Vmac VR70 Installation Manual
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Vmac VR70 Installation Manual

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V R 7 0 U N D E R H O O D
A I R C O MP R E S S O R
I N S T A L L A T I O N MA N U A L
S y s t e m V 9 0 0 0 9 5
1 9 9 9 - 2 0 0 2 G MC / C h e v r o l e t C K 2 5 0 0 , C K 3 5 0 0 H D
S e i r r a a n d S i l v e r a d o 6 . 0 L G a s
w w w . v ma c a i r . c o m

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  • Page 1 V R 7 0 U N D E R H O O D A I R C O MP R E S S O R I N S T A L L A T I O N MA N U A L S y s t e m V 9 0 0 0 9 5 1 9 9 9 - 2 0 0 2 G MC / C h e v r o l e t C K 2 5 0 0 , C K 3 5 0 0 H D S e i r r a a n d S i l v e r a d o 6 .

  • Page 3: Table Of Contents

    5.3 After Starting the Engine Checklist........33 5.4 Setup, Performance Testing and Adjustments....33 5.5 System Identification and Warnings........34 5.6 Auxiliary Air Receiver ............36 Accessory Products from VMAC ..........37 VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 4: Installation Manual For Vmac System V900095

    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.

  • Page 5: General Information

    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...

  • Page 6: Additional Requirements

    Trucks with a 5.3L engine will require accessory pack # A700042. This accessory pack contains the correct radiator hose and instructions for the lower radiator-to-cooler connection. Special Tools OEM flywheel locking tool part number J42386. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 7: Part 1: Preparing For Installation

    Locate light green wire in this harness Figure 1.1 There are two light green wires in the bundle. Only one of the wires can be used for system control. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 8 □ Remove the bracket holding the large, red battery cable splitter box from the alternator and power steering pump bracket. Keep the two M6 OEM cap screws. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 9 (do not disconnect the wiring) and place the module out of the way. □ Bend the PCM locating tab on the fender down so that it is flush with the surface (Figure 1.2). Figure 1.2 VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 10 If equipped, remove the OEM wire harness securing bracket from the top of the frame so that it can be moved out of the way when mounting the tank. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 11: Part 2: Installing The Control Components

    Remove the center panel from under the steering wheel and mount the switching box under the dash using plastic ties. Make sure that it does not interfere with other parts. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 12 VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 13: Connecting The Wiring

    □ Unplug the connector from the park brake switch. You may have to remove the cover from the OEM electrical connector to gain access to the connection. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 14 Shrink sleeve OEM wire Soldered joint DDC wire Figure 2.2 □ Replace the tape on the bundle. Fit the loom back over the harness and tape it in place. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 15: Part 3: Installing The Tank And Hoses

    Remove the two 1/4 inch pinch bolts from the C-clamps. Expand the clamps slightly and slide them over the front of the tank. □ Position the C-clamps about 6 inches from each end of the tank. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 16 C-clamps. □ Place the two insulated tube clips over the steel lines with the mounting holes upward and align them with the top C-clamp mounting holes (Figure 3.3). VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 17 A 90 degree fitting is recommended. Tighten it to about the four o’clock position for testing, then reposition as required for final connections (Figure 3.4). Figure 3.4 VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 18: Installing The Tank Assembly

    Make sure that the cable straps are behind the two steel lines and the OEM wire harness and that there are no lines or wires pinched between the cable and the mount. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 19 □ Thread a second nut on each cable clamp and lock the two nuts together using two wrenches. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 20: Part 4: Installing The Cooler, Bracket And Compressor

    M12 x 30 mm hex head bolt through the hole in the frame from the inside of the frame so that the threads point downward through the hole. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 21 □ Route the OEM wire harness so that it does not touch the cooler and fasten it securely out of the way. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 22: Installing The Main Bracket And Compressor

    □ Make sure that the bracket sits flat against the engine. If the bracket does not sit flat, remove it and correct the problem. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 23 Install the red battery cable splitter box to the back of the VR compressor bracket (Figure 4.3). The two OEM M6 bolts attach through the two top holes on the VMAC supplied bracket and the two supplied M6 x 18 mm bolts, nuts and washers attach the VMAC bracket to the OEM splitter box mount bracket.
  • Page 24 M8 x 110 socket head bolts with Loctite and torque to specifications. □ Install the OEM belt, then the VR belt (Figure 4.4). □ Visually check belt alignment to make sure that it is correct. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 25: Connecting The Hoses

    Route the hose behind the power steering pump. □ Connect the 1 inch hose to the matching fitting on the back of the compressor. □ Tighten all fittings. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 26: Completing The Installation

    □ Install the battery mounting platform. One of the battery mounting screws should go through the rear hole in the OEM PCM bracket and the VMAC PCM locating bracket. The forward hole in the PCM is not used. □ Install the battery and retainer.
  • Page 27 OEM wire harnesses. □ Fill the cooling system with the recommended coolant. □ Connect the wire with the green 4 pin connector to the matching connector from the compressor. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 28: Adding Oil To The System

    Connect the white wire with the bullet connector to the matching connector from the compressor clutch. 4.6 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.
  • Page 29 Route the black poly line from the throttle control around the back of the compressor and connect it to the 90 degree quick connect fitting at the front of the inlet valve. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 30 □ Remove the two button head cap screws from the supplied throttle pull assembly and separate the throttle pull clamp from the throttle pull bracket. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 31 OEM throttle body quadrant (Figure 4.9). □ Slide the VR70 throttle pull securing clamp over the feet of the VR70 throttle pull bracket and under the OEM throttle cruise control arm. This will enable these items to be clamped securely together.
  • Page 32 If you do not trim the cable, it will hit the air inlet duct and interfere with throttle return. OEM shift quadrant OEM cruise control VR pull bracket VR clamp bracket Cruise control cable support Figure 4.9 VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 33: Part 5: Finishing The Installation

    Replace the dash panel and the fuse panel cover. □ Connect the red wire to the matching connector on the pneumatic throttle control. □ Install the plastic cover on the engine. VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 34: 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. 5.2 Before Starting the Engine Checklist Make sure that the following have been completed: □...

  • Page 35: After Starting The Engine Checklist

    You can test the system operation using the tools that will be operated by the system or you can test operations sing an orifice in the outlet to simulate tool use (Figure 5.1). VMAC – Truck Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 36: System Identification And Warnings

    The System Identification Number Plate must be attached to the truck at the time of installation (Figure 5.2). 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.
  • Page 37 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 truck operators (Figure 5.3). This Vehicle is Equipped with a VMAC Air Compressor System OPERATING INSTRUCTIONS Daily Pre-Start Check...

  • Page 38: 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 to stop moisture from entering the VMAC tank (Figure 5.4).

  • Page 39: 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 1-800-738-8622. Eliminator Aftercooler Removes up to 80% of moisture from compressed air. Quick installation,...
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  • Page 44 Ma n u f a c t u r e d b y P H 2 5 0 - 7 4 0 - 3 2 0 0 F X 2 5 0 - 7 4 0 - 3 2 0 1 T F 1 - 8 0 0 - 7 3 8 - 8 6 2 2 1 3 3 3 K i p p R o a d , N a n a i mo , B C , V 9 X 1 R 3 C a n a d a w w w .

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