Vmac UNDERHOOD 70 Installation Manual
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Vmac UNDERHOOD 70 Installation Manual

For chevrolet 4500 – 6500 chassis cab 2019+, international cv515 chassis cab 6.6 l duramax diesel
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AIR COMPRESSORS
Installation Manual for VMAC
2019 + Chevrolet 4500 – 6500 Chassis Cab
2019 + International CV515 Chassis Cab
System
V900135
6.6 L Duramax Diesel
www.vmacair.com
www.vmacair.com
TM
TM
TM
TM

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Summary of Contents for Vmac UNDERHOOD 70

  • Page 1 AIR COMPRESSORS Installation Manual for VMAC System V900135 2019 + Chevrolet 4500 – 6500 Chassis Cab 2019 + International CV515 Chassis Cab 6.6 L Duramax Diesel www.vmacair.com www.vmacair.com...

  • Page 3: Table Of Contents

    Accessory Products from VMAC ........
  • Page 4 • 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. Registered Trademarks All trademarks mentioned in this manual are the property of their respective owners.

  • Page 5: Safety

    VMAC will not be held responsible for any liability, consequential damages, injuries, loss or damage to individuals or to equipment as a result of the failure of anyone to properly adhere to the procedures set out in this manual or standard safety practices.

  • Page 6: Warranty

    1 October, 2015. Warranty Registration The VMAC warranty registration form is located near the back of this manual. This warranty registration form must be completed and sent to VMAC at the time of installation for any subsequent warranty claim to be considered valid.
  • Page 7 VMAC if requested (along with the RMA number) for evaluation, unless otherwise instructed by VMAC. 4. Dealers may login to the VMAC website to view the "VMAC Labour Time Guide" (under “Agreements”) to see the allowable warranty labour times. 5. Warranty invoices must include the Service Ticket (CSR) number, VMAC System ID#, hours on the compressor, mileage on the vehicle, and a detailed description of the work performed.

  • Page 8: General Information

    Please contact VMAC for replacement hoses and further information. Ordering Parts To order parts, contact a VMAC dealer. The dealer will ask for the VMAC serial number, part number, description and quantity. Locate the nearest dealer online at www.vmacair.com/dealer-locator or call 1-877-912-6605.
  • Page 9 All fasteners must be torqued to specifications. Use manufacturers’ torque values for OEM fasteners. The torque values supplied in Table 1 are intended for VMAC supplied components, or for use as a guide in the absence of a torque value provided by an OEM.

  • Page 10: System Identification, Warranty Registration And Warning Labels

    ☐ 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.
  • Page 11 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). Figure 3 — Advisory decal VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...

  • Page 12: Preparing For Installation

    Preparing for Installation Ensure the VMAC Warranty Registration has been completed and the System Identification Plate and Operating Instruction Label are installed prior to proceeding (Please see page 8 for details). To improve access while installing the system, park the vehicle with the wheels turned all of the way to the driver side.
  • Page 13 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). Radiator side 1 in Figure 6 — Modify lower radiator hose VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 14 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 VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...

  • Page 15: Installing The Crank Pulley And Oil Cooler

    Installing the Crank Pulley and Oil Cooler ☐ Using the (×3) OEM crank pulley fasteners, install the VMAC crank pulley (Figure 9). Figure 9 — Install VMAC crank pulley ☐ Tension the fan drive belt. ☐ Install the supplied coupler with spigot using the supplied gear clamp (Figure 10).
  • Page 16 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). Modified Figure 12 — Install modified hose VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 17 Figure 13 — Install radiator hose ☐ Using the clamp retained earlier, install the oil cooler onto the lower radiator hose (Figure 14). Figure 14 — Install oil cooler VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 18 ☐ Using the supplied M6 fasteners and lock nuts, secure the oil cooler to the modified radiator brace (Figure 16). Figure 16 — Install oil cooler VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 19 OEM coolant drain back hose. Cut the hose in the marked location, ensuring the cut is square to the hose section (Figure 18). To “hard line” 3 in Figure 18 — Modify coolant drain back hose VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 20 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. ☐...

  • Page 21: Installing The Air Oil Separator Tank (Aost)

    (AOST) Dependent upon other installed equipment, it may be necessary to move the AOST from its intended location. The hoses used in VMAC compressor systems 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.
  • Page 22 Front of vehicle “Outboard” AOST mounting bracket (For reference only) (×2) M12 × 1.75 × 25 fasteners (×2) M12 nuts Figure 23 — Installing the AOST VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 23 ☐ Tighten the AOST mounting bolts. VMAC recommends using a using smooth radius 90° hose crimp fitting at the AOST discharge for best performance and exhaust clearance VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...

  • Page 24: Installing The Main Bracket And Compressor

    Discard bracket and fastener Figure 25 — Remove fan stator mount ☐ Install the fan stator post onto the VMAC main bracket (Figure 26). Install post Figure 26 — Install fan stator post VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289...
  • Page 25 Figure 27 — Remove lower idler ☐ Remove and discard the fastener directly below the power steering pulley (Figure 28). Power steering pulley Remove fastener Figure 28 — Remover OEM fastener VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 26 ☐ 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 VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 27 (Figure 33). (×2) M10 × 1.5 × 45 Modified M10 × 1.5 × 80 Figure 33 — Install main bracket (OEM drive belt not shown for clarity) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 28 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. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 29 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 VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 30 Figure 38 — Install loom ☐ Install the compressor onto the VMAC main bracket; install the shortest fastener in the front passenger side of the compressor (Figure 39). M8 × 1.25 × 110 (×3) M8 × 1.25 × 120 Figure 39 —...
  • Page 31 ☐ Install and tension the VMAC FEAD belt (Figure 40). Figure 40 — VMAC FEAD belt routing VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...

  • Page 32: Hose Requirements

    Dependant upon the desired location of the AOST, the hose lengths provided with this system may not be ideal. VMAC suggests first trying to adjust the AOST within its mounts to take up any excess slack in the hoses. If this is not effective, the hoses can be shortened or replaced as necessary, or hose extenders can be used.

  • Page 33: Connecting The Hoses

    Slide the collet out once the tube is fully inserted proper tubing cutters as side cutters will deform the tube. O-ring Figure 41 — Push-to-connect fittings VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 34 Secure the hose to the cab using the supplied P-clips and fasteners (Figure 43). Supplied P-clips Figure 43 — Connect discharge hose (Step / battery box removed for clarity) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 35 From the OEM wire bundles, route the 1/2 in hose up to the compressor and connect it to appropriate fitting (Figure 45). Figure 45 — Connect compressor oil supply hose VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 36 AOST along the bottom of the battery box (Figure 47). Figure 47 — Connect compressor oil return hose VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 37 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 VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...

  • Page 38: Adding Oil To The System

    Adding Oil to the System The VMAC supplied and approved compressor oil must be used in this system. Failure to use this special oil will result in damage to the compressor and will void warranty. Do not overfill the system. Overfilling the system with oil can flood the sight glass window and make the system appear empty.

  • Page 39: Installing The Control Components

    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. •...
  • Page 40 Analog Throttle Control Wire Schematic Figure 50 — Analog throttle control VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 41 Digital Throttle Control Wire Schematic Figure 51 — Digital throttle control VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 42 Pin 85 Pin 38 X2 Engine Control Module (ECM) Transmission Control Module (TCM) Figure 52 — ECM / TCM Connectors (As viewed from “mating” side) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 43 *Twist the light blue wire from the throttle control together with the blue wire; using the supplied butt connector, splice these paired wires to the blue wire at pin 6. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 44 Locate the X2 ECM connector (the X2 connector is the leftmost connector) located on the driver side radiator support. ☐ Splice the white wire from the VMAC throttle control to the green wire located at pin 85 (Figure 52 on page 40). ☐...
  • Page 45 The instructions provided below can be used in cases where no upfitter switched power circuits (minimum 10 A free) are available. The VMAC system can be wired using the directions below or as per GM bulletin UI #148 (Scan or click the QR code).
  • Page 46 Figure 55 — Remove PDC (as viewed from mating side) ☐ Splice the red wire from the VMAC 4 pin interface connector to the violet 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.

  • Page 47: Air Receiver Tank

    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 moisture from the receiver tank...

  • Page 48: Recommended Accessories

    Recommended Accessories While the compressor system will function without the following accessories, VMAC strongly recommends their use for optimal performance. See the “Accessory Product” section of this manual on page 54 for a list of products available for purchase through VMAC.

  • Page 49: Completing The Installation

    Install the power steering reservoir using the supplied spacers and fasteners (Figure 57). (×2) Spacer Supplied fasteners Figure 57 — Install radiator hose support bracket ☐ Connect the batteries. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...

  • Page 50: Testing The Installation

    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.
  • Page 51 Analog Throttle Control ☐ When the VMAC system is first engaged, the engine speed should increase to between 1,800 rpm and 2,200 rpm and then drop down to VMAC base idle (approximately 1,000 rpm) once system pressure is reached. Digital Throttle Control The VMAC digital throttle is a “slow ramp”...
  • Page 52 Final Testing Ensure the following has been completed: ☐ Operate the system with an air tool (or the VMAC Air Test Tool with the appropriate orifice installed) for at least 1/2 hour (1 hour preferred). ☐ Road test the vehicle for approximately 14 miles (20 km).

  • Page 53: Performance Testing And System Adjustments

    Performance Testing and System Adjustment System operation can be tested using the tools that will be operated by the system or by using the VMAC Test Tool (A700052) with the 70 cfm (0.190 in) orifice in the outlet to simulate tool use (Figure 58).

  • Page 54: Digital Throttle Control Operation And Adjustments

    The throttle control is configured at the factory for optimum performance at maximum cfm. In applications where maximum cfm is not required, or noise is a concern, the throttle control can be adjusted to reduce the maximum VMAC rpm. Safety features...
  • Page 55 The cfm produced by the system is directly related to engine speed; this system delivers 70 cfm at 2,400 rpm. Maximum VMAC rpm can be adjusted between 1,000 rpm and 2,600 rpm (in 50 rpm increments) via the ““ or “” buttons in the “MAX RPM” column.

  • Page 56: Accessory Products From Vmac

    Compressor Service Kits 200 Hour or 6 Month Service Kit - Part number: A700019 Includes 5 L VMAC high performance compressor oil, oil filter, air filter, and next service due decal. 400 Hour or 1-Year Service Kit - Part number: A700020...
  • Page 57 VMAC De-icer Kit Part number: A700031 Cold climate heater package for operating VMAC compressors in cold climates; proven at temperatures of -30 °C (-22 °F). Requires 12V DC at 10A. 10 Gallon, 200 psi Air Receiver Tank w/ Mounting Feet...
  • Page 58 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 59 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 60 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...
  • Page 61 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: www.kb.vmacair.com...

  • Page 62: Warranty Registration

    Warranty Registration This form must be fully completed and returned to VMAC at the time of installation. Warranty may be void if this form is not received by VMAC within 30 days of installation. VMAC’s Warranty policy and registration can be viewed online at: www.vmacair.com/warranty...
  • Page 64 Manufactured by ® 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...

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