Vmac Underhood 70 Installation Manual Download

Page: 4 / 64

VMAC - Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: www.kb.vmacair.com

Document: 1930390

Changes and Revisions

Revision

Revision Details

Revised by

Checked by

Implemented

Eng.

Tech. Qual.

Mech.

Elec.

ECN: 19-100 Add digital throttle information

MSP

N/A

ASE

MSP AWM

25 Sept 2019

ECN: 20-066 Update stud torque value

MSP

MRH

N/A

MSP

N/A

11 Mar 2020

Additional Application Information

•

2019+ Chevrolet 4500 – 6500 Chassis Cab equipped with 6.6 L Duramax

Diesel.

•

2019+ International CV515 Chassis Cab equipped with 6.6 L Duramax Diesel.

•

Note that this VMAC system may be equipped with either a digital or analog

throttle control.

Important Information

The information in this manual is intended for certified VMAC installers who

have been trained in installation and service procedures and/or for anyone with

mechanical trade certification who has the tools and equipment to properly and

safely perform the installation or service. Do not attempt installation or service

without the appropriate mechanical training, knowledge and experience.

Follow all safety precautions. Any fabrication for correct fit in modified vehicles

must follow industry standard “best practices”.

Notice

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. Printing or copying of any page

in this document in whole or in part is only permitted for personal use. 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

Registered Trademarks

All trademarks mentioned in this manual are the property of their respective

owners. VMAC’s use of manufacturers’ trademarks in this manual is for

identification of the products only and does not imply any affiliation to, or

endorsement of said companies.

Loctite®

Loctite® 242

and

Loctite® 567

are registered trademarks of Henkel AG &

Company KGaA.

Eaton Aeroquip®

is a registered trademark of EATON AEROQUIP INC.

Chevrolete®

and

Duramax®

are registered trademarks of General Motors Company

LLC.

nternational®

is a registered trademark of NAVISTAR INTERNATIONAL

CORPORATION.

Summary of Contents for Underhood 70

Page 1: ...air com Installation Manual for VMAC System V900135 2019 Chevrolet 4500 6500 Chassis Cab 2019 International CV515 Chassis Cab 6 6 L Duramax Diesel UNDERHOOD UNDERHOOD UNDERHOOD UNDERHOOD70 70 70 70 TM TM TM TM AIR COMPRESSORS ...

Page 2: ......

Page 3: ... Pulley and Oil Cooler 13 Installing the Air Oil Separator Tank AOST 19 Installing the Main Bracket and Compressor 22 Hose Requirements 30 Connecting the Hoses 31 Adding Oil to the System 36 Installing the Control Components 37 Air Receiver Tank 45 Recommended Accessories 46 Completing the Installation 47 Testing the Installation 48 Performance Testing and System Adjustments 51 Digital Throttle Co...

Page 4: ...ght 2020 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...

Page 5: ...ilure of anyone to properly adhere to the procedures set out in this manual or standard safety practices Safety should be the first consideration when performing any service operations If there are any questions concerning the procedures in this manual or more information is required please contact VMAC Technical Support prior to beginning work Safety Messages This manual contains various warnings...

Page 6: ...roducts as defined by VMAC provided that i the purchaser fully completes and submits a warranty registration form within 3 months of purchase or 200 hours of operation whichever occurs first ii services are completed in accordance with the Owner s Manual iii proof of purchase of applicable service kits are made available to VMAC upon request The VMAC Lifetime Warranty is applicable to new products...

Page 7: ...nclude the Service Ticket CSR number VMAC System ID hours on the compressor mileage on the vehicle and a detailed description of the work performed 6 VMAC Warranty does not cover consequential damages overtime charges mileage travel time towing recovery cleaning or shop supplies 7 Dealers submit warranty claims on behalf of the Vehicle Owner End User affected by the defective part s The dealer ens...

Page 8: ...installation manual Before Starting Read this manual prior to beginning the installation to ensure familiarity with the components and how they will fit on the vehicle Identify any variations from the application list such as vehicle model engines or optional equipment e g dual alternator active steering assist etc Open the package unpack the components and identify them using the IPL included in ...

Page 9: ...ided by an OEM Apply Loctite 242 blue or equivalent on all engine mounted fasteners Torque values are with Loctite applied unless otherwise specified Table 1 Torque Table Standard Grade 8 National Coarse Thread Size in 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 in 3 8 7 16 1 ...

Page 10: ...MAC warranty form must be completed and returned to VMAC at the time of installation for any subsequent warranty claim to be considered valid Complete the warranty form The VMAC warranty form is located at the back of this manual as well as online at www vmacair com warranty The System Identification Plate must be attached to the vehicle at the time of installation This plate provides information ...

Page 11: ... 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 servicing caution contact decal in a conspicuous area in the engine bay where the decal will be easily noticed Figure 3 F...

Page 12: ...k the vehicle with the wheels turned all of the way to the driver side Disconnect the negative terminal from the batteries Drain the coolant into a clean container and set it aside for use later Figure 4 Remove lower radiator Hard line Remove hard line Radiator for reference only Ensure the hose is not damaged when removing the shrink cuffs Cut shrink cuff Separate the lower radiator hose from the...

Page 13: ...se where it met the hard line Cut the radiator hose in the marked location ensuring the cut is square to the hose section Figure 5 Lay the curved section of the lower radiator hose flat on a bench From the engine side of the hose measure 1 in towards the center of the hose and mark it with a grease pen Figure 6 Figure 5 Modify 5 8 in hose Figure 6 Modify lower radiator hose Cut hose Radiator side ...

Page 14: ... to the hose section discard the 1 in section of hose Figure 6 on page 11 Cut 1 in from the front edge of each of the OEM lower radiator braces Figure 7 Figure 7 Modify lower radiator support braces Cut 1 in from braces Remove the tension from the fan drive belt Remove and discard the front OEM pulley but retain the 3 OEM crank pulley fasteners Figure 8 Figure 8 Remove front OEM pulley ...

Page 15: ...om 13 Using the 3 OEM crank pulley fasteners install the VMAC crank pulley Figure 9 Tension the fan drive belt Install the supplied coupler with spigot using the supplied gear clamp Figure 10 Figure 9 Install VMAC crank pulley Figure 10 Install coupler Installing the Crank Pulley and Oil Cooler Install coupler ...

Page 16: ...ing clamp connect the modified 5 8 in hose to the spigot on the coupler Figure 11 Using one of the supplied gear clamps install the modified lower radiator hose onto the coupler install the hose with the unmodified end of the hose toward the coupler Figure 12 Figure 11 Install 5 8 in hose Figure 12 Install modified hose Modified end ...

Page 17: ...cair com 15 Using one of the supplied gear clamps install the supplied 2 in radiator hose onto the radiator Figure 13 Using the clamp retained earlier install the oil cooler onto the lower radiator hose Figure 14 Figure 13 Install radiator hose Figure 14 Install oil cooler Install supplied radiator hose ...

Page 18: ...www kb vmacair com 16 Using one of the supplied gear clamps connect the modified lower radiator hose to the oil cooler Figure 15 Using the supplied M6 fasteners and lock nuts secure the oil cooler to the modified radiator brace Figure 16 Figure 15 Install oil cooler Figure 16 Install oil cooler ...

Page 19: ... approximately 3 in past the curve on the 5 8 in OEM coolant drain back hose Cut the hose in the marked location ensuring the cut is square to the hose section Figure 18 Figure 17 Remove coolant drain back hose Figure 18 Modify coolant drain back hose Coolant drain back hard line 3 in To hard line Remove coolant drain back hose The coolant drain back hard line can either be removed and discarded o...

Page 20: ...d coolant drain back hose Figure 20 Figure 19 Install coolant drain back hose Figure 20 Install hose barb Using one of the supplied gear clamps connect the supplied heater hose to the hose barb on the coolant drain back hose Route the hose down toward the VMAC oil cooler securing it as necessary with rubber coated P clips or cable ties Using one of the supplied gear clamps connect the heater hose ...

Page 21: ...s 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 the warranty Installing the AOST Figure 21 AOST installed Front of vehicle The AOST must be level for proper air oil separation and to ensure that the oil level will display accurately in the sight glass The AOST will mount...

Page 22: ...ry box and step Figure 22 Figure 22 Installing the AOST Front of vehicle 3 M6 nuts 3 M6 1 25 fasteners Using the 2 M12 1 75 25 fasteners and 2 M12 nuts install the Inboard AOST mounting bracket to the frame cross member adjacent to the body mount that the Outboard AOST mounting bracket is installed on Figure 23 Figure 23 Installing the AOST Front of vehicle Battery box 2 M12 nuts 2 M12 1 75 25 fas...

Page 23: ...proximately 5 in 6 in past the tank strap Apply loctite 242 blue to the 2 3 in 1 4 in pinch bolts and install them into the mounting clamps Rotate the tank so that the directional arrow on the blowdown cap at the rear of the tank is pointing upward 4 M8 nut 2 Tank clamp lock nut 2 Pinch bolt 4 M8 1 25 20 fastener AOST orientation is critical The arrow on the blowdown cap at the rear of the tank mu...

Page 24: ... discard the bracket and fastener Figure 25 Discard bracket and fastener Retain post Install the fan stator post onto the VMAC main bracket Figure 26 Figure 25 Remove fan stator mount Apply Loctite 242 blue to all engine mounted fasteners Fan stator brace Install post Figure 26 Install fan stator post In order to accommodate the VMAC main bracket it may be necessary to deflect brackets supporting ...

Page 25: ...ww kb vmacair com 23 Remove fastener Power steering pulley Remove and discard the fastener directly below the power steering pulley Figure 28 Figure 27 Remove lower idler Remove the lower idler from the FEAD bracket assembly and set it aside Figure 27 Figure 28 Remover OEM fastener Remove idler ...

Page 26: ... exposed Figure 29 Insert the roll pin into the extension post followed by the idler fastener retained earlier Thread the idler fastener in until it locks against the roll pin Figure 30 Figure 29 Install extension post Figure 30 Install extension post 3 1 2 in Install the stud into the engine below the power steering pulley and torque it to 21 ft lb Figure 31 Figure 31 Install extension post ...

Page 27: ...tener Discard the roll pin Torque the extension post to 21 ft lb Figure 32 Using the supplied fasteners install the main bracket onto the OEM AC bracket Figure 33 Figure 32 Install extension post Figure 33 Install main bracket OEM drive belt not shown for clarity Remove fastener and roll pin Torque extension post 2 M10 1 5 45 Modified M10 1 5 80 ...

Page 28: ...om 26 Using the supplied fasteners install the FEAD bracket assembly Figure 34 Figure 34 Install the FEAD bracket 2 M10 1 5 60 M10 1 5 60 M10 1 5 150 M10 1 5 90 Reinstall the lower idler onto the FEAD assembly bracket Figure 35 Figure 35 Install idler Torque the tensioner and all of the idlers to specification ...

Page 29: ...re 36 Figure 36 Mount fan stator brace Fan stator brace post Fan stator brace VMAC FEAD bracket assembly Install the fan harness extension ensuring the plug and pins are firmly seated Route the fan stator harness past the air conditioner pump and secure it to the air conditioner pump fastener using the supplied P clip and nut Figure 37 Figure 37 Route fan stator harness ...

Page 30: ...onnect it to the OEM connector Apply the supplied protective loom on the OEM harness where it passes near the rear of the compressor Figure 38 Figure 38 Install loom Apply protective loom Install the compressor onto the VMAC main bracket install the shortest fastener in the front passenger side of the compressor Figure 39 Figure 39 Install compressor 3 M8 1 25 120 M8 1 25 110 ...

Page 31: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 29 Install and tension the VMAC FEAD belt Figure 40 Figure 40 VMAC FEAD belt routing ...

Page 32: ...s If this is not effective the hoses can be shortened or replaced as necessary or hose extenders can be used VMAC recommends shortening these hoses as a preferred alternative to coiling up and securing the excess Shorter hose length will maximize system performance Avoid using 90 fittings wherever possible as they cause flow restrictions and negatively impact performance The following hoses are in...

Page 33: ... tubing cutters as side cutters will deform the tube Slide the collet out once the tube is fully inserted Figure 41 Push to connect fittings O ring Push To Connect Fittings Figure 41 Lubricate the tube and firmly push it into the fitting so that the tube fully seats in the fitting Slide the collet out away from the body of the fitting to lock the tubing in place Ensure the tube does not have any p...

Page 34: ... of the compressor From the compressor route the hose down to the top of the frame rail and to the inside of the cab mount Figure 42 From the cab mount route the hose along the cab then down to the AOST Secure the hose to the cab using the supplied P clips and fasteners Figure 43 Figure 42 Connect discharge hose Figure 43 Connect discharge hose Step battery box removed for clarity Supplied P clips...

Page 35: ...fuel lines to the fuel filter From the fuel filter route the PTFE tubes along the top of the AOST and connect them to the push to connect fittings in the blowdown cap Connect the 90 fitting on the shorter 1 2 in hose to the passenger side fitting on the VMAC oil cooler Route the 1 2 in hose to the driver side of the vehicle then up toward the OEM wiring bundles Figure 44 From the OEM wire bundles ...

Page 36: ...Route the 1 2 in hose over the engine cross member following the transmission cooler lines then down toward the bottom of the driver side frame rail Figure 46 Continue to route the 1 2 in hose along the same path as the transmission cooler lines then loop the hose toward the AOST along the bottom of the battery box Figure 47 Figure 46 Connect compressor oil return hose Figure 47 Connect compressor...

Page 37: ... Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 35 Using the supplied 90 fitting connect the 1 2 in hose to the fitting on the AOST Figure 48 Figure 48 Connect compressor oil return hose ...

Page 38: ...ove the oil filter from the AOST and discard the cardboard warning tag Apply a light film of compressor oil to the filter gasket and thread the filter onto the AOST until the gasket makes contact Tighten the filter an additional 3 4 to 1 turn after the gasket contacts the base Remove the fitting from the inlet Figure 49 Using a funnel fill the system with the supplied oil When dry the system will ...

Page 39: ...including the park brake mechanism steering column and pedals Before drilling any holes ensure there are no OEM wires hoses or components that may be damaged Do not use a test light to probe for power on vehicle circuits the increased current draw of the test light may damage components VMAC recommends using only sealed crimp and solder butt connectors for all electrical connections To ensure a du...

Page 40: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 38 Figure 50 Analog throttle control Analog Throttle Control Wire Schematic ...

Page 41: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 39 Figure 51 Digital throttle control Digital Throttle Control Wire Schematic ...

Page 42: ...ir Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 40 Figure 52 ECM TCM Connectors As viewed from mating side X2 Engine Control Module ECM Transmission Control Module TCM Pin 38 Pin 85 ...

Page 43: ...le control into the matching connector on the accelerator pedal Connect the interface harness to the matching connector from the Control Box Replace the kick panel Attach the 2 green wires with ring connectors to a good ground under the dash Digital Throttle Control only Locate the OBD II port generally located under the dashboard beneath the steering wheel column Remove the fasteners securing the...

Page 44: ...perature sensor Grey cable with the black 3 pin connector pressure sensor Red wire from the white 4 pin interface key switched 12 V Long blue wire automatic transmission only Cover all of the engine compartment wires with plastic loom Analog throttle control only Locate the X2 ECM connector the X2 connector is the leftmost connector located on the driver side radiator support Splice the white wire...

Page 45: ...lletin UI 148 Scan or click the QR code Locate the junction block located in the driver side foot well near or below the parking brake mechanism Remove the plastic cover on the junction block by gently prying the 3 locking tabs away from the housing to release the cover Remove the 3 nuts securing the junction block Figure 54 Lift the assembly up and out of the way to give clearance to the electric...

Page 46: ...t 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 X1 connector into the junction block 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 p...

Page 47: ... as high as possible Air Receiver Tank AOST Check valve If an air receiver tank will be used with this system the following installation procedure must be used to prevent damage to the system The VMAC compressor system will automatically depressurize when it is shutdown therefore the hose from the VMAC AOST to the air receiver tank must have a check valve installed this prevents blow back and mois...

Page 48: ...the advantage of lowering the duty cycle of the compressor system Pressure Gauge While not critical to system performance a pressure gauge is important for fine tuning the system and simplifies any potential troubleshooting Install a 200 psi pressure gauge downstream of the air discharge valve Pressure Regulator and or Lubricator or FRL The compressor can produce air pressures up to approximately ...

Page 49: ...ure all wiring hoses and tubes are secured with cable ties and protected with loom as required Pull any excess wiring back into the cab and tie it up and out of the way under the dash with cable ties Replace all dash panels and covers removed during installation Install the power steering reservoir using the supplied spacers and fasteners Figure 57 Completing the Installation Connect the batteries...

Page 50: ... correct Perform a final inspection of the installation to ensure everything has been completed Check all wiring for security and protection Ensure nothing is touching the compressor body Install the VMAC Air Test Tool P N A700052 with the 70 cfm 0 190 in orifice installed and the ball valve closed Ensure all of the compressor outlets are closed Ensure the parking brake is engaged and the transmis...

Page 51: ...ottle will respond normally to air demand When the VMAC system is first engaged the engine speed should increase to 1 500 rpm and then drop down to VMAC base idle approximately 1 000 rpm once system pressure is reached With the system running check for Coolant leaks Compressor oil leaks Allow the compressor to run until the system reaches full system pressure Engine speed should reduce to between ...

Page 52: ...then on again to reset the safety parameters Repeat these steps in all gear selector positions to ensure the engine speed does not increase unless the gear selector is in PARK or NEUTRAL Allow the compressor to run until the system reaches full system pressure Confirm all air valves are closed and the system has no air leaks Turn off the compressor Ensure any stored air is drained from the system ...

Page 53: ...transmission in PARK and fully apply the park brake Allow the engine to run until it is at operating temperature Turn on the air compressor system and allow it to operate until the oil is warm Observe the pressure gauge Pressure should be approximately 150 psi Open the ball valve on the test tool and observe the engine tachometer Analog throttle control Engine speed should increase to approximatel...

Page 54: ...l can be adjusted to reduce the maximum VMAC rpm Safety features The throttle control has built in safety features that will disable the system if an unsafe condition is detected or either of the lock out parameters is not met the vehicle must be in PARK and the park brake must be engaged If an unsafe condition is detected the STATUS LED will turn off and engine speed will return to idle Once all ...

Page 55: ...of air use without the need to increase engine speed RAMP UP PRESSURE should only be adjusted if the maximum system pressure is changed via the inlet regulator To maintain proper performance and rapid response to air demand ensure the RAMP UP PRESSURE is set at no more than 20 psi below the maximum system pressure The RAMP UP PRESSURE can be set to 100 PSI 120 PSI 140 PSI or 160 PSI via the or but...

Page 56: ...3 cm W 14 5 in 36 8 cm H Weight 35 lb 15 8 kg Filter Regulator Lubricator FRL 70 cfm Part number A700151 Extends the life of air tools filter removes contaminants from the compressed air adjustable regulator can reduce air pressure going to tools lubricator adds atomized tool oil to the air stream to lubricate air tools Tool oil not included Max air flow up to 70 cfm 150 psi Port size 3 4 in NPT i...

Page 57: ...nsions 73 3 4 in 187 3 cm L 14 in 35 6 cm D Weight 95 lb 43 1 kg 10 Gallon 200 psi Air Receiver Tank w Mounting Feet Part number A300047 Air receiver tanks are used for lowering compressor duty cycle and removing water from compressed air Recommended for optimum operation of VMAC Hydraulic Air Compressors VMAC Diesel Driven Air Compressors UNDERHOOD40 UNDERHOOD70 including Green Series Air Compres...

Page 58: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 56 Notes ...

Page 59: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 57 Notes ...

Page 60: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 58 Notes ...

Page 61: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base www kb vmacair com 59 Notes ...

Page 62: ...t 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 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 ...

Page 63: ......

Page 64: ...888 241 2289 tech vmacair com 877 740 3202 warranty vmacair com www vmacair com www kb vmacair com 1333 Kipp Road Nanaimo B C V9X 1R3 Canada Manufactured by ...

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