vr70 underhood air compressor installation manual

Installation Manual for VMAC System V900127

2012+ GM 2500 – 3500 Pickup, Crew Cab

6.0 L Vortec Gas

VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201 1

Installation Manual for VMAC System V900127

GM 2500 – 3500 Pickup, Crew Cab 6.0 L Vortec Gas

Safety ................................................................................................. 3

Warranty ............................................................................................. 4

General Information .......................................................................... 5

System Identification, Warranty and Warnings .............................. 7

Preparing for Installation .................................................................. 9

Installing the Control Components ................................................. 12

Installing the Air Oil Separator Tank and Hoses ............................ 18

Installing the Cooler, Bracket and Compressor ............................. 22

Adding Oil to the System ................................................................. 31

Completing and testing the Installation .......................................... 32

Setup, Performance Testing and Adjustments .............................. 35

Air Receiver Tank .............................................................................. 37

Accessory Products ......................................................................... 38

Warranty Registration ....................................................................... 39

VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289

Fax: 1-250-740-3201 2

Document: 1930191 Changes and Revisions

Additional Application Information • VR 70 V900127: 2012+ GM 2500 – 3500 Pickup, Crew Cab 6.0 L Vortec

Gas.

• If vehicle equipped with Active Hydraulic Assist power steering(RPO code: NV8), VMAC P/N: A900017 must be used.

Registered Trademarks All trademarks mentioned in this manual are the property of their respective owners. Their use by VMAC is for identification of the manufacturers’ products only and does not imply any affiliation to, or endorsement of said companies.

Loctite®, Loctite® 242 and Loctite® 567 PST are registered trademarks of Henkel AG & Company KGaA.

GM® is a registered trademark of General Motors Company LLC.

Vortec™ is a trademark owned by General Motors Company LLC.

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 mechanical work. Any grinding, bending or restructuring operations for correct fit in modified vehicles must follow standard shop practices.

Notice Copyright © 2017 VMAC Global Technology Inc. All Rights Reserved. These materials are provided by VMAC for informational purposes only, without representation or warranty of any kind, and VMAC shall not be liable for errors or omissions with respect to the materials. The only warranties for VMAC products and services are those set forth in the express warranty statements accompanying such products and services, if any, and nothing herein shall be construed as constituting an additional warranty. You may print or copy for your personal use any whole page or pages in this document. All other use, copying or reproduction in both print and electronic form of any part of this document without the written consent of VMAC is prohibited. The information contained herein may be changed without prior notice.

Printed in Canada

Revision Revision Details Revised

by

Checked by

Implemented Eng. Tech. Qual.

Mech. Elec.

H ECN 15-063 RF SC N/A RD N/A 18 Jun 2015

J ECN 15-090 (F2.2 30/06/16) RF CH N/A JC N/A 30 Jul 2015

K ECN 17-012 Include AHA / other improve. MSP CH AJH DSB AMG 7 Feb 2017

VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201

3

Safety Important Safety Notice The information contained in this manual is based on sound engineering principles, research, extensive field experience and technical information. Information is constantly changing with the addition of new models, assemblies and service techniques. If a discrepancy is noted in this manual, contact VMAC prior to initiating or proceeding with installation, service or repair. Current information may clarify the issue. Any person with knowledge of such discrepancies who performs service and repair assumes all risks.

Only proven service procedures are recommended. Anyone who departs from the specific instructions provided in this manual must first assure that their safety and that of others is not being compromised and that there will be no adverse effects on performance or the operational safety of the equipment.

VMAC will not be held responsible for any liability, consequential damages, injuries, loss or damage to individuals or to equipment as a result of the failure of any person to properly adhere to the procedures set out in this manual or standard safety practices. Safety should be your first consideration in performing service operations. If you have any questions concerning the procedures in this manual or require any more information on details that are not included in this manual, please contact VMAC before beginning repairs.

Safety Messages This manual contains various warnings, cautions and notices that must be observed to reduce the risk of personal injury during installation, service or repair and the possibility that improper installation, service or repair may damage the equipment or render it unsafe.

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. As 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 instructions on a specific procedure that if not followed may damage or reduce the useful life of the compressor or other equipment.

This symbol is used to call your attention to additional instructions or special emphasis on a specific procedure.


Fax: 1-250-740-3201 4

Warranty Standard Product Warranty For complete warranty information, including both our standard Product Warranty and Limited Lifetime Warranty requirements, please refer to our current published warranty located at:

www.vmacair.com/warranty

If you do not have access to a computer, please contact us and we will be happy to send you our warranty.

VMAC’s warranty is subject to change without notice.

Limited Lifetime Warranty Effective 1 October 2015 - The Compressor Assembly (excluding Inlet and Clutch, where applicable) is warranted against manufacturer defects in materials and workmanship for the lifetime of the Compressor Assembly. Restrictions apply – refer to VMAC Warranty Policy and VMAC Limited Lifetime Warranty for full details.

Warranty Registration The VMAC warranty form is located at the back of this manual. This warranty form must be completed and sent to VMAC at the time of installation for any subsequent warranty claim to be considered valid.

There are 4 ways warranty forms can be submitted to VMAC:

Online www.vmacair.com/warranty/

Email [email protected]

Fax (250) 740-3201

Mail VMAC - Vehicle Mounted Air Compressors 1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3

http://vmacair.com/support/warranty/


5

General Information

Optional Equipment Compatibility Whilst VMAC strives to design systems compatible with optional OEM equipment (such as running boards), it is impractical to develop systems that accommodate every OEM and aftermarket option or add-on. Whenever possible, VMAC endeavors to advise of compatibility issues in the “Additional Application Information” section of the manual. Even when specific optional equipment is determined by VMAC to be incompatible, it does not preclude the vehicle upfitter or end user from modifying the optional equipment to make it compatible with the installed VMAC system. VMAC does not warranty or accept responsibility or liability for the fitment, function or safety of any products modified in any way not expressly outlined in the installation manual.

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 engine models and different situations that are listed in the manual. Open the package, unpack the components and identify them.

Special Tools Required • GM flywheel locking tool P/N: J42386.

• Pneumatic fan wrench removal set (such as Lisle® 43300) or a manual fan pulley holder (such as KD Tool® KD3900).

• Pulley removal tool kit (such as a Lilse 39000, Jet H3565 or Performance Tool 389708 or equivalent).

• Optional: GM specialty tool P/N: J45059 (Angle meter).

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 systems have a specific inner liner that is compatible with VMAC 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.

Ordering Parts 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 1-877-912-6605 or online at www.vmacair.com.

http://www.vmacair.com/


Fax: 1-250-740-3201 6

Torque Specifications All fasteners must be torqued to specifications. Use manufacturers’ torque values for OEM fasteners. Apply Loctite 242 (blue) 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 3/4

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 3/4

Foot-pounds (ft•lb) 40 60 90 180 320

Newton meter (N•m) 54 81 122 244 434

METRIC CLASS 10.9

Size M6 M8 M10 M12 M14 M16

Foot-pounds (ft•lb) 4.5 19 41 69 104 174

Newton meter (N•m) 6 25 55 93 141 236

Table 1 – Torque Table

VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201 7

System Identification, Warranty and Warnings

Preparation for installation is very important. Missing a step or an item can cause problems in the installation or damage to components.

Check off each item as it is completed so that you do not miss any steps.

Check through the illustrated parts list to ensure that all components are

present and that they are in the correct quantity. If any components are

missing, have the system ID ready and call VMAC technical support at

(888) 241-2289.

Complete the warranty form. The VMAC warranty form is located at the

back of this manual, as well as online at:

http://vmacair.com/warranty/ This warranty form must be completed and returned to VMAC at the time of installation for any subsequent warranty claim to be considered valid.

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 with parts and repairs.

Mark and drill 2 x 7/64 in holes in the top of the cross member in front of

the hood support. Secure the plate with supplied self- tapping screws

(Figure 1).

Figure 1 – System Identification Plate


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As part of the installation process, ensure that the operating instruction

label 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 2).

Figure 2 – Operating Instruction Label

To alert any technicians that may service the vehicle, affix the warning

label in the engine compartment near the hood latch in a visible location.

Thoroughly clean the selected area before affixing the label (Figure 3).

Figure 3 – Warning Label


9

Preparing for Installation

Do not use a test light to probe for power on vehicle circuits, the increased current draw of the test light may damage components.

Ensure that the VMAC Warranty Registration has been filled out. Install the System Identification Number Plate and operating instruction label. (Please see page 7 for details).

Determine if the vehicle is equipped with Active Hydraulic Assist (AHA). Vehicles equipped with AHA will require VMAC P/N: A900017 to relocate the module (Figure 4).

Figure 5 – Active Hydraulic Assist module

Locate the Engine Control Module (ECM) on the inside of the driver side fender, at the front near the fuse panel (Figure 6).

Figure 6 – ECM location

Remove the electrical tape and peel back the plastic loom for the X1 (smallest connector at the top of ECM) and X2 (larger connector beside X1) connectors.

2012 - 2014 vehicles have different colour wires than 2015+ vehicles. Pay attention to model year and wire colours.

ECM

Fuse Panel

Steering column

AHA module


Fax: 1-250-740-3201 10

The ECM X1 connector has multiple wires with the same colour. Follow the tests below to determine the correct wire. 2015+: There are 2 white wires with grey stripe 2014: There are 2 orange wires with black stripe

Locate the wire going to pin 34 in the ECM X1 connector (Figure 7).

• 2012 - 2014 Orange wire with black stripe.

• 2015+ White wire with grey stripe.

Figure 7 – ECM Connector X1 Front View

Turn the ignition to “RUN” but do not start the vehicle. Use a multimeter to verify the correct wire. The correct wire will show 0 V in “PARK” or “NEUTRAL” and 12 V in all other gear selector positions.

Turn the ignition switch to “OFF”. Mark the correct wire for electrical connections later in the installation process.

Locate the 2 light green wires in the bundle of the ECM X2 connector (larger connector beside X1) (Figure 8).

Figure 8 – ECM Connector X2 Front View

Pin 56


11

There are 2 light green wires in the bundle for ECM-X2. Follow the tests below to determine the correct wire.

Start the vehicle and use a multimeter to probe each light green wire. The correct wire will show a stable voltage reading of 2.3 V - 2.8 V while the engine is idling.

Turn the ignition switch to “OFF”. Mark the correct wire for electrical connections later in the installation process.

2012 – 2013 only. Remove the fuse panel cover. Turn the ignition switch to “RUN” and using a multimeter, locate an ignition switched fuse.

2012 – 2013 only. Remove the fuse and using the multimeter, make a

note of which side is the supply/hot side and which side is the fused side.

Turn the ignition switch to “OFF”.

Disconnect the battery terminals.

Remove the air filter box, air intake tube and resonator box.

Remove the engine fan.

Drain the coolant into a clean container. Set the coolant aside for use later.

Remove lower radiator hose and set aside for later.

Remove the OEM belt.

The power steering pump bolts can be accessed through pulley. Do not remove the pulley from the pump.

Remove the power steering pump from the OEM bracket and without disconnecting the power steering lines, shift the pump out of the way.

Disconnect the alternator wiring and remove the alternator.

Remove OEM idler pulley from alternator bracket and set aside for use later.

Remove the aluminum OEM alternator and power steering pump mounting bracket.

Save the 2 alternator mount spacers and mounting bolts for use later.

Clean the inside of the OEM crank pulley.

Remove the OEM crank pulley center bolt and discard.

Remove the passenger side air intake box-mounting tray. Retain these bolts as they will be used later.

Remove the 2 OEM bolts holding the air intake tray support to the front radiator support. Retain these bolts as they will be used later.


Fax: 1-250-740-3201 12

Installing the Control Components

Figure 9 – Wiring diagram


13

Installing the control components VMAC suggests not cutting OEM wires whenever practical. The preferred method is to remove the pin from the connector using an appropriate tool and slide the shrink tube onto the wire. Strip the wire at the desired location and solder the VMAC wire into place. Slide the shrink tube up to the soldered joint and seal it. Finally, replace the pin in the connector taking special care to ensure the pin is fully inserted and the locking tabs are engaged (Figure 10).

If this is not practical, cut the OEM wire and solder and seal using shrink tube.

Figure 10 – Splice onto OEM wire

Keep wires away from the park brake mechanism. Route wires clear of the steering column and pedals so they do not contact moving parts. Before drilling holes, ensure that there are no OEM wires, hoses, or components in the way.

Ensure all wires are protected and routed so that they do not contact hot, sharp or moving components.

Install the display box in a convenient location in the cab, positioned so that the wire harness will reach the compressor. The preferred location is between the driver seat and the door.

If using the preferred display box location, route the cables from the display box along the doorsill, under the trim panel, behind the kick panel and up under the dashboard.

If routing the cables along the doorsill, a notch will need to be cut into

the sill where the cable enters from the display box.

Cable tie the throttle control under the dashboard, away from moving

parts and positioned so that the idle down pressure (IDP) and maximum

rpm adjusting screws are accessible.


Fax: 1-250-740-3201 14

Connecting the In-Cab Wiring

Unplug the OEM cable from the accelerator pedal and plug it into the

matching connector from the throttle control box. Plug the cable from the

throttle control into the matching connector on the accelerator pedal.

Connect the red wire from the throttle controller to the matching red wire

from the display box

Connect the green wires from the interface connector and the throttle control to a confirmed good quality ground location.

Connect the interface wire harness connector to the matching connector from the VMAC display box.

Route the following wires through a suitable firewall grommet under the dash: (if necessary, cut a slit in one of the rubber grommets and pull the wires through into the engine compartment)

• Cable with the black 3 pin connector.

• Cable with the green 4 pin connector.

• White wire with the bullet connector.

• White wire from the throttle control box.

• Blue wire from the throttle control box.

• Red wire from interface cable with inline fuse.

Unplug the connector from the park brake switch and connect the black wire with the piggyback connector from the interface cable to the connector on the park brake switch.

Connect the OEM park brake connector to the piggyback connector.

Connecting the Under-Hood Wiring

2012 - 2014 Solder and seal the long blue wire from the VMAC throttle control to the ECM X1 orange wire with the black stripe (marked earlier).

2015: Solder and seal the long blue wire from the VMAC throttle control

to the ECM X1 white wire with the grey stripe (marked earlier).

Cover the soldered wire with 1/4 in loom, insert the wires back into the OEM loom and secure with a cable tie (Figure 11).

Figure 11 – Protecting the wires

Solder and seal the white wire from the VMAC throttle control to the ECM X2 light green wire (marked earlier).

Cover the soldered wire with 1/4 in loom, insert the wires back into the OEM loom and secure with a cable tie (Figure 11).


15

Connecting to Switched Power 2012 - 2013 Remove the vehicle fuse located earlier.

Ensure the fuse tap is inserted with the correct tap orientation.

Install the VMAC fuse tap. Ensure the populated fuse in the fuse tap for the VMAC system is obtaining power from the supply/hot fuse connection. Plug the vehicle fuse back into the empty (lower) fuse tap socket and ensure the supplied 10 A fuse is in the upper socket. Ensure the fuse is seated properly (Figure 12).

Figure 12 – VMAC fuse tap (for 2012 – 2013 vehicles only)

Connecting Switched Power 2014+

The supplied tap fuse cannot be used on 2014+ vehicles. The VMAC system can be wired using the directions below or as per GM bulletin UI #115C (Scan or click the QR code).

Locate the ICEM (formally referred to as the MidBEC or MBEC) which is located in the driver side foot well, near or below the parking brake mechanism (Figure 13).

Figure 13 – ICEM location

10A VMAC System

Fuse

Vehicle fuse location

Connect to fused side

Connect to supply / hot side

ICEM cover

https://www.gmupfitter.com/files/media/photo/545/UI Bulletin_115c.pdf


Fax: 1-250-740-3201 16

Remove the plastic cover on the ICEM by gently prying the 3 locking tabs away from the housing to release the cover.

Remove the 3 nuts securing the module (Figure 14).

Figure 14 – Accessing the rear of the ICEM

Lift the assembly up and out of the way to give clearance to the electrical connectors on the back of the module.

There are 2 electrical connectors on the rear of the ICEM assembly. Squeeze the 2 tabs and rotate the locking lever on the passenger side connector to remove it from the ICEM module (Figure 15).

Figure 15 – ICEM connector


17

Locate the violet wire with white stripe running to pin 46 of the ICEM connector (Figure 7.9).

Figure 16 – Locating ignition switched power

Solder and seal the red wire from the VMAC interface connector to the violet wire with white stripe.

Cover the soldered wire with 1/4 in loom, insert the wires back into the OEM loom and secure with a cable tie.

Reinsert the ICEM connector into the ICEM module.

Reinstall the ICEM module.

Securing the Wiring

Cover the white and the blue wires with 1/4 in loom or equivalent protection and ensure they are secured.

Replace the fuse panel cover.

Pull all excess wires and harnesses into the cab of the truck.

Neatly bundle all the wiring in the cab and secure the bundles with cable ties to keep them away from the park brake mechanism, the steering column, and the accelerator and service brake pedals.

Replace the dashboard panel.

Pin 46


Fax: 1-250-740-3201 18

Installing the Air Oil Separator Tank and Hoses

Installing the AOST and Brackets

The AOST will mount to the passenger side frame rail between the 2 body mounts (Figure 17).

Figure 17 – Installing the AOST

Place the AOST on a work bench with the front (oil filter end) of the AOST to the left. Remove the oil filter from the front of the AOST and plug the opening.

Remove the (2x) 1/4 in pinch bolts from the C-clamps.

Expand the clamps slightly and slide them over the front of the AOST.

Position the C-clamps approximately 6 in from each end of the AOST.

Place the 2 “L” shaped tank strap mounts under the C-clamps with the right angle ends hanging over the edge of the work bench.

Apply Loctite 242 (blue) to the 5/16 in x 1/2 in bolts, align the holes and insert the bolts with the flat washers into the bottom hole on each bracket. Do not tighten.

Reinstall the (2x) 1/4 in pinch bolts in the C-clamps so that the heads of the bolts face toward the front of the bench and install the nuts loosely.

C-clamp

Tank strap mount

Tank strap cable

Backing strap

5/16 in nuts

and washers

1/4 in and 3/16 in tubes

3/4 in hose fitting

1/2 in hose fitting

Oil filter


19

Rotate the AOST so that the directional arrow on the rear of the tank is parallel to the work bench (Figure 18).

Figure 18 – Aligning the AOST

Check the distance of each C-clamp from the ends of the tank and tighten the clamp bolts so that the clamps grip the tank securely.

Apply Loctite and insert 5/16 in x 1/2 in bolts through the clips and the C-clamp and thread them into the mount brackets.

Center the bolts in the C-clamp slots and tighten them.

Thread the 1/2 in and 3/4 in swivel elbows onto the matching fittings on the front of the tank, but do not tighten them.

A 3/4 in 90° fitting (not supplied) is required to connect the discharge hose. Apply Loctite 567 PST pipe thread sealant and install the fitting.

Tighten the fitting to approximately the 4 o’clock position. Final positioning will be set once the hose is installed (Figure 19).

Figure 19 – Installing the discharge fitting


Fax: 1-250-740-3201 20

Installing the AOST Assembly

Remove the fuel line from the plastic clips (if equipped) so that the fuel line can be shifted out of the way when mounting the AOST.

Remove the OEM wire harness securing bracket on the top of the frame rail (if equipped) so that the harness can be shifted out of the way when mounting the AOST.

Insert the threaded end of the cable strap through the side of the bar strap that has the single hole.

An additional 17 1/2 in cable strap (P/N: 2200169) and bar strap (P/N: 2200111) is provided to accommodate any frame size variations.

Place the bar straps in position on the inside of the frame rail, one in front of the transmission cross-member and one behind, with the cable straps over the top of the frame (Figure 20).

Figure 20 – Mounting the AOST

Ensure the OEM wire harness is not pinched between the mounts and the frame.

Lift the AOST assembly and support it in position so the tops of the 2 strap mounts fit over the top of the frame rail.

Wrap the 2 tank cable straps around the tank strap mounts and ensure they fit in the upper and lower cut-outs of the tank strap mounts (Figure 20).


21

Ensure the fuel line and any harnesses or wires are not pinched between the cable and the mount.

Insert the threaded end of the cable through the one of the lower holes on the tank strap flat bars. Select the appropriate holes that best match the frame of the truck.

Place a thick 5/16 in flat washer and nut on each tank cable strap and tighten just enough to hold the AOST in place but loose enough to allow the tank to be positioned along the frame.

Slide the AOST toward the rear of the vehicle along the frame to provide clearance to attach the hoses.

All hoses, tubes and wires that are rerouted or shifted during installation must be secure so that they do not contact sharp edges, hot or moving parts. Use rubber coated P-clips wherever possible. Follow the routing suggestions in this manual and cover all hoses with plastic loom.

Route the 45° end of the 3/4 in hose and the straight end of the longest 1/2 in hose from the passenger side engine compartment over the body mount to the AOST.

Connect the 3/4 in hose to the matching fitting on the AOST. Angle the fitting upwards to allow the hose to easily pass around the body mount and to allow the oil level sight glass cover sufficient room to lift. and tighten the fitting.

Connect the 1/2 in hose to the matching fitting on the front of the AOST and tighten the fitting.

Slide the AOST forward, providing sufficient space for connections to the fitting on the rear of the tank.

Tighten the nuts on the cable straps until the AOST and the bar straps are tight against the frame and the AOST is secure.

Thread a second nut on each cable clamp and lock the 2 nuts together using 2 wrenches.


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Installing the Cooler, Bracket and Compressor

Installing the Crank Pulley

Remove the starter motor and install the OEM flywheel locking tool (GM P/N: J 42386-A: Flywheel Holding Tool).

Inspect the face of the OEM pulley and remove any surface burrs to ensure there is a clean mating surface for the VMAC crank pulley.

Place the VMAC crank pulley in position over the OEM pulley. Ensure that it fits flat against the OEM pulley.

Liquid Loctite 242 must be used to achieve correct torque on the crankshaft bolt as it functions as a thread lubricant, as well as a locking compound. Solid or Stick Loctite cannot be used.

Completely coat the threads with Loctite 242 (blue) and install the M16 x 120 mm VMAC crankshaft bolt (P/N: 1520631), along with the supplied washer (P/N: 1570233) finger tight (Figure 21).

Figure 21 – M16 x 120 mm Fastener with Loctite 242 (blue)

Rotate the VMAC crank pulley counter clockwise until the lugs on the back of the pulley are tight against the OEM pulley spokes (Figure 22).

Ensure the VMAC crank pulley does not move off of the OEM pulley face before tightening the pulley bolt. Ensure the pulley is rotated tight against the pulley lugs.

Figure 22 – Engage VMAC crank pulley lugs on OEM pulley


23

Tighten the crankshaft pulley bolt sufficiently to hold the pulley in position.

Do not use an impact tool to tighten the pulley bolt.

Torque the VMAC crank pulley bolt as per GM specifications. The GM specifications as of 18 June 2015: 1) Torque to 110 ft•lbs (150 N•m).

2) Loosen 360°.

3) Torque to 59 ft•lbs (80 N•m).

4) Turn an additional 125°.

*Angle can be measured with GM P/N: J 45059: Angle Meter

Remove the OEM flywheel locking tool and reinstall the starter motor.


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Modifying the Radiator Hoses

Measure and cut the lower radiator hose 12 in from the engine side of the hose (Figure 23).

12”

Radiator End

Engine End

Figure 23 – Modifying the lower radiator hose

Measure and cut the lower radiator hose 6 in from the OEM quick connect (Figure 24).

6”

OEM Quick Connect

Engine End

Radiator End

Figure 24 – Modifying the lower radiator hose

Do not use air tools or electric impact guns to tighten hose clamps, they can easily over torque the clamp causing it to deform resulting in coolant leaks. Use hand tools only.

Connect the modified 6 in lower radiator hose to the radiator.

12 in

Engine side

Radiator side

Engine side

Radiator side

6 in

OEM quick connect


25

Installing the Cooler The oil cooler is installed on the passenger side of the vehicle with the oil fittings facing to the driver side.

Place the cooler in position above the frame.

Connect the lower radiator hose to the cooler using the supplied hose clamp and install the 2 OEM radiator support bolts and supplied washers to hold the cooler bracket in place (Figure 25 and Figure 26).

Connect the modified 12 in radiator hose from the engine to the cooler using supplied hose clamp (Figure 25 and Figure 26).

Figure 25 – Cooler installation

Figure 26 – Cooler installation

Adjust the OEM bolts and 2 adjustment bolts on the bracket to align the holes and for best fit. Tighten the 5 bolts.

Radiator support

Cooler bracket OEM bolts and supplied washers

Adjustment bolts

Connect to engine

From AOST

To compressor

Cooler

From radiator

Front

Battery tray mount

Cooler Radiator shroud

Longest 1/2 in hose


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Installing the Hoses Apply protective loom to the cooler hoses.

Route the straight end of the shorter 1/2 in hose from the bottom of the cooler under the shroud to the driver side of the engine compartment, in front of steering box, back along the top of the frame rail, and up to the rear of the power steering pump. It will be connected to the compressor later during the installation (Figure 27).

Route the straight end of the longer 1/2 in hose from the top of the cooler, back along the top of the frame rail, over the upper control arm mount, and out between the inner fender and the cab mount to the front of the AOST (Figure 27).

Figure 27 - Installing the cooler hoses

Longer 1/2 in hose Shorter 1/2 in hose


27

Installing the Main Bracket and Compressor Remove the idler and the complete tensioner assembly from the VMAC

main bracket (Figure 28).

Install the alternator spacers retained from the OEM bracket.

Place the main bracket on the front of the driver side cylinder head and install the 4 OEM M10 bolts from the alternator casting into the matching locations on the VMAC bracket.

Ensure the bracket sits flat against the engine. If the bracket does not sit flat, remove it and correct the problem.

Torque all bolts to specifications.

Apply Loctite 242 (blue) to the OEM fasteners and install the power steering pump on the main bracket and torque to specification.

Apply Loctite 242 (blue) and install the VMAC idler.

Install the tensioner assembly and torque to specification.

Figure 28 – Installing the main bracket

Alternator mount

M8 x 110 mm

socket head bolt

Compressor

mount OEM idler mount location

Engine mount

Tensioner

assembly

M8 x 25 mm bolts

Idler Power steering mount

Engine mount


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Apply Loctite 242 (blue) to (1x) M8 x 110 mm socket head bolt and (2x) M8 x 25mm hex head bolts and install the compressor onto the VMAC bracket. To access the M8 socket head bolt, remove the pressure sensor. After the bolt is tight, reinstall the pressure sensor using Loctite 567 PST (Figure 29).

The inlet valve is secured with bolts of 2 different lengths. Install the longer bolts nearest to the air filter. Installing the bolts in the wrong location will damage the compressor housing when tightened (Figure 29).

Figure 29 – Installing the inlet

Do not use an impact wrench to the install inlet bolts. The torque specification for the inlet bolts is 19 ft•lbs.

Install the alternator on the main bracket using the OEM bolts. The spacers will pull into position as the retaining bolts are torqued to specification.

Install the OEM idler onto the VMAC bracket.

Pressure sensor

Shorter bolts

Longer bolts


29

VMAC Belt Routing Install the OEM belt.

Install the VMAC belt (Figure 30).

Figure 30 – VMAC belt routing

Install the engine fan.


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Connecting the Hoses

Lubricate the tube and firmly push it into the fitting so that it fully seats past the internal O-ring. Slide the collet back to lock the tubing in place (Figure 31).

Figure 31 – Push to connect fittings

Insert the 3/16 in and 1/4 in PTFE tubes into the fittings on the back of the AOST and cover them with high temperature loom.

Route the 3/16 in and 1/4 in PTFE tubes with the 3/4 in hose up from the cab mount, over the top of the engine and against the firewall to the compressor.

Connect the 3/16 in and 1/4 in PTFE tubes to the matching fittings on the compressor inlet.

Connect the 1/2 in hose from the cooler to the matching fitting on the compressor.

Connect the 3/4 in hose to the matching fitting on the back of the compressor.

Tighten all 1/2 in and 3/4 in fittings, ensuring the hoses do not twist or kink.

Remove the cardboard protector from the filter mount base on the AOST.

Apply a thin coating of compressor oil to the oil filter gasket and install the filter on the AOST.

After the gasket contacts the base, tighten the filter an additional 3/4 turn


31

Adding Oil to the System

The VMAC supplied and approved compressor oil must be used in this system. Failure to use this special oil will result in damage to the compressor and will void warranty.

Do not overfill the system. Overfilling the system with oil can flood the sight glass window and make the system appear empty.

Remove the fill plug from the inlet and pour approximately 4 L of the supplied VMAC oil into the oil fill hole on the inlet using a funnel.

Turn the compressor clutch clockwise with a ratchet and a 1/2 in socket using the hex head bolt at the center of the compressor clutch during the fill process.

Allow at least 5 minutes for the oil to drain into the AOST; then check the level at the sight glass at the front of the tank. Continue adding oil until the level is correct on the AOST sight glass.

Install the fill plug in the inlet and tighten it securely.

Figure 32 – Adding oil to the system


Fax: 1-250-740-3201 32

Completing and testing the Installation

Install the air intake box mounting tray, air intake box, air intake tube and resonator box.

Connect the upper radiator hose to the radiator.

Check all fasteners, clamps, fittings and retainers to ensure that they are tight and secure all OEM wire harnesses.

Fill the cooling system with the coolant retained earlier.

Connect the white wire with the bullet connector, the green 4 pin connector and the black 3 pin connector to the matching connections at the compressor.

Reconnect the Battery.

Ensure all wiring to is secured and will not contact any hot, sharp or moving components and will not interfere with the operation of the truck. Secure all wiring with cable ties and loom as required.


33

Testing the installation Place the automatic transmission in “PARK” and apply the park brake.

Turn the ignition to “ON” but do not start the engine.

Check the control box to see if it is illuminated. If it is not illuminated, there is no power to the control box.

Press the “ON” button. The green light should come on and the compressor clutch will engage, this should be audible.

Release the park brake. The green light should flash and the compressor clutch should disengage and flash “PARK BRAKE”. Apply the park brake again and press the “ON” button. The light should come on and the clutch should engage.

Press the “OFF” button.

Turn the ignition switch to “OFF”. The engine must be running to complete the final step in the safety test. This will be done after the pre-start checks have been completed.

If the truck fails the test, check the wiring to ensure that all the connections are correct and secure. If additional assistance is required, contact VMAC technical support at 1-888-241-2289 or 250-740-3200.

Before Starting the Engine Checklist Ensure that the following have been completed:

Check the coolant.

Check the compressor oil level at the AOST sight glass.

Perform a final inspection to ensure that everything has been completed and secured.

Perform a final belt alignment check.

Check all wiring for security and protection.

Ensure all compressor outlet valves are closed.

Ensure the parking brake is engaged and the transmission is in “PARK”.

Start the engine.


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After Starting the Engine Checklist

Place the truck in a safe operating position and adequately block the wheels. Ensure that there are no people around the truck before beginning the test.

Check for any leaks, confirm belt alignment and ensure the belts are rotating properly.

Close and latch the hood.

Allow the engine to reach normal operating temperature.

Press the “ON” button on the display box to start the compressor.

The engine speed should increase to between 2,000 rpm and 2,500 rpm and then drop down to VMAC base idle (approximately 1,000 rpm).

With the system running, check for any leaks.

Release the park brake.

• The display box should read “PARK BRAKE”, the compressor clutch should disengage and engine speed should reduce to OEM idle.

Re-engage the park brake and start the compressor.

Allow engine speed to stabilize after re-engaging the compressor.

With the brake pedal firmly depressed, shift the truck into “REVERSE”. Engine speed should reduce to OEM base idle (approximately 650 rpm).

Return the gear selector to “PARK” and repeat this test in all gear selector positions. Ensure that engine speed does not increase unless the selector is in “PARK”.

Confirm all air valves are closed and the system has no air leaks.

Turn on the vehicle’s air conditioning (if equipped).

• Turn the steering wheel from lock to lock.

• Listen for any belt squeal.

• Confirm that the discharge hose has adequate clearance from the front wheels.


35

Setup, Performance Testing and Adjustments

This system requires minimal adjustment. The maximum system pressure is adjusted via the regulator on the inlet valve, and the output is adjusted with the throttle control. Refer to the owner’s manual for specific instructions on how to adjust the system.

Test the system operation using the tools that will be operated by the system. Alternatively, the system can be tested using a 3/16 in orifice in the outlet to simulate tool use (Figure 33).

Figure 33 - VMAC Air Test Tool (A700052)

1. Install the test tool at the system outlet. If using the VMAC test tool, the appropriate orifice size is 3/16 in.

2. Ensure that the ball valve is closed.

3. Place the transmission in “PARK” and fully apply the park brake.

4. Allow the engine to run until it is at operating temperature.

5. Turn on the air compressor system and allow it to operate until the oil is warm.

6. Observe the pressure gauge. Pressure should be approximately 150 psi.

7. Open the ball valve on the test tool and observe the engine tachometer. Engine speed should increase to approximately 2,000 rpm – 2,500 rpm.

8. Close the air valve slowly to allow the system pressure to rise.

9. Once system pressure is at maximum, slowly open the ball valve on the test tool until the pressure on the gauge begins to drop. Engine speed should ramp when the pressure drops to approximately 140 psi.


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Final Testing

Ensure that the following have been completed:

Operate the system with an air tool (or the VMAC Air Test Tool) for at least 1/2 hour (1 hour preferred).

Road test the truck for approximately 20 km (14 miles).

Watch the under-hood operation to ensure that the belts rotate properly, pulleys rotate smoothly and nothing is rubbing or contacting hot parts.

Check all components, connections and fasteners once the engine is turned off and the system has cooled.

Check the coolant level after the engine has been operated.

Check the compressor oil level after the engine has been shut down and the oil level has had time to stabilize.


37

Air Receiver Tank Pressure in the air receiver tank will not be relieved when the

compressor system blows down. This is normal operation. Prior to performing any service work on the system, relieve the pressure in the air receiver tank.

If an air receiver tank will be used with this system, the following installation procedure must be used to prevent damage to the system.

An air receiver tank provides a buffer as it gives the compressor time to react by increasing the engine speed and producing air before the tool stalls. It also has the advantage of lowering the duty cycle of the compressor system.

The VMAC compressor system will automatically depressurize when it is shutdown, therefore the line from the VMAC Air/Oil Separator Tank (AOST) to the air receiver tank must have a 1-way check valve installed. This prevents blow back and moisture from the receiver tank entering the AOST (Figure 34).

The line to the receiver tank must be installed as high as possible to prevent water from entering the line.

Figure 34 – Air Receiver Tank

Install the line as

high as possible

1-way check

valve


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Accessory Products These accessory products for your under-hood compressor system are available from VMAC. For more information or to order these products, call 1-877-912-6605 or email [email protected].

Eliminator Aftercooler Part Number A800070

Removes up to 80% of moisture from compressed air. Quick installation, automatic drain and compact design

Filter Regulator Lubricator Part Number A700151

Removes lubricants, water and dirt from the air stream. Adds atomized tool oil to lubricate tools. Reduces pressure for longer tool life.

Hose Reel Part Number A700007

Secure, compact, retractable hose storage in a sturdy reel.

Air Receiver Tank Part number A300047 10 gallon capacity in a compact tank, complete with fittings and a gauge. Part Number A300010 35 gallon capacity in a compact tank, complete with fittings and a gauge.

3/4 in NPTF Check Valve not included Part number 3600117

De-icer Kit Part Number A700031

Insulated rope heater prevents freezing of lines and regulator.

Service Kits VR70 200 hour Part Number A700019 VR70 400 hour Part Number A700020

Using OEM service products will extend the life of your system. Includes oil, filters, seals and O-rings. 200 hour and 400 hour service interval kits are available

mailto:[email protected]


39

Warranty Registration This form must be fully completed and returned to VMAC at the time of installation. Warranty may be void if this form is not received by VMAC within 30 days of installation.

VMAC’s Warranty policy and registration can be viewed online at: www.vmacair.com/warranty

VMAC Dealer Information

Company Name: __________________________________________ City: _____________________ State / Province:_______________

Installer Information

Company Name: _____________________________________ City: _____________________ State / Province:______________ Installation Date: _____/_____/_____

Day Month Year

Owner Information

Company Name: __________________________________________ Address: ________________________________________________ City: _____________________ State / Province:_______________ Zip/Postal: ________________ Phone #: (____) ____ - _____

Email Address: ___________________________________________

Vehicle Information

Year: ____________________ Make: _________________ Vehicle Identification Number: ___________________________ Unit #: ___________________

Product Information

System Identification Number: V _ _ _ _ _ _ _ _ _ _ _ _

Compressor Serial Number: P_ _ _ _ _ _ _ _ _ _ _ _

Throttle Control Serial Number: _ _ _ _ _ _ _ _ _ _ _ _ AOST Serial Number: _ _ _ _ _ _ _ _ _ _ _ _

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vr70 underhood air compressor installation manual

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