Vmac VR70 Manuale utente

System V900093

2007 – 2006 GM 2500HD – 3500HD

Duramax Diesel

System V900103

2010 – 2007 GM 2500HD – 3500HD

GMT900 Duramax Diesel

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

Installation Manual for VMAC

System V900093

2007 –2006 GM 2500HD –3500HD

Duramax Diesel

System V900103

2010 –2007 GM 2500HD –3500HD

GMT900 Duramax Diesel

General Information..................................................................... 3

Before You Start....................................................................... 3

Special Installation Notes......................................................... 3

Part 1: Warranty and System ID................................................. 5

Part 2: Preparing for Installation............................................... 8

2.1 Preparing for Installation .................................................... 8

Part 3: Installing the Control Components .............................. 15

3.1 Installing the Components.................................................. 17

3.2 Connecting the In-cab Wiring............................................. 17

3.3 Connecting the Under-hood Wiring.................................... 19

Part 4: Installing the Tank and Hoses....................................... 21

4.1 Installing the Tank and Brackets........................................ 21

4.2 Installing the Tank Assembly.............................................. 23

Part 5: Installing the Main Bracket and Compressor.............. 27

5.1 Installing the Cooler............................................................ 27

5.2 Installing the Main Bracket................................................. 28

5.3 Connecting the Hoses........................................................ 33

5.4 Completing the Installation................................................. 34

5.5 Adding Oil to the System.................................................... 36

Part 6: Finishing the Installation................................................ 37

6.1 Before Starting the Engine Checklist.................................. 37

6.2 After Starting the Engine Checklist .................................... 38

6.3 Setup, Performance Testing and Adjustments................... 39

6.5 Auxiliary Air Receiver ......................................................... 40

Accessory Products from VMAC ............................................... 41

VMAC –Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Installation Manual - Document #1930105

System V900093

2007 –2006 GM 2500HD –3500HD Duramax Diesel

System V900103

2010 –2007 GM 2500HD –3500HD GMT900 Duramax Diesel

Changes and Revisions

Version

Revision Details

Revised by/date

Approved

Implemented

ECN 09-081

SL 1 Oct 2009

PD 1 Oct 2009

1 Oct 2009

ECN 09-109

SL 27 Oct 2009

TG 27 Oct 2009

28 Oct 2009

ECN 10-041

SH 1 Sept 2010

SM 1 Oct 2010

6 Oct 2010

ECN 12-156

SAR 14 Nov 2012

MH 16 Nov 2012

28 Nov 2012

ECN 13-013

SH 18 Jul 2013

SC 13 Oct 2013

22 Oct 2013

Important Information

The information in this manual is intended for certified VMAC

installers who have been trained in installation procedures and for

people with mechanical trade certification who have the tools and

equipment to properly and safely perform the installation. Do not

attempt this installation if you do not have the appropriate

mechanical training, knowledge and experience.

Follow all safety precautions for underhood mechanical work. Any

grinding, bending or restructuring operations for correct fit in modified

vehicles must follow standard shop practices.

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.

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 that have had other changes without

additional modifications to the truck. If you have difficulty with the

installation, contact VMAC.

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: 1-888-241-2289

Fax: 1-250-740-3201

General Information

Before You Start

Read this manual before attempting installation so that you can

familiarize yourself with the components and how they fit on the

vehicle. Identify variations for different model years and different

situations that are listed in the manual. Open the package, unpack

the components and identify them.

All fasteners must be torqued to specifications. Use manufacturers

torque values for OEM fasteners. Apply Loctite 242 or equivalent on

all engine-mounted fasteners. Torque values are with Loctite applied

unless otherwise specified.

STANDARD GRADE 8 NATIONAL COARSE THREAD

Size

1/4

5/16

3/8

7/16

1/2

9/16

5/8

Foot-pounds (ft-lb)

110

170

280

Newton meter (N•m)

108

149

230

379

STANDARD GRADE 8 NATIONAL FINE THREAD

Size

3/8

7/16

1/2

5/8

Foot-pounds (ft-lb)

180

320

Newton meter (N•m)

122

244

434

METRIC CLASS 10.9

Size

M10

M12

M14

M16

Foot-pounds (ft-lb)

104

174

Newton meter (N•m)

141

236

Special Tools

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)

VMAC –Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

The following additional materials are recommended:

assorted sizes of fireproof protective plastic loom

assorted lengths of nylon tie-straps

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

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

Figure 1.1

VMAC –Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

□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

Part 2: Preparing for Installation

2.1 Preparing for Installation

Preparation for installation is very important. Missing an item can

cause problems in the installation or even damage components.

Check off each item as it is completed.

2.1.1 V900093 Automatic Transmission Trucks

□Locate the ECM in the engine compartment (Figure 2.1) and find

all wires that are orange with a black stripe in the bottom

connector. Use a digital voltmeter (DO NOT USE A TEST

LIGHT) to determine which wire has 0 Volts in Park/Neutral and

12 Volts in all other gear selector positions with the ignition on.

Mark the wire with a piece of tape and turn the ignition off.

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