Vmac VR70 Manuale utente

System V900079

2004.5 - 2005 GMC C4500 - 5500

6.6L Duramax Diesel

www.vmacair.com

VR70 UNDERHOOD

AIR COMPRESSOR

INSTALLATION MANUAL

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 1

Installation Manual for VMAC

System V900079

General Motors 2004.5 – 2005

Duramax Diesel

C4500 – 5500

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

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

Special Installation Notes ......................................................... 4

Part 1: Preparing for Installation............................................... 5

1.0 Preparing for Installation .................................................... 5

1.1 Dual Alternator Trucks........................................................ 7

Part 2: Installing the Main Bracket and Compressor.............. 8

2.1 Installing the Main Bracket ................................................. 8

2.2 Installing the Cooler............................................................ 11

2.3 Connecting the Hoses ........................................................ 13

Part 3: Installing the Tank and Hoses....................................... 14

3.1 Installing the Tank and Brackets ........................................ 14

3.2 Filling the System with Oil .................................................. 16

3.3 Completing the Installation ................................................. 17

Part 4: Installing the Control Components .............................. 19

4.1 Installing the Control Components ..................................... 20

4.2 Connecting the In-cab Wiring ............................................. 21

4.3 Connecting the Underhood Wiring ..................................... 22

4.4 Connecting the Power Supply Wire ................................... 24

4.5 Completing and Testing the Installation ............................. 24

Part 5: Finishing the Installation................................................ 26

5.1 Before Starting the Engine Checklist ................................. 26

5.2 After Starting the Engine Checklist..................................... 27

5.3 Setup, Performance Testing and Adjustments................... 28

5.4 System Identification and Warnings................................... 29

5.5 Auxiliary Air Receiver ......................................................... 30

Accessory Products from VMAC............................................... 31

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

Document #1930076

Installation Manual for VMAC System V900079

General Motors 2004.5 – 2005 Duramax Diesel C4500 - 5500

Changes and Revisions

Version Revision Details Revised by/date Approved Implemented

00 Original manual IB Nov 06 2004 SM/SC 26 Jan 2005 26 Jan 2005

a Electrical changes IB 29 Jan 2005 SM 02 Feb 2005 04 Feb 2005

b Content revisions IB 12 Feb 2005 SC 10 Mar 2005 14 Mar 2005

c Main bracket mount IB 15 Sep 2005 SM 20 Sep 2005 23 Sep 2005

d ECN 06-179 main brkt bolt IB 13 Aug 2006

e ECN 06-239 main brkt chng IB 23 Nov 2006 TG 29 Nov 2006 01 Dec 2006

f ECN 06-265 comp. mount IB 21 Dec 2006 TG 21 Dec 2006 27 Dec 2006

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.

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.

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 1-800-738-8622.

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: 1-800-738-8622

Fax: 1-250-740-3201 3

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 Coding

Different frame designations will affect the tank mounting position.

You may have to move the tank rearward from the standard position

on your application. If you must move the tank, the lines may be too

short. If this is the case, measure the hose shortfall and order a

Hose Extender Kit. The following table shows the color code used

by VMAC to define the different hose diameters.

Hose Diameter Colour-Coded Label

1/4 inch

5/16 inch

1/2 inch

5/8 inch

3/4 inch

1 inch

Yellow

Orange

Blue

Green

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

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

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 5

Part 1: Preparing for Installation

1.0 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.

□Disconnect the batteries.

□Drain the coolant.

□Disconnect the MAF sensor wire from the air cleaner and

remove the complete air intake assembly, complete with rubber

air intake pipe, air ducting and the plastic intake resonator

chamber from the top of the engine.

□On trucks with dual alternators, remove the plastic centering lug

from the back of the air cleaner housing.

□Remove the plastic inner fender liner on the passenger side.

□Disconnect the hoses from the coolant expansion tank,

disconnect the level sensor connector and remove the tank.

□Remove the air cleaner base mounting plate and the air cleaner

support bracket.

□Remove the top radiator hose.

□Remove the upper fan shroud. Remove the mount bolts from the

lower fan shroud, but leave the shroud in position.

□Remove the fan using the appropriate fan wrench.

□Remove the passenger side intercooler tube and hoses.

□Remove and discard the heater hose and metal connector pipe

from the lower radiator hose.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

□Disconnect the fuel inlet and outlet banjos from the fuel

management module, remove the module and move it out of the

way. Remove the rubber washers, plastic spacers, mounting

bolts and banjo fitting seals so they will not get lost.

□Remove and discard the rubber hose that connects between the

fuel rail and the module.

□Remove the OEM belt.

□Remove all wire harness retainers from the OEM alternator

mount bracket.

□Remove the alternator (passenger side on dual alternator trucks)

and keep the bolts.

□Remove the OEM idler and tensioner from the alternator mount

bracket.

□Remove the OEM alternator mount bracket.

□Remove the rock guard from under the front of the truck (if

equipped).

□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 protruding center-piece of the cross-

member under the front of the engine.

□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 downward with the slide-hammer to

make sure that it is seated correctly

•tighten the pinch bolt securely

•use the hammer action of the slider in an upward motion to

remove the pin from the crankshaft

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 7

□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 1.1).

High-strength

crank pin

Figure 1.1

□Apply a light wipe of oil to the inside of the OEM crank pulley and

install the pulley back onto the crankshaft.

1.1 Dual Alternator Trucks

□Loosen the top mounting bolt on the driver’s side alternator and

remove the lower mounting bolts.

□Install the supplied bracket under the alternator and insert the

mounting bolts.

□Push the alternator upward and tighten all the bolts.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-800-738-8622

Fax: 1-250-740-3201

Part 2: Installing the Main Bracket

and Compressor

2.1 Installing the Main Bracket

□Remove the belt tensioner assembly from the VR main bracket.

□Remove the plastic caps and remove the four M10 x 85 mm low

profile socket head screws from the bracket. Place the bracket in

position on the front of the engine.

□Insert the two M10 x 85 low profile socket bolts and thread the

two OEM 10 mm flange nuts onto the two studs. Thread all

fasteners in just enough to hold the bracket in place (Figure 2.1).

Check the fit of the bracket against the engine to make sure that

it fits flat and has no obstructions, tighten the bolts evenly and

then torque them to specifications.

Install OEM

back idler here

M10 x 85 mm

socket head bolts

(one behind the VR tensioner

)

OEM 10 mm nuts

Install the OEM

tensioner here

Figure 2.1

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