Vmac V900098 Installation guide

Type
Installation guide

This manual is also suitable for

System V900099
2008-2007 GM C4500 C5500 LMM Duramax 6.6L Diesel
without dual alternators
System V900098
2007-2006 GM C4500 C5500 Duramax 6.6L Diesel
without dual alternators
www.vmacair.com
VR70 UNDERHOOD
AIR COMPRESSOR
INSTALLATION MANUAL
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
1
Installation Manual for VMAC
System V900099
2008-2007 GM C4500 C5500
LMM Duramax 6.6L Diesel without dual alternators
System V900098
2007-2006 GM C4500 C5500
Duramax 6.6L Diesel without dual alternators
General Information..................................................................... 4
Before You Start ....................................................................... 4
Special Installation Notes ......................................................... 5
Part 1: Warranty and System ID ................................................. 6
Part 2: Preparing for Installation ............................................... 9
2.0 Preparing for Installation .................................................... 9
Part 3: Installing the Main Bracket and Compressor .............. 16
3.1 Installing the Main Bracket ................................................. 16
3.2 Installing the Cooler ............................................................ 18
Part 4: Installing the Tank and Hoses....................................... 20
4.1 Inside the Step Assembly ................................................... 20
4.2 Below the Step ................................................................... 21
4.3 Installing the Tank and Fittings........................................... 22
4.4 Filling the System with Oil .................................................. 24
4.5 Completing the Installation ................................................. 24
Part 5: Installing the Control Components .............................. 30
5.1 Installing the Control Components ..................................... 31
5.2 Connecting the In-cab Wiring ............................................. 31
5.3 Connecting the Underhood Wiring ..................................... 33
5.4 Connecting the Power Supply Wire.................................... 34
5.5 Completing and Testing the Installation ............................. 35
Part 6: Finishing the Installation ................................................ 37
6.1 Before Starting the Engine Checklist.................................. 37
6.2 After Starting the Engine Checklist .................................... 37
6.3 Setup, Performance Testing and Adjustments ................... 38
6.4 Auxiliary Air Receiver ......................................................... 39
Accessory Products from VMAC ............................................... 40
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-8829
Fax: 1-250-740-3201
2
!
Document #1930143
Installation Manual for VMAC System V900099
2008-2007 GM C4500 C5500 LMM Duramax 6.6L Diesel without dual alternators
Installation Manual for VMAC System V900098
2007-2006 GM C4500 C5500 Duramax 6.6L Diesel without dual alternators
Changes and Revisions
Version
Revision Details
Revised by/date
Approved
Implemented
B
ECN 07-145
IB 10 Nov 2007
SH 23 Nov 2007
26 Nov 2007
C
ECN 08-037
SL 20 Feb 2008
SH 22 Feb 2008
22 Feb 2008
D
ECN 09-058
SL 11 May 2009
PD 11 May 2009
12 May 2009
E
ECN 12-156
SAR 15 Nov 2012
MH 16 Nov 2012
30 Nov 2012
F
ECN 13-013
SH 18 Jul 2013
SC 22 Nov 2013
25 Nov 2013
Important Information
This symbol is used to call your attention to instructions
concerning your personal safety. Watch for this symbol; it
points out important safety precautions, it means “attention,
become alert! Your personal safety is involved. Read the
message that follows and be alert to the possibility of personal
injury or death. Be alert; your safety is involved. While it is
impossible to warn about every conceivable hazard, let good
common sense be your guide.
This symbol is used to call your attention to additional
instructions or special emphasis on a specific procedure.
The information in this manual is intended for certified VMAC
installers who have been trained in installation procedures and for
people with mechanical trade certification who have the tools and
equipment to properly and safely perform the installation. Do not
attempt this installation if you do not have the appropriate
mechanical training, knowledge and experience.
Follow all safety precautions for under hood mechanical work. Any
grinding, bending or restructuring operations for correct fit in modified
trucks must follow standard shop practices.
All hoses, tubes, and wires that are rerouted or shifted
during installation must be secure so that they do not
contact excessively hot areas or sharp edges. Where
possible, use rubber coated P-clips. Follow the routing
suggestions in this manual and cover all hoses with the
supplied plastic loom.
!
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
3
These instructions are a general guide for installing this system on
standard production trucks and do not contain information for
installation on non-standard trucks. This system may not fit special
order models or those which have had other changes without
additional modifications. If you have difficulty with the installation,
contact VMAC.
The VMAC warranty form is located at the back of this manual. This
warranty form must be completed and mailed or faxed to VMAC at
the time of installation for any subsequent warranty claim to be
considered valid.
Copyright 2010
All trademarks used in this manual are the property of the respective copyright holder.
The contents of this manual may not be reproduced in any form without the express
written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3.
Printed in Canada
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-8829
Fax: 1-250-740-3201
4
!
General Information
Before You Start
Read this manual before attempting installation so that you can
familiarize yourself with the components and how they fit on the
vehicle. Open the package, unpack the components and identify the
parts. Identify variations for different model years or OEM options
that are listed in the manual.
All fasteners must be torqued to specifications. Use manufacturers
torque values for OEM fasteners. Apply Loctite 242 or equivalent on
all engine-mounted fasteners. Torque values are with Loctite applied
unless otherwise specified.
STANDARD GRADE 8 NATIONAL COARSE THREAD
Size
1/4
5/16
3/8
7/16
1/2
9/16
5/8
¾
Foot-pounds (ft-lb)
9
18
35
55
80
110
170
280
Newton meter (N•m)
12
24
47
74
108
149
230
379
STANDARD GRADE 8 NATIONAL FINE THREAD
Size
3/8
7/16
1/2
5/8
¾
Foot-pounds (ft-lb)
40
60
90
180
320
Newton meter (N•m)
54
81
122
244
434
METRIC CLASS 10.9
Size
M8
M10
M12
M14
M16
Foot-pounds (ft-lb)
19
41
69
104
174
Newton meter (N•m)
25
55
93
141
236
Hose 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 our compressor oil. Use of hoses other
than those supplied or recommended by VMAC may
cause compressor damage and may void your
warranty. Please contact VMAC for replacement hoses
and further information.
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
5
Special Installation Notes
The following special tools are required:
36 mm 12 point 1/2 inch drive socket for removing the OEM
crankshaft bolt
crankshaft locking tool (GM #J-44643) or VMAC equivalent
(Part #5900010)
VMAC crankshaft pin extraction tool (Part #5900076) or
equivalent
The following additional materials are recommended:
assorted sizes of fireproof protective plastic loom
assorted lengths of nylon tie-straps
An alternate tank mounting system using frame hangers is available.
Contact VMAC to order the tank mount bracket accessory pack.
This manual contains installation instructions for both the V900098
and V900099 systems. Make sure that you locate and follow the
specific instructions for each system.
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-8829
Fax: 1-250-740-3201
6
Part 1: Warranty and System ID
Complete the warranty form. The VMAC warranty form is located
at the back of this manual. This warranty form must be
completed and mailed or faxed to VMAC at the time of
installation for any subsequent warranty claim to be considered
valid.
System Identification and Operating Instructions
The System Identification Number Plate must be attached to the
vehicle at the time of installation. This plate provides information that
allows VMAC to assist in customer inquiries and the ordering of
parts.
Mark and drill two 7/64-inch holes in the top of the cross member
in front of the OEM air filter box. Secure the plate with supplied
self- tapping screws
Clean cross member beside the number plate and stick the
VMAC belt routing diagram to the cross member.
Apply battery warning label to driver side of primary cooling
reservoir.
As part of the installation process, ensure that the safety and
operational instruction decal is affixed in an obvious location so
that it can be seen by vehicle operators. A good spot for this is
usually on the inside of the door or on the panel underneath the
steering wheel. (Figure 1.1).
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
7
Figure 1.1
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-8829
Fax: 1-250-740-3201
8
To alert any technicians that may service the vehicle, affix the
servicing caution/contact label in the engine compartment near
the hood latch in a visible location. Thoroughly clean the
selected area before affixing the label (figure 1.2)
Figure 1.2
To order parts, contact your VMAC dealer. Your dealer will ask for
the VMAC serial number, part number, description and quantity. To
locate your nearest dealer, call 1-888-241-2289.
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
9
Part 2: Preparing for Installation
2.0 Preparing for Installation
Preparation for installation is very important. Missing an item can
cause problems in the installation or even damage to components.
Check off each item as it is completed so that you do not miss any
preparation steps.
For better access, remove the hood and front bumper.
Locate the two orange wires
with a black stripe in this
ECM connector
Figure 2.1
If the truck has an automatic transmission, locate the two orange
wires with black stripes at the ECM connector closest to the
engine (Figure 2.1).
Test each wire with a digital Voltmeter set to DC Volts with the
ignition on. The correct wire will show 0 Volts in Park or Neutral
and 12 Volts in all other gear positions. Mark the correct wire
with a piece of tape.
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-8829
Fax: 1-250-740-3201
10
Disconnect the batteries.
Drain the coolant by cutting a section out of the middle of the
lower radiator hose leaving 1-1/2 inches of straight section from
each elbow (Figure 2.2).
Remove the air box and coolant expansion reservoir.
Remove the upper radiator hose.
Remove the driver’s side intercooler tube and cover the
openings.
If the hood has been removed, you can disconnect the
radiator ends of the side support struts to allow the
radiator to tip forward to make removal of the fan,
shroud and stator easier. These struts support the
hood.
To engine
To Radiator
To coolant
expansion tank
Heater hose
connection
Discard
this section
1-1/21-1/2
Figure 2.2
Disconnect the fan electrical connector (V900099 only), remove
the bolt holding the fan connector to the shroud and remove the
upper fan shroud.
Remove the fan, then the fan stator (if equipped) and finally the
OEM belt.
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
11
Remove the mount bolts from the lower fan shroud, but leave the
shroud in position.
On trucks with air conditioning, remove the driver’s side rear
compressor mounting bolt.
Install a crankshaft locking tool, remove the crank pulley bolt and
remove the crank pulley. If you are using the VMAC tool:
put the socket on the nut
put the single-pin end of the tool on the front of the pulley with
the locking tool hanging straight down
put a short extension and long flex-bar on the socket
turn the engine until the pin on the tool makes contact and the
tool jams against the frame rail
Rotate the crankshaft so that the pin points downward and
remove the crankshaft pin. If you are using the VMAC extraction
tool:
fit the split end of the tool (on the end of the shaft) over the
crankshaft pin and tap with the slide-hammer to make sure
that it is seated correctly
tighten the pinch bolt securely
use the hammer action of the slider to remove the pin from
the crankshaft
Install the replacement crankshaft/harmonic balancer locating pin
and tap it home using a brass drift and a small hammer. Ensure
that the head of the pin is aligned with the crankshaft. You may
have to twist it into position (Figure 2.3).
Apply a light wipe of oil to the inside of the OEM crank pulley and
install the pulley back onto the crankshaft.
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-8829
Fax: 1-250-740-3201
12
High-strength
crank pin
Figure 2.3
Place the VR crank pulley in position with the two roll pins on
both sides of the counter balance weight of the OEM pulley
(Figure 2.4).
Thread the M18 x 100 mm center bolt with OEM washer into the
crankshaft. Install a crankshaft-locking tool and torque the center
bolt to manufacturer’s specifications (usually about 250 ft-lbs
(340 N.m).
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
13
Position the roll pins here
Figure 2.4
Remove the M8 bolt holding the coolant tube flange onto the top
of the engine and install the modified M8 bolt (Figure 2.5).
Tighten the bolt, then loosen it 1/4 turn.
Remove the two M8 bolts on the coolant tube support bracket.
Space it up with the two supplied 5/16 inch aluminum spacers
and replace the OEM bolts. Tighten all the bolts.
Mark the position of the steering shaft relative to the steering
box, then disconnect the steering shaft joint at the steering box.
Coolant tube
Modified bolt
Spacer
Figure 2.5
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-8829
Fax: 1-250-740-3201
14
Unclip the wiring connector in front of the fuel filter from the
driver’s side of the bracket and relocate it to the passenger side.
Bend the bracket toward the engine until the connector almost
touches the valve cover (Figure 2.6).
Unclip the connector, flip
it over and clip it to the other
side of the bracket
Bend the bracket
in until the connector
almost touches the
valve cover
Figure 2.6
2.1 V900099 Only
Modify the fan stator by cutting off the two vanes at the 2 and 3
O’clock positions (Figure 2.7) when looking at it from the front.
Cut the tabs off the two bottom vanes as shown.
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
15
TOP
Remove this
section and
the two vanes
Cut off these tabs
Figure 2.7
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-8829
Fax: 1-250-740-3201
16
Part 3: Installing the Main Bracket
and Compressor
3.1 Installing the Main Bracket
Remove the idlers and tensioner from the main bracket and
tensioner bracket.
Remove the bolts securing the power steering pump to the
engine. Leave the hoses connected.
Place the VR bracket on the driver’s side of the engine, insert
two M12 X 220 mm bolts with washers through the bracket and
the power steering pump mounting holes and thread them into
place but do not tighten. Use Loctite on the bolts.
Tensioner bracket
Driver’s side A/C bolt
Second alternator mount
Power steering
pump
VR bracket
Tensioner M10 x 80
M10 x 35
M10 x 100
M12 x 220
M10 nut
Figure 3.1
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
17
Install the M10 x 80 mm bolt through the VR bracket and the
OEM second alternator mounting hole. Use Loctite on the bolt.
Tighten the M10 bolt finger tight, then torque the top M10 bolt
then the two M12 bolts to specifications in that order.
The bolts must be tightened in the correct sequence to
ensure proper belt alignment.
Install the tensioner bracket onto the front of the engine with an
M10 x 100 mm bolt with nut and an M10 x 35 mm bolt. Install the
tensioner and idlers and on both brackets. Use Loctite.
Remove the inlet valve from the compressor and cover the
opening. Install the compressor on the bracket and thread in the
three mounting bolts.
Tighten all the fasteners evenly making sure that the compressor
and support bracket fit properly, then torque the fasteners to
specifications. Ensure that the compressor is fully tightened
down and secured. Make sure that the bolts have not bottomed
out in the holes.
Carefully check around the body of the compressor to
make sure that nothing is touching the body, such as
wiring harnesses, hoses or electrical connectors.
Re-install the inlet valve complete with support bracket (Figure
3.2) and install the supplied M10 X 130 mm bolt to replace the
removed air conditioning compressor bolt.
Never use an impact wrench to install inlet bolts. If an
impact is used or the bolts are over tightened this can
damage the compressor housing. This type of damage
would not be covered under warranty. The torque spec
for inlet bolts is 19 ft lbs.
It should be noted that this system uses three different
lengths of bolts to attach the inlet valve to the air end.
If the bolts used to attach the inlet valve are installed
incorrectly, major damage to the air end can occur.
Please refer to Figure 3.2 for bolt sizes and orientation.
!
!
!
VMAC Vehicle Mounted Air Compressors
Toll Free: 1-888-241-8829
Fax: 1-250-740-3201
18
Support
Bracket
M8 x 55
M8 x 50
M10 x 130 M8 x 60
Figure 3.2
3.2 Installing the Cooler
Remove the bolts and mount bracket from the cooler assembly
(Figure 3.3).
Move the lower fan shroud up to provide clearance and position
the cooler (from under the truck) on the inside of the U-channel
cross-member with the oil fittings pointing down.
Be careful not to pinch the wiring harness that runs on
the inside of the U-channel. If necessary, re-route the
harness above the U-channel
Place the mount bracket on the front side of the U-channel and
thread in the mounting bolts.
Install hose clamps and fit the cut ends of the lower hose over
the spigots on the cooler. Tighten the clamps.
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Vmac V900098 Installation guide

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Installation guide
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