Vmac V900098 Installation guide

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

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!

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.

!

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These instructions are a general guide for installing this system on

standard production trucks and do not contain information for

installation on non-standard trucks. This system may not fit special

order models or those which have had other changes without

additional modifications. If you have difficulty with the installation,

contact VMAC.

The VMAC warranty form is located at the back of this manual. This

warranty form must be completed and mailed or faxed to VMAC at

the time of installation for any subsequent warranty claim to be

considered valid.

All trademarks used in this manual are the property of the respective copyright holder.

The contents of this manual may not be reproduced in any form without the express

written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3.

Printed in Canada

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!

General Information

Before You Start

Read this manual before attempting installation so that you can

familiarize yourself with the components and how they fit on the

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.

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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.

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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).

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Figure 1.1

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

servicing caution/contact label in the engine compartment near

the hood latch in a visible location. Thoroughly clean the

selected area before affixing the label (figure 1.2)

Figure 1.2

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.

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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.

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□ 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

1-1/2”1-1/2”

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.

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□ 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.

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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).

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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

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□ 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.

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TOP

Remove this

section and

the two vanes

Cut off these tabs

Figure 2.7

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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

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□ 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.

!

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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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