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Vmac V900113 Installation Manual

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Installation Manual for VMAC
2013-2011 GM 2500HD-3500HD
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
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
6.7 Auxiliary Air Receiver ......................................................... 41
Accessory Products from VMAC ............................................... 42
VMAC - Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
System V900113
6.6L Duramax Diesel
1

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Summary of Contents for Vmac V900113

  • Page 1: Table Of Contents

    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 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 2 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.

  • Page 3: General Information

    Newton meter (N•m) Additional Requirements Special Tools OEM crankshaft locking tool (GM #J-44643) or VMAC #5900010. 36mm 12-point socket for removing OEM crankshaft bolt. VMAC crankshaft pin extraction tool #5900076 Pneumatic fan wrench removal set (such as Lisle 43300) or a manual fan pulley holder (such as KD3900).
  • Page 4 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 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.

  • Page 5: Part 1: Warranty And System Id

    Complete the warranty form. 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.
  • Page 6 Figure 1. 1 VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 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 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 8: Part 2: Preparing For Installation

    Locate the two orange with black stripe wires in the bundle. There are two orange wires with black stripe in the bundle. Follow the tests below to determine the correct wire. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 9 Locate the wiring harness below the engine intake which runs to the bottom of the passenger side of the engine bay. (Figure 2.2) Engine intake White wire with black stripe Coolant reservoir Figure 2.2 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 10 Cut the OEM connector off and splice the supplied extension cable onto the harness ensuring the wire colors match. Use a heat gun to seal the heat shrink connectors. Re-wrap harness with protective loom. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 11: Preparing For Installation - Mechanical

    Remove the top radiator hose. Do not damage the radiator hose as it will be modified and reused later. □ Remove the automatic transmission control module (ATCM) mounted on the driver side of the fan shroud. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 12 (Figure 2.6) Front of truck Engine oil fill spigot Supplied fan wire bracket pin replacement Figure 2.6 VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 13 Install a crankshaft-locking tool, (see Additional Requirements above) and remove the crank pulley bolt and OEM crank pulley. If you are using the VMAC tool:  Put the appropriate socket on the nut  Put the single-pin end of the tool on the front of the pulley ...
  • Page 14 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. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 15 250 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 □...

  • Page 16: Part 3: Installing The Control Components

    Part 3: Installing the Control Components Figure 3.1 VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 17: Installing The Components

    3.2 Connecting the In-Cab Wiring □ Connect the interface wire harness connector to the matching connector from the VMAC control box. □ Disconnect the 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.

  • Page 18: Connecting The Under-Hood Wiring

    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 shown in Figure 3.3. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 19 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 details. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 20: Part 4: Installing The Tank And Hoses

    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 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.
  • Page 21 A 90° fitting is required (but not supplied). Tighten it to about the seven o’clock position for testing, then reposition as required for final connections (Figure 4.2). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 22: Installing The Tank Assembly

    5” bolts. □ Place the backing plates in position on the inside of the frame, one in front of the transmission cross-member and one behind, (Figure 4. 3). VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 23 □ Route the 45° end of the 3/4” hose from the engine compartment around the body mount to the tank. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 24 If the frame allows use of the upper holes the bottom of the tank brackets can be cut off to increase ground clearance. Touch up paint after cutting to help prevent rusting. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 25: Part 5: Installing The Main Bracket, Compressor, And Cooler

    OEM Power Steering and AC bracket 3/8 Flat Washer (3x) M10 x 130mm M10 x 60mm M10 Fender Washer M10 Nut M10 x 60mm Supplied Remove OEM Bolt Spacer Figure 5.1 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 26 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 gasket stays in place. (Figure 5.3) VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 27 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) VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 28 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 filter. (Figure 5.5) VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 29 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 it is installed on the truck. (Figure 5.7) VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 30: Installing The Oil Cooler

    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 coming off the plastic molded tees, as they will be used again. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 31 Connect the lower radiator hoses to the cooler with supplied hose clamps. Reinstall the modified OEM hose clamp and ensure the smaller diameter hose is positioned so it does not come in contact with the stabilizer bar.(Figure 5.10) VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 32 Attach 1/2” hose to fitting and tighten all fittings. □ Fasten both 1/2” hoses using tie straps so that they do not contact any hot or moving parts. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 33: Connecting The Hoses

    Connect the 3/16” and 1/4” hoses to the matching fittings on the inlet control valve. □ Install the oil fill tee and cap on the compressor discharge fitting. The oil fill cap should face upwards.(Figure 5.12) VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 34: Completing The Installation

    5.4 Completing the Installation □ Install the air filter assembly and air intake tube. □ Measure and cut the upper radiator hose 14-1/2” from the engine side. Save the engine-side piece.(Figure 5.14) VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 35 VMAC radiator hose and tube connector. When connecting the modified OEM upper radiator hose rotate the hose so the end that previously went to the engine before being modified will now connect to the supplied VMAC tube connector.(Figure 5.15) To engine...

  • Page 36: Adding Oil To The System

    □ Reconnect the batteries. 5.5 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.

  • Page 37: Part 6: Finishing The Installation

    □ Neatly bundle all the wiring in the cab, secure the bundles with nylon ties or electrical tape and fasten them up under the VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 38: Safety Test

    If the truck 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. 6.4 Before Starting the Engine Checklist Make sure that the following have been completed: □...

  • Page 39: After Starting The Engine Checklist

    Check the compressor oil level after the engine and compressor have been shut down and the oil level has had time to stabilize. Top up or drain as required. 6.5.1 Transmission Test VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 40: Setup, Performance Testing And Adjustments

    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. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 41: Auxiliary Air Receiver

    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 and to stop moisture from entering the VMAC tank (Figure 6.2).

  • Page 42: Accessory Products From Vmac

    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 toll free 1-888-241-2289 or local 250-740-3200. Eliminator Aftercooler Part Number A800070 Removes up to 80% of moisture from compressed air.
  • Page 43 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

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