressor bracket
Figure 3.3

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□Torque the M8 x 50 socket head bolts first, then the two M8 x 30
hex head bolts.
□Apply Loctite and install the idlers and tensioner. Torque the
fasteners to specifications.
□Remove the four socket head bolts and remove the inlet control
valve from the compressor. Immediately cover the opening with
a clean cloth or tape.
□Place the compressor on the mount bracket, apply Loctite,
thread the four M8 x 120 mm socket head bolts into the base
plate and hand-tighten them.
□Check the alignment of the compressor pulley with the crank
pulley using a straight edge or laser alignment tool. Correct as
necessary by moving the compressor, then torque the
compressor bolts to specifications.
□Install the compressor belt (Figure 3.4).
Figure 3.4

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3.3 Connecting the Hoses
□Connect the 3/4 inch hose from the tank to the matching fitting
on the compressor.
□Connect the 1/2 inch hose from the tank to the driver’s side fitting
on the oil cooler.
□Connect the 90 degree end of the remaining 1/2 inch hose to the
passenger side fitting on the oil cooler and the straight end to the
fitting on the compressor. Route the hose around the steering
box to the front, then under the frame to the cooler.
□Tighten all the hose fittings. Check the routing of the hoses to
make sure that they are not near hot engine parts and do not
contact any moving parts. Protect the hoses as necessary using
plastic loom in areas where they might rub.
3.4 Adding Oil to the System
You must use VMAC 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 cloth or tape from the air inlet control valve and pour
oil into the compressor. Turn the compressor clutch clockwise to
speed the fill process.
□Allow 5 minutes for the oil to drain into the tank, then check the
level at the sight glass at the front of the tank. Continue adding
oil until the level is correct.
□Install the inlet control valve on the compressor and torque the
fasteners to specifications. Connect the 1/4 and 5/16 inch hoses
to the matching fittings on the compressor.
Do not overfill the system. Overfilling the system with
oil can flood the sight glass window and make the
system appear empty.
!
!

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3.5 Completing the Installation
□Install the metal coolant tube support bracket and rubber clip to
the threaded hole in the front passenger side of the timing cover
just below the alternator. (This may be the top bolt locating the
passenger side lower fan shroud mounting bracket on some
models).
□Install the replacement bracket on the power steering reservoir
and bolt it back to the original location using the OEM bolts
□Connect the hoses and route the small hose around the outside
of the windshield washer bottle. Fill the reservoir.
□Install the fan and shroud.
□Install the OEM hose between the intercooler and the engine
intake on the driver side and the intercooler tube on the
passenger side of the engine.
□Install the coolant expansion bottle to the front of the radiator and
secure the coolant fill hose under the engine using ties.
□Fill the cooling system to manufacturer’s specifications.
□Install the front wheel mud shields.

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Part 4: Installing the Control
Components
4.1 Installing Components
□Remove the screws holding the plastic door sill trim in place on
the floor inside the driver’s door. Remove the plastic pin near the
seat belt base and remove the trim.
□Remove the plastic cover from the Electrical System Controller
on the driver’s side kick panel to the left of the brake pedal.
□Remove the rear seat rail bolt and fasten the control box mount
bracket to the floor (Figure 4.1).
Mount bracket usin
g
this hole
Mount control
boxl using these
holes
Figure 4.1
□Cut a small slot in the rubber floor mat below the control box
mount and feed the wire harness from the control box under the
floor mat, along the floor and under the dash.
□Attach the control box to the bracket using four machine screws,
with the wire harness coming out from the bottom.
□Mount the throttle box under the dash near the accelerator pedal
using nylon ties. Position it so that the adjusting screws are
accessible. Avoid mounting it near heating ducts.

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Control Box
White
Interface
Connector
Throttle
Controller
Throttle
Controller
Green 4 pin
connector
White
White
Red
Red
Red
Red White
(not used; tape up)
Compressor
Inlet valve
Clutch
Green
Green
Black
Connect to accelerator pedal
OEM Connector from
accelerator
p
edal
Black 3 pin connector
To ground
To ground
Connect
Blue
Blue
Blue
Blue
Connect to key switched 12 volts at the OEM fuse panel
AUTOMATIC TRANSMISSION
Connect long blue wire to the wire
identified in the instructions for
the appropriate transmission model
Do not use short blue wire with
crimp connector
Connect the blue wires MANUAL TRANSMISSION
Throttle
Controller
Blue
Blue
ENGINE COMPARTMENT
See the section on either hydraulic or air brakes for connection details
Yellow
Automatic transmissions with Third Generation Controls and
Manual Transmissions