Transcript
VR70 UNDERHOOD AIR COMPRESSOR INSTALLATION MANUAL System V900127
2012 - 2015 GM 2500-3500 Pickup 6.0L Vortec Gas
Installation Manual for VMAC System V900127 2012 - 2015 GM 2500-3500 Pickup, Crew Cab 6.0L Vortec Gas General Information..................................................................... 4 Before You Start ....................................................................... 4 Part 1: Warranty and System ID ................................................. 5 Part 2: Preparing for Installation ................................................ 7 2.1 Preparing for Installation .................................................... 7 Part 3: Installing the Control Components ............................... 11 3.1 Installing the Components .................................................. 12 3.2 Connecting the In-Cab Wiring ............................................ 12 3.3 Connecting the Under-Hood Wiring ................................... 13 Part 4: Installing the Tank and Hoses........................................ 16 4.1 Installing the Tank and Brackets ........................................ 16 4.2 Installing the Tank Assembly.............................................. 18 Part 5: Installing the Cooler, Bracket and Compressor ........... 21 5.1 Installing the Crank Pulley .................................................. 21 5.2 Modifying the Radiator Hoses ............................................ 23 5.3 Installing the Cooler ............................................................ 24 5.4 Installing the Hoses ............................................................ 25 5.5 Installing the Main Bracket and Compressor ..................... 26 5.6 Connecting the Hoses ........................................................ 29 5.7 Completing the Installation ................................................. 30 Part 6: Adding Oil to the System ............................................... 31 Part 7: Finishing the Installation ................................................ 32 7.1 Connecting to Switched Power 2012 - 2013 ...................... 32 7.2 Connecting Switched Power 2014 - 2015 .......................... 33 7.3 Securing the Wiring ............................................................ 39 Part 8 Completing and Testing the Installation ........................ 40 Safety Test ............................................................................... 40 Part 9: Finishing the Installation ................................................ 41 9.1 Before Starting the Engine Checklist.................................. 41 9.2 After Starting the Engine Checklist .................................... 41 9.3 Final Testing ....................................................................... 42 Part 10: Setup, Performance Testing and Adjustments ......... 43 Part 11: Optional Accessory Installation ................................. 44 Part 12: Auxiliary Air Receiver ................................................... 45 Part 13: Accessory Products ...................................................... 46 1 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201
Document 1930191 Installation Manual for VMAC System V900127 2012-2015 GM 2500-3500 Vortec 6.0 Gas Changes and Revisions Version E F G H J
Revision Details ECN 13-106 ECN 14-030 ECN 14-084 ECN 15-063 ECN 15-090
Revised by/date MC 06 Nov 2013 AJH 15 May 2014 JR 08 Dec 2014 RF 17 Jun 2015 RF 21 Jun 2015
Approved by/date MP/RD 19 Dec 2013 MP/DB 26 May 2014 MH/RD 23 Dec 2014 SC/RD 18 Jun 2015 CH/JC 30 July 2015
Implemented 19 Dec 2013 26 May 2014 23 Dec 2014 18 Jun 2015 30 July 2015
Important Information This symbol is used to call your attention to instructions concerning your personal safety. Watch for this symbol; it points out important safety precautions, it means “attention, become alert! Your personal safety is involved. Read the message that follows and be alert to the possibility of personal injury or death. Be alert; your safety is involved. While it is impossible to warn about every conceivable hazard, let good common sense be your guide. 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. Do not attempt this installation if you do not have the appropriate mechanical training, knowledge and experience. Follow all safety precautions for under hood mechanical work. Any grinding, bending or restructuring operations for correct fit in modified trucks must follow standard shop practices.
All hoses, tubes, and wires that are rerouted or shifted during installation must be secure so that they do not contact excessively hot areas or sharp edges. Where possible, use rubber coated P-clips. Follow the routing suggestions in this manual and cover all hoses with plastic loom or equivalent hose protection.
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These instructions are a general guide for installing this system on standard production trucks and do not contain information for installation on non-standard trucks. This system may not fit special order models or those which have had other changes without additional modifications. If you have difficulty with the installation, contact 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. Alternatively, the warranty form can also be found at:
http://vmacair.com/support/warranty 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:
http://vmacair.com/dealer-locator/
Copyright 2015 All trademarks used in this manual are the property of the respective copyright holder. The contents of this manual may not be reproduced in any form without the express written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3. Printed in Canada
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General Information Before You Start Read this manual before attempting installation so that you can familiarize yourself with the components and how they fit on the truck. Identify variations for different model years and different situations that are listed in the manual. Open the package, unpack the components and identify them. All fasteners must be torqued to specifications. Use manufacturers torque values for OEM fasteners. Apply Loctite 242 or equivalent on all engine-mounted fasteners. Torque values are with Loctite applied unless otherwise specified. STANDARD GRADE 8 NATIONAL COARSE THREAD Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 Foot-pounds (ft-lb) 9 18 35 55 80 110 170 Newton meter 12 24 47 74 108 149 230 (N•m) STANDARD GRADE 8 NATIONAL FINE THREAD Size 3/8 7/16 1/2 5/8 Foot-pounds (ft-lb) 40 60 90 180 Newton meter (N•m) 54 81 122 244 Size Foot-pounds (ft-lb) Newton meter (N•m)
METRIC CLASS 10.9 M8 M10 M12 19 41 69 25 55 93
M14 104 141
¾ 280 379
¾ 320 434 M16 174 236
Special Tools Required • OEM flywheel locking tool part number J42386. • Pneumatic fan wrench removal set (such as Lisle 43300) or a manual fan pulley holder (such as KD3900) • Loctite 242 Hose 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. Please contact VMAC for replacement hoses and further information.
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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/ System Identification and Operating Instructions The System Identification Number Plate must be attached to the vehicle at the time of installation. This plate provides information that allows VMAC to assist in customer inquiries and ordering of parts.
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Mark and drill two 7/64-inch holes in the top of the cross member in front of the OEM air filter box. Secure the plate with supplied self- tapping screws. (Figure 1.1)
Passenger Side Fender
System Identification Number Plate
Passenger Side Headlight
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Figure 1.1 – System Identification Plate Clean cross member beside the number plate and stick the VMAC belt routing diagram to the cross member. 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 vehicle operators. A good spot for this is usually on the inside of the door or on the panel underneath the steering wheel. (Figure 1.2)
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Figure 1.2 – Operating Instructions 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 1.3)
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
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Part 2: Preparing for Installation 2.1 Preparing for Installation Preparation for installation is very important. Missing an item can cause problems in the installation or even damage to components. Check off each item as it is completed so that you do not miss any preparation steps.
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Locate the Engine Control Module (ECM) on the inside of the driver side fender, at the front near the fuse panel. (Figure 2.1)
Fuse Pane
ECM
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Figure 2.1 – ECM Location Remove electrical tape and peel back plastic loom for connectors X1 (smallest connector at the top of ECM) and X2 (larger connector beside X1) Do not use a test light to probe for power on vehicle circuits, the increased current draw of the test light may damage components
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2012 - 2014 trucks have different colour wires than 2015 trucks, pay attention to model year and wire colours.
ECM connector X1 has multiple wires with the same color. Follow the tests below to determine the correct wire. 2015: There are two white wires with grey stripe 2014: There are two orange wires with black stripe
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Do not use a test light to probe for power on vehicle circuits, the increased current draw of the test light may damage components Locate the wire going to pin 34 in ECM connector X1 (Figure 2.2) • 2015 white wire with grey stripe • 2012 - 2014 orange wire with black stripe
Pin 34
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Figure 2.2 - ECM Connector X1 Front View With the engine off, using a voltmeter, probe each wire • 2015 white wire with grey stripe • 2012 - 2014 orange wire with black stripe and turn the ignition switch to RUN. The correct wire will show 0 Volts in PARK or NEUTRAL and 12 Volts in all other gear selector positions. Turn the ignition switch off. Mark the correct wire for electrical connections later in the installation process. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201
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Cut the tape, open and locate the two light green wires in bundle of the connector ECM-X2 (larger connector beside X1) (Figure 2.3)
Pin 56 Figure 2.3 - ECM Connector X2 Front View
There are two light green wires in the bundle for ECMX2. Follow the tests below to determine the correct wire. Do not use a test light to probe for power on vehicle circuits, the increased current draw of the test light may damage components
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Using a voltmeter, probe each light green wire and start the engine. The correct wire will show a stable voltage reading of 2.3-2.8 Volts while the engine is idling. Turn the ignition switch off. Mark the correct wire for electrical connections later in the installation process. Disconnect the battery terminals. Remove the air filter box, air intake tube and resonator box. Remove the engine fan (right hand thread).
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Drain the coolant. Save the coolant, as it will be reused later. Remove lower radiator hose. Remove the OEM belt. Remove the power steering pump from the OEM bracket and move out of the way, but do not disconnect any of the power steering lines. Bolts for power steering pump can be accessed through pulley. Do not remove pulley from pump. Disconnect the wiring and remove the alternator. Remove OEM idler pulley from alternator bracket. Save for later use. Remove the OEM aluminum alternator and power steering pump mounting bracket. Remove the two alternator mount spacers and save for use in new bracket. Save mounting bolts for use later. Clean the inside of the OEM crankshaft pulley and remove the OEM crankshaft pulley center bolt. Remove the air intake box-mounting tray (passenger side). Keep these bolts, as they will be used later. Remove the 2 OEM bolts holding the air intake tray support to the front radiator support. Keep these bolts, as they will be used later. If equipped, remove the fuel line from the plastic clips so that it can be moved out of the way when mounting the tank. 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.
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Part 3: Installing the Control Components
Figure 3.1 – Electrical Schematic
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3.1 Installing the Components The control box is not weather proof, ensure it is sufficiently protected from the elements and physical damage.
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Install the control box in a convenient location in the cab, positioned so the wire harness will reach the compressor located at the front driver side of the engine. Mount the throttle control box under the dash using plastic ties. Select a location that will allow access to the adjusting screws.
3.2 Connecting the In-Cab Wiring
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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. Connect the wires with the ring connector from the throttle control box and from the interface connector to a good metal ground. Connect the red wire from the control box to the red wire from the throttle control. Route the following wires through a suitable firewall plug under the dash. If necessary, cut a slit in one of the rubber plugs and pull the wires through into the engine compartment. • cable with the black 3 pin connector • cable with the green 4 pin connector • white wire with the bullet connector • white wire from the throttle control box • blue wire from the throttle control box • red wire from interface cable with inline fuse Unplug the connector from the park brake switch and connect the black wire with the piggyback connector from the interface cable to the connector on the park brake switch: then connect the OEM park brake connector to the piggyback connector. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201
3.3 Connecting the Under-Hood Wiring
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Locate the wire marked earlier in the install at ECM X1: • 2015 white wire with grey stripe • 2012 - 2014 orange wire with black stripe
2015: Solder and seal the long blue wire from the VMAC throttle to the white wire with the grey stripe (Figure 3.2)
Figure 3.2 2012 - 2014 Solder and seal the long blue wire from the VMAC throttle to the orange wire with the black stripe (Figure 3.3)
Figure 3.3 Slide the heat shrink over the soldered joint and shrink with a heat gun. Do not overheat and be sure to protect the other nearby wire bundles with cardboard or sheet metal. (Figure 3.4)
Figure 3.4 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201
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Put the wires back into the OEM loom and wrap with electrical tape. Use ¼” wire loom to cover wire. Secure with zip-tie (Figure 3.5)
Figure 3.5 Locate the light green wire at connector ECM-X2 (wire marked earlier during the install). Solder and seal the white wire from the throttle control to the light green wire at connector ECM-X2 as shown (Figure 3.6)
Figure 3.6 Slide the heat shrink over the soldered joint and shrink with a heat gun. Do not overheat and be sure to protect the other nearby wire bundles with cardboard or sheet metal. (Figure 3.7)
Figure 3.7
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Put the wires back into the OEM loom and wrap with electrical tape. Use ¼” wire loom to cover wire. Secure with zip-tie (Figure 3.8)
Figure 3.8 Remove the cover from the fuse panel and route the red wire with the fuse tap/holder to the panel. Refer to Part 7.1 for connection details.
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Part 4: Installing the Tank and Hoses 4.1 Installing the Tank and Brackets The tank will mount to the passenger side frame rail between the two body mounts (Figure 4.1)
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Figure 4.1 Place the tank on a work bench with the front (oil filter end) of the tank to your left. Remove the oil filter from the front of the tank. Remove the two ¼” clamp 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. 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. Align the holes, apply Loctite and thread 5/16 x 1/2 inch bolts with flat washers into the bottom hole on each bracket, but do not tighten. VMAC – Truck Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201
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Reinstall the two ¼” clamp bolts in the C-clamps so that the heads of the bolts face toward you and install the nuts loosely. Rotate the tank so that the directional arrow on the end of the tank is parallel to the work bench and faces toward you (Figure 4.2) Check the distance of each C-clamp from the ends of the tank and tighten the clamp bolts so that the clamps grip the tank securely.
Figure 4.2 Apply Loctite and insert 5/16 x 1/2 inch bolts through the clips and the C-clamp and thread them into the mount brackets. Center the bolts in the C-clamp slots and tighten them. Thread the 1/2 inch and 3/4 inch swivel elbows onto the matching fittings on the front of the tank, but do not tighten them Apply Loctite pipe thread sealant and install a suitable ¾” fitting in the outlet on the tank. A 90° fitting is required (but not supplied). Tighten it to about the Four o’clock position for testing, then reposition as required for final connections (Figure 4.3)
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Figure 4.3
4.2 Installing the Tank Assembly
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Insert the threaded end of the cable strap through the single hole end of the bar straps. Place the bar straps in position on the inside of the frame, one in front of the transmission cross-member and one behind, with the cable straps over the top of the frame (Figure 4.4) An additional 17.5” cable strap (2200169) and bar strap 2200111) is provided to accommodate any frame size variation.
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Lift the tank assembly and support it in position so the tops of the two strap mounts fit over the top of the frame rail. Make sure that the OEM wire harness is not pinched between the mounts and the frame.
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Figure 4.4 Wrap the two tank cable straps around the tank strap mounts. Make sure that they fit in the upper and lower cut-outs of the tank strap mounts (Figure 4.4) 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. Insert the threaded end of the cable through the one of the lower holes on the tank strap flat bars. Select the appropriate holes that best match the frame of the truck.
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Place a thick 5/16 flat washer and nut on each tank cable strap and tighten just enough to hold the tank in place but loose enough to allow the tank to be positioned along the frame. Slide the tank rearward on the frame to provide clearance for attaching the hoses.
All hoses, tubes, and wires that are rerouted or shifted during installation must be secure so that they do not contact excessively hot areas or sharp edges. Where possible, use rubber coated P-clips. Follow the routing suggestions in this manual and cover all hoses with plastic loom or equivalent hose protection..
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Route the 45 degree end of the 3/4 inch hose and the straight end of the shortest 1/2 inch hose from the passenger side engine compartment over the body mount to the tank. Connect the ¾” hose to the matching fitting on the tank. Angle the fitting upwards to allow the hose to easily pass around the body mount and to allow the level sight-glass cover sufficient room to lift; then tighten the fitting. Connect the 1/2 inch hose to the matching fitting on the front of the tank and then tighten the fitting. Slide the tank forward, providing sufficient space for connections to the fitting on the rear of the tank. 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.
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Part 5: Installing the Cooler, Bracket and Compressor 5.1 Installing the Crank Pulley
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Remove the starter motor and install the OEM flywheel-locking tool. •
GM specialty tool, (J 42386-A : Flywheel Holding Tool)
Check the face of the OEM pulley and remove any surface burrs, so there is a clear mating surface for the VR crankshaft pulley. Place the VR crankshaft pulley in position over the OEM pulley. Make sure that it fits flat against the OEM pulley. Completely coat the threads with Blue 242 Loctite and install the M16 x 120mm replacement VR crankshaft bolt (1520631), along with the supplied washer (1570233) finger tight. (Figure 5.1)
Figure 5.1 – M16x120 Fastener with Blue Loctite 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.
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Rotate the VR crankshaft pulley counterclockwise until the lugs on the back of the pulley are tight against the sides of the OEM pulley lugs (Figure 5.2) and tighten the crankshaft pulley bolt sufficiently to hold the pulley in position Ensure VR pulley does not move off OEM pulley face before tightening pulley bolt. Ensure pulley is rotated tight against the pulley lugs.
VM AC CRANK PULLEY
D E TA IL A A O E M H A R M O N IC B A L A N C E R
Figure 5.2
Do not use an impact tool to tighten pulley bolt.
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Torque the VR crankshaft pulley bolt as per GM specifications. For your convenience, the specifications at the time of printing were: 1) Torque to 110 ft*lbs (150Nm) 2) Loosen 360 degrees 3) Torque 59 ft*lbs (80Nm) 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.
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5.2 Modifying the Radiator Hoses
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Measure & cut the lower radiator hose 12” long from the engine side of the hose. (Figure 5.3)
12” Engine End
Radiator End
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Figure 5.3 Measure & cut the lower radiator hose 6” long from the OEM quick connect. (Figure 5.4)
Engine End
6” Radiator End OEM Quick Connect
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Figure 5.4 Connect the modified 6” long lower radiator hose to the radiator.
Do not use air tools or electric impact guns to tighten hose clamps, they may over-torque the clamp and cause coolant leaks. Use hand tools only.
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5.3 Installing the Cooler The oil cooler is installed on the passenger side of the truck with the oil fittings facing to the driver side or left.
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Place the cooler in position above the frame. Connect the lower radiator hose to the cooler using supplied hose clamp and install the 2 OEM radiator support bolts and supplied washers to hold the cooler bracket in place. (Figure 5.5) Connect the modified 12” long radiator hose from the engine to the cooler using supplied hose clamp. (Figure 5.5)
Figure 5.5 Adjust OEM bolts and two adjustment bolts on bracket for best fit and alignment of the hoses. Tighten the five bolts.
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5.4 Installing the Hoses
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Apply protective loom and route the straight end of the shorter ½” hose from the bottom of the cooler under the shroud to the driver’s side of the engine compartment, in front of steering box, back along the top of the frame rail and up to the rear of the power steering pump, to be connected to the compressor later during the installation. (Figure 5.6) Apply protective loom and route the straight end of the longer ½” hose from the top of the cooler, parallel to the shorter ½” hose, under the shroud, in front of the steering box, back along the top of the frame rail, over the upper control arm mount, and out between the inner fender and the cab mount to the front of the tank. (Figure 5.6)
Longer 1/2" hose
Shorter 1/2" hose
Figure 5.6
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Fasten both ½” hoses using tie straps so that they do not contact any hot or moving parts.
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5.5 Installing the Main Bracket and Compressor
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Remove the idler and the complete tensioner assembly from the main bracket (Figure 5.7) Install alternator spacers saved from OEM bracket Place the main bracket on the front of the driver side cylinder head and install the four OEM M10 bolts from the alternator casting into the same locations on the VMAC bracket. Make sure that the bracket sits flat against the engine. If the bracket does not sit flat, remove it and correct the problem. Torque all bolts to specifications. Install the power steering pump on the main bracket using the OEM bolts. Apply Loctite and torque to specifications. Apply Loctite, install the VR idler. Install the tensioner assembly and torque to specifications. Alternator Mount
M8x 110 s oc k et head bolt
Compres s or Mount
OEM idler Mount Loc ation
Engine Mounts
Tens ioner As s embly
M8x 25 bolts
Idler Power Steering Mount Engine Mount
Figure 5.7
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Place the VR compressor onto the mounting bracket, install one M8 x 110 socket head bolt and 2 M8x25 hex head bolts with Loctite and torque to specifications. To access the M8 socket head bolt remove the pressure sensor. After bolt is tight reinstall pressure sensor using thread sealant. (Figure 5.8) If for any reason the inlet valve is removed it must be noted that most systems use two different length bolts in the inlet valves. The longer bolts go in the two holes closest to the air filter and the two shorter bolts go in the holes furthest away from the air filter. (Figure 5.8)
Longer bolts
Shorter bolts
Figure 5.8 Never use an impact wrench to install inlet bolts. The torque spec for inlet bolts is 19 ft lbs.
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Install the alternator on the main bracket using the OEM bolts. The spacers will pull into position as you torque the retaining bolts to specifications. Install OEM idler on VMAC bracket.
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Install the OEM belt, then the VMAC VR belt. Visually check belt alignment to make sure that it is correct. (Figure 5.9)
Figure 5.9 Install engine fan.
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5.6 Connecting the Hoses Use a flat blade screw driver to gently pry between the fitting and the Colet, lubricate and firmly push the tube into the fitting so that it fully seats past the internal O-ring. (Figure 5.10) Ensure tubing is cut square, and that there are no sharp edges. Do not use side cutters as this will deform the tube. Fitting Colet
O-ring
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Figure 5.10 Insert the 3/16 and 1/4 inch tubes into the fittings on the back of the tank and cover them with high temperature loom. Route the 3/16 and 1/4 with the 3/4 inch hose up from the cab mount, over the top of the engine and against the firewall to the compressor. Connect the 3/16 and 1/4 inch hoses to the matching fittings on the inlet control valve.
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Connect the 1/2 inch hose from the cooler to the matching fitting on the compressor. Route the hose behind the power steering pump. Connect the 3/4 inch hose to the matching fitting on the back of the compressor. Tighten all 1/2" and 3/4" fittings. Remove the cardboard protector from the filter mount base on the tank. Apply a thin coating of compressor oil to the oil filter gasket and install the filter on the tank. Tighten the filter an additional 3/4 turn after the gasket contacts the base.
5.7 Completing the Installation
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Install the air intake box mounting tray, air intake box, air intake tube and resonator box. Connect the upper radiator hose to the radiator. Check all fasteners, clamps, fittings and retainers to make sure that they are tight and secure all OEM wire harnesses. Fill the cooling system with the recommended coolant. Connect the white wire with the bullet connector, the green 4 pin connector and the black 3 pin connector to the matching connections at the compressor. Reconnect Battery.
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Part 6: Adding Oil to the System
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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. Remove the fill plug from the air inlet control valve and pour about 4 US quarts (4 liters) of the supplied oil into the oil fill hole on the inlet control valve using a funnel. Turn the compressor clutch clockwise with a ratchet and a 1/2 inch socket using the hex head bolt at the center of the compressor clutch during the fill process. Allow at least 5 minutes for the oil to drain into the tank; then check the level at the sight glass at the front of the tank. Continue adding oil until the level is correct on the tank sight glass. Install the fill plug in and tighten it securely. Do not overfill the system. Overfilling the system with oil can flood the sight glass window and make the system appear empty.
Figure 6
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Part 7: Finishing the Installation 7.1 Connecting to Switched Power 2012 - 2013
□ □ □ □
Ensure that wiring is complete according to wiring diagram in Part 3 of the installation manual. (Figure 3.1) Do not use a test light to probe for power on vehicle circuits, the increased current draw of the test light may damage components! Use a voltmeter to locate the fuse in the panel that provides power only when ignition switch is in the “ON” position. Remove the fuse, use a volt meter to determine the key-switch side (supply/hot) and fused side. 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. Use needle-nose pliers to make sure the fuse is seated properly. (Figure 7)
10A VMAC System Fuse Install truck Fuse
Connect to supply / hot side
Connect to fused side Figure 7.1
Make sure that the fuse-tap is inserted with correct tap orientation.
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7.2 Connecting Switched Power 2014 - 2015 The supplied tap fuse cannot be used on 2015 trucks, the VMAC system must be wired in per GM bulletin UI #115C View Bulletin #115C Here Do not use a test light to probe for power on vehicle circuits, the increased current draw of the test light may damage components!
□ Locate the ICEM (formally referred to as the MidBEC or MBEC) which is located in the driver's side foot well, near or below the parking brake mechanism (Figure 7.2) IECM COVER
Figure 7.2
□ Remove plastic cover on ICEM, there will be three locking tabs with you will need to gently pry away from the housing to release the cover.
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□ ICEM cover removed
(Figure 7.3)
Figure 7.3
□ Remove the three nuts securing the module
(Figure 7.4)
Figure 7.4
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□ Lift the assembly up, out of the way to give clearance to the electrical connectors on the back of it. (Figure 7.5)
Figure 7.5
□ Once you have the assembly lifted enough, you should be able to access the electrical connectors on the back of it. (Figure 7.6)
Figure 7.6 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201
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□ There will be two electrical connectors on the rear of the ICEM assembly. Locate the connector on the passenger side of the ICEM, squeeze the two tabs and rotate the locking lever and remove the electrical connector from the ICEM assembly. (Figure 7.7)
Figure 7.7
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□ This is the correct connector
(Figure 7.8)
Figure 7.8
□ exposing Remove the electrical tape and peel back the fabric wire cover, the wire bundle (Figure 7.8)
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□ Locate violet wire with the white stripe going to pin 46 of the electrical connector. (Figure 7.9)
PIN 46
Figure 7.9
□ Solder and seal the red wire from the VMAC interface connector to the violet wire with the white stripe.
(Figure 7.10)
□
Figure 7.10 Slide the heat shrink over the soldered joint and shrink with a heat gun. Do not overheat and be sure to protect the other nearby wire bundles with cardboard or sheet metal. (Figure 7.11)
Figure 7.11
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□
Put the wires back into the OEM loom and wrap with electrical tape. Use ¼” wire loom to cover wire. Secure with zip-tie (Figure 7.12)
Figure 7.12
7.3 Securing the Wiring
□ □ □ □ □
Under the hood, group all the wires and harnesses from the compressor and secure them together with electrical tape, then protect them from damage with plastic loom. Cover the white wire and the blue wire with 1/4" plastic loom or equivalent protection and make sure that they are secured. Pull all wire and harnesses into the cab of the truck so that there are no loose loops under the hood. Neatly bundle all the wiring in the cab, secure the bundles with nylon ties or electrical tape and fasten them up under the dash, away from the steering column, brake pedal, accelerator pedal and park brake mechanism. Secure them with nylon ties. Replace the dash panel and the fuse panel cover.
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Part 8 Completing and Testing the Installation
□ □ □
Check all wiring to ensure that it will not contact any hot or moving components and will not interfere with the operation of the truck. Secure all wiring with nylon ties and loom as required. Install the air box in its original mounting position. Secure the air box and connect the intake ducting. Connect the batteries.
Safety Test
□ □ □ □ □ □
Place the automatic transmission in Park or manual transmission in neutral and apply the park brake. Turn the ignition key “ON” but do not start the engine. Check the control box to see if there is a number showing in the hour-meter. If there is no display, there is no power to the control box. Press the “ON” button. The green light should come on and you should hear the compressor clutch engage. Release the park brake. The green light should flash and the compressor clutch should disengage and flash PARK BRAKE. Apply the park brake again and press the “ON” button. The light should come on and the clutch should engage. On automatic transmission trucks, the engine must be running to complete the final step in the safety test. This will be done after the pre-start checks have been completed. 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.
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Part 9: Finishing the Installation 9.1 Before Starting the Engine Checklist Ensure that the following has been completed:
□ □ □ □ □
Check the coolant. Check the compressor oil level at the tank sight glass. Do a final inspection to make sure that everything has been completed and tightened. Perform a final belt alignment check. Check all wiring for security and protection. Make sure nothing is touching the compressor body.
9.2 After Starting the Engine Checklist Place the truck in a safe operating position and block the wheels. Ensure that there are no people around the truck before beginning the test.
Ensure that the following has been completed:
□
Ensure all compressor outlet valves are closed. Do not operate the compressor with a wide open ball valve or air line, the system needs a minimum of 60 PSI of back pressure for the coalescing filter to function correctly. Failure to follow this may result in compressor oil coming down the tool line.
□ □
With the engine running, engage the park brake; place your foot firmly on the brake pedal. Start the compressor and let the truck ramp up to 1800 rpm and then drop down to 1000 rpm. Shift the truck into gear. The engine should go to base truck idle (around 700 RPM).
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□
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.
9.3 Final Testing Ensure that the following has been completed:
□ □ □ □ □ □
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Operate the system with an air tool for at least 1/2 hour (1 hour preferred). Road test the truck for approximately 14 miles (20 km). Watch the underhood operation to make sure that belts rotate properly, pulleys rotate smoothly and nothing is rubbing or contacting hot parts. Check all components, connections and fasteners once the engine is turned off and the system has cooled. 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.
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Part 10: Setup, Performance Testing and Adjustments This system has been adjusted at the factory for general operation. If your operation requires different settings, refer to the owner’s manual for specific instructions on how to adjust the system. You can test the system operation using the tools that will be operated by the system or you can test operations using an 3/16" orifice in the outlet to simulate tool use (Figure 10).
Figure 10 1.
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).
2.
Make sure that the ball valve is closed.
3.
Place the transmission in park and fully apply the park brake.
4.
Allow the engine to run until it is at operating temperature.
5.
Operate the air compressor system until the oil is warm.
6.
Observe the pressure gauge. Pressure should be approximately 150 psi.
7.
Open the ball valve on the test tool and observe the engine tachometer. Engine speed should increase to 1,800 to 2,200 RPM.
8.
Close the air valve slowly to allow the system pressure to rise.
9.
Once the system pressure is at maximum, slowly open the ball valve on the test tool until the pressure on the gauge begins to drop. Engine speed should start to increase when air pressure drops to approximately 140 PSI.
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Part 11: Optional Accessory Installation While the compressor system will function without the following accessories, VMAC recommends their use for optimal performance. See part 13 of this manual for a list of Accessories
Auxiliary Receiver Tank The air/oil separator tank (AOST) automatically depressurizes on compressor shut-down to protect the compressor and clutch from damage that may occur if the compressor starts while pressurized. The use of a receiver tank provides a buffer so that tools may be used immediately upon system startup. • •
For information on installing a receiver tank see part 12 of this manual. Receiver tanks are available for purchase through VMAC and include: Tank Safety valve Manual water drain
Pressure Gauge
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•
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.
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Part 12: Auxiliary Air Receiver If you intend to use an auxiliary air receiver with this system you must observe the following installation procedure to prevent damage to the system.
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) The VMAC compressor system will automatically depressurize when it is shut-down, a check valve must be used to isolate the Auxiliary tank from the automatic blow-down, located on the Rear of the VR Tank. The line to the auxiliary tank must not be installed in the bottom of the tank, but must be installed as high as possible to prevent water from entering the line. Auxiliary Tank
One-way check valve VR Tank
Install the line as high as possible, NOT on the bottom of the auxiliary tank
Figure 12
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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 drain and compact design
Filter Regulator Lubricator Part Number A700151 Removes lubricants, water and dirt from the air stream. Adds atomized tool oil to lubricate tools. Reduces pressure for longer tool life.
Hose Reel Part Number A700007 Secure, compact, retractable hose storage in a sturdy reel.
Air Receiver Tank Part Number A300010 Thirty-five gallon capacity in a compact tank, complete with fittings and a gauge.
De-icer Kit Part Number A700031 Insulated rope heater prevents freezing of lines and regulator.
Service Kits VR150 200 hour Part Number A700059 VR150 400 hour Part Number A700060 VR70 200 hour Part Number A700019 VR70 400 hour Part Number A700020 Using OEM service products will extend the life of your system. Includes oil, filters, seals and O-rings. 200 hour and 400 hour service interval kits are available
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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: ______________________________________ City: _____________________
State/Prov:______________
Installer Information Company Name: ______________________________________ City: _____________________
State/Prov:______________
Installation Date: _____/_____/_____ Day
Month
Year
Owner Information Company Name: ______________________________________ Address: ____________________________________________ City: _____________________
State/Prov:______________
Zip/Postal: ________________
Phone #: (____)____-_____
Vehicle Information Year: ____________________
Make: _________________
Vehicle Identification Number: ___________________________ Unit #: ___________________
Product Information System Identification Number: V _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Compressor Serial Number: P_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Throttle Control Serial Number: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201
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PH2507403200 FX2507403201 TF18007388622
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