Vmac VR70 User manual
System V900095
1999 - 2002 GMC/Chevrolet CK2500, CK3500HD
Seirra and Silverado 6.0L Gas
www.vmacair.com
VR70 UNDERHOOD
AIR COMPRESSOR
INSTALLATION MANUAL
VMAC – Truck Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201 1
Installation Manual for VMAC
System V900095
GMC/Chevrolet 1999 – 2002 6.0L
Sierra and Silverado CK2500 and CK3500HD
General Information..................................................................... 3
Before You Start ....................................................................... 3
Additional Requirements .......................................................... 4
Part 1: Preparing for Installation................................................ 5
1.1 Preparing for Installation .................................................... 5
Part 2: Installing the Control Components ............................... 9
2.1 Installing the Control Box ................................................... 9
2.2 Connecting the Wiring ........................................................ 11
Part 3: Installing the Tank and Hoses........................................ 13
3.1 Installing the Tank and Brackets ........................................ 13
3.2 Installing the Tank Assembly.............................................. 16
Part 4: Installing the Cooler, Bracket and Compressor........... 18
4.1 Installing the Crank Pulley.................................................. 18
4.2 Installing the Oil Cooler ...................................................... 18
4.3 Installing the Main Bracket and Compressor ..................... 20
4.4 Connecting the Hoses ........................................................ 23
4.5 Completing the Installation ................................................. 24
4.6 Adding Oil to the System.................................................... 26
4.7 Installing the Pneumatic Throttle ........................................ 26
Part 5: Finishing the Installation................................................ 31
5.1 Safety Test ......................................................................... 32
5.2 Before Starting the Engine Checklist ................................. 32
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
2
Installation Manual - Document #1930125
Installation Manual for VMAC System V900095
GMC/Chevrolet 1999 - 2002, 6.0L SIERRA and SILVERADO
CK2500 and CK3500HD
Changes and Revisions
Version Revision Details Revised by/date Approved by/date Implemented
00 Original manual IB 14 July 2006 SC 14 July 2006 17 July 2006
a ECN 06-184 Sequence chg IB 22 Aug 2006 TG 24 Aug 2006 28 Auug 2006
Important Information
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 underhood mechanical work. Any
grinding, bending or restructuring operations for correct fit in modified
trucks must follow standard shop practices.
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 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. To
locate your nearest dealer, call 1-800-738-8622.
Copyright 2006
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
VMAC – Truck Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201 3
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 ¾
Foot-pounds (ft-lb) 9 18 35 55 80 110 170 280
Newton meter (N•m) 12 24 47 74 108 149 230 379
STANDARD GRADE 8 NATIONAL FINE THREAD
Size 3/8 7/16 1/2 5/8 ¾
Foot-pounds (ft-lb) 40 60 90 180 320
Newton meter (N•m) 54 81 122 244 434
METRIC CLASS 10.9
Size M8 M10 M12 M14 M16
Foot-pounds (ft-lb) 19 41 69 104 174
Newton meter (N•m) 25 55 93 141 236
Hose Coding
Different frame designations will affect the tank mounting position.
You may have to move the tank rearward from the standard position
on your application. 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
1/4 inch
5/16 inch
1/2 inch
5/8 inch
3/4 inch
1 inch
Yellow
Orange
Blue
Blue
Green
Green
VMAC – Truck Mounted Air Compressors
Toll Free: 1-800-738-8622
Fax: 1-250-740-3201
4
Additional Requirements
Accessory Packs
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 5
Part 1: Preparing for Installation
1.1 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.
□Remove the plastic cover from the top center of the engine.
□If the truck has an automatic transmission, locate the wiring
harness that runs up from the transmission and over the center
of the engine intake manifold, through the trough on the driver’s
side of the intake (Figure 1.1). Remove the harness from the
protective loom, cut the tape open and locate the light green
wires in the bundle.
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
6
□Turn on the ignition switch and probe the green wires.
□The correct wire will show 12 Volts in PARK and 0 Volts in all
other gear selector positions.
□Turn the ignition switch off. Mark the wire for electrical
connections later in the installation process.
□Disconnect the battery terminals and remove the battery.
□Remove the battery mounting plate.
□Remove the air intake tube and resonator box.
□Drain the coolant.
□Remove the radiator end of the top OEM radiator hose, unclip it
from the fan shroud and move it out of the way.
□Remove the upper radiator fan shroud.
□Remove the fan assembly and the lower radiator fan shroud.
□Remove the engine end of the lower radiator hose.
□Remove the OEM belt
□Mark the position of the power steering pump pulley in relation to
the pump shaft and remove the pulley with a recommended
puller.
□Remove the power steering pump. Remove the support bracket
from the back of the power steering pump and bend the tab that
attaches to the side of the engine block upwards about 5
degrees to align with the compressor bracket. Install the modified
bracket onto the power steering pump.
□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 7
□Unclip the large wiring harness from the driver side valve cover
and the small wiring harness attached to the red battery cable
splitter box bracket.
□Disconnect the wiring and remove the alternator.
□Remove the OEM aluminum alternator and power steering pump
mounting bracket.
□Remove the OEM back idler from the bracket.
□Clean the inside of the OEM crankshaft pulley and remove the
OEM crankshaft pulley center bolt.
□Clean the driver side of the engine. Check all threaded holes to
make sure that they are clean and free from damage.
□Remove the driver side fender liner.
□Remove the Power Train Control Module (PCM) from the driver
side fender (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
8
□Remove both OEM fasteners from the fender support bracket on
the passenger side of the truck (Figure 1.3). On four-wheel drive
trucks, remove the hex head bolt on the bottom of the frame that
holds the tow hook in place. Some trucks may have a hole in the
frame where the tow hook would be attached.
□Replace the inner fastener with the supplied low profile M10 x 30
mm hex head bolt without a flat washer, as the high profile head
on the OEM bolt will interfere with the cooler bracket.
Remove these bolts
Front of truck
Passengersidefender
Figure 1.3
□Clean the frame on the passenger side of the truck between the
two body mounts. 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.
Other manuals for VR70
24
Table of contents
Other Vmac Air Compressor manuals
Vmac
Vmac VR70 User manual
Vmac
Vmac UNDERHOOD 40 Series User manual
Vmac
Vmac G300004 User manual
Vmac
Vmac Underhood 70 User manual
Vmac
Vmac AIR INNOVATED H600009 Installation instructions
Vmac
Vmac VR70 User manual
Vmac
Vmac AIR INNOVATED H400006 Installation instructions
Vmac
Vmac VR70 User manual
Vmac
Vmac VR70 Manual
Vmac
Vmac V400015 User manual
Vmac
Vmac RAPTAIR-G30 User manual
Vmac
Vmac VR70 User manual
Vmac
Vmac V400007 User manual
Vmac
Vmac Underhood 70 User manual
Vmac
Vmac UNDERHOOD 40 Series User manual
Vmac
Vmac H600013 Installation instructions
Vmac
Vmac VR70 User manual
Vmac
Vmac H400005 Installation instructions
Vmac
Vmac PREDATAIR User manual
Vmac
Vmac UNDERHOOD 150 User manual
