Vmac V400015 Installation Manual
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Vmac V400015 Installation Manual

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Installation Manual for VMAC
System
V400015
2017 – 2020 GM Savana
2017 – 2020 Chevrolet Express
6.0 L Vortec
www.vmacair.com

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Summary of Contents for Vmac V400015

  • Page 1 Installation Manual for VMAC System V400015 2017 – 2020 GM Savana 2017 – 2020 Chevrolet Express 6.0 L Vortec www.vmacair.com...

  • Page 3: Table Of Contents

    Accessory Products from VMAC ........
  • Page 4 Copyright © 2020 VMAC Global Technology Inc. All Rights Reserved. These materials are provided by VMAC for informational purposes only, without representation or warranty of any kind, and VMAC shall not be liable for errors or omissions with respect to the materials. The only warranties for VMAC...

  • 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 2. VMAC will provide direction for repair or replacement of the failed components. 3. If requested, failed parts must be returned to VMAC for evaluation. 4. Dealers may login to the VMAC website to view the "VMAC Labour Time Guide" (under “Agreements”) to see the allowable warranty labour times.

  • 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 label in the engine compartment near the hood latch in a visible location (Figure 3). Figure 3 — Advisory label VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 12: Preparing For Installation

    Preparing for Installation Ensure the VMAC Warranty Registration has been filled out and the System Identification Plate and Operating Instruction Label are installed prior to proceeding (Please see page 8 for details). Do not use a test light to probe for power on vehicle circuits, the increased current draw of the test light may damage components.
  • Page 13 Locate the white wire with black stripe going to pin 56 in the ECM X2 connector (Figure 6). Pin 56 Figure 6 — ECM connector X2 (connector “face” view) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 14 Disconnect the Positive Crankcase Ventilation (PCV) hose from the passenger side of the intake tube. ☐ Remove intake tube from between the airbox and the throttle body. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 15 ☐ Remove the Front End Accessory Drive (FEAD) belt and retain it in the vehicle. In the unlikely event of a compressor failure, the VMAC belt can be removed and the OEM belt can be reinstalled to operate the vehicle.
  • Page 16 Remove the 3 power steering pump bolts (the bolts can be accessed through the holes in the pulley). Retain the bolts for reinstallation later (Figure 10). Remove power steering pump bolts Figure 10 — Remove power steering pump VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 17 Figure 11 — Accessory bracket removal ☐ Remove the bushings from the OEM bracket (Figure 12). Remove OEM bushings Figure 12 — Bracket bushing removal VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 18 ☐ Remove the idler installed on the VMAC bracket. ☐ Install the 2 OEM bushings, and the 2 supplied dowels into the VMAC main bracket (Figure 13). bushings VMAC supplied dowels Figure 13 — VMAC bracket bushing and dowel installation...

  • Page 19: Installing The Main Bracket And Compressor

    Install the VMAC main bracket in the location shown and torque the fasteners to specification (Figure 14). Figure 14 — Main bracket installation ☐ Install the OEM idler in the original position on the VMAC bracket (Figure 15). OEM idler VMAC idler Figure 15 — Installing FEAD components ☐...
  • Page 20 There are 2 dowels on the side of the VMAC bracket, these are used to locate the compressor in the correct position for bolt installation and belt alignment. ☐ Position the compressor on the 2 dowels on the VMAC bracket.
  • Page 21 OEM bolts Figure 18 — Power steering pump installation ☐ Install the VMAC supplied FEAD belt, ensuring the belt is properly seated on all of the pulleys (Figure 19). Figure 19 — FEAD belt routing VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 22 One rib visible on each side Figure 20 — Compressor belt alignment ☐ Install the VMAC compressor air filter assembly using the supplied nuts (Figure 21). Figure 21 — Mount air filter VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289...
  • Page 23 ☐ Secure the top power steering hose to the lower hose with the supplied cable tie to ensure the hose is kept away from the belt. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 24: Installing The Waste Heat Air Separator Package (Whasp) Tank

    Illustrated Parts List (IPL). If the WHASP Tank or bulkhead fitting location requires longer hoses, contact a local VMAC dealer. See page 6 for ordering information . VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289...
  • Page 25 18 1/8 in 15 3/8 in 4 1/2 in 5/16 in or M8 mounting holes Figure 23 — Minimum WHASP Tank mounting clearances VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 26 (Figure 25). Front of vehicle Provide a minimum of 6 in of clearance for air flow Figure 25 — WHASP ventilation VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 27: Installing The Bulkhead Fittings

    To maximize compressor performance, hose lengths should be kept as short as possible; if longer hoses are required please follow the hose requirements listed on page 29 of this manual. Figure 26 — Bulkhead fittings VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 28 Oil scavenge: 5/8 in. • ø Remote blowdown: 5/8 in. ø 1 1/16 in ø ø 5/8 in 9/16 in Figure 27 — Bulkhead fitting location VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 29 Suggested WHASP Bulkhead Tank location fitting location Figure 28 — Long wheel base Suggested WHASP Bulkhead Tank location fitting location Figure 29 — Short wheel base VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 30 Apply Loctite 567 (thread sealant) when installing the 1/4 in push-to-connect fittings in the bulkhead fittings (Figure 30 and Figure 31). Figure 30 — Interior view Figure 31 — Exterior View VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 31: Hose Requirements

    • 1/4 in (PTFE Tube) × 60 in. If longer hoses are required: To order parts, contact a VMAC dealer. The dealer will ask for the VMAC serial number, part number, description and quantity. See page 6 for ordering information.

  • Page 32: Connecting The Hoses

    Slide the collet out once proper tubing cutters as side cutters the tube is fully inserted will deform the tube. O-ring Figure 32 — Push-to-connect fittings VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 33 Use of an air receiver tank (minimum 6 USG) is required with this application. Follow the instructions on page 45 of this manual to prevent damage to the system. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 34 (Figure 35). Install push-to- connect fitting Figure 35 — Install push-to-connect fitting VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 35 Install the tube into the push-to-connect bulkhead fitting (Figure 37) Figure 37 — Tubing Installation Remote Blowdown Muffler assembly ☐ Secure the tube with the supplied cable ties. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 36 ☐ Connect the straight end of the 3/4 in × 75 in hose to the matching fitting on the rear of the VMAC compressor. ☐ Bundle the 1/4 in PTFE tube and the 3/4 in, 3/8 in hoses and route them to where the bulkhead fittings were installed.

  • Page 37: 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 38: Installing The Control System

    Strip the wire at the desired location and solder the VMAC wire into place. Slide the shrink tube up to the soldered joint and seal it. Finally, replace the pin in the connector, taking special care to ensure the pin is fully inserted and the locking tabs are engaged.
  • Page 39 Control Components Overview Compressor Control Module Throttle Control WHASP Interface Tank Panel Figure 41 — General component overview (Actual installation locations may vary) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 40 Control Module (Figure 42) The Control Module serves as the primary input/output interface between the vehicle and the various VMAC components (compressor, Throttle Control, WHASP Tank, Control Interface, etc.). Power, 12 V Clutch, Throttle WHASP Compressor (switched), and Control, and...
  • Page 41 “SPEED1” adjusting screw (under side) Figure 44 — VMAC Throttle Controls Mechanical Pressure Switch (Figure 45) The mechanical pressure switch is mounted on the side of the WHASP Tank and limits the maximum pressure to a safe amount by disengaging the clutch once system pressure is achieved.
  • Page 42 Figure 46 — Electrical schematic VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 43 Grey cable Grey cable Figure 47 — Wire schematic VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 44 Ensure the fuse holder is installed as close to the power source as possible. ☐ Connect the other end of the fuse holder to the positive battery terminal. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 45 Connect the green connector on the grey cable running from the Control Module to the matching connector on the compressor. ☐ Splice the white wire from the VMAC Throttle Control to the white wire with black stripe at pin 56 of the ECM X2 connector. ☐...
  • Page 46 ☐ Ensure all wires and harnesses are protected with loom and routed away from sharp, hot, or moving components and away from high traffic areas. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 47: Air Receiver Tank

    This is normal operation. Prior to performing any service work on the system, discharge any stored air in the air receiver tank. The VMAC WHASP Tank has a built-in check valve. Use of an additional check valve is not required and may cause erratic performance.

  • 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 53 for a list of products available for purchase through VMAC.

  • Page 49: Completing The Installation

    Completing the Installation ☐ Check all VMAC and OEM wiring to ensure that it will not contact any hot, sharp or moving components and will not interfere with the operation of the vehicle. Secure all wiring with rubber coated P-clips, cable ties and loom as required.

  • Page 50: Testing The Installation

    If the vehicle fails the test, ensure the wiring to all of the connections are correct and secure. If additional assistance is required, contact your local VMAC dealer or call VMAC Technical Support 1-888-241-2289 or 250-740-3200. Safety Test Ensure the following has been completed: ☐...
  • Page 51 The second person will actuate the compressor switch and ball valve as necessary ☐ Install the VMAC Air Test Tool (P/N: A700052) with the 40 cfm (5/32 in) orifice installed and the ball valve closed. ☐ With the engine running and the vehicle in “PARK”, release the parking brake.
  • Page 52 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). The WHASP Tank cooling fan is thermostatically controlled, and may start or stop without warning.

  • Page 53: Performance Testing And System Adjustments

    Try turning the engine speed down and observe the performance. When testing the system or adjusting the VMAC Throttle Control, ensure the system does not exceed 2,500 engine rpm. Exceeding this speed will cause erratic system performance and in extreme cases may also cause long term damage to the compressor.
  • Page 54 Control. 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 40 cfm (5/32 in) orifice in the outlet to simulate tool use (Figure 53).

  • Page 55: Accessory Products From Vmac

    Compressor Service Kits 200 Hour or 6 Month Service Kit - Part number: A700263 Includes 4 L VMAC high performance compressor oil, oil filter, air filter, and next service due decal. 400 Hour or 1-Year Service Kit - Part number: A700264...
  • Page 56 Air receiver tanks are used for lowering compressor duty cycle and removing water from compressed air; recommended for optimum operation of all VMAC Gas Driven, Diesel Driven, Hydraulic, and UNDERHOOD40 air compressors. Manufactured to FMVSS 121 standard; includes fittings, 170 psi pressure relief valve, and tank drain.
  • Page 57 Interface Harness Extension Part number: A700265 This interface harness extension provides an additional 10 ft of cable which allows for greater flexibility in locating the Interface Panel. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 58 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 59 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 60 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 61 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 62: Warranty Registration

    Warranty Registration This form must be fully completed and returned to VMAC at the time the vehicle is put into service. Warranty may be void if this form is not received by VMAC within 3 months of receiving the vehicle, or 200 hours of operation, whichever occurs first.
  • Page 64 Manufactured by ® 888-241-2289 tech@vmacair.com 877-740-3202 warranty@vmacair.com www.vmacair.com kb.vmacair.com 1333 Kipp Road, Nanaimo, B.C., V9X 1R3 Canada...

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Underhood 40

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