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VMAC

–

Vehicle Mounted Air Compressors

Toll Free:

1-888-241-2289

Fax: 1-250-740-3201

Installation Manual for VMAC

System

V900113

2013-2011 GM 2500HD-3500HD

6.6L Duramax Diesel

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

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

Additional Requirements .......................................................... 3

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

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

2.1 Preparing for Installation - Electrical................................... 8

2.2 Preparing for Installation - Mechanical ............................... 11

Part 3: Installing the Control Components ............................... 16

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

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

3.3 Connecting the Under-Hood Wiring ................................... 18

Part 4: Installing the Tank and Hoses........................................ 20

4.1 Installing the Tank and Brackets ........................................ 20

4.2 Installing the Tank Assembly .............................................. 22

Part 5: Installing the Main Bracket, Compressor, and Cooler 25

5.1 Installing the Main Bracket and Compressor ..................... 25

5.2 Installing the Oil Cooler ...................................................... 30

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 Connecting to Switched Power .......................................... 37

6.2 Securing the Wiring ............................................................ 37

6.3 Safety Test ......................................................................... 38

6.4 Before Starting the Engine Checklist.................................. 38

6.5 After Starting the Engine Checklist .................................... 39

6.6 Setup, Performance Testing and Adjustments ................... 40

6.7 Auxiliary Air Receiver ......................................................... 41

Accessory Products from VMAC ............................................... 42

Содержание V900113

Страница 1: ... 3 3 Connecting the Under Hood Wiring 18 Part 4 Installing the Tank and Hoses 20 4 1 Installing the Tank and Brackets 20 4 2 Installing the Tank Assembly 22 Part 5 Installing the Main Bracket Compressor and Cooler 25 5 1 Installing the Main Bracket and Compressor 25 5 2 Installing the Oil Cooler 30 5 3 Connecting the Hoses 33 5 4 Completing the Installation 34 5 5 Adding Oil to the System 36 Part ...

Страница 2: ... and wires that are rerouted or shifted during installation must be secure so that they do not contact excessively hot areas or sharp edges When 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 informat...

Страница 3: ...ers 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 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 3 8 7 16 1 2 5 8 3 4 Foot pounds ft lb 40 60 90 180 320 Newton meter N m 54 81 122 244 434 METRIC CLASS 10 9 Size M8 M...

Страница 4: ...e 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 information on replacement hoses and hose extension kits ...

Страница 5: ...t allows VMAC to assist in customer inquiries and the ordering of parts Place the system identification number plate on the plastic upper radiator cover in an appropriate area close to the compressor 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 s...

Страница 6: ...VMAC Truck Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 6 Figure 1 1 ...

Страница 7: ...x 1 250 740 3201 7 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 ...

Страница 8: ...steps 2 1 Preparing for Installation Electrical Locate the wiring harness on the inside of the driver side frame rail crossing from the driver side frame rail to the transmission above the driver side PTO cover Figure 2 1 This harness is close to connector X300 Figure 2 1 Remove electrical tape and peel back plastic loom from the harness Locate the two orange with black stripe wires in the bundle ...

Страница 9: ...n the ignition switch off Mark the wire for electrical connections later in the installation process Remove air filter assembly and air intake tube from the front passenger side of the engine Whenever the engine or turbo intake is exposed care must be taken to cover all openings to ensure that no foreign objects can enter and cause damage Locate the wiring harness below the engine intake which run...

Страница 10: ... the engine is idling If the voltmeter has a frequency setting it should read the same frequency as the engine RPM Turn the ignition switch off Mark the wire for electrical connections later in the installation process Locate the Air Conditioning pressure sensor located at the front driver s side of the engine Figure 2 3 A C pressure switch Figure 2 3 Remove loom and plastic tape Cut the OEM conne...

Страница 11: ...ose and modify as shown Figure 2 4 and save for reinstallation later Cut off tab flush with bottom of hose clamp Figure 2 4 Drain the coolant Save the coolant as it will be reused later Remove lower radiator hose To remove the hose it must be disconnected at The engine block water pump spigot The radiator The surge tank The hard pipe running to the heater core The last three connections can all be...

Страница 12: ...ator out of the truck together Modify the lower stator mount by cutting a notch to clear the VR pulley and belt that will be installed later Figure 2 5 3 4 2 1 2 1 4 Remove shaded area Stator partial view Lower Mount Figure 2 5 Remove the OEM fan wire bracket pin from the engine block This pin was used to connect the fan wire harness bracket to the engine Install the supplied fan wire bracket pin ...

Страница 13: ...ing the VMAC extraction tool Figure 2 7 Reinstall the crankshaft bolt and use the flex bar to slowly turn the engine over CW until the pin is facing upwards 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 Fit the split end of the tool on the end of the shaft over the crankshaft pin and tap...

Страница 14: ... 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 by twisting it into position with a crescent wrench Figure 2 8 High strength crank pin Figure 2 8 Apply a light wipe of oil to the inside of the OEM crank pulley and install the pulley back onto the crankshaft ...

Страница 15: ...on the OEM pulley Figure 2 9 Thread the M18 x 100 mm center bolt with OEM washer into the crankshaft Install an engine locking tool and torque the center bolt to 250 ft lbs Figure 2 9 The VMAC crankshaft locking tool can be used again by fitting the two pins on the other end of the tool into the holes on the VMAC pulley Position the roll pins here Figure 2 9 Reinstall the OEM belt ...

Страница 16: ...Inle t va lve Clutch Green Gree n Bla ck OEM FU SE PANEL Black 3 pin co nnector To ground Park Brake Switch C onnect T hrottle Co ntroll er Conne ct to a ccelera tor p edal OEM Conn ecto r from To ground Blue F irewall C on trol bo x White Blue White wire w Black stripe under Filter Asse mbly Oran ge wire w Black stripe in harness near Connector X300 0 V in Park N eutral 1 2 V in other gears accel...

Страница 17: ...he multi pin connector from the accelerator pedal and plug it into to the matching connector at the throttle control box then plug the connector from the throttle control box into the accelerator pedal Connect the wires with the ring connector from the throttle control box and from the interface connector to a good metal ground Connect the red wire from the control box to the red wire from the thr...

Страница 18: ...rk brake switch then connect the OEM park brake connector to the piggyback connector 3 3 Connecting the Under Hood Wiring Locate the orange wire with black stripe in harness going from driver side frame rail to drive side PTO cover harness close to connector X300 wire marked earlier during the install Solder and seal the long blue wire from the throttle to the orange wire with black stripe as show...

Страница 19: ...pe Locate the white wire with black stripe below the throttle body wire marked earlier during the install Solder and seal the white wire from the throttle control to the white wire with black stripe as shown in Figure 3 4 Fit the loom back over the wires and replace the tape Remove the cover from the fuse panel and route the red wire with the inline fuse to the panel Refer to Part 6 for connection...

Страница 20: ...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 information on replacement hoses and hose extension kits 4 1 Installing the Tank and Brackets The tank will mount to the driver s side frame rail between the two front body mounts Figure 4 1 5 3 8 bolts 3 8 flat wash...

Страница 21: ...end of the tank Reinstall the two 1 4 clamp bolts in the C clamps so that the heads of the bolts face toward you and install the nuts loosely Rotate the tank so that the directional arrow on the end of the tank is parallel to the work bench and faces away from you Check the distance of each C clamp from the ends of the tank and tighten the clamp bolts so that the clamps grip the tank securely Appl...

Страница 22: ...oute above the F mount Place the rear F shaped tank mount 18 towards the rear and against the frame Route the emergency brake cable between the raised mounts of the F mount Dislodge the wiring harness plastic locator if necessary to allow the wiring harness to route around the F mount Insert the 5 long 3 8 bolts with flat washer through the upper hole on the tank strap flat bars Select the appropr...

Страница 23: ... wire harness is not pinched between the mounts and the frame Apply Loctite and install 5 16 x 1 bolts with flat washers and nuts into the two holes on each bracket but do not tighten Slide the tank rearward on the frame to provide clearance for attaching the hoses All hoses tubes and wires that are rerouted or shifted during installation must be secure so that they do not contact excessively hot ...

Страница 24: ...de the tank forward providing sufficient space for connections to the fitting on the rear of the tank and enough room to easily change the oil filter at the front Position the tank to center the bolts in the C clamp slots and tighten them Tighten all the fasteners Check for clearance around the tank and no interferences Re adjust as required If the frame allows use of the upper holes the bottom of...

Страница 25: ...ley Discard this bolt Figure 5 1 Install the tensioner bracket assembly with supplied bolts and spacer as shown Apply loctite and torque bolts to specification Figure 5 1 Lower the fan and stator back into the engine bay but do not attach to engine Leave fan resting on the lower shroud You will not be able to lower fan and stator into place after the tensioner and idlers have been installed Figure...

Страница 26: ...lts to specification Note the OEM alternator mount bushing comes supplied from the factory in the location You may need to slide the bushing towards the front of the truck before installing the main bracket Figure 5 2 Install the tensioner and idlers Figure 5 1 Remove the two bolts holding the EGR elbow on the top of the engine Discard these bolts as they will not be used again Ensure the metal ga...

Страница 27: ...ure 5 3 Install the compressor and brace as shown with supplied fasteners Apply loctite and torque to specifications Ensure that any wire bundles are repositioned and not pinched underneath the compressor or bracket Figure 5 4 Install the VR belt Figure 5 6 Remove EGR Elbow Bolts 2x Front ...

Страница 28: ...nector near the power steering pump When routing harness make sure it is clear of the fan blades and belts Secure with tie straps where appropriate If for any reason the inlet valve is removed it must be noted that this system use two different length bolts in the inlet valve Two 55mm bolts go in the two holes closest to the air filter and 50mm bolts go in the holes furthest away from the air filt...

Страница 29: ...ey Tensioner Idler VR Belt Figure 5 6 Drill 1 4 hole in upper fan shroud 3 1 4 directly below existing ATCM mount hole as shown and then use the ATCM to locate a second 1 4 hole below the first and 1 toward the center of the shroud Figure 5 7 Apply Loctite and install the two supplied M6 flange head bolts and flange nuts into the holes as shown Test fit ATCM but don t mount it to the shroud until ...

Страница 30: ...ss connector is reattached securely Figure 5 7 5 2 Installing the Oil Cooler Measure and cut the lower radiator hose 2 below the plastic molded tee on the engine side of the radiator hose 2 will bring you to the start of bend 1 in the hose Figure 5 8 Measure to the end of bend 2 on the lower radiator hose and cut Leave all the straight section after bend 2 Figure 5 8 Do not damage the 1 hoses comi...

Страница 31: ...ator hose sections Install the cooler under the tubular front cross member ahead of the stabilizer bar with the oil ports facing forward using the OEM skid plate bolts Leave bolts slightly loose to allow for optimal radiator hose fitment Figure 5 9 OEM Bolts Front Tubular Cross Member Stabilizer Bar Front Figure 5 9 Connect the lower radiator hoses to the cooler with supplied hose clamps Reinstall...

Страница 32: ...onnect the 90 end of the hose to the passenger side of the cooler Apply protective loom and route the straight end of the longer 1 2 hose from the cooler parallel to the shorter 1 2 hose under the shroud to the left of the steering box rearward along the top of the frame rail over the upper control arm mount and between the inner fender and the cab mount to the front of the tank Connect the 90 end...

Страница 33: ...e 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 Insert the 3 16 and 1 4 tubes into the fittings on the back of the tank and cover them with protective loom Route them with the 3 4 hose up ...

Страница 34: ...5 13 Tighten all fittings Remove the cardboard protector from the filter mount base on the tank Apply a thin coating of compressor oil to the oil filter gasket and install the filter on the tank Tighten the filter an additional 3 4 turn after the gasket contacts the base 5 4 Completing the Installation Install the air filter assembly and air intake tube Measure and cut the upper radiator hose 14 1...

Страница 35: ...se so the end that previously went to the engine before being modified will now connect to the supplied VMAC tube connector Figure 5 15 Supplied VMAC rad hose Supplied VMAC tube connector Modified OEM upper rad hose From radiator To engine This end was attached to engine before being modified Figure 5 15 Install VMAC logo plate onto the top of the compressor Secure oil return hose and main wire ha...

Страница 36: ...oil in this system Failure to use this special oil will result in damage to the compressor and will void your warranty Remove the fill cap from the main discharge line tee at the rear of the compressor and pour about 4 US quarts 4 litres of the supplied oil into the oil fill hole Add oil slowly as it might take some time for the oil to flow down the hose and into the tank Allow at least 5 minutes ...

Страница 37: ...a voltmeter to determine which side is switched 12V 6 2 Securing the Wiring Under the hood group all the wires and harnesses from the compressor and secure them together with electrical tape then protect them from damage with plastic loom Cover the white wire and the blue wire with loom and make sure that they are secured Route and secure the white wire with loom along the driver side frame contin...

Страница 38: ...clutch engage Release the park brake The green LED should flash PARK BRAKE will show on the display and the compressor clutch should disengage Apply the park brake again wait 20 seconds and push the ON button The green LED should come on and the compressor clutch should engage Turn the ignition key OFF If the truck fails the test check the wiring to make sure that all the connections are correct a...

Страница 39: ...ev up to 1800 2200 rpm and then idle down to 900 1000 rpm Release the park brake The green light should flash PARK BRAKE will be displayed and the clutch will disengage Apply the park brake Wait for the twenty second internal timer to reset and then press the ON button The green light should illuminate the clutch should engage and the engine should rev up to 1800 2200 rpm and then idle down to 900...

Страница 40: ...s 1 hour preferred Road test the truck for approximately 14 miles 20km 6 6 Setup Performance Testing and Adjustments This system has been adjusted at the factory for general operation If your tests indicate that adjustment is necessary refer 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 sys...

Страница 41: ...auge begins to drop Engine speed should start to ramp up when air pressure drops to approximately 140 PSI 6 7 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 the VMAC tank to the auxiliary air receiver must have a one way check valve installed part 3600078 to p...

Страница 42: ...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 Tank Part Number A300010 Thirty five gallon capacity in a compact tank complete with fittings and a gauge DE ICING HEATER De icer Kit Part Number A700031 Insulated rope heater prevents freezing of lin...

Страница 43: ...VMAC Vehicle Mounted Air Compressors Toll Free 1 888 241 2289 Fax 1 250 740 3201 43 ...

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