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VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201

1

Installation Manual for VMAC System V900063

General Motors 2002 – 2005 Duramax Diesel

2500 HD – 3500

General Information..................................................................... 3 Before You Start ....................................................................... 3 Special Installation Notes ......................................................... 4

Part 1: Preparing for Installation............................................... 5 1.1 Preparing for Installation................................................. 5

Part 2: Installing the Tank and Hoses....................................... 10 2.1 Installing the Tank and Brackets ........................................ 10 2.2 Installing the Tank Assembly.............................................. 13

Part 3: Installing the Main Bracket and Compressor .............. 15 3.1 Installing the Main Bracket ................................................. 15 3.2 Installing the Cooler............................................................ 18 3.3 Connecting the Hoses ........................................................ 19 3.4 Mounting the Fuel Module and Hoses ............................... 20 3.5 Completing the Installation ................................................. 26 3.6 Adding Oil to the System.................................................... 29

Part 4: Installing the Control Components .............................. 30 4.1 Installing the Components.................................................. 32 4.2 Connecting the In-cab Wiring ............................................. 33 4.3 Connecting the Under-hood Wiring.................................... 33 4.4 Connecting the Power Supply Wire ................................... 36 4.5 Completing and Testing the Installation ............................. 37

Part 5: Finishing the Installation ................................................ 38 5.1 Before Starting the Engine Checklist ................................. 38 5.2 After Starting the Engine Checklist..................................... 39 5.3 Setup, Performance Testing and Adjustments................... 40 5.4 System Identification and Warnings................................... 41 5.5 Auxiliary Air Receiver ......................................................... 42

Accessory Products from VMAC ............................................... 43

VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622

Fax: 1-250-740-3201 2

Installation Manual - Document #1930014 Installation Manual for VMAC System V900063 General Motors 2002 – 2005 Duramax Diesel 2500HD - 3500 Changes and Revisions

Version Revision Details Revised by/date Approved Implemented 00 Original manual IB 10 Feb 2004 SC 23 Apr 2004 23 Apr 2004 a General revisions IB 14 Oct 2004 SM/BC 18 Jan 2005 18 Jan 2005 b Sched. review, minor graphic IB 13 Apr 2005 SC 13 Apr 2005 15 Apr 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

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.

Copyright 2005 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


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. 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 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 Blue Green Green


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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)

The following additional materials are recommended:

• assorted sizes of fireproof protective plastic loom • assorted lengths of nylon tie-straps


5

Part 1: Preparing for Installation

1.1 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.

□ 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.

□ On trucks with an automatic transmission, remove the automatic transmission control module (ATCM) and cover assembly from the driver’s side of the upper fan shroud. Move the module out of the way but do not disconnect the wire harness.

□ Remove the upper fan shroud.

□ Remove the fan using the appropriate fan wrench.

□ Remove the passenger side intercooler tube and hoses.


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□ Remove and discard the metal coolant tube between the heater hose and the lower radiator hose.

□ Remove the bolt securing the oil filler tube to the front of the intake manifold.

□ 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 the OEM belt.

□ Remove all wire harness retainers from the OEM alternator mount bracket.

□ Remove the alternator.

□ Remove the OEM idlers and tensioner from the alternator mount bracket.

□ Remove the OEM alternator mount bracket.

□ Remove the rock guard from under the front of the truck. Keep the bolts.

□ Remove the lower radiator hose.

□ 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


7

□ Remove the crankshaft pin 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

□ 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 by twisting it into position with a crescent wrench (Figure 1.1).

High-strengthcrank 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.

□ On trucks after 2004.5, remove and discard the OEM cast mounting bracket from the front of the engine.


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1.1.1 Trucks prior to 2004.5

□ Remove the breather hose from between the lower engine block and the check valve in the bottom of the breather chamber casting (Figure 1.2).

Breather check valve Figure 1.2

□ Remove the 8 mm bolt from the cast alternator mounting bracket that holds the breather tube and wire harness (Figure 1.3).

□ Remove the bolt securing the engine breather hose and steel pipe from the breather chamber in the cast aluminum bracket and remove the hose and pipe.

□ Cut the tie wrap holding the loom and breather tube together.

□ Remove and discard the steel breather pipe from the end of the rubber breather hose.

□ Remove the two nuts from the fuel bleed valve studs.

□ Remove the short fuel outlet hose and angled banjo fitting from the engine-side fuel rail. Remove the banjo from the hose and discard the hose.


9

Engine breather chamber

Fuel bleed valve studs

8 mm bolt for breathertube clamp

Breather tube

Figure 1.3

□ On trucks up to 2004.5, remove the OEM check valve fitted in the bottom of the casting.

□ Remove and discard the cast mounting bracket.

□ Remove the two OEM studs from the engine block, located below the alternator mount, that held the OEM bracket in place.

□ Unclip the top of the wire harness plastic channel attached to the engine fuel rail, carefully lift out the wiring and cut the ties holding the module-end of the channel.


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Part 2: Installing the Tank and Hoses

2.1 Installing the Tank and Brackets The tank will mount to the passenger side frame rail between the two body mounts (Figure 2.1).

1/4” line

5/16” line3/4” hose fitting

1/2” hose fitting

C-clamp

Tank strap mount

Tank strap cable

Tube clamp

Oil filter

5/16” nuts andwasher

Tank strap flat bar

Figure 2.1

□ Remove the oil filter from the front of the tank, fill it with compressor oil, cover it and place it out of the way.

□ Place the tank on a work bench with the front (oil filter end) of the tank to your left.

□ Remove the two 1/4 inch pinch bolts from the C-clamps. Expand the clamps slightly, slide them over the front of the tank and position them about 6 inches from each end of the tank.


11

□ Place the two L-shaped tank strap mounts under the C-clamps with the right-angle ends facing you and hanging over the edge of the work bench.

□ Apply Loctite and thread 5/16 x 1/2 inch bolts with flat washers into the bottom hole on each bracket, but do not tighten.

□ Install the 1/4 inch pinch 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 the work bench and faces toward you (Figure 2.2), check the distance of each C-clamp from the ends of the tank and tighten the pinch bolts so that the clamps grip the tank securely.

Figure 2.2

□ Thread the 1/4 and 5/16 inch fittings on the steel lines to the matching fittings on the back end of the tank, but do not tighten the fittings. Route the lines along the top of the tank across the two C-clamps.

□ Place the two insulated tube clips over the steel lines with the mounting holes downward and align them with the top C-clamp mounting holes (Figure 2.3).

□ Apply Loctite and insert 5/16 x 1/2 inch bolts through the clips and the C-clamp and thread them into the mount brackets.


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□ Center the bolts in the C-clamp slots and tighten them.

Tank strap mount

5/16" tube

1/4" tube

Insulated double tube clamp

5/16" x 1/2" bolt

Figure 2.3

□ Apply Loctite pipe thread sealant and install a 90 degree fitting to the outlet on the tank. Tighten it to about the four O’clock position (Figure 2.4) for testing, then reposition as required for operational connections.

Figure 2.4

□ Thread the 1/2 inch 45 degree elbow and the 3/4 inch 90 degree elbow onto the matching fittings on the front of the tank, but do not tighten them.

□ Push the insulated tube clips toward the tank to provide clearance for the mounting cables (Figure 2.5).


13

Push forward slightly for cable clearance

Figure 2.5

2.2 Installing the Tank Assembly

□ On 2500 HD models, install the 1/2 inch spacer on each cable strap and slide them to the stop ends of the cables.

□ Insert the threaded ends of the cable straps through the end hole on each of the bar straps.

□ Place the bar straps in position on the inside of the frame, one in front of the transmission cross-member and one behind, with the cable straps over the top of the frame (Figure 2.6).

□ Lay the tank assembly under the passenger side of the vehicle and route the 5/16 and 1/4 inch hoses over the top of the body mount into the engine compartment.

□ Lift the tank assembly and support it in position so the tops of the two tank strap mounts fit over the top of the frame rail. If there is an OEM wire harness, make sure that it is outside the mounts and is not pinched between the mounts and the frame.

□ Wrap the two tank cable straps around the tank strap mounts. Make sure that they fit in the upper and lower cut-outs of the tank strap mounts (Figure 2.6).


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Cable must fitin the grooves

Figure 2.6

□ Insert the threaded end of the cable through one of the lower holes on the tank strap flat bars. Select the appropriate hole that best matches the frame of the vehicle.

□ Place a 5/16 flat washer and nut on each tank cable strap and tighten just enough to hold the tank in place but loose enough to allow the tank to be positioned along the frame.

□ Slide the tank rearward on the frame to provide clearance for attaching the hoses.

□ Route the straight ends of the 3/4 inch hose and longest 1/2 inch hose from the engine compartment over the body mount to the tank, connect them to the matching fittings on the tank, but do not tighten.

Make sure that the cable straps are behind the two steel lines and that no OEM lines or wires are pinched between the cable and the mount. !


15

Part 3: Installing the Main Bracket and Compressor

3.1 Installing the Main Bracket

□ Remove the three socket head bolts and remove the belt tensioner assembly (complete with mounting pad) from the VR main bracket.

□ On trucks before 2004.5, transfer the OEM check valve from the alternator cast bracket to the bottom of 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.

Install OEM back idler here

M10 x 85 mmsocket head bolts(one behind the VR tensioner)

Install the OEMtensioner here

Figure 3.1


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□ Apply Loctite and thread the four M10 x 85 low profile socket bolts in just enough to hold the bracket in place (Figure 3.1). 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.

□ Apply Loctite and install the VR tensioner, the OEM belt tensioner and one OEM back idler (Figure 3.1).

□ Install the alternator.

□ 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 3.2).

Position the roll pins here

Figure 3.2

□ Apply Loctite and 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 200 ft-lbs (280 N.m).

□ Install the OEM belt (Figure 3.3) on trucks built before 2004.5; on trucks after 2004.5, use the replacement belt.

□ Remove the nuts and bolt holding the compressor to the packaging base.


17

OEM ribbed idler

OEM tensioner

Alternator

OEM back idler

A/C

P/SFan

OEM crank pulley

Figure 3.3

□ Attach the straight end of the short 1/2 inch hose to the fitting on the side of the compressor with the hose routed over the top of the compressor just behind the clutch assembly. Tighten the fitting.

□ Place the compressor on the mounting bracket, apply Loctite and install the two nuts and the supplied bolt (shorter than the one you discarded) to the underside of the compressor. Torque them to 19 ft-lbs (25 N.m).

□ Install the VR drive belt (Figure 3.4).


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VR70 Tensioner

VR70 Ribbed idler

VR70 Compressor

VR70 Idler

Crankshaft pulley

Figure 3.4

3.2 Installing the Cooler

□ Apply Loctite and attach the cooler to the rock guard, (with the oil hose connections facing to the rear) using the 5/16 x 1/2 inch NC bolts, then install the assembly to the vehicle using the OEM fasteners (Figure 3.5).

1/2” hoseto compressor

1/2” hose from tank

Figure 3.5

□ Remove and discard the coolant fill hose plastic alignment clips from the OEM lower radiator hose.

□ Cut the lower radiator hose to length (Figure 3.6). The third cut may vary slightly according to vehicle model.


19

Always cut the least amount indicated and shorten additionally as required.

To engine

To driver side of cooler

To passenger side of cooler

Coolant fill hose

DISCARD

6-3/4” 11”

1-1/4”

Heater return hose

To radiator

Figure 3.6

□ Install each hose section as shown in Figure 3.6. Route the coolant fill hose between the radiator and the transmission cooling line (on automatic transmission trucks).

□ Check clearance between the radiator end of the hose and the bottom VR pulley. If necessary, cut an additional 1/4” from the radiator end to provide more clearance.

3.3 Connecting the Hoses

□ Route the 90 degree end of the 1/2 inch hose from the tank along the frame and under the compressor and connect it to the driver side fitting on the cooler.

□ Route the 1/2 inch hose from the compressor under the compressor and connect the 45 degree end to the passenger side fitting on the cooler.

□ Route the 3/4 inch hose from the tank and connect it to the matching fitting on the compressor. Loop it so that it forms a smooth curve parallel to the middle of the compressor and will sit on the fender liner once it is installed.


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No part of the 3/4 inch hose can be higher than the compressor. If it is, the system will not function correctly.

□ Route the 1/4 and 5/16 inch hoses to the compressor and connect them to the matching fittings.

□ Secure all hoses together and in place using plastic ties at regular intervals along the frame, other harnesses or the cross-member so that they do not touch exhaust parts or any moving parts.

□ Tighten all the hose fittings, adjusting the fittings on the tank as necessary to provide clearance for the oil filter.

□ Reposition the tank on the frame (if necessary) and tighten the cable clamps. Thread a second nut on each cable and tighten it against the first nut to act as a lock.

□ Apply a light coat of oil to the filter gasket, install the filter on the tank. Tighten the filter 1/2-3/4 turns after gasket contact.

□ Connect the heater return line from the lower radiator hose to the hose at the heater using the supplied plastic connectors and the replacement hose, cutting the hose as required to fit.

3.4 Mounting the Fuel Module and Hoses 3.4.1 Trucks from 2004.5 and Newer

□ Install the supplied fuel control module bracket to the VMAC main bracket and oil filler tube intake manifold mount (Figure 3.7). Use the OEM bolt from the filler tube.

□ Mount the fuel control module onto the new mount plate with the OEM fasteners, making sure that you install all the rubber and plastic mount parts.

□ Install the supplied banjo fitting to the top fitting on the fuel control module. Point it toward the firewall and tighten the fitting.


21

□ Install the straight hose connector fitting to the banjo fitting on the steel fuel rail (originally connected to the top of the module) with the hose connector pointing up and toward the driver side of the truck.

Fuel control modulemounting plate

Figure 3.7

□ Cut a suitable length of fuel hose to connect between the banjo fitting on the fuel rail and the top fitting on the fuel control module. Leave enough length so that the line bends in a smooth curve without crimping.

□ Remove the OEM fuel hose from the fuel filter and remove the banjo fitting from the module end.

□ Cut a length of the supplied fuel hose to route between the fuel filter and remaining connection on the fuel control module. Install the OEM banjo fitting into the hose, connect it between the filter and the module and tighten the fitting.


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□ Bend the dipstick tube back toward the fuel filter and install the supplied bracket to a suitable OEM bolt on the valve cover. Fasten the other end to the dipstick using the supplied 8 x 10 mm hex head cap screw, serrated lock washer and nut (Figure 3.8).

Figure 3.8

3.4.2 Trucks Built Before 2004.5

□ Install the supplied 5/8 x 13” long breather hose to the 90 degree fitting on the back of the main bracket and secure it with a clamp.

□ Cut the OEM engine breather hose on the straight section just after the second bend from the free end (Figure 3.9). Install the connector and clamp.

Cut here

Figure 3.9


23

□ Route the OEM breather hose over the engine and down the outside of the oil lines going to the compressor. Slide a clamp onto the installed hose. Push the connector onto the OEM hose and clamp it in place.

□ Place an HS10 hose clamp onto the 5/8 x 29” hose and install it on the straight outlet on the main bracket. Tighten the clamp and route the hose to the bottom of the engine.

□ Secure the hose in place with a P-clip in the threaded hole in the lower part of the engine using an OEM M8 x 10 mm bolt.

□ Install the new fuel control module mounting plate to the main VR bracket next to the alternator (Figure 3.10). Use 1/4 x 1/2 inch NC bolts.

□ Attach the fuel module to the bracket (with the fuel hose connections facing to the rear) using the OEM mounting rubber spacers and bolts.

□ Remove the banjo fitting and fuel line from the fuel filter. The fuel hose may have to be slit with a knife to remove it from the filter.

An extra piece of fuel hose is supplied in case the hose has to be cut off.

□ Swap the steel banjo (with the bend) from the engine fuel line to the filter fuel line.

□ Install the other fuel banjo to the 4 inch long section of fuel hose.

□ Attach the other end of the 4 inch long fuel line to the engine fuel tube with the hose clamp and tighten. Leave the banjo end loose.

□ Install the hose with the bent banjo onto the fuel filter and install the OEM clamp. Slide the rubber protection down over the steel tube from the fuel filter to prevent chafing on the intercooler tube.


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Fuel control modulemounting plate

Figure 3.10

□ Loosen the nut holding the wire strap to the passenger side front glow plug. Rotate the connection 90 degrees counter-clockwise and tighten the nut.

□ Mark the upper and lower wire harness plastic channel and cut off approximately 2 inches of the front section (Figure 3.11). Feed the OEM wires out through the correct cut outs in the channel and re-clip the smaller harness with the white tape protection to the clips on the rear of the plastic channel.

□ Ensure the plastic channel is re-clipped in position to the fuel pipes and install the channel top cover.


25

2”

Figure 3.11

□ Install the dipstick bracket (Figure 3.12) incorporating the fuel bleed bracket to the cast threaded studs on the right cylinder head valve cover.

Figure 3.12

□ Install the fuel bleed valve using the OEM 8 mm x 15 mm mounting bolt (Figure 3.13).


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Fuel bleed valve

Mounting bracket on right cylinder head Figure 3.13

Make sure that the dipstick tube is clear of the glow plug wire connection to prevent a short circuit. The tube may require slight bending upwards.

3.5 Completing the Installation

□ Install the intercooler tube, making sure that the tube is pushed in all the way and that the clamps are securely tightened. Do not apply any lubricant to the metal pipe or rubber connectors.

□ You may have to cut the air cleaner/coolant fill tank support bracket to provide clearance for rerouting the fill tube from the lower radiator hose (Figure 3.14). This cut is approximate and may require additional modifications. Check the routing and fit before making any modifications.

□ Place spacers under the air cleaner mounting plate as shown in Figure 3.15 and install the mounting plate.

!


27

□ Position the coolant expansion bottle in the original location and place the spacer under the bottle where it attaches next to the battery.

Cut here

Figure 3.14

Spacers

Air cleaner support bracket

Fender panel

Figure 3.15


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□ Install the coolant fill tank into the original position and install the OEM nut by the battery. Move the front mounting tab toward the front of the engine and mark a spot on the modified mount bracket next to the mounting tab. Drill a suitably sized hole and fasten the coolant tank to the bracket with a nylon tie.

□ Cut approximately 1 inch from the short end of the supplied 90 degree bottle fill hose and install it on the expansion bottle with the long end pointing downward.

□ Install the 90 degree plastic fitting into the hose with the end of the fitting pointing to the front of the truck. Cut the OEM fill hose to length for best fit, connect it to the 90 degree fitting and tighten the clamps.

□ Install the small OEM hose between the coolant fill bottle and the radiator, tighten the clamp at the fill bottle but not at the radiator.

□ Install the OEM air cleaner assembly so that the small coolant hose is under the air intake piping. Twist the small coolant hose on the radiator connection so that it sits against the air intake piping and clears the VR compressor clutch. Tighten the clamp and secure the hose to the air intake piping with a nylon tie.

□ Connect the MAF sensor plug and the coolant bottle-wiring plug.

□ Install the fan, upper fan shroud and top radiator hose.

□ Fill the cooling system with coolant to the correct level.

□ Install all other OEM parts removed previously.

□ Check all the hoses, lines and OEM harnesses to make sure that they are secured and protected.


29

3.6 Adding Oil to the System

You must use the VMAC supplied and approved compressor 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 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 using the hex head bolt at the centre of the compressor clutch during the fill process.

□ Allow 5 minutes for the oil to drain into the tank, then check the level at the sight glass at the front of the tank. Continue adding oil until the level is correct.

□ Install the fill plug in the inlet control valve and tighten it securely.

Do not overfill the system. Overfilling the system with oil can flood the sight glass window and make the system appear empty.

!

!


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Part 4: Installing the Control Components

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Up to 2004.5


Fax: 1-250-740-3201 32

Lay out all of the control components and identify the wiring and connections according to the wiring diagram for the specific model year vehicle. 4.1 Installing the Components

□ Install the control box where it will be accessible but will not be subject to damage, such as under the center of the dash above the transmission hump.

□ Tighten the two side brackets, mark the position of the mounting holes, drill two 7/64 inch holes for the brackets, then mount the control box with the wire harness coming out the bottom or the back of the unit. • If the control box is mounted to the dash, route the wiring

under the dash and secure the excess wiring out of the way

using plastic ties. • If the control box is mounted to the body panel, remove the

plastic door trim and route the wiring along the body panel under the trim and up under the dash.

□ Remove the center panel under the steering column on the dash.

□ Mount the switching box under the dash near the steering column using plastic ties.

□ Mount the throttle control under the dash near the steering column using plastic ties or the tab on the box. Ensure that the harness connectors on the throttle control will reach the OEM accelerator connectors.

□ Route the following wires into the engine compartment through a suitable OEM plug in the firewall. One location 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 • automatic transmission vehicles – blue wire with no connector


33

4.2 Connecting the In-cab Wiring

□ Unplug the OEM cable from the accelerator pedal and plug it into the matching connector from the throttle control box. Plug the cable from the throttle control into the matching connector on the accelerator pedal.

□ Connect the grey cable with the green 7 pin connector from the control box to the matching cable on the switching box.

□ Connect the two white interface connectors together.

□ Connect the red wire from the throttle controller to the red wire from the interface cable.

□ Connect the ground wires from the interface connector and the throttle control to a good ground under the dash.

□ Remove the connector from the park brake switch, connect it to the piggyback connector on the black park brake jumper wire and plug the connector back onto the park brake switch. Connect the other end to the black wire from the interface cable and tape the connection.

□ If there is a yellow wire, it is not used; tie it up out of the way. 4.3 Connecting the Under-hood Wiring

Cover all underhood wiring with plastic loom. Secure the harnesses with nylon ties and pull all excess wire back into the cab.

□ Route the two grey wires and the white wire with the plug connector across the engine to the compressor. Connect the wires to the matching connectors at the compressor.

4.3.1 All Trucks from 2004.5 and Newer

□ Route the white wire to the ECM (Figure 4.1).

□ Locate the bottom connector on the ECM (there are three connectors stacked vertically).

!


Fax: 1-250-740-3201 34

□ Peel back the tape to access the wires. Solder the white tachometer wire from the throttle controller to the dark blue wire with a white stripe and seal the connection with shrink sleeve. The preferred connection method is shown in Figure 4.2.

FWD

Do not connect to the ATCM which is mounted on theradiator shroud onall trucks with an automatic transmission

Rad

iato

r

Bottom connector

Power steering fill

ECM - under the radiatorhose between the powersteering fill and the driverside battery. Has a black cover

Bat

tery

Figure 4.1

OEM wire

VR wire

Shrink sleeve

Soldered joint

Figure 4.2


35

4.3.2 Manual Transmission Trucks from 2004.5 and Newer

□ Cut the long blue wire to approximately 6 inches, strip and crimp it to the short blue wire with the butt connector.

4.3.3 Automatic Transmission Trucks from 2004.5 and Newer

□ Solder the blue wire to the orange wire with a black stripe at the lower ECM connector and seal the connection with shrink sleeve.

There may also be a solid orange wire at the connector. Do not solder to the solid orange wire.

4.3.4 All Trucks Built Before 2004.5

□ Route the white wire to the ECM. Remove the cover from the ECM, unclip it and rotate the connectors to the top. Remove the grey cover on the connector nearest the power steering fill cap.

□ Identify location 12 on the connector (Figure 4.3) containing a dark blue wire with a white stripe. Pull back the loom to access the wire away from the ECM. Solder the white tachometer wire from the throttle controller to this wire and seal the connection using shrink sleeve

141

2161

545

2565

1050

3070

1555

3575

2060

4080

#12 dark blue wire with a white stripe

Figure 4.3

There may be more than one dark blue with white stripe wire in the harness. Make sure that the wire is at location 12 on the connector.


Fax: 1-250-740-3201 36

4.3.5 Manual Transmission Trucks Built Before 2004.5

□ Cut the long blue wire to approximately 6 inches, strip and crimp it to the short blue wire with the butt connector.

4.3.6 Automatic Transmission Trucks Built Before 2004.5

□ Locate the Park/Neutral position switch on the driver’s side of the transmission near the rear. The top connector is a seven-pin connector labeled A to G. Locate the wire that is orange with a black stripe at pin “A” of the top seven-pin connector on the transmission (Figure 4.4).

□ Pull the loom back to access the wire away from the connector. Solder the long blue wire with no connector to this wire and seal the connection using shrink sleeve.

ABCD

Park/Neutralpositionswitch

Orange wirewith black strip

Figure 4.4

4.4 Connecting the Power Supply Wire

□ Route the red wire from the interface connector (with the inline fuse) to the fuse panel.

□ Connect the truck batteries.

□ Locate a fuse in the fuse panel dash that provides power when the ignition switch is in the “ON” position. Remove the selected fuse from the panel and connect the fuse tap to one side. Plug the fuse back into the empty socket using needle-nose pliers to make sure that it seats properly.


37

Make sure that the fuse is inserted with the tap on the battery power side (hot), not the fused side.

4.5 Completing and Testing the Installation

□ Pull all excess wiring back into the cab, bundle the wiring together and tie it up out of the way under the dash.

□ Replace all dash panels and other covers removed during installation.

4.5.1 Safety Test

□ Place the automatic transmission in Park or manual transmission in neutral 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 the control box.

□ Turn the control box switch to the “ON” position. The green light should come on and you should hear the compressor clutch engage.

□ Release the park brake. The green light should go out and the compressor clutch should disengage. Apply the park brake again and the light should come on and the clutch should engage.

□ For trucks with automatic transmissions, the engine must be running to complete the final step in the safety test. This will be done after the pre-start checks have been completed.

□ Turn the ignition key “OFF”.

If the vehicle fails the test, check the wiring to make sure that all the connections are correct and secure. If you require additional assistance, contact your local VMAC dealer. Call 1-800-738-8622 or 250-740-3200.

!


Fax: 1-250-740-3201 38

Part 5: Finishing the Installation

5.1 Before Starting the Engine Checklist Make sure that the following have been completed:

□ Check the vehicle coolant.

□ Check the compressor oil level.

□ Do a final inspection to make sure that everything has been completed and tightened.

□ Perform a final belt alignment check.

□ Check all wiring for security and protection.

□ Pump the primer on the fuel filter (Figure 5.1) until you feel fuel pressure resistance at the pump.

Fuel filter

Hand push pump

Figure 5.1


39

□ Start the engine. If the engine stops, pump the primer again until you feel fuel pressure resistance and restart the engine.

You may have to prime two or three times to eliminate air from the fuel system.

5.2 After Starting the Engine Checklist Make sure that the following have been completed: 5.2.1 Completing the Safety Test

Place the truck in a safe operating position and block the wheels. Ensure that there are no people around the truck before beginning the test.

□ On automatic transmission trucks, with the engine running, engage the park brake; place your foot firmly on the brake pedal, shift the automatic transmission out of Park and into gear.

□ Turn the switch on the control box to the “on” position. The green light will come on and the compressor will engage, but the engine will not idle up. Turn the switch off.

□ Repeat this test in all gear selector positions to make sure that the engine does not idle up unless the selector is in Park or Neutral.

5.2.2 Operational Tests for All Trucks

□ Operate the system with an air tool for at least 1/2 hour (1 hour preferred).

□ Road test the vehicle for approximately 14 miles (20 km).

□ Watch the underhood operation to make sure that belts rotate properly and nothing is rubbing or contacting hot parts.

If you see unusual belt fluctuations during initial operation, stop the engine and move the tensioners back and forth, then restart the engine. Belt fluctuations should stop within the first 30 minutes of operation.

!


Fax: 1-250-740-3201 40

□ Check all components once the engine is turned off and the system has cooled.

□ Check the vehicle coolant after the vehicle reaches operating temperature.

□ Check the compressor oil level after the vehicle has been shut down and the oil level has had time to stabilize.

5.3 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 system or you can test operations using an orifice in the outlet to simulate tool use (Figure 5.2).

Figure 5.2

1. Install the test tool in the tank outlet fitting.

2. Make sure that the ball valve is closed.

3. Place the manual transmission in neutral or the automatic transmission in park and fully apply the park brake.

4. Allow the vehicle to run until the engine is at operating temperature.

5. Operate the air compressor system until the oil is warm.

6. Observe the pressure gauge. Pressure should be approximately 150 psi (See the owner’s manual for adjustment procedures).


41

7. Open the ball valve on the test tool and observe the engine tachometer. Engine speed should increase to about 1,800 to 2,200 RPM.

8. Close the air valve slowly to allow the system pressure to rise.

9. Once the system pressure is at maximum, slowly open the ball valve on the test tool until the pressure on the gauge begins to drop. Engine speed should start to ramp-up when air pressure drops to approximately 140 psi.

5.4 System Identification and Warnings The System Identification Number Plate must be attached to the vehicle at the time of installation (Figure 5.3). This plate provides information which allows VMAC to assist in customer inquiries and the ordering of parts. Mark and drill two 7/64 inch holes, then secure the plate with self-tapping screws.

System ID number plate

Left Front

Figure 5.3

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 (Figure 5.4).


Fax: 1-250-740-3201 42

Daily Pre-Start Check Start Up Procedure Shutdown Procedure

This Vehicle is Equipped with a VMAC Air Compressor System

1. Check Oil Level in Tank2. Check Drive Belt3. Check for Leaks

1. Allow engine to idle for 1 minute2. Turn OFF compressor3. Wait for system to discharge for 1 minute before restarting

1. Ensure Compressor is OFF2. Ensure discharge valve is CLOSED3. Ensure air system is discharged4. Place vehicle in Neutral or Park and engage vehicle safety features - park brake5. Start engine and bring up to operating temperature6. Turn ON compressor

For Technical Support/Parts contact your VMAC DealerTo locate your nearest dealer call 1-800-738-8622 (250-740-3200)

OPERATING INSTRUCTIONS

Always allow system pressure to discharge before restartingWARNING!

Figure 5.4

5.5 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 the VMAC tank to the auxiliary air receiver must have a one-way check valve installed (part #3600078) to prevent blow back from the auxiliary tank to stop moisture from entering the VMAC tank (Figure 5.5). The line to the auxiliary tank must not be installed in the bottom of the tank, but must be installed as high as possible to prevent water from entering the line.

Install the line as high as possible, NOT on the bottom of the auxiliary tank

VR Tank

One-way check valve Auxiliary Tank

Figure 5.5

!


43

Accessory Products from VMAC The following accessory products for your VR compressor system are available from VMAC. For more information or to order these products, call 1-800-738-8622.

Eliminator Aftercooler Removes up to 80% of moisture from compressed air. Quick installation, automatic drain and compact design

Filter Regulator Lubricator Removes lubricants, water and dirt from the air stream. Adds atomized tool oil to lubricate tools. Reduces pressure for longer tool life.

Hose Reel Secure, compact, retractable hose storage in a sturdy reel.

Air Receiver Tank Thirty-five gallon capacity in a compact tank, complete with fittings and a gauge.

DE-ICING HEATER

De-icer Kit Insulated rope heater prevents freezing of lines and regulator.

Service Kits Using OEM service products will extend the life of your system. Includes oil, filters, seals and O-rings. 200 hour and 400 hour service interval kits are available

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