Vmac V900093 Page 46 Installation Manual Download

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Summary of Contents for V900093

Page 1: ...H D 3 5 0 0 H D D u r a ma xD i e s e l S y s t e m V 9 0 0 1 0 3 2 0 1 0 2 0 0 7G M2 5 0 0 H D 3 5 0 0 H D G MT 9 0 0D u r a ma xD i e s e l w w w v ma c a i r c o m V R 7 0U N D E R H O O D A I RC...

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Page 3: ...ng 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...

Page 4: ...e 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 fo...

Page 5: ...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 po...

Page 6: ...formation 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 li...

Page 7: ...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 Se...

Page 8: ...VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 6 Figure 1 1...

Page 9: ...cing 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...

Page 10: ...age 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 st...

Page 11: ...ack stripe FWD Figure 2 1 2 1 2 V900103 Automatic Transmission Trucks Locate the engine control module and connector ECMX2 Locate the three orange wires with a black stripe Switch the ignition on and...

Page 12: ...white wire with a black stripe find the three wires that are dark blue with a white stripe in the top connector Use the same verification process as for the 2007 Classic to locate the correct wire Mar...

Page 13: ...e the top engine coolant tube from the thermostat housing and the top of the engine and remove the O ring and thermostatic switch Remove the wiring harness from the retaining clip on the driver s side...

Page 14: ...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 b...

Page 15: ...VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 13 Slide Pinch Bolt OEM Crank Pin Figure 2 3 High strength crank pin Figure 2 4...

Page 16: ...the pulley back onto the crankshaft 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 5 Thread the M18 x 100 mm center...

Page 17: ...Connect to accelerator pedal OEM Connector from accelerator pedal To ground Blue Blue Throttle Controller Blue Blue Connect the blue wires MANUAL TRANSMISSION AUTOMATIC TRANSMISSION Do not use short b...

Page 18: ...r pedal To ground Blue Blue Throttle Controller Blue Blue Connect the blue wires MANUAL TRANSMISSION AUTOMATIC TRANSMISSION Do not use short blue wire with crimp connector Throttle Controller Blue Blu...

Page 19: ...tion is the large wire harness plug behind the park brake grey wire with a 3 pin black connector grey wire with a 4 pin green connector white wire with a plug connector white wire with no connector au...

Page 20: ...Figure 3 1 Mid Bussed Electrical Center SEO Port Figure 3 1 Remove the cover and locate the SEO port Connect the power and ground plug from the interface cable to the SEO port Figure 3 2 and replace...

Page 21: ...the ON position 3 2 3 Power Connection 2008 2010 models Locate the electrical box on the firewall between the park brake and the steering column Test the connections in the center of the electrical b...

Page 22: ...3 3 3 1 Automatic Transmission Solder the blue wire to the orange wire with a black stripe at the lower ECM connector located and marked with tape in Part 2 Preparing for Installation and seal the co...

Page 23: ...ositioned to conform to variations in chassis configuration This will affect the positioning of the rear C clamp 1 4 and 3 16 tubes 3 4 hose fitting 1 2 hose fitting C clamp Tank strap mount Tank stra...

Page 24: ...stall the 1 4 inch clamp bolts into the C clamps so that the heads of the bolts face toward you and install the nuts Rotate the tank so that the directional arrow on the end of the tank is parallel to...

Page 25: ...three clips holding the wire harness on the outside of the driver s side frame rail Remove the front park brake cable guide from the frame and leave it attached to the cable Remove the brake line from...

Page 26: ...may have to be positioned either in front of or behind the electronic brake module on the inside of the frame Select the best location once the tank is in position Place the tank assembly under the dr...

Page 27: ...re attached at both ends and are properly routed 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 ed...

Page 28: ...41 2289 Fax 1 250 740 3201 26 Place the OEM park brake cable bracket on top of the flat bracket and fasten it in place with the OEM bolt Position the brackets so that it pulls the cable down enough to...

Page 29: ...lowest section of the radiator hose Connect the cooler spigots to the cut ends of the lower radiator hose so that the cooler is between the radiator and engine with the oil connection fittings toward...

Page 30: ...can be done easily from above 5 2 Installing the Main Bracket Place the replacement metal coolant tube Figure 5 2 in position with the upper bracket facing the front of the truck so that it will faste...

Page 31: ...mps Remove the belt tensioner assembly and the idlers from the VR main bracket Figure 5 3 VR compressor Main Bracket Idlers Idlers Tensioner Figure 5 3 Place the VR bracket on the front of the engine...

Page 32: ...t sits flat on the mount pad of the VR casting If necessary pivot the power steering pump upwards or downwards on the front center bolt until the rear bracket sits flat on the VR bracket mount pad Tig...

Page 33: ...elt Figure 5 5 Crank Pulley Tensioner VR Compressor Back Idler Back Idler Ribbed Idler Ribbed Idler Figure 5 5 Remove the compressor inlet valve and cover the opening to protect the compressor Place t...

Page 34: ...wo holes closest to the air filter and the two shorter bolts go in the holes furthest away from the air filter figure 5 6 Figure 5 6 Never use an impact wrench to install inlet bolts The torque spec f...

Page 35: ...connect the straight end to the fitting on the side of the compressor Tighten the fittings at both ends of the hose Connect the 45 degree end of the 3 4 inch hose fitting to the fitting on the back o...

Page 36: ...clearance for the oil filter Tighten the swivel fittings and hose fittings Reposition the tank on the frame if necessary and tighten the cable clamps Thread a second nut on each cable and tighten it a...

Page 37: ...l the air intake resonator chamber Install the supplied P clamp over the intercooler tube Install the supplied bracket over the mounting stud behind the intercooler tube with the bracket facing the in...

Page 38: ...the fill plug from the air inlet control valve and pour oil into the oil fill hole on the inlet control valve using a funnel Turn the compressor clutch clockwise with a ratchet and a 1 2 inch socket...

Page 39: ...and apply the park brake Turn the ignition key ON but do not start the engine Check the control box to see if there is a number showing in the hour meter If there is no display there is no power to t...

Page 40: ...unning engage the park brake place your foot firmly on the brake pedal Start the compressor and let the truck ramp up to 1800 rpm and then drop down to 1000 rpm Shift the truck into gear The engine sh...

Page 41: ...to the owner s manual for specific instructions on how to adjust the system You can test the system operation using the tools that will be operated by the system or you can test operations using an o...

Page 42: ...140 psi 6 5 Auxiliary Air Receiver If you intend to use an auxiliary air receiver with this system you must observe the following installation procedure to prevent damage to the system The line from t...

Page 43: ...from the air stream Adds atomized tool oil to lubricate tools Reduces pressure for longer tool life Hose Reel Part Number A700007 Secure compact retractable hose storage in a sturdy reel Air Receiver...

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Page 45: ...y _____________________ State Prov ______________ Installation Date _____ _____ _____ Day Month Year Owner Information Company Name ______________________________________ Address _____________________...

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Vmac V900093, Installation Manual

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