Installation Manual - VMAC · PDF fileInstallation Manual For The 2003 FREIGHTLINER FL60-FL70 MERCEDES MBE 900, W/WOAB System # V900073. Installation Manual Document Number: ... 1.4

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Installation ManualFor The

2003 FREIGHTLINER FL60-FL70MERCEDES MBE 900, W/WOAB

System # V900073

Installation Manual Document Number: 1930024

VR70 Underhood Air Compressor System Number V900073

Application

2003 FREIGHTLINER FL60-FL70 MERCEDES MBE 900

Publication Date: Revised by T. W. Mitchner, 26 August 2003

Notice

Manuals and products are subject to change without notice.

Registered Trademarks

VR70, VMAC and Throttle Commander are registered trademarks of VMAC.

FL60-70 and MBE 900 are registered trademarks of Freightliner and Mercedes Benz.

Loctite, Klean N’ Prime, 242 and PST are registered trademarks of Loctite Corporation.

Nylok is a registered trademark of Nylok Fastener Corporation.

Copyright 2003 The contents of this manual may not be reproduced in any form without express, written permission.

Contents PART 1 GENERAL INFORMATION ............................................................................................. 3

1.1 INTRODUCTION............................................................................................................................ 5 1.2 INSTALLATION STEPS................................................................................................................... 5 1.3 TERMS AND SYMBOLS ................................................................................................................. 5 1.4 INSTALLATION NOTES.................................................................................................................. 5 1.5 SYSTEM IDENTIFICATION NUMBER PLATE.................................................................................... 6 1.6 WARRANTY................................................................................................................................. 7 1.7 ORDERING PARTS ........................................................................................................................ 7 1.8 TOOL REQUIREMENTS.................................................................................................................. 7 1.9 SPECIAL INSTALLATION NOTES.................................................................................................... 8 1.10 CHANGES AND IMPROVEMENTS................................................................................................. 8

PART 2 PREPARING FOR INSTALLATION............................................................................... 9 2.1 PREPARATION FOR INSTALLATION............................................................................................. 11

PART 3 INSTALLING THE AIR TANK AND LINES ............................................................... 15 3.1 INSTALLING THE TANK BRACKETS............................................................................................. 17 3.2 INSTALLING THE C-CLAMPS ...................................................................................................... 17 3.3 INSTALLING THE TANK AND LINES............................................................................................. 18 3.4 ALTERNATE TANK MOUNTING FOR 2000 MODEL YEAR TRUCKS ................................................ 19

PART 4 INSTALLING THE COMPRESSOR AND OIL COOLER ......................................... 21 4.1 COOLER INSTALLATION............................................................................................................. 23 4.2 INSTALLING THE MAIN BRACKET ............................................................................................... 26 4.3 INSTALLING THE COMPRESSOR .................................................................................................. 28 4.4 INSTALLING THE VR IDLER/TENSIONER BRACKET..................................................................... 29 4.5 INSTALLING THE CRANK PULLEY AND VR BELT ........................................................................ 30 4.6 ATTACHING THE LINES TO THE COMPRESSOR ........................................................................ 31 4.7 INSTALLING THE FAN SPACER.................................................................................................... 33 4.8 COMPLETING THE INSTALLATION .............................................................................................. 34 4.9 ADDING OIL TO THE SYSTEM ..................................................................................................... 35

PART 5 INSTALLING THE CONTROL COMPONENTS ........................................................ 37 5.1 INSTALLING THE CONTROL PANEL ............................................................................................. 39 5.2 INSTALLING THE SWITCHING BOX.............................................................................................. 39 5.3 CONNECTING THE WIRING ......................................................................................................... 41 5.4 BRAKE SYSTEMS........................................................................................................................ 42 5.5 INSTALLING THE THROTTLE....................................................................................................... 44 5.6 FINAL TESTING AND ASSEMBLY................................................................................................. 47 5.7 ADJUSTING THE THROTTLE........................................................................................................ 48

PART 6 ILLUSTRATED PARTS LIST......................................................................................... 51

WARRANTY..................................................................................................................................... 57

Page 1

Page 2

DOCUMENT #1930024

Part 1 General Information

System #V900073

2003 FREIGHTLINER FL60-FL70 MERCEDES MBE 900 W/WOAB


Page 3

Page 4

1.1 Introduction This book provides installation instructions for the VMAC underhood air compressor installation kit. 1.2 Installation steps The installation procedure in this manual has four main steps:

• Preparing for Installation • Installing the Air Tank and Lines • Installing the Compressor and Oil Cooler • Installing the Control Components

1.3 Terms and symbols This manual uses the following terms and symbols:

• OEM - Original Equipment Manufacturer • HHCS - Hex Head Cap Screw (also called a hex bolt) • SHCS - Socket Head Cap Screw (also called an Allen head bolt)

This symbol indicates that there is additional information or special emphasis on a specific procedure.

This symbol indicates that there is a possibility of personal injury or damage to the equipment if the indicated warning is not followed.

1.4 Installation notes

1. It is important that you complete all the installation steps before operating the system.

2. Follow all safety precautions for underhood mechanical work.

3. Use Loctite 242 or equivalent on all engine-mounted fasteners.

4. All hoses, tubes and wires which are re-routed or shifted during installation must be secured so that they do not contact excessively hot areas or sharp edges. Where possible, follow the routing suggestions in this manual.

5. These installation instructions are intended as a general guide. In some instances, due to variations in vehicle manufacture or if prior modifications have been made to the vehicle, it may be necessary to carry out grinding, bending or rearranging operations for correct fit. These operations must follow sound, standard shop practices.

6. Left and right definitions in this manual are determined when sitting in the driver’s seat, facing forward.

7. All fasteners must be of the correct size and torqued according to the following specifications. Torque specifications are in foot pounds (ft-lb) and are only applicable when Loctite is used. If the threads are dry, add 20% to the torque values.

Page 5

STANDARD GRADE 8 NATIONAL COARSE THREAD Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 Foot-pounds 9 18 35 55 80 110 170 280 STANDARD GRADE 8 NATIONAL FINE THREAD Size 3/8 7/16 1/2 5/8 3/4 Foot-pounds 40 60 90 180 320 METRIC CLASS 10.9 Size M8 M10 M12 M14 M16 Foot-pounds 19 41 69 104 174

Table 1 Torque Specifications

Hose diameter Color coded label Part number prefix 1/4” Yellow 173 5/16” Orange 174

1/2” & 5/8” Blue 175 & 176 3/4” & 1” Green 177 & 178

Table 2- Hose color codes

Table 2 above illustrates the color code used by VMAC to define the different hose diameters. Check that system hoses are all tight before running the system. Refer to setup procedure in the Owner’s Manual before attempting to run this air system. Different frame designations will affect the tank mounting position. You may have to move the tank rearward from the standard position on your application. If you must move the tank, the lines may be too short. If this is the case, measure the hose shortfall and order a “Hose Extender Kit”, P/N (A410XXX). The last three digits in the P/N indicate the length of the extension, for example, A410055 is a 55-inch hose extender kit. 1.5 System identification number plate

The System Identification Number Plate included with the kit must be attached to the vehicle at the time of installation. Locate the plate as shown below. Mark and drill two holes using a 7/64” drill bit. Secure the plate in position using the supplied #6 pan head, self-tapping screws.

Page 6

1.6 Warranty

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.

1.7 Ordering parts

To order parts, contact your nearest VMAC dealer. Please quote the VMAC part number, the description and the quantity. You must also quote the number from the System Identification Number Plate to ensure that you get the right parts.

1.8 Tool requirements The following tools are required for compressor installation:

• 1/2” drive metric socket set • 8 –24 mm metric wrench set

• 1/2” drive SAE socket set

• 7/16 – 1 1/4” SAE wrench set

• Allen key sets – metric and SAE

• mechanic’s screwdriver set

• nut drivers – 5/16”- 3/8”

• 1/2” drill with assorted bits up to 1/2”

• hacksaw or zip wheel suitable for cutting metal

Page 7

The following tools are required for throttle component installation:

• small soldering gun or soldering pen • wire cutters

• wire strippers

• crimping tool

• digital multi-meter – preferably with a frequency (Hz) setting

• small jeweler’s screwdriver set for the adjustment of the throttle control

1.9 Special installation notes

If you intend to use an auxiliary air receiver with this system you must observe the following installation procedure. Failure to observe this procedure will result in damage to the system.

1. The line from the VR70 tank to the auxiliary air receiver must have an auxiliary check valve installed to prevent blowback from the auxiliary tank and to prevent moisture from entering the VR70 tank.

2. The line to the auxiliary tank must not be installed in the bottom of the tank, but must be

installed as high as possible to prevent water from clogging the line.

VR70 TankAuxiliary check valve

possible, NOT on the bottom of the tank

Install the line as high as Auxiliary Receiver

1.10 Changes and improvements

These products and documents are subject to changes or improvements without notice.

Page 8

DOCUMENT #1930024

Part 2 Preparing for Installation

System #V900073



Page 9

Page 10

2.1 Preparation for installation

Intercooler tube

Figure ? – Remove the intercooler tube and radiatorFigure ? – Disconnect the batteries

1. Disconnect the battery.

2. Disconnect all of the electrical connections running to the hood.

3. Unbolt and remove the hood.

4. Drain the coolant into a suitable container.

Figure ? – Releasing the cooler hose clamp

5. Undo the hose clamp restraining the oil hoses running to the oil cooler. Undo the 4 bolts

securing the oil cooler, and move the cooler to the side with the oil lines still attached. Give adequate protection to the cooler.

Page 11

6. Unbolt and remove the passenger side inner fender.

7. Undo the four bolts that hold the passenger side bumper section and swing it out of the way

for easier access.

8. Unclip the two small hoses running from the coolant expansion tank at the radiator and water pump. Leave them connected to the expansion tank and secure them out of the way

9. Undo all of the hose clamps on the air filter intake hose assembly. Remove the pipes and

hoses in separate component parts.

10. Remove all of the fasteners securing the air filter assembly. Remove the air filter.

11. Disconnect the top radiator hose at the radiator only

12. Disconnect the two hoses running into the inter cooler.

13. Undo and remove the remaining short section of intercooler tube on the passenger side. 14. Remove the large black radiator to engine intercooler tube.

15. Unclamp the bottom radiator hose at the radiator end and remove the hose completely.

Remove the passenger side radiator supporting brace bar and bracket from the frame rail. 16. Undo the six bolts securing the fan shroud. Move the fan shroud as far back towards the

engine as possible.

17. Remove the radiator and intercooler as a unit. 18. Remove the fan shroud.

19. Undo the six Nylock nuts, (four bolts for an Eaton fan) on the fan and remove the fan. Figure ? – OEM hose removal

Remove this hose

Figure ? – OEM hose removal

Page 12

20. Unclamp and remove the section of rubber hose running from the 90-degree tee to the cooler

expansion tank (Figure ?).

Remove brass

s

s

Ifa

21. Remo

22. Using

90-de 23. Re-in

all fa 24. Re-in 27. Undo

UndoReplato spFully

Remove bolt
fitting
the brass fitting shown in Figure ? can be removed without remssembly proceed directly to (step 24).

ve the brass 90-degree fitting from the lower section of the steel tu

pipe sealant, install the supplied 3/4-inch NPT socket head plug ingree fitting was removed.

stall the section of steel tube running up the side of the driver side fsteners to specification.

stall the flexible hose to the water pump.

the brass fitting on the water pump. Remove the bolt securing the r the clamp on the rubber 90-degree connector (Figure ?). Remove tce the bolt with Loctite and torque to specification. Replace the bra

ecification. Undo the retaining clamp holding the rubber section of t disassemble the remaining sections of the road draft tube.

Remove bolt

Figure ? – Remove OEM bolts
Figure ? – Remove OEM bolts
oval of the whole

be (Figure ?).

to the port where the

rame rail. Tighten

oad draft steel tube. he bracket assembly. ss fitting and tighten he road draft tube.

Page 13

Water pump bolt

Figure ? – Removal of road draft steel tube

Figure ? – Loosening the intercooler tube

Loosen the OEM clamps

Remove the OEM boltRoad draft tube

Brass Fitting

28. Remove the bolt securing both intercooler tubes to the support bracket mounted to the cylinder head. Undo the clamps for the intercooler tubes enough to allow the tubes to rotate (Figure ?).

29. Remove the tension from the OEM belt and slide the belt off the alternator pulley 30. Disconnect the electrical connections to the alternator. 31. Unbolt the alternator and its bracket. Make a special note of any spacers that are

associated with the alternator bracket and the order of how they are applied for later re-installation.

32. Unbolt and remove the two clamps restraining the main battery cable located on the inside of

the frame rail on the driver’s side behind the fuel tank.

Figure ? – Remove the alternatorFigure ? – OEM battery cable clamps

Page 14

DOCUMENT #1930024

Part 3 Installing the Air Tank and

Lines

System #V900073



Page 15

Page 16

Battery cable clamp

p

Figure ? – Tank brackets mounted Figure ? – Detail of c 3.1 Installing the tank brackets

1. Place one of the tank mounting brackets on the inside of the drivers sidunderneath the metal bracket used to locate the battery cable clamp. Loonto the inside of the frame rail with the 45-degree bend pointing out tPass a tank strap through the hole at the top of the bracket and route it the frame rail and back through the hole close to the 45-degree bend in

2. Loosely secure the strap in place with the supplied 5/16-inch ID x 3/4-

one of the 5/16-inch nuts. Ensure the bracket is mounted vertically andconflict with any other installed equipment. Fully tighten the strap andinch nut to lock the previous nut in place.

3. Take one of the previously removed battery cable support brackets and

tank bracket using the supplied 5/16-inch x 2 1/2-inch hex head bolt inbolt. Mount to the centrally placed hole. Leave the clamp slightly loosealignment later.

4. Mount the second tank bracket on the frame rail forward of the first tan

ensuring that it butts up to the OEM bracket previously used for mountsupport clamp. Install the tank-mounting bracket following the same prbracket. Ensure the strap goes through the space between the fuel tank

5. Reinstall the battery cable into the clamp and tighten to specification.

3.2 Installing the C-clamps

1. Remove the bolts from the supplied C-clamps and slide them onto the the weld on the end where the oil filter is located. Measure the distancetank mounting brackets and position the second C-clamp the same dist12.4 inches). Install the bolts into the clamps and hand tighten.

2. With the tank placed on a flat surface, rotate the tank until the mountin

45-degrees. Tighten the C-clamp brackets.

Cable stra

able routing

e frame rail cate the pressed lug

o the driver’s side. down the outside of the bracket.

inch OD washer and the strap does not use a second 5/16-

mount to the second place of the OEM to allow for final

k mounting bracket ing the battery cable ocedure as the first mounting structure.

tank. Slide one up to between the installed

ance apart (approx

g direction arrow is at

Page 17

3.3 Installing the tank and lines

1. Use a pair of jack stands or other suitable means of support to hold the weight of the tank during installation. Lift the tank into position on the tank mounting brackets with the filter end pointing forward.

2. Place a supplied 5/16-inch x 1 1/4-inch bolt through one of the 5/16-inch washers and

through the bottom hole in the rear C-clamp and the mating bottom hole in the bracket. Loosely secure the bolt with another 5/16-inch flat washer and a 5/16-inch Nylock nut.

3. Repeat this procedure for the forward bottom mounting hole on the other C-clamp. Align the

tank horizontally and tighten the installed bolt to stop the tank from moving.

4. Pass the 5/16-inch and 1/4-inch oil lines on the outside of the rear tank mounting bracket and the inside of the forward tank mounting bracket. Pass the lines over the lower frame cross members.

5. Loosely install the lines to the rear of the tank. Group the lines together close to the tank mounting bracket.

1/4” Line

12.4” 5/16” Line Figure ? – Rear line attachmentsFigure ? – Positioning the C-clamps

6. Place the supplied P-clips over the 5/16-inch and 1/4-inch steel lines. The rear P-clip mounts to the outside face of the tank bracket with the bolthole at the top. The forward P-clip mounts to the inside face of the tank mounting bracket with the bolthole at the bottom (Figure ?).

7. Place a supplied 5/16-inch x 1 1/4-inch bolt through one of the 5/16-inch washers and

through the top hole in the rear C-clamp and the mating bottom hole in the bracket. Place the P-clip onto the bolt and loosely secure the bolt with a 5/16-inch flat washer and a 5/16-inch Nylock nut.

8. Place a supplied 5/16-inch x 1 1/4-inch bolt through the remaining 5/16-inch washer and pass

it through the forward P-clip and the top hole in the tank C-clamp and corresponding tank bracket. Loosely secure the bolt with a 5/16-inch flat washer and a 5/16-inch Nylock nut.

9. Check the alignment of tank horizontally and that the direction arrow on the tank end cap is

pointing vertically. Adjust as necessary. Fully tighten to specification all tank bracket-mounting bolts and C-clamp bolts.

Page 18

10. Adjust the routing of the 5/16-inch and 1/4-inch steel lines. Fully tighten the fittings into the

tank end cap.

Figure ? – P-clip mounting detail

P-clip locations

Figure ? – Routing the lines

11. Gently bend the 5/16-inch and 1/4-inch steel lines so that they do not rub against the tank brackets. The lines require a double bend to ensure they run parallel to the face of the tank brackets. Also a slight upward bend may be required at the point where the steel lines go into the black hose oil line to enable clearance between the hose ferrules (Figure ?).

3.4 Alternate tank mounting for 2000 model year trucks

With the batteries positioned differently in 2000 model year trucks, there is an opportunity to mount your tank in a different manner than was described for later models.

s described for later models.

Figure ? – P-clip detail of the linesFigure ? – Driver side mount (FL70).

Page 19

1. Measure 11 3/4 inches from the passenger side spring hanger and make a mark. Measure an

additional 20 1/2 inches along the frame rail and make a second mark.

2. Mount the first tank mount bracket on the driver side frame rail so that it is centered on the first mark closest to the spring hanger. Make sure that the longest vertical section of the tank bracket is flush with the inside face of the frame rail and the locating tab at the bottom of the bracket is flush with the bottom of the frame rail. The 45-degree angled bottom portion of the bracket should face towards the outside of the vehicle.

3. Pass the threaded end of the tank bracket cable through the top hole of the bracket so that the

stop on the cable is flush with the inside edge of the bracket. Route this cable across the top of the frame rail and then in a straight vertical line down the outside frame rail edge. Push the threaded end of the cable through the lower hole in the bracket and secure it loosely in place with the supplied 3/4-inch washer and 5/16-inch nut.

4. Remove the bolts from the supplied C-clamps and slide them onto the tank. Slide one up to

the weld on the end where the oil filter is located. Measure the distance between the installed tank mounting brackets and position the second C-clamp the same distance apart. Install the bolts into the clamps and hand tighten.

5. With the tank placed on a flat surface, rotate the tank until the mounting direction arrow is at

45-degrees. Tighten the C-clamp brackets.

6. Follow the directions for mounting the tank as outlined in section 3.3.

7. For attachment of the 1/4-inch pressure and 5/16-inch scavenge lines, the main difference is that there are P-clips employed on each bracket and C-clamp to secure the 1/4-inch and 5/16-inch lines. No special bending of the steel portion of the lines is necessary for this particular installation and the lines run parallel down the length of the tank with the 1/4-inch line in the P-clips attached to each mounting bracket, (upper) and the 5/16-inch line in the P-clips attached to each C-clamp,(lower) (Figure ?).

Page 20

DOCUMENT #1930024

Part 4 Installing the Compressor

and Oil Cooler

System #V900073



Page 21

Page 22

4.1 Cooler Installation

Figure ? – Cooler mounted in position

Holes for cooler mounting bolts

Figure ? – Cooler mounting location

1. Position the VR oil cooler on the front main cross member just below the front engine mount. Place a supplied 7/16-inch x 2-inch bolt through a 7/16-inch flat washer and install through the cooler and the corresponding hole in the front engine cross member. Secure with a 7/16-inch split washer and 7/16-inch plain nut. Repeat for the remaining three bolts. Ensure the cooler is correctly positioned and fully tighten to specification all four bolts (Figure ?).

2. Install the 90-degree fitting of the longest 1/2-inch hose to the driver side fitting on the oil

cooler. Route the hose towards the passenger side and go between the engine wishbone bracket and the frame cross member. Pass the hose over the top of the lower cross members and back towards the VR tank. Fully tighten to specification the hose fitting at the cooler (Figure ?).

l

1/2” fitting

3/4” fitting

Figure ? – Front tan hose detai

Page 23

3. Loosely install the supplied 90-degree elbow onto the passenger side oil fitting of the cooler.

Install the straight female end of the shorter 1/2-inch oil hose onto the 90-degree elbow. Route the hose along the side of the other 1/2-inch oil line from the cooler. Rotate the fittings on the cooler for best position. Do not tighten.

4. Connect the 45-degree fitting on the end of the 3/4-inch hose to the tank. Rotate the fitting

for maximum clearance from the leaf spring. (Temporary removal of the oil filter may give increased access) fully tighten to specification (Figure ?).

5. Connect the straight female connector of the 1/2-inch oil line from the cooler to the lower

fitting on the tank (Figure ?).

6. Gather the 5/16-inch, 1/4-inch, 1/2-inch and 3/4-inch lines from the tank and route them forward and under the transmission. Secure them in place to the OEM battery cable support brackets with the supplied nylon tie wraps. Ensure that all the lines are secured and routed to bring the lines up to the passenger side of the engine near to the alternator.

Later model year trucks Cut

Figure ? – Cutting the expansio

7. Cut eleven inches off of th

the 11-inch straight sectionclamps. Install the other enOEM clamp (Figure ?).

8. Measure 10 inches on the

radiator hose and cut it offsecure with the supplied H

9. Measure 9 1/2 inches back

radiator hose and cut it offusing the supplied HS32 h

Page 24

11”

11” hose section attached

n tank hose Figure ? – Cooler radiator and engine connections

e straight section of the OEM rubber expansion tank hose. Install to the passenger side spigot on the cooler using the OEM hose d of the 11-inch section to the steel expansion tank line using the

outside of the bend from the 2-inch diameter end of the lower . Attach this cut hose to the driver side cooler radiator spigot and S32 hose clamp (Figure ?).

on the outside of the bend from the 2 1/4 inch end of the lower . Attach this end to the passenger side radiator spigot on the cooler ose clamps.

7 3/4”10”

9 1/2”

2” end

Cut 2 1/4” end Driver side radiator hose connection Figure ? – Lower radiator hose cutting detail Figure ? – Lower radiator hose connection detail

10. Attach the radiator hose on the driver side of the cooler to the steel pipe that goes to the

engine using the OEM hose clamp.

Cooler

Supplied cooler to radiator hose

Coolant expansion tank hose

Supplied engine to cooler hose

Supplied steel pipe

Heater return hose

Figure ? – Cooler hose connection detail (2000 model year).

Page 25

4.2 Installing the main bracket (Main bracket fastener pack) A

G L B

H

K J

J F I

C

E

D Figure ? – Main bracket assembly detail

Detail Letter Description Part Number A Bracket, Freightliner MBE 900 1100149 B Bracket, idler assembly 1100150 C Clip 1200359 D Tensioner, modified 2600112 E Bolt, HHCS, G10.9, M10 x 1.5 x 40 1520201 F 4 x Bolt, SHCS, M16 X 1.5 X 60 1540527 G Bolt, SHCS, M10 x 1.5 x 40 1540132 H Idler, Serpentine, 7 rib back 1300009 I 3 x Bolt, HHCS FL G8, 1/2 x 1 1/2 1510153 J Spacer, idler bolt 1400051 K 3 x Bolt, SHCS, M12 x 1.75 x 35 1540088 L Washer, modified 3200249

Table 1 – Main bracket assembly part descriptions

Page 26

1. Remove any adhesive tape covering the four M16 threaded holes in the passenger side of the

engine below and behind the alternator mounting position. Thoroughly clean and check for burrs on the machined faces around the bolt holes.

2. Install the main VR mounting bracket in position on the passenger side of the engine block.

Apply Loctite to the four supplied M16 x 1.5mm x 60mm bolts with flat washers. Ensure that the modified flat washer is applied to the top front hole of the bracket. The washer should be positioned so that the flat edge of the washer is against the main reinforcement rib that runs vertically down the underside of the bracket. Sequentially tighten the bolts ensuring the bracket seats on the machined faces of the engine block.

3. Reinstall the alternator and OEM bracket.

In order for the alternator to fit properly in conjunction with the main bracket, it is important that any spacers or washers on the alternator bracket that were removed during the preparation for installation be re-installed in their original position.

4. Fully tighten all fasteners to specification. Reconnect the electrical connections to the

alternator.

On large amperage alternators, it may be easier to lift the alternator in close to its mounting position then connect the electrical connections before mounting it in place.

5. Reinstall the OEM drive belt (Figure ?).

Figure ? – Main VR mounting bracket holes

Figure ? – Modified washer mounting position

Page 27

W/P

FAN

ALT

OEM TENSIONER

CRANKPULLEY

A/C

Figure ? – OEM belt routing 4.3 Installing the compressor

6. Remove the VR compressor from it’s wooden packing base.

7. Using Loctite, install the supplied M8 studs into the base of the compressor.

8. Take the VR compressor and feed the temperature sensor probe through the hole to the rear of the bracket. Carefully lower the compressor onto the mounting face taking care not to damage the threads on the 1/2-inch JIC brass fitting at the bottom of the compressor and that the temperature probe wire does not get trapped between the compressor and the mounting bracket.

9. Secure the VR compressor in place by threading the double serrated lock nuts onto the studs

at the bottom of the compressor. Tighten to specification. Compressor studs View from underneath Figure ? – Compressor mounting position Figure ? – View of the compressor studs

Page 28

4.4 Installing the VR idler/tensioner bracket

Figure ? – Tensioner bracket installedFigure ? – Fan clutch support bracket bolt

1. Remove the M10x20mm bolt from the fan clutch support strap bracket.

The VR tensioner is supplied with a pre-tensioner transit clip in place, DO NOT REMOVE THIS AS THE UNIT WILL TURN AND MAY CAUSE PERSONAL INJURY.

2. Remove the tensioner and idlers from the supplied VR idler bracket (Figure ?).

3. Take the VR idler/tensioner bracket and loosely install to the front of the main VR cast

bracket using the supplied M8 x 18 and the three M12 x 35 low profile bolts and Loctite ( Figure?).

4. Replace the OEM bolt securing the fan clutch support strap bracket with the supplied M10 x

40 Socket head cap screw. Fully tighten all fasteners to specification.

5. Install the three supplied back idlers to the VR bracket using the spacers and 1/2-inch NC x 1 1/4-inch and Loctite. Fully tighten to specification.

6. Install the VR tensioner to the bracket using the supplied M10 x 80 hex head cap screw, and

3/8-inch flat washer and Loctite (Figure ?). Fully tighten to specification.

Page 29

4.5 Installing the crank pulley and VR belt

Figure ? – VR crank pulley installedFigure ? – OEM crank Pulley

1. Thoroughly clean and check for burrs, the machined face of the OEM crank pulley.

2. Install the VR crank pulley to the OEM crank pulley using the six supplied M10 x 40mm

bolts and 3/8-inch flat washers and Loctite. Ensure correct seating of the VR crank pulley on the OEM crank pulley and fully tighten to specification.

Figure ? - Cutting detail - air inta

VR tensioner Figure ? - Belt routing and idler detail

3. Route the VR drive belt around the VR system pulleys, idlers and tensioner. Tenstensioner and carefully remove the pretension transit clip. Let the tensioner go baccorrect seating of the VR ribbed drive belt on all ribbed pulleys (Figure ?).

Page 30

Cut off 1/2”

ke boot

ion the VR k ensuring

IDLER

CLUTCH

IDLER

IDLER

VR TENSIONER CRANKPULLEY

Figure ? - VR70 belt routing detail

4. Take the OEM 90 degree air intake rubber boot that installs onto the fan end of the assembly. Cut 1/2 inch from the side that fits onto the fan (Figure ?).

5. Reinstall the rubber boot onto the fan housing. It may be necessary to install the clamp after

the boot has been correctly seated on the housing. Also the use of appropriate lubricant may help the rubber connector to slide onto the cast housing. Install but do not tighten the clamp at this point.

4.6 Attaching the lines to the compressor

Figure ? – 1/2” oil line connectionFigure ? – 3/4” discharge line connection

6. Route the 3/4-inch VR hose up through the space between the frame rail and the engine on

the passenger side. Install the fitting to the rear of the VR compressor. Ensure correct routing and fully tighten the fitting.

Page 31

7. Route the 1/2-inch VR hose from the oil cooler up through the space between the frame rail

and the engine on the passenger side. Install the 90-degree fitting to the underside of the VR compressor. The mating fitting can be located on the inside of the VR mounting bracket. Rotate the hose for best routing. Fully tighten the oil cooler end.

Figure ? – 1/4” pressure line connection Figure ? – 5/16” scavenge line connection

8. Route the 5/16-inch VR hose up through the space between the frame rail and the engine on the passenger side. The hose goes over the top on the intercooler intake tube. Install the hose fitting to the side of the inlet control valve. Check routing of the hose and fully tighten (Figure ?).

9. Route the 1/4-inch VR hose up through the space between the frame rail and the engine on

the passenger side. Route the hose over the back of the compressor. Install the fitting to the side of the inlet control valve. Check routing of the hose and fully tighten (Figure ?).

Figure ? – Road draft tube attached

Figure ? – Securing the lines to the VR bracket

Supplied clamp

Page 32

10. Take the OEM 90-degree rubber connector, which was removed from the road draft outlet on

the top of the engine. Reinstall the connector to the engine and rotate the end so that it is pointing up. Lightly clamp the connector so that it allows some slight movement.

11. Insert the opposite end of the steel road draft tube into the rubber connector and lightly

tighten the clamp. Rotate the steel tube assembly until the bracket on the tube is as close as possible to the M8 bolt in the top of the inlet control valve.

12. Remove the M8 x 90 bolt from the top of the inlet control valve. Install a supplied 5/16-inch

washer onto the bolt, then pass the bolt through the holes in the supplied 1 inch clamp and steel road draft tube bracket (Figure ?).

13. Reinstall the bolt to the inlet control valve. Bend the bracket and any lugs to ensure best

routing of the tube and rubber boot. Fully tighten the M8 bolt and all of the hose clamps.

It will be necessary on older model trucks to use a zip wheel or similar tool to cut the bracket off of the metal portion of the road draft tube. A rubber coated metal clamp will be provided to allow the securing of the road draft tube to the socket head cap screw on the top of the inlet control valve.

14. Install the supplied 56-inch long 3/4-inch road draft hose to the end of the steel line and

clamp with the supplied HS 12 clamp. Route the hose down between the engine and frame rail. Reinstall the OEM road draft hose clamp located on the side of the engine (Figure ?).

15. Gather all of the lines running up to the compressor and arrange them to ensure best routing.

Secure the hoses using the supplied 1 1/4” clamp and 1/4-inch x 3/4-inch bolt with flat washer and split lock washer to the hole in the side of the main VR mounting bracket (Figure ?).

4.7 Installing the fan spacer

New model trucks New model trucks

Figure ? – OEM fan re-installedFigure ? – VR fan spacer mounted

Page 33

Older model trucks Older model trucks Figure ? – OEM fan re-installedFigure ? – VR fan spacer mounted

1. Install the supplied fan spacer onto the fan clutch so that the studs in the fan clutch go through the counter bored holes. Reinstall the six OEM 5/16-inch Nylock nuts. Ensure the fan spacer is correctly seated. Fully tighten the Nylock nuts (Figure ?).

2. Reinstall the fan using the supplied 5/16-inch NC x 3/4-inch button head bolts with the 5/16-

inch lock washers. Tighten the bolts to specification (Figure ?). 4.8 Completing the installation

1. Loosely place the fan shroud over the fan.

2. Re-install the radiator assembly using the OEM fasteners.

3. Reinstall the intercooler tubing using the OEM clamps. Make sure the clamps are tight to provide a proper seal.

4. Reinstall the fan shroud using the OEM fasteners.

5. Connect the lower radiator hose from the cooler to the radiator. Secure it in place with the

OEM hose clamp.

6. Re-install the air filter unit.

7. Re-install the air filter intake tubes and rubber connectors – align for best fit and then tighten the clamps

8. Tighten up the air intake boot assembly.

9. Tighten up all clamps for the air intake.

10. Reconnect the two small lines coming from the coolant expansion tank. Use the OEM clamps

to secure them in place and snug the clamps up to prevent leakage.

Page 34

11. Reinstall the oil cooler on the front of the radiator assembly. Use the OEM clamps to secure

the lines to the oil cooler in place. Re-install the hose clamp restraints. 12. Do a final check to ensure that all clamps and securing devices in the air and coolant system

have been tightened to prevent leakage and top up system coolant fluids. 13. Re-install the hood. 14. Reconnect any electrical connections disconnected during the installation. 15. Re-connect the negative terminals on the batteries. 4.9 Adding oil to the system

Oil fill plug

Figure 51 – Oil fill plug location

Conduct a final check of all oil hoses at the cooler and the compressor to ensure that they have been tightened securely before adding oil to the system.

1. Remove the fill plug from the air inlet control valve (Figure 51).

2. Pour some of the VMAC certified and approved oil into the oil fill hole on the inlet control valve using a funnel.

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.

3. Turn the compressor clutch clockwise with a ratchet and a 1/2-inch socket using the hex head

cap screw at the center of the compressor clutch during the fill process.

4. 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. Do not overfill the system.

Page 35

Overfilling the system with oil can flood the sight glass window and make the system appear empty.

5. Install the fill plug in the inlet control valve and tighten it securely.

Page 36

DOCUMENT #1930024

Part 5 Installing the Control

Components

System #V900073

2003 FREIGHTLINER FL60-FL70 MERCEDES MBE 900


Page 37

Page 36

Part 5: Installing the control components 5.1 Installing the control panel

1.

2.

3.

4.

1.

2.

Locate a suitable location for the control unit on or under the dash (Figure ?).

Tighten the two side brackets on the control unit and position it in the selected mounting location.

Mark the position of the mounting holes and drill two 9/64-inch holes for the brackets.

Mount the control unit with the wire harness coming out from the bottom or the back of the unit.

Figure ? – Control panel mounting location

5.2 Installing the switching box

Mount the switching box under the dash using the supplied plastic ties.

Make sure that the switching box does not interfere with other parts.

Connect the grey cable from the control unit to the shorter of the two grey cables on the switching box and plug them together.

Page 39

FIREWALL BULKHEAD

TEMPERATUREPROBE

COMPRESSOR

CLUTCH

INLET VALVE

16GA WHT

CLUTCH

PA

RK

BR

AKE

XXXXXXXXXXXX

LEGEND

WIRELABEL

OEM FUSEPANEL

IGNITION OFF: NO VOLTAGE

IGNITION ON: BATTERY VOLTAGE

BOTTOM HALF OFA-5 IS ONEPOSSIBILITY

THROTTLECONTROL

GR

OU

ND

IGN

ITION

SW

ITCH

ED

12V

OLTS

RED

BLK

GRN

WHT

RED

16GA WHT

CHASSISGROUND

SEE APPROPRIATE INSTRUCTIONS

FORBRAKETYPE R

ED

THROTTLEGRY

ACCELERATORPEDAL

OEM HARNESS(UNPLUGGED FROM

ACCELERATOR PEDAL)

INTE

RFA

CE

CA

BLE

BLU

BL U

CRIMP ONOEM WIRE

T-TAP CONNECTION

22-18

CRIMP ONBLUE DDC WIRE

SOLDER CONNECTIONPREFERED OR

T-TAP CONNECTION

TRA

NSM

ISS

ION

NEU

TRA

LSI

GN

AL

BLU

STANDARDTRANSMISSIONONLY

CONNECT THESE TWOONLY ON STANDARD

TRANSMISSIONS

SEE APPROPRIATE INSTRUCTIONS

FORTRANSMISSION

TYPE

GREY

3 PINCONNECTOR

(BLACK)

PR

E SSU

RE

SEN

SO

R

4 PINCONNECTOR

(GREEN)

7 PINCONNECTOR

(GREEN)SWITCHINGBOX

CURTIS 1/10

HOURS

CONTROL PANEL

GR

OU

ND

GR

N

Figure ? – Main circuit diagram Page 38

5.3 Connecting the wiring

1.

2.

3.

Connect the two interface cable connectors. A wiring diagram is shown in Figure ?.

Route the green interface cable wire to the passenger side fuse panel and connect it to the ground stud on the side of the fuse panel (Figure ?). Hand tighten only until the ground is connected.

t

Locate a gcable and t

Ground Pos

Figure ?

Passenger side fuse panel

rommet or other opening in the firewall and feed the white wire from the interface he grey cable from the switching box, through to the engine compartment.

Steering Column

Firewall Grommet

Figure ?

Page 41

4.

5.

6.

7.

1.

Connect the white wire to the matching connector at the compressor clutch, and the grey cable to the temperature probe cable.

Leave the red wire under the dash near the accelerator pedal for connection to the throttle control.

Figure ?

Bottom half of A-5

Route the red wire with the fuse holder under the dash to the fuse panel.

Locate a fuse in the fuse panel that will provide power only when the ignition switch is in the “ON” position, fuse A-5 is one possibility. Use the bottom half as this is the “Hot” side (Figure ?).

On some older models the fuse may look different from the one shown. 5.4 Brake systems 5.3.1 Air Brakes For trucks equipped with air brakes, accessory pack A700099 is required. Hydraulic brakes

Remove the cover on the park brake. Route the black wire under the floor mat to the park brake (Figure ?).

Page 40

Figure - ?

Park brake

HYDRAULIC BRAK

INTERFACECABLE

BLK PAR

KB

RA K

E

OEMPARK BRAKE

WIRE

SOLDER ANDSEAL THIS

CONNECTION

Figure ?

2. Pull back the loom from the Park Brake wire. Splice the bOEM wire. Seal this connection. Refer to Appendix A for

OEM “Park”Brake wire

VR black “Park”Brake wire
Solder and seal
this connection

ES

PARK BRAKE

lack “Park Brake” wire onto the generic soldering instructions.

Page 43

5.5 Installing the throttle

1. Using the supplied nylon ties, mount the throttle up under the dash near the accelerator pedal. Keep the adjustment screws accessible and avoid all heating ducts.

2. Disconnect the OEM connector at the accelerator pedal position sensor, and connect it to the

connector on the throttle.

3. Connect the black throttle connector to the accelerator pedal position sensor.

4. Connect the green “Ground” wire from the throttle to the same post as the ground wire in Section 5.3 – step 2. Tighten the nut.

5. Route the red throttle wire to the red wire from the interface cable that was set aside in

section 5.3, step 4. Connect these wires.

6. Route the grey “Pressure sensor” cable from the throttle through the firewall to the compressor, alongside the white “Clutch” wire and connect it to the pressure sensor on the inlet control valve.

7a. For automatic transmissions:

Route the blue “TRANSMISSION NEUTRAL SIGNAL” wire through the firewall and down to the driver’s side of the transmission. For Allison 1000/2000/2400 series transmissions:

Locate the connector shown in figure ?

Figure ?

Locate the pink wire labeled “L17E” at pin “G” of the connectRefer to figure 50.

Solder the blue DDC wire to the pink wire labeled “L17E” on

Page 42

Pin “G”

Pink wirePin “G”

or shown at the transmission.

pin “G” as shown in Appendix A.

VMAC recommends that all wire connections be soldered for reliability. A T-Tap connector has been supplied if this is not practical.

For Allison 3000/3500 Series Transmissions

Locate the Transmission Control Module (TCM). It is above the drive shaft right behind the transmission (Figure ?).

Transmission

TCM

Figure ?

Remove the cover. Locate the connector labeled “Grey” (Figure ?).

Remove the black wrap from this wire bundle.

Find the tan wire labeled “L92#123”. It is in pin 6 of the connector.

Solder the blue “DDC” wire from the throttle to this wire (See Appendix A for generic soldering instructions).

Page 45

WARNINGFAILURE TO PROPERLY INSTAVERIFY FUNCTION OF THE S

INTERCONNECT FEATURE CAN SERIOUS PERSONAL INJURY O

If the vehicle has an automatic transThrottle Control must be connectedinoperable unless the transmission

neutral.

!

“

Figure ?

VMAC recommends that all wire connectionconnector has been supplied if this is not prac

7b. For standard transmissions:

Leaving 3 – 6 inches of wire, cut the blue “TRANSMISStrip 3/8 inches from the end and connect to the blue “SONLY” wire using the supplied butt connector (Figure

Page 44 1900XXX

Tan wireL92#123”

LL AND AFETY RESULT IN R DEATH

mission, the so as to be is in park or

s be soldered for reliability. A T-tap tical.

SION NEUTRAL SIGNAL” wire. TANDARD TRANSMISSION ?).


BLU

BL U

THROTTLE

TRA

NS

MIS

SIO

NN

EUT R

A LS

IGN

AL

BLU

STANDARD TRANSMISSION CONNECTION

CUT TO 3-6" LONG


CRIMP THE TWO BLUE WIRESUSING THE BUTT CONNECTOR

THROTTLE

BLU

BL U

STEP 1 STEP 2

BUTT CONNECTOR

Figure ? 5.6 Final testing and assembly

These tests must be done to ensure the safe operation of the VR system. 5.6.1 Park brake test

1.

2.

Move the vehicle away from people and objects. Block the wheels of the vehicle. Apply the park brake, and if it is an automatic, put the transmission in neutral.

With the battery reconnected, turn the ignition to the “Run” position. Do not start the engine.

3.

4.

5.

6.

Turn on the control panel. The green light should come on and the clutch should “click” and engage.

Release the park brake. The green light should go off and the clutch should disengage.

Reapply the park brake. The green light and the clutch should come back on.

Turn off the control panel and ignition.

5.6.2 Automatic transmission test (for vehicles with automatic transmission only)

1. Make sure no one is near the truck and the wheels are blocked. Apply the park brake and put the transmission in neutral. Start the engine.

Page 47

2. Momentarily turn on the control panel by turning the switch on and then off again quickly.

The green light should come on and the engine should start to idle up.

3. Firmly apply the vehicle’s foot brake. Shift into gear.

4. Again, momentarily turn on the control panel as before. The green light should come on but the engine should not idle up.

5. Turn off the control panel and the engine.

If the vehicle fails either the park brake test or the automatic transmission test, check your wiring to make sure that all the connections are correct and secure. If you require additional assistance, please contact your nearest VMAC dealer.

5.6.3 Final assembly

1. Secure the wires in place under the dash and make sure that none of the wires interfere with any moving parts.

5.7 Adjusting the throttle

1. Due to foot pedal variations and end user operational requirements, some adjustment may be required. All adjustments should be done with a typical load (tool – etc.) or the VMAC setup tool connected to the system.

2. This throttle has three (3) adjustment screws. “MAXIMUM RPM” – for adjusting the

maximum engine speed at low system pressure (high air use). A typical value should be 1800 RPM.

3. “IDLE-DOWN-PRESSURE” – for adjusting the point at which a drop in pressure will cause

the throttle to elevate the engine speed to compensate. This is usually set to approximately 10 PSI less than full system pressure.

4. “VR IDLE” – for adjusting the engine speed that the system will idle at with full system

pressure. A typical value for this should be 950 – 1000 RPM.

Do not adjust “VR IDLE” below 900 RPM. A “CHECK ENGINE” light may come on. If it does during adjustment, turn off the VR system and the engine. Turn the “VR IDLE” screw clockwise (CW) 1 – 2 turns. Wait 1- 2 minutes for the vehicle’s computer to reset then restart the engine and turn on the compressor. Re-adjust the throttle as necessary. Make these adjustments ONLY when the engine has reached normal operating temperature. The system should only be operated once the engine has reached normal operating temperature.

Page 46

Appendix A – Generic soldering instructions

1. Cut the OEM wire, and strip approx. 1/2” from each end and from the VR wire (Figure A1).

Figure A1

2. Slide the heat shrink provided onto one OEM wire and the VR wire. Twist the 3 wires together (Figure A2).

Figure A2

3. Heat all 3 wires at the joint with a soldering gun/pen, then apply the provided solder. Ensure the solder “flows” into the joint to bond the wires together (Figure A3).

Page 49

Figure A3

4. Slide the heat shrink over the joint, and shrink onto the joint using a heat gun. Make sure the shrink is heated until the liner melts and makes a good seal (Figure A4).

Figure A4

Page 48

DOCUMENT #1930024

Part 6 Illustrated Parts List

System #V900073



Page 51

Page 52

ILLUSTRATE PARTS LIST FOR SYSTEM V900073 - 2003 FREIGHTLINER FL60-FL70

MERCEDES MBE 900 W/WOAB

ASSY. ITEM UNIT QTY PART# DESCRIPTION 1.0 4800344 Main Bracket Assembly

1.1 ea 1 1100149 Bracket, Freightliner MBE 900 1.2 ea 1 1100150 Bracket, Freightliner MBE 900 1.3 ea 1 1540389 1.4 ea 1 1200359 Clip 1.5 ea 1 2600112 Tensioner, modified 1.6 ea 1 1570044 Washer alloy PL SAE, 3/8” 1.7 ea 1 1520210 Bolt, HHCS G10.9, M10 x 1.5 x 80 1.8 ea 3 1510153 Bolt, HHCS FL G8, 1/2” x 1 1/2” 1.9 ea 3 1400051 Spacer, idler - bolt 1.10 ea 3 1300009 Idler, serpentine 7 rib back 1.11 ea 1 1540132 Bolt, SHCS, M10 X 1.5 X 40 1.12 ea 1 4300079 Bushing, split flared 1.13 ea 3 1540088 Bolt, SHCS, M12 X 1.75 X 35 1.14 ea 6 1540132 Bolt, SHCS, M10 X 1.5 X 40 1.15 ea 1 3400050 Spacer, fan 1.16 ea 1 1800171 Crank pulley, MBE 900 1.17 ea 6 1570044 Washer, alloy PL SAE, 3/8” 1.18 ea 1 1650353 VR belt

2.0 P120073 Compressor Assembly 2.1 ea 1 P120002 Compressor, VR70 2.2 ea 1 9200213 Modified fitting, 4900032 2.3 ea 1 5830045 O-ring, Viton, 3/4” ID X 3/32” 2.4 ea 1 4900070 Elbow, JIC, 7/8” - 14 X 1 1/16” - 12 2.5 ea 1 3530682 Temperature probe 2.6 ea 3 5830004 O-ring, Viton, 3 1/8” ID X 1/8” 2.7 ea 1 9200036 Adaptor, angle mount 2.8 ea 4 1540389 Bolt, SHCS, low profile, M8 X 1.25 X 18 2.9 ea 1 9200202 Inlet valve extension 2.10 ea 1 5000121 Tee, street, 1/8” - 1/8” 2.11 ea 1 5000085 Elbow, brass NPT-SAE 45 deg,1/8”-1/4” 2.12 ea 1 3500288 Sensor, pressure 2.13 ea 1 5000112 Elbow, brass street 45 DEG, 1/8 2.14 ea 2 1540494 Bolt, SHCS, M8 X 1.25 X 90 G12.9 2.15 ea 2 1540495 Bolt, SHCS, M8 X 1.25 X 100 G12.9 2.16 ea 1 9200212 Valve, inlet control 2.17 ea 1 3600037 Filter, paper element 2.18 ea 1 1550221 Nut, hex NC PL, GR 8, 1/4“

Bolt, SHCS, low profile, M8 x 1.25 x 18

Page 53



ASSY ITEM UNIT QTY PART# DESCRIPTION

2.0 Compressor Assembly (Continued)

2.19 ea 1 1500519 Rod, threaded, 1/4” X 2.62”

2.20 ea 1 3600066 Filter cap, plastic

2.21 ea 1 1570038 Washer, flat SAE, 1/4”

2.22 ea 1 1550029 Nut, Nylock NC, 1/4”

2.23 ea 1 5000081 Elbow, brass NPT-TUBE, 1/8”-5/16”

2.24 ea 1 5830002 O-ring, Viton, 2 3/8” ID X 3/32” 2.25 ea 1 9200104 Plate, blanking 2.26 ea 1 5830045 O-ring, Viton, 3/4” ID X 3/32” 2.27 ea 1 9200103 Filter, blank plate, fitting 2.28 ea 1 P200035 Clutch, complete 6 groove 2.29 ea 1 5000060 Connector, brass NPT-SAE, ½*”-1/2”

3.0 9200380 Tank Assembly 3.1 ea 1 9200378 Oil separator tank weldment

3.2 ea 1 5830066 O-ring, Viton, 4 3/4” ID X 1/8”

3.3 ea 1 5840068 Spring, compression

3.4 ea 1 3600036 Coalescing filter element

3.5 ea 1 3600064 Seal, tank rear cap

3.6 ea 1 5840069 Spring, compression FL1.5 OD 0.54

3.7 ea 1 3600090 Thimble screen

3.8 ea 1 9200217 Blow down cap

3.9 ea 1 3600054 Valve, safety 200 PSI

3.10 ea 1 5000089 Connector, brass NPT-SAE, 3/8” – 1/2”

3.11 ea 1 4900035 Nipple, steel straight thread, 3/4” - 16

3.12 ea 1 9200039 Oil filter, VR70

3.13 ea 1 4900033 Connector, steel NPT-JIC 3/4”-3/4”

3.14 ea 1 5830043 O-ring, Viton 1 7/8” ID x 1/8”

3.15 ea 1 3600096 Window,Pyrex

3.16 ea 1 1400235 Ring, 2.12 OD x 1.72 ID x 0.15

3.17 ea 1 1500385 Retaining ring

3.18 ea 1 3200231 Cover, sight glass

Page 52



ASSY. ITEM UNIT QTY PART# DESCRIPTION 4.0 Hose Kit

4.1 ea 1 1771090 Hose, crimped, 3/4” x 90” 4.2 ea 1 1752049 Hose, crimped, 1/2” x 49” 4.3 ea 1 1752103 Hose, crimped, 1/2” x 103” 4.4 ea 1 1730126 Hose, crimped, 1/4” x 126” 4.5 ea 1 1740133 Hose, crimped, 5/16” x 133”

4.6 ea 1 1710607 Hose, fuel/oil, 3/4 X 56" (1700421) 4.7 ea 1 2200048 Clamp, HS12

5.0 3560091 Throttle Control 5.1 ea 1 3560091 Throttle control

6.0 Tank Bracket Assembly 6.1 ea 2 1200358 Bracket, tank

6.2 ea 2 2200115 Strap, tank cable, 20.2”

6.3 ea 8 1550067 Washer, 5/16”

6.4 ea 4 1550066 Nut, hex NC, 6/16”

6.5 ea 2 2200133 Clamp, insulated double tube

6.6 ea 2 2200105 Clamp, mounting bracket C6

7.0 4800337 Cooler Assembly 7.1 ea 9200231 Cooler

7.2 ea 4900047 Elbow, steel JIC 1/2” – v1/2”

8.0 Electrical 8.1 ea 1 3550404 Low profile control panel

8.2 ea 1 3550681 Interface cable

8.3 ea 1 3550412 Switching box

9.0 Miscellaneous 9.1 ea 1 1200360 Bracket

9.2 ea 1 4300006 Pipe fitting, socket head plug, 3/4”

Page 55

Page 52

Documents

Installation Manual - VMAC · PDF fileInstallation Manual For The 2003 FREIGHTLINER FL60-FL70 MERCEDES MBE 900, W/WOAB System # V900073. Installation Manual Document Number: ... 1.4