Vmac VR70 Installation Manual
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Vmac VR70 Installation Manual

Underhood air compressor
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VR70 UNDERHOOD
AIR COMPRESSOR
INSTALLATION MANUAL
System V900087
2003-2005 GMC/Chevrolet CK2500-3500
6.0L Vortec Gas

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Summary of Contents for Vmac VR70

  • Page 1 VR70 UNDERHOOD AIR COMPRESSOR INSTALLATION MANUAL System V900087 2003-2005 GMC/Chevrolet CK2500-3500 6.0L Vortec Gas...

  • Page 3: Table Of Contents

    Part 10: Setup, Performance Testing and Adjustments ..36 Part 11: Optional Accessory Installation ......... 37 Part 12: Auxiliary Air Receiver ........... 38 Part 13: Accessory Products ............39 VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 4: Installation Manual For Vmac System V900087

    This symbol is used to call your attention to additional instructions or special emphasis on a specific procedure. 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.
  • Page 5 VMAC. The VMAC warranty form is included in the documentation package. 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: General Information

    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 7: 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. This form can also be found online at: http://vmacair.com/support/warranty/...
  • Page 8 (Figure 1.3) Figure 1.3 – Service label 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 1-888-241-2289 or visit www.vmacair.com VMAC –...

  • Page 9: Part 2: Preparing For Installation

    There are two light green wires in the bundle. Only one of the wires can be used for system control. □ Turn on the ignition switch and probe the green wires. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 10 M6 OEM cap screws. □ U nclip the large wiring harness from the driver side valve cover and the small wiring harness attached to the red battery cable splitter box bracket. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 11 Some trucks may have a hole in the frame where the tow hook would be attached. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 12 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: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 13: Part 3: Installing The Control Components

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

  • Page 14: Installing The Control Box

    Remove the cover from the fuse panel and route the red wire with the fuse tap/holder to the panel. Refer to section 7.1 Connecting to Switched Power for connection details. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 15: Connecting The Under-Hood Wiring

    Be careful not to damage or cut the wires. □ Cut the electrical tape on the bundle of wires to access the blue wire with the white stripe as far back from the PCM as possible. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 16 Remove about 1 inch of insulation from the throttle control box blue wire, join the wires, solder and seal the joint. □ 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: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 17: Part 4: Installing The Tank And Hoses

    Position the C-clamps about 6 inches from each end of the tank. □ 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. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 18 Center the bolts in the C-clamp slots and tighten them. □ Thread the ½ inch and ¾ inch swivel elbows onto the matching fittings on the front of the tank, but do not tighten them. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 19 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 4.3). Figure 4.3 VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 20: Installing The Tank Assembly

    Make sure that the cable straps are behind the tubes 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: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 21 Tighten the nuts on the cable straps until the tank and the bar straps are tight against the frame and the tank is secure. □ Thread a second nut on each cable clamp and lock the two nuts together using two wrenches. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 22: Part 5: Installing The Cooler, Bracket And Compressor

    Liquid Loctite 242 must be used to achieve correct torque on the crankshaft bolt as it functions as a thread lubricant, as well as a locking compound. Solid or Stick Loctite cannot be used. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 23 4) Turn an additional 125 degrees Angle can be measured with GM specialty tool (J 45059 : Angle Meter) □ Remove the OEM flywheel-locking tool and install the starter motor. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 24: Installing The Oil Cooler

    To radiator To engine Nut and bolt or bolt Figure 5.3 VMAC adaptor kit (part number A700042) must be purchased if you intend to install this kit on the Vortec 5.3L engine. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289...
  • Page 25 Fasten both 1/2 inch hoses using tie straps so that they do not contact any hot or moving parts. The hose running under the engine can be tied to the brackets holding the OEM wiring harness. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 26: Installing The Main Bracket And Compressor

    Torque all bolts to specifications. □ Install the power steering pump on the main bracket using the supplied M10 x 40 mm bolts. Apply Loctite and torque to specifications. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 27 (Figure 5.5). 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 28 Install the OEM belt, then the VR belt (Figure 5.6). □ Visually check belt alignment to make sure that it is correct. Compressor Idler Idler Tensioner Idler Crankshaft Figure 5.6 VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 29: Connecting The Hoses

    Apply a thin coating of compressor oil to the oil filter gasket and install the filter on the tank. Tighten the filter an additional 1/2 turn after the gasket contacts the base. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 30: Completing The Installation

    □ Install an OEM bolt through the remaining hole on the triangular bracket and into the original front mounting location for the PCM. Tighten all fasteners. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 31 □ 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 32: Part 6: Adding Oil To The System

    Part 6: Adding Oil to the System You must use the VMAC supplied and approved compressor oil in this system. Failure to use this oil may result in damage to the compressor and will void your warranty. □ Remove the plug or open the outlet of the tank.

  • Page 33: Part 7: Finishing The Installation

    □ Connect the fuse-tap ensuring the populated fuse in the fuse-tap for the VMAC system is obtaining power from the supply/hot fuse connection. Plug the removed fuse back into the lower empty fuse- tap socket and ensure the supplied 10A fuse is in the upper socket.

  • Page 34: Securing The Wiring

    Secure them with nylon ties. □ Replace the dash panel and the fuse panel cover. □ Install the plastic engine cover. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 35: Part 8 Completing And Testing The Installation

    Turn the ignition key “OFF”. 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 VMAC technical support at 1-888-241-2289 or 250-740-3200. VMAC – Truck Mounted Air Compressors...

  • Page 36: Part 9: Finishing The Installation

    (around 700 RPM). □ 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. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 37: Final Testing

    Check the coolant level after the engine has been operated. □ Check the compressor oil level after the engine has been shut down and the oil level has had time to stabilize. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 38: Part 10: Setup, Performance Testing And Adjustments

    Figure 10 Install the test tool in the tank outlet fitting. If you are using the VMAC test tool, use the correct orifice fitting (small hole for VR70, large hole for VR150). Make sure that the ball valve is closed.

  • Page 39: Part 11: Optional Accessory Installation

    Safety valve  Manual water drain Pressure Gauge • Install a 200 PSI pressure gauge downstream of the VMAC tank outlet. • While not critical to system performance, a pressure gauge is important for fine tuning the system and simplifies any potential troubleshooting.

  • Page 40: Part 12: Auxiliary Air Receiver

    The line from the VMAC tank to the auxiliary air receiver must have a one-way check valve installed to prevent blow back from the auxiliary tank to stop moisture from entering the VMAC tank. (Figure 12)

  • Page 41: Part 13: Accessory Products

    Part 13: Accessory Products The following accessory products for your VR compressor system are available from VMAC. For more information or to order these products, call 1-888-241-2289. Eliminator Aftercooler Part Number A800070 Removes up to 80% of moisture from compressed air. Quick installation, automatic...
  • Page 43 VMAC Product Warranty Registration This form must be fully completed and returned to VMAC at the time of installation. Warranty will be void if this form is not received by VMAC within 30 days of installation. VMAC Dealer Information Company Name: ______________________________________...
  • Page 48 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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