Installation Manual for VMAC System V GM SAVANA 6.0 L Vortec

Transcription

1 Installation Manual for VMAC System V GM SAVANA 6.0 L Vortec

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3 Installation Manual for VMAC System V GM Savana 6.0 L Vortec Safety... 3 Warranty... 4 General Information... 5 System Identification, Warranty and Warnings... 7 Preparing for Installation... 9 Installing the Main Bracket and Compressor Installing the WHASP Tank Installing the Bulkhead Fittings Hose Requirements Connecting the Hoses Recommended Accessories Adding Oil to the System Installing the Control Components Installing the Relay Harness Air Receiver Tank Completing the Installation Testing the Installation Setup, Performance Testing and Adjustments Accessory Products Warranty Registration

4 Document: Changes and Revisions Revision Revision Details Revised by Checked by Eng. Tech. Mech. Elec. Implemented A Initial Release MSP KRM AJH GB AMG 10 May 2017 B ECN Bulkhead locations MSP KRM N/A GB AMG 24 May 2017 Additional Application Information GM Savana, 6.0 L Vortec Registered Trademarks All trademarks mentioned in this manual are the property of their respective owners. Their use by VMAC is for identification of the manufacturers products only and does not imply any affiliation to, or endorsement of said companies. Loctite, Loctite 242 and Loctite 567 are registered trademarks of Henkel AG & Company KGaA. GM is a registered trademark of General Motors. Vortec is a trademark owned by General Motors Company LLC. Eaton Aeroquip is a registered trademark of EATON AEROQUIP INC. Important Information The information in this manual is intended for certified VMAC installers who have been trained in installation procedures and/or for people with mechanical trade certification who have the tools and equipment to properly and safely perform the installation. Do not attempt this installation without the appropriate mechanical training, knowledge and experience. Follow all safety precautions for mechanical work. Any fabrication for correct fit in modified vehicles must follow industry standard best practices. Qual. Notice Copyright 2017 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 products and services are those set forth in the express warranty statements accompanying such products and services, if any, and nothing herein shall be construed as constituting an additional warranty. Printing or copying of any page in this document in whole or in part is only permitted for personal use. All other use, copying or reproduction in both print and electronic form of any part of this document without the written consent of VMAC is prohibited. The information contained herein may be changed without prior notice. Printed in Canada 2

5 Safety Important Safety Notice The information contained in this manual is based on sound engineering principles, research, extensive field experience and technical information. Information is constantly changing with the addition of new models, assemblies, service techniques and running OEM changes. If a discrepancy is found in this manual, contact VMAC prior to initiating or proceeding with installation, service or repair. Current information may clarify the issue. Any person with knowledge of such discrepancies, who proceeds to perform service and repair assumes all risks. Only proven service procedures are recommended. Anyone who departs from the specific instructions provided in this manual must first assure that their safety and that of others is not being compromised and that there will be no adverse effects on the operational safety or performance of the equipment. 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 any person to properly adhere to the procedures set out in this manual or standard safety practices. Safety should be the first consideration when performing any service operations. If you have any questions concerning the procedures in this manual or require any more information on details that are not included in this manual, please contact VMAC before beginning repairs. Safety Messages This manual contains various warnings, cautions and notices that must be observed to reduce the risk of personal injury during installation, service or repair and the possibility that improper installation, service or repair may damage the equipment or render it unsafe. This symbol is used to call attention to instructions concerning 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 aware of the possibility of personal injury or death. As it is impossible to warn about every conceivable hazard, common sense and industry standard safety practices must be observed. This symbol is used to call attention to instructions on a specific procedure that if not followed may damage or reduce the useful life of the compressor or other equipment. This symbol is used to call attention to additional instructions or special emphasis on a specific procedure. 3

6 Warranty VMAC Standard Warranty (Limited) For complete warranty information, including both our VMAC Standard Warranty (Limited) and VMAC Lifetime Warranty (Limited) requirements, please refer to our current published warranty located at: If you do not have access to a computer, please contact us and we will be happy to send you our warranty. VMAC s warranty is subject to change without notice. VMAC Lifetime Warranty (Limited) A VMAC Lifetime Limited Warranty is offered on the base air compressor only and only on UNDERHOOD, Hydraulic Driven, Transmission Mounted, Gas and Diesel Engine Driven Air Compressors, Multifunction Power Systems, and other products as defined by VMAC, provided that (i) the purchaser fully completes and submits a warranty registration form within 3 months of purchase, or 200 hours of operation, whichever occurs first; (ii) services are completed in accordance with the Owner s Manual; (iii) proof of purchase of applicable service kits are made available to VMAC upon request. The VMAC Lifetime Warranty is applicable to new products shipped on or after 1 October, Warranty Registration The VMAC warranty form is located at the back of this manual. This warranty form must be completed and sent to VMAC at the time of installation for any subsequent warranty claim to be considered valid. There are 4 ways warranty forms can be submitted to VMAC: Online warranty@vmacair.com Fax (250) Mail VMAC - Vehicle Mounted Air Compressors 1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3 4

7 General Information Optional Equipment Compatibility Whilst VMAC strives to design systems compatible with optional OEM equipment (such as running boards), it is impractical to develop systems that accommodate every OEM and aftermarket option or add-on. Whenever possible, VMAC endeavors to advise of compatibility issues in the Additional Application Information section of the manual. Even when specific optional equipment is determined by VMAC to be incompatible, it does not preclude the vehicle upfitter or end user from modifying the optional equipment to make it compatible with the installed VMAC system. VMAC does not warranty or accept responsibility or liability for the fitment, function or safety of any products modified in any way not expressly outlined in the installation manual. Before You Start Read this manual before attempting installation so that you can familiarize yourself with the components and how they fit on the vehicle. Identify variations for different engine models and different situations that are listed in the manual. Open the package, unpack the components and identify them. 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 VMAC 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. Ordering Parts To order parts, contact a VMAC dealer. The dealer will ask for the VMAC serial number, part number, description and quantity. To locate the nearest dealer, call or online at Specialty Tools Required for installation M6 Hex Ball End Extended Socket Pulley removal tool kit (such as a Lilse 39000, Jet H3565 or Performance Tool or equivalent. Pneumatic fan wrench removal set (such as Lisle 43300) or a manual fan pulley holder (such as KD3900) 5

8 Torque Specifications All fasteners must be torqued to specifications. Use manufacturers torque values for OEM fasteners. Apply Loctite 242 (blue) 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 3/4 Foot-pounds (ft lb) Newton meter (N m) STANDARD GRADE 8 NATIONAL FINE THREAD Size 3/8 7/16 1/2 5/8 3/4 Foot-pounds (ft lb) Newton meter (N m) METRIC CLASS 10.9 Size M6 M8 M10 M12 M14 M16 Foot-pounds (ft lb) Newton meter (N m) Table 1 Torque Table 6

9 System Identification, Warranty and Warnings Preparation for installation is very important. Missing a step or an item can cause problems in the installation or damage to components. Check off each item as it is completed so that no steps are missed. Review the contents of the system using the illustrated parts list to ensure all components are present and in the correct quantity. If any components are missing, have the system ID ready and call VMAC technical support at (888) The VMAC warranty form must be completed and returned to VMAC at the time of installation for any subsequent warranty claim to be considered valid. Complete the warranty form. The VMAC warranty form is located at the back of this manual, as well as online at: 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 with parts and repairs. Mark and drill 2 x 7/64 in holes in the top of the cross member in front of the hood support. Secure the plate with the supplied self-tapping screws (Figure 1). Figure 1 - System Identification Number Plate 7

10 As part of the installation process, ensure the operating instruction label 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 2). Figure 2 - Operating Instruction Label To alert any technicians that may service the vehicle, affix the warning label in the engine compartment near the hood latch in a visible location. Thoroughly clean the selected area before affixing the label (Figure 3). Figure 3 - Warning Label 8

11 Preparing for Installation Ensure the VMAC Warranty Registration has been completed and the System Identification Number Plate and Operating Instruction Label are installed (see page 6 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. Locate the Engine Control Module (ECM) on the driver side fender near the brake fluid reservoir (Figure 4). ECM connectors Figure 4 ECM location Remove the electrical tape and peel back the plastic loom for the X1 connector (the smallest connector at the top of the ECM) and the X2 connector (the larger connector beside X1). 9

12 There are 2 orange wires with black stripe in the ECM X1 bundle. Follow the test below to determine the correct wire. Locate the orange wire with black stripe going to pin 34 in the ECM X1 connector (Figure 5). Pin 34 Figure 5 ECM connector X1 (connector face view) Turn the ignition to RUN but do not start the vehicle. Use a multimeter to verify the correct wire. The correct wire will show 0 V in PARK or NEUTRAL and 12 V in all other gear selector positions. Turn the ignition switch to OFF. Mark the correct wire for electrical connections later in the installation process. Locate the white wire with black stripe going to pin 56 in the ECM X2 connector (Figure 6). Pin Figure 6 ECM connector X2 (connector face view)

13 Start the vehicle and use a multimeter to verify the correct wire. The correct wire will show a stable voltage reading of 2.3 V V while the engine is idling. Turn the ignition switch to OFF and mark the correct wire for electrical connections later in the installation process. Disconnect the battery terminals. Optional: Raise the front of the vehicle and support on axle stands. (if the vehicle is raised, ensure it is adequately supported on axle stands) Disconnect the Mass Airflow (MAF) sensor (Figure 7). Remove the 2 front bolts on the airbox and pull the airbox upwards to remove it (Figure 7). Figure 7 MAF sensor Disconnect the Positive Crankcase Ventilation (PCV) hose from the passenger side of the intake tube (Figure 8). Figure 8 PCV hose Remove intake tube from between the airbox and the throttle body. 11

14 Cover the throttle body to prevent contaminants from entering the engine. Remove the bolt securing the front of the coolant reservoir, orient the overflow drain hose upwards, and pull the coolant reservoir forward, out of the rear securing tabs. The hose does not need to be disconnected or the coolant drained. Position the reservoir on the passenger side of the engine so that it will not spill. Disconnect the support clips on the upper radiator hose and the wiring loom running over the top of the fan shroud. Remove the upper fan shroud. There are 2 bolts on the top and 3 bolts on each side of the shroud. Optional: Remove the radiator fan (the installation can be performed with the fan in place but is much easier with the fan removed). 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. Use a 10 mm wrench or socket to remove the power wire from the alternator. Disconnect the 3 wire electrical connector from the alternator (Figure 9). Use a 15 mm socket to remove the 2 alternator bolts and remove the alternator. Set it aside for reinstallation later (Figure 9). Figure 9 Alternator removal 12

15 Use a 15 mm socket to remove the OEM idler from the top of the bracket and set it aside for reinstallation later (Figure 10). Figure 10 Idler removal Leave the power steering hoses connected to the power steering pump. Secure the pump out of the way with bailing wire. Use a 15 mm socket to 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 11). Remove Figure 11 Power steering pump removal 13

16 Use a 15 mm socket to remove the 4 OEM alternator/power steering bracket bolts and remove the bracket. Retain the bolts for reinstallation later (Figure 12). Figure 12 Accessory bracket removal Remove the bushings from the OEM bracket (Figure 13). OEM bushing Figure 13 Bracket bushing removal 14

17 Install the 2 OEM bushings, and the 2 supplied dowels into the VMAC main bracket (Figure 14). OEM bushing Supplied dowels Figure 14 VMAC bracket bushing and dowel installation 15

18 Installing the Main Bracket and Compressor Apply Loctite 242 (blue) to all engine mounted fasteners. Install the VMAC main bracket in the location shown (Figure 15). OEM Bolts Figure 15 Main bracket installation Install the OEM idler in the original position on the VMAC bracket (Figure 16). Install the VMAC idler onto the VMAC bracket (Figure 16). Install the OEM alternator using the OEM bolts. Connect the power wire, and the 3 wire electrical connector. OEM Idler VMAC Idler 16 Figure 16 Installing FEAD components

19 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. Position the air filter bracket on the top 2 bolt holes on the compressor (Figure 17). Use a 6 mm Hex drive to install the (3x) M8 x 40 compressor bolts (Figure 17). Bracket P/N (3x) M8 x 40 Figure 17 Compressor installation Connect the straight end of the supplied longer 3/8 in hose to the matching fitting on the side of the VMAC compressor and tighten the fitting. The remainder of the hose installation will be covered later in the installation. Install the power steering pump onto the VMAC bracket using the 3 OEM bolts. The fasteners can be accessed through the holes in the pulley (Figure 18). OEM Bolts Figure 18 Power steering pump installation 17

20 Install the VMAC supplied FEAD belt, ensuring the belt is properly seated on all of the pulleys (Figure 19). Supplied belt Figure 19 Belt installation and routing Ensure the belt spans the middle 6 ribs of the compressor pulley leaving 1 rib visible on either side of belt (Figure 20). 1 Rib visible on each side Figure 20 Compressor belt alignment 18

21 Install the VMAC compressor air filter assembly using the supplied nuts, hose, and hose clamps (Figure 21). Compressor air filter Hose clamps Figure 21 Compressor air filter Reinstall the upper radiator fan shroud, ensuring the rubber radiator bushings are in place (3 bolts on each side and 2 on the front). Secure the radiator hose and wire loom to the fan shroud using the OEM clips. Locate the top power steering hose near the steering arm (Figure 22). Top hose Figure 22 Power steering hose 19

22 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 (Figure 23). Cable tie hoses together Figure 23 Power steering hose secured 20

23 Installing the WHASP Tank Waste Heat Air Separator Package (WHASP) Tank location guidelines When determining a mounting location for the WHASP Tank, ensure the following conditions are met: Adequate supply of fresh air and venting for the cooling fan. Minimum of 12 in of clearance at the front of the cooling fan. Minimum of 6 in clearance at the rear of the unit. Hose connections and wiring are accessible. Mounted on a level surface. Impact protection. The oil level sight glass is easily accessible. The oil fill and drain ports are accessible for servicing. Minimize the hose lengths to maximize performance. Mounting the WHASP Tank Refer to (Figure 24) for mounting dimensions. Special consideration must be made to ensure the WHASP tank will be protected from damage and to ensure that it has adequate ventilation. In some cases, it may be necessary to fabricate a mounting bracket to position the tank in an appropriate location. Secure the WHASP tank by bolting the mounting feet to the installation surface, use M8 or 5/16 in fasteners (not supplied). Mounting in an Enclosure or Body Mounting the WHASP tank in an enclosure will limit access to cooling air or restrict the escape of hot air from around the unit and will have an adverse effect on cooling. Ensure adequate ventilation is provided for the cooling system to function properly. It is not possible to make absolute recommendations regarding ventilation because of the widely differing configurations that are possible. Duty cycle, ambient temperature and enclosure shape are some of the important variables. Cool air ducted to the cooler and installing an exhaust fan to remove hot air is recommended. Confirm the hose lengths included in this kit when determining the location of the WHASP Tank and bulkhead fittings. Hose lengths can be found in the Illustrated Parts List (IPL). If the WHASP Tank or bulkhead fitting location requires longer hoses, contact a local VMAC dealer. See page 5 for ordering information. 21

24 20 1/4 in 12 in Fan out Clearance for servicing 18 1/8 in 6 in Min 15 3/8 in 4 1/2 in 4 x M8 or 5/16 in Rectangular Mount Pattern Figure 24 Minimum WHASP Tank mounting clearances 22

25 Mounting inside of a Van Body The WHASP Tank uses a puller fan to cool the air/oil mixture. Position the WHASP Tank so that the fan is blowing out towards the cargo door. During operation, the door should be kept open to ensure there is a constant supply of cool air to prevent the system from overheating (Figure 25). Provide ample space to check the oil level, as well as access to the filters and compressor oil drain to facilitate servicing. Provide enough space to check the oil level and to remove the filter for servicing Front of Vehicle Figure 25 WHASP ventilation A minimum of 6 in of clearance is recommended around the radiator (intake) side of the WHASP Tank to allow fresh, cool air to circulate into the cooler and fan (Figure 26). Front of Vehicle Figure 26 WHASP ventilation Provide a minimum of 6 in of clearance for air flow 23

26 Installing the Bulkhead Fittings 4 bulkhead fittings are supplied with the system. 3 Bulkhead fittings are used to pass the system discharge, oil, and scavenge hoses/tubes into the body of the vehicle. 1 bulkhead fitting is used to locate the blowdown muffler outside of the vehicle. This kit includes hoses of a fixed length to run from the compressor to the bulkhead fittings, and from the fittings to the WHASP Tank. 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 28 of this manual. Figure 27 Bulkhead fittings 24

27 Use good judgement during installation. Prior to drilling any holes in the vehicle, confirm the installation location of the WHASP tank and the bulkhead fittings. Confirm that the supplied hoses will reach from the compressor to the bulkhead fittings, and from the bulkhead fittings to the WHASP tank. Also ensure that there are no wires, hoses, or other components on the other side of the panel that may be damaged. For best fit ensure bulkhead fittings are centered on the top of the structural ribs. Drill the bulkhead fitting holes using a drill, step drill or hole saw. Leave enough room between the fittings to allow access for a wrench (Figure 28, Figure 29, Figure 30). Discharge from the compressor: 1 1/16 in. Oil return: 9/16 in. Oil scavenge: 5/8 in. Remote blowdown: 5/8 in. Clutch wire grommet (not supplied): 3/8 in. 3/8 in 1 1/6 in 5/8 in 9/16 in Figure 28 Bulkhead fitting location 25

28 Suggested WHASP Tank location Bulkhead location Figure 29 Long Wheel Base Suggested WHASP Tank location Bulkhead location Figure 30 Short wheel base 26

29 Fit the bulkhead fittings through the top of the hole, and secure from the bottom with the supplied nuts. Apply Loctite 567 (thread sealant) when installing the 1/4 in push-to-connect fittings in the top and bottom of the bulkhead fittings (Figure 31 and Figure 32). Grommet for clutch wire (not included) Figure 31 Top view Figure 32 Bottom View Route the clutch wire extension from the WHASP Tank out through the grommet and to the compressor. 27

30 Hose Requirements VMAC Compressor oil will degrade rubber lined hoses, use only hoses with an AQP elastomer type liner. Contact VMAC Technical Support at for further information. Only attempt to shorten the supplied hose if there is access to the the appropriate equipement. Do not cut and splice the hose using hose clamps. The 3/8 in and 3/4 in hoses have an AQP elastomer liner, the 1/4 in PTFE tubes are specifically designed to work with VMAC compressor oil and at operating temperatures. Based on the selected installation location of the WHSAP tank, the hose lengths provided may not be ideal. They can be shortened or replaced as necessary, or hose extenders can be used. VMAC recommends shortening these hoses as a preferred alternative to coiling up and securing the excess. Shorter hose length will maximize system performance. Avoid using 90 fittings wherever possible as they cause flow restrictions and negatively impact performance. The following hoses are included with this compressor kit: From the compressor to the bulkhead fittings: 3/4 in x 75 in 3/8 in x 74 in 1/4 in (PTFE Tube) x 99 in From the WHASP Tank to the bulkhead fittings: 3/4 in x 38 in 3/8 in x 60 in 1/4 in (PTFE Tube) x 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. To locate the nearest dealer, call or online at Eaton Aeroquip hoses with an AQP type inner liner are required. OTC fittings are required for the VMAC supplied hose. Push-lock fittings are suitable if FC332 hose is used. If Push-lock fittings are being used, do not use hose clamps as they will damage the hose and cause leaks. 28

31 Connecting the Hoses All hoses, tubes and wires that are rerouted or shifted during installation must be secure so that they do not contact hot, sharp or moving objects. Use rubber coated P- clips wherever possible. Follow the routing suggestions in this manual and cover all hoses with plastic loom. Installing the hoses Lubricate the tube and firmly push it into the fitting so that the tube fully seats in the fitting. Slide the collet out, away from the body of the fitting to lock the tubing in place. Ensure the tube does not have any play to prevent the O-ring from wearing. Cut the tube square. Do not use side cutters as they will deform the tube Slide the collet out once the tube is fully inserted O-ring Figure 33 Push-to-connect fittings When routing hoses, ensure cap plugs are installed so that contaminants do not get in the line. Take care when routing hoses, as a hose failure may damage the compressor. Apply high temperature split loom (or equivalent hose protection) to the 3/4 in hoses, 3/8 in hoses, and 1/4 in PTFE tube. Connect the long 1/4 in PTFE tube to the 90 push-to-connect fitting on the front of the compressor. Ensure the tube fully seats in the fitting (Figure 33) Connect the straight end of the long 3/4 in hose to the matching fitting on the rear of the VMAC compressor. Ensure the hoses have enough slack to allow for engine movement. Bundle the hoses and route them to where the bulkhead fittings were installed. Connect the hoses to the appropriate bulkhead fittings. 29

32 Determine a suitable hose routing from the bulkhead fittings installed earlier to the WHASP Tank. The system is supplied with generic length hoses to connect the bulkhead fittings to the tank. These are the 1/4 in x 60 in and 1/4 in x 36 in PTFE tubes as well as the 3/4 in x 38 in and 3/8 in x 60 in hoses with the 90 crimp fittings on one end, and straight fittings on the other. Dependent on the installation location of the WHASP Tank, these hose lengths may not be ideal. They can be shortened or replaced as necessary, or hose extenders can be used. VMAC recommends shortening these hoses as a preferred alternative to coiling up and securing the excess. Shorter hose length will maximize system performance. Route and connect the straight ends of the 3/4 in x 38 in and 3/8 in x 60 in hoses to the top side of the bulkhead fittings. Route and connect the 1/4 in x 60 in PTFE tube to the top side of the bulkhead fitting. Connect the 90 fitting on the 3/4 in x 38 in hose to the #12 JIC fitting (air/oil inlet) on the cooler above the fan (Figure 34). Connect the 90 fitting on the 3/8 in x 60 in hose to the #6 JIC fitting (oil return fitting) beneath the oil filter on the tank (Figure 34). Connect the other end of the 1/4 in x 60 in tube to the 1/4 in push-toconnect (oil scavenge) fitting near the coalescing filter (Figure 34). Connect the discharge fitting (#8 male JIC) to the remainder of the customer s air system (hose not supplied). Secure all hoses, tubes, and wires with cable ties. Air/oil inlet from compressor (#12 JIC) Discharge to user tools (#8 JIC) Oil return line (#6 JIC) 1/4 in PTFE scavenge tube Figure 34 WHASP Tank connections VMAC recommends using a receiver tank with this system. Follow the instructions on page 44 of this manual to prevent damage to the system. 30

33 Remote Muffler Installation The WHASP Tank automatically depressurizes when the clutch disengages. This prevents damage to the compressor on the next start up. Installing the blowdown muffler outside of the vehicle will reduce cabin noise during blowdown, and will ensure any oil vapor will be safely discharged outside of the vehicle. Remove the blowdown muffler from the side of the WHASP Tank (below the coalescing filter) (Figure 35). Figure 35 Blowdown muffler Ensure no debris enters the WHASP Tank manifold. Contamination of the assembly may cause erratic performance. Separate the PTFE tube from both fittings. Apply the supplied 1/4 in split loom to the 1/4 in PTFE tube. Apply Loctite 567 (thread sealing) compound to the 1/4 in push-toconnect fitting and install it into the threaded hole which previously held the blowdown muffler (Figure 36). Figure 36 Fitting installation 31

34 Connect the 1/4 in PTFE tube into the push-to-connect fitting installed in the WHASP Tank (Figure 37). Figure 37 Tubing Installation Route the 1/4 in PTFE tube to the bulkhead fitting. Ensure the tube will not kink, and cut the hose to length. Ensure the tube is cut square and that there are no sharp edges. Do not use side cutters as this will deform the hose. Install the tube into the push-to-connect bulkhead fitting (Figure 38) Figure 38 Remote Blowdown Muffler assembly Secure the tube with the supplied cable ties. 32

35 Recommended Accessories It is highly recommended to use a receiver tank with this system. While the compressor system will function without the following accessories, VMAC strongly recommends their use for optimal performance. Receiver Tank The separator/cooler tank (WHASP tank) 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 start-up. The addition of a receiver tank will also reduce the frequency of clutch and system cycling. For information on installing a receiver tank see page 44 of this manual. Receiver tanks are available for purchase through VMAC. See the Accessory Product page of this manual for more information. Pressure Gauge While not critical to system performance, a pressure gauge is important for fine tuning the system and simplifies any potential troubleshooting. Install a 200 psi pressure gauge downstream of the VMAC WHASP tank outlet. Pressure regulator and/or lubricator The compressor can produce air pressures up to approximately 150 psi (1205 kpa). It is the responsibility of the user to know the pressure and air flow requirements of the tools powered by the air compressor system. An appropriate air pressure regulator and lubricator can be installed on the tool line. Failure to regulate the air pressure may cause damage to the tool or downstream equipment. 33

36 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. Remove the fill cap on the WHASP Tank (above the sight glass). Using a funnel, pour oil into the tank until the oil level in the sight glass reaches the MAX line. The system capacity is 4 L. Reinstall the fill cap and tighten it securely. Ensure the fill port remains accessible as it will be necessary to check and top up the oil after the first compressor start. Fill cap Sight glass Figure 39 - Filling the WHASP Tank 34

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38 Installing the Control Components Red Grn/Yel 1 Grn/Yel 2 White Yellow 36 Figure 40 Wiring schematic

39 Red GRN/Yel 1 GRN/Yel 2 White Yellow Figure 41 Wiring schematic 37

40 Splice OEM Wires VMAC suggests not cutting OEM wires whenever practical. The preferred method is to remove the pin from the connector using an appropriate tool and slide the shrink tube onto the wire. 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 (Figure 42). If this is not practical, cut the OEM wire and solder and seal using shrink tube. Figure 42 - Splice onto OEM wire Keep wires away from the park brake mechanism. Route wires clear of the steering column and pedals so they do not contact moving parts. Before drilling holes, ensure there are no OEM wires, hoses, or components in the way. Ensure all wires are protected and routed so that they do not contact hot, sharp or moving components. 38

41 Connecting the throttle Control Position the throttle controller under the dashboard in a location where it will be protected from accidental damage but the SPEED 1 adjusting screw is accessible. Unplug the cable from the foot pedal assembly and connect it to the throttle control. Connect the green ground wire from the throttle control to a chassis ground point. To confirm a good ground, use an ohm meter to measure the resistance between the ground point and the negative battery terminal. Resistance should be less than 1 Ω. Locate a grommet in the firewall and pass the following wires from the throttle control through to the engine bay and over to the ECM. White wire. Blue wire. Solder and seal the white wire from the VMAC throttle controller to the orange wire with the black stripe at pin 34 of the ECM X1 connector (located on page 10). Solder and seal the blue wire from the throttle controller to the white wire with black stripe at pin 56 of the ECM X2 connector (located on page 10). Put the wires back into the OEM loom and wrap with electrical tape. Use 1/4 in wire loom to protect the wire and secure it with a cable tie. Route the black wire from the throttle control to the park brake connector X220 (in the driver side foot-well (Figure 43). Park Brake Connector X220 Figure 43 X220 park brake connector location 39

42 Solder and seal the black wire from the throttle controller to the light blue wire running between the X220 2 pin connector and the park brake assembly (Figure 44). Figure 44 X220 Park Brake Connector Installing the Control Panel Determine an appropriate location for the control panel and install the control panel using the 4 x 7/32 in holes (Figure 45). Dependent on the mounting location and/or requirements, a mounting bracket may need to be fabricated (bracket and hardware not included with kit). Apply plastic loom, or equivalent protection, to all wiring prior to installation. Figure 45 Installing the control panel The control panel is not weatherproof. It should be installed either inside the cab or inside a cabinet on the service body (if equipped). Keep the rear of the control panel protected. Flush Mounting the Control Panel to a Bulkhead In order to mount the control panel flush to a bulkhead, a 2 1/2 in x 5 1/2 hole will need to be made to accommodate the relays and other electronics. 40

43 Using the supplied extension wires, connect the 4 control panel wires to the respective WHASP Tank harness wires. Ensure the correct gauge wire is used. Connect: Blue to Blue 14 AWG. Orange to Orange 14 AWG. Black to Black 18 AWG. White to White 18 AWG. WHASP Tank Control Panel Description Gauge Colour Gauge Colour 14 Blue 14 Blue Fan Enable 18 Black 18 Black Overtemp. Signal 14 Orange 14 Orange Compressor Enable 18 White 18 White Hour Meter Table 2 Control Panel Wire Legend Figure 46 Control Panel to WHASP Tank Connections Connect the green wires with the yellow stripe from the control panel and WHASP tank harness to a chassis ground. To confirm a good ground, use an ohm meter to measure the resistance between the ground point and the battery negative terminal. Resistance should be less than 1 Ω. If not done previously, run the white 14 AWG wire (clutch wire) from the WHASP Tank harness, through the bulkhead hole with a suitable grommet. Route the wire with the discharge and oil return hoses up to the compressor, securing it along the way with cable ties as necessary, and connect it to the bullet connector on the black clutch wire. Run the yellow 18 AWG wire from the WHASP Tank to the throttle control under the dashboard and connect it to the matching yellow wire. 41

44 Installing the Relay Harness Do not use a test light to probe for power on vehicle circuits, the increased current draw of the test light may damage components! If a key switched source rated for 20 A is not available, find a low current key switched 12 V source and use the supplied relay harness to switch main battery power when the key is turned to RUN (Figure 47). Positive Battery Terminal Key Switched +12V Source Ground Figure 47 - Relay Overview VMAC Control Panel The battery and switched power are located underneath the driver side seat. Remove the driver seat. Remove the 3 nuts securing the fuse box to the floor. Remove the lower fuse box shroud (2 clips hold it together). There are 2 connectors on the underside of the fuse box; the X1 connector is light grey (Figure 48, page 43). The connector can be removed from the fuse box by removing another plastic shroud and loosening the captive bolt running through the center of the connector. Mount the relay harness where it will be accessible, close to the main battery, and protected from weather. Connect the black wire with the 20 A fuse to the large gauge red wire running to the stud on the upper side of fuse box under the driver seat. 42

45 X1 socket Pin C7 Figure 48 Underside of Fuse Panel Connect the green wire with yellow stripe on the relay module to a chassis ground or the negative battery terminal. Splice, solder and seal the orange wire from the relay module to the orange wire at pin C7 (Figure 49). Pin C7 Figure 49 Electrical Connector X1 Route the red 14 AWG wire from the control panel to the relay module. Solder and seal the short red wire on the relay module to the red 14 AWG wire from the VMAC control panel. 43

46 Air Receiver Tank Pressure in the air receiver tank will not be relieved when the compressor system blows down. This is normal operation. Prior to performing any service work on the system, relieve the pressure 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. If an air receiver tank will be used with this system, the following installation procedure must be used to prevent damage to the system. An air receiver tank provides a buffer as it gives the compressor time to react by increasing the engine speed and producing air before the tool stalls. It also has the advantage of lowering the duty cycle of the compressor system. The VMAC compressor system automatically depressurizes when it is shutdown. The VMAC Waste Heat Air Separation Package (WHASP) Tank has a 1-way check valve installed from the factory which prevents blow back and moisture from the receiver tank entering the WASP Tank. Installation of an additional 1-way check valve will cause erratic performance (Figure 50). The line to the receiver tank must be installed as high as possible to prevent water from entering the line. Install the line to the receiver tank as high as possible Figure 50 Air receiver tank 44

47 Completing the Installation Check all 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 cable ties and loom as required. Reinstall the radiator fan. Reinstall the upper radiator fan shroud (there are 3 bolts on each side and 2 on the front). Ensure the rubber radiator bushings are in place. Secure the radiator hose and wire loom to the fan shroud using the OEM clips. Reinstall the coolant reservoir and install the overflow hose in the stock location (slide the reservoir onto the firewall, secure it with the front bolt and point the overflow hose downwards). Reinstall the intake duct and air box. Reconnect the PCV tube to the intake duct. Connect the MAF sensor wire. Reconnect the battery. 45

48 Testing the Installation Lift the vehicle, ensuring the driven wheels are off of the ground. Support the vehicle securely with appropriately rated jack stands. Ensure there are no people around the vehicle before beginning the test. 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 or Safety Test Ensure the following has been completed: Place the transmission in PARK and apply the park brake. Turn the ignition key to ON but do not start the engine. Turn on the compressor and listen for the compressor clutch to engage. Confirm that the WHASP tank cooling fan turns on. Observe the hour meter, and ensure the hourglass icon is blinking. Turn off the compressor switch and ensure the clutch has disengaged and the WHASP fan turns off. Before Starting the Engine Checklist Ensure the following has been completed: Check that the compressor oil level at the tank sight glass is correct. Complete a final inspection of the installation to ensure everything has been completed. Perform a final belt alignment check. Check all wiring for security and protection. Ensure nothing is touching the compressor body. Ensure all of the compressor outlets are closed. Ensure the parking brake is engaged and the transmission is in PARK. Start the engine. After Starting the Engine Checklist Allow the vehicle to reach operating temperature. Turn on the compressor. The compressor clutch should engage, and the engine speed should increase in response to the throttle control. The vehicle s tachometer should read approximately 2800 rpm. Allow the compressor to run for approximately 10 seconds. Turn off the compressor. Shut down the engine and check the compressor oil level. Add oil as necessary to bring the level to the FULL line in the sight glass and check for leaks. Ensure any stored air is drained from the system. Start the engine. Assistance may be required for the next steps. 46

49 The following tests confirm that the drive disable system is working correctly. The drive disable system prevents the VMAC throttle from increasing engine rpm unless the transmission is in PARK and the park brake is engaged. 2 people are required to perform this safety test. 1 person must remain in the driver seat and be prepared to actuate the service (foot) brake if necessary. The second person will actuate the compressor switch and ball valve as necessary. Install the VMAC Air Test Tool (P/N: A700052) with the 30 cfm (1/8 in) orifice installed and the ball valve closed. With the engine running and the vehicle in PARK, release the parking brake. Turn on the compressor and open the ball valve. The clutch should engage, but engine speed should NOT increase. Close the ball valve. Turn off the compressor. Reapply the park brake. The steps marked with asterisks will be repeated. *With the engine running, Depress the service (foot) brake and shift the transmission out of PARK. *Turn on the compressor and open the ball valve. The clutch should engage, but engine speed should NOT increase. *Close the ball valve. *Turn off the compressor. *Drain any accumulated air from the system. *Shift the transmission into PARK. Repeat the steps marked with asterisks for all transmission selector positions, returning the gear selector to PARK after each gear is tested. Engine speed should not increase unless the vehicle is in PARK or NEUTRAL. Drain any air that may have accumulated during the previous tests. Ensure the parking brake is engaged. Turn on the compressor and open the ball valve. Release the park brake. The engine speed should drop to base idle. Reapply the park brake. The engine speed should increase as soon as the park brake is engaged. Close the ball valve, allow the system to build to full pressure and the engine speed to return to VMAC base idle. Turn the compressor off and shut down the engine. Drain any accumulated air from the system. 47

50 Setup, Performance Testing and Adjustments This system requires minimal adjustment. The maximum system pressure is adjusted via the pressure switch on the tank and the output is adjusted with the throttle control. Refer to the owner s manual for specific instructions on how to adjust the system. 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 30 cfm (1/8 in) orifice in the outlet to simulate tool use (Figure 51). Figure 51 - A VMAC Test Tool Install the VMAC test tool at the system outlet with the 30 cfm orifice (1/8 in). Ensure the ball valve is closed. Place the transmission in PARK and fully apply the park brake. Allow the engine to run until it is at operating temperature. Turn on the air compressor system and allow it to operate until the oil is warm. Observe the pressure gauge. Pressure should be approximately 150 psi. Open the ball valve on the test tool and observe the engine tachometer. Engine speed should increase to approximately 2,800 rpm. The pressure on the gauge should be psi. Close the air valve slowly to allow the system pressure to rise. When the pressure reaches the pressure switch set-point of 150 psi, the system will disengage the compressor clutch and reduce the engine speed to base idle. 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 ramp up to approximately 2,800 rpm when the pressure drops approximately 40 psi below the pressure switch setpoint. 48

51 Throttle Control Adjustment Locate the VMAC throttle controller. It is typically installed under the dashboard, near the park brake pedal. Figure 52 shows an example of throttle control mounting, actual installation may vary. Throttle controller Adjustment screw Figure 52 - Throttle Control Adjustment is made by turning the SPEED 1 adjustment screw. Turn the screw counter-clockwise to decrease engine speed, or clockwise to increase engine speed. Engine speed adjustments may be made so that the amount of air delivered by the system matches the requirements of the tools or equipment that will be used. If the system is cycling on and off rapidly when using a particular tool, the engine speed is likely higher than necessary for that tool. Try turning the engine speed down and observe the performance. If the system is unable to keep up with a specific tool the engine speed is too low. Try increasing the engine speed gradually, until the desired performance is obtained. The VMAC control system is designed such that the user cannot increase the engine speed beyond a safe level. Adjusting the engine speed is a low risk activity. 49

52 Final Testing 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). Road test the vehicle for approximately 20 km (14 miles). Watch the underhood operation to ensure the 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. 50

53 Accessory Products These accessory products for your underhood compressor system are available from VMAC. For more information or to order these products, call or Eliminator Aftercooler Part number: A Removes up to 80% of moisture from compressed air. Quick installation, automatic drain and compact design. Filter Regulator Lubricator Part number: A Removes lubricants, water and dirt from the air stream. Adds atomized tool oil to lubricate tools. Reduces pressure for longer tool life. Compressor Service Kits 200 Hour - Part number: A Includes compressor oil, oil filter and air filter. Air Receiver Tanks 400 Hour - Part number: A Includes compressor oil, oil filter, air filter, blow-down muffler, and pressure relief valve. 35 Gallon - Part number: A Gallon capacity in a compact tank, complete with fittings and a gauge. 10 Gallon - Part number: A Gallon capacity in a compact tank, complete with fittings and a gauge. 6 Gallon - Part number: A Gallon capacity in a compact tank, complete with fittings and a gauge. Hose Reel Part number: A Secure, compact, retractable hose storage in a sturdy reel. 51

54 Bulkhead Fittings All Bulkheads - Part number: Bulkhead fittings are used for passing the system discharge, oil, and scavenge hoses through panels. 3/4 in JIC Bulkhead - Part number: Used for passing the 3/4 in system discharge hose through panels. 3/8 in JIC Bulkhead - Part number: Used for passing the 3/8 in system oil hose through panels. 1/8 in NPT Bulkhead - Part number: Used for passing the 1/4 in system scavenge tube through panels. Hose Fittings 45 1/4 in Fitting - Part number: Quick connect fitting for the 1/4 in PTFE tube. 90 1/4 in Fitting - Part number: Quick connect fitting for the 1/4 in PTFE tube. Straight 1/4 in Fitting - Part number: Straight Quick connect fitting for the 1/4 in PTFE tube. 90 3/8 in Fitting - Part number: Fitting for the 3/8 in Oil Return Hose. 90 3/4 in Fitting - Part number: Fitting for the 3/4 in Compressor Discharge Hose. Remote Muffler Accessory Pack Part number: A The A WHASP remote mount muffler kit is designed to relocate the blowdown muffler to an external location. This is recommended for applications where the WHASP Tank will be located inside of a van or service body, the remote mounted muffler will reduce cabin noise when the compressor blowdown operates, and will ensure any oil vapor will be safely discharged outside of the vehicle. 52

55 Warranty Registration This form must be fully completed and returned to VMAC at the time of installation. Warranty may be void if this form is not received by VMAC within 30 days of installation. VMAC s Warranty policy and registration can be viewed online at: VMAC Dealer Information Company Name: City: Installer Information State / Province: Company Name: City: Installation Date: / / Day Month Year Owner Information State / Province: Company Name: Address: City: Zip/Postal: State / Province: Phone #: ( ) - Address Vehicle Information Year: Make: Vehicle Identification Number: Unit #: Product Information System Identification Number: V Compressor Serial Number: P Throttle Control Serial Number: WHASP Tank Serial Number: Submitted by Name: Contact: 53

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