Vmac 9028 Installation guide

Brand: Vmac

Model: 9028

Category: Air compressors

Type: Installation guide

Vmac 9028 is an underhood air compressor designed for 1990-1996 GMC C5500, C6500, C7500, and C8500 vehicles with CATERPILLAR 3126 engines. It features a VR7000 compressor, regulator, oil cooler, air tank, and lines. The Vmac 9028 can be used to power pneumatic tools, air horns, air bags, and other accessories. It has a maximum pressure of 150 PSI and a flow rate of 10 CFM at 100 PSI. The compressor is mounted on a bracket that attaches to the engine block and is driven by a belt from the crankshaft. The regulator is mounted on a bracket on the cylinder head and controls the air pressure.

Installation Manual

For The

System #9028

UNDERHOOD AIR COMPRESSOR

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3

DOCUMENT 19281

1990-1996 GMC C5500, C6500, C7500 & C8500

CATERPILLAR 3116 W/WOAB

Installation Manual Document 19281

VR7000 Underhood Air Compressor

System Number 9028

Application: 1990-1996 GMC C5500, C6500 C7500 & C8500 CATERPILLAR 3126

W/WOAB

Publication Date: Jan 27, 2000

Publication Number: 19281

Origination Documents: #19281a - general information

#19282 - installing the compressor, regulator and oil cooler

#19283 - installing the air tank and lines

#19285- installing the throttle controller

#19284 - installing the control unit

#19286 - illustrated parts list

#19130 - warranty registration

Registered Trademarks:

VR7000, VMAC, Throttle Controller and Throttle Commander are registered trademarks

of VMAC, a division of Mangonel Corporation.

GMC, C5500, C6500, C7500 and C8500 are registered tradmarks of General Motors

Corporation.

Caterpillar 3116 is a registered trademark of Caterpillar Inc.

Loctite, Prime N’ Clean, 242 and PST are registered trademarks of Loctite Corporation.

Nylok is a registered trademark of Nylok Fastener Corporation.

The contents of this manual may not be reproduced in any form without the express written

permission of VMAC

General Information

System #9028

1990-1996 GMC C5500, C6500, C7500 & C8500

CATERPILLAR 3116 W/WOAB

UNDERHOOD AIR COMPRESSOR

DOCUMENT 19281

This symbol indicates that there is additional information or special emphasis

on a specific procedure.

This symbol indicates that there is a possibility of personal injury or damage to

the equipment if the indicated warning is not followed.

General Information

Introduction

This book provides installation instructions for:

VMAC underhood air compressor installation kit

VMAC Pneumatic Throttle Control

This kit has been designed for:

1990-1996 GMC C5500, C6500, C7500 & C8500 W/WOAB

Installation steps

The installation procedure in this manual has four main steps:

Part 1: Installing the Compressor

Part 2: Installing the Regulator, Oil Cooler, Air Tank and Lines

Part 3: Installing the Control Unit

Part 4: Installing the Pneumatic Throttle Control

Terms and symbols

This manual uses the following terms and symbols:

•OEM - Original Equipment Manufacturer

•HHCS - Hex Head Cap Screw (also called a hex bolt)

•SHCS - Socket Head Cap Screw (also called an Allen head bolt)

NOTE

WARNING

DOCUMENT 19281

Installation Notes

1. It is important that you complete all the installation steps before operating the system.

2. Follow all safety precautions for underhood mechanical work.

3. Use Loctite 242 or equivalent on all engine-mounted fasteners.

4. All hoses, tubes and wires which are re-routed or shifted during installation must be

secured so that they do not contact excessively hot areas or sharp edges. Where

possible, follow the routing instructions in this manual.

5. These installation instructions are intended as a general guide. In some instances, due

to variations in vehicle manufacture or if prior modifications have been made to the

vehicle, it may be necessary to carry out grinding, bending or rearranging operations

for correct fit. These operations must follow sound, standard shop practices.

6. Left and right definitions in this manual are determined when sitting in the driver’s

seat, facing forward.

7. All fasteners must be of the correct size and torqued according to the specifications

shown below. Torque specifications are in foot pounds (ft-lb).

8. The possibility exists that the primary installer may be color-blind. Always ensure

that another person confirms the color codes on the wires.

Type Grade 8 plated Class 10.9 unplated

Size In Cast or

Steel

Aluminum

In Cast or

Steel

Aluminum

3/8 48 45

7/16 77 70

1/2 117 95

M8 25 20

M10 45 40

M12 80 70

M14 145 130

DOCUMENT 19281

Ordering Parts

To order parts, contact VMAC at:

Telephone 250-754-6997

Facsimile 250-754-6972

Office Hours 8:00 AM to 4:30 PM Pacific Time

Please quote the VMAC part number, the description and the quantity.

Warranty

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.

Changes and improvements

These products and documents are subject to changes or improvements without notice.

DOCUMENT 19281

Part 1

Installing

the Compressor,

Regulator

and

Oil Cooler

System #9028

1990-1996 GMC C5500, C6500, C7500 & C8500

CATERPILLAR 3116 W/WOAB

UNDERHOOD AIR COMPRESSOR

DOCUMENT 19282

Part 1: Installing the Compressor, Regulator and Oil

Cooler

1.1 Preparing for installation

1. Drain the coolant.

2. Remove both fender inserts.

3. Remove the radiator stabilizer bar from the driver’s side of the truck.

4. Loosen the OEM clamps on both ends of the intercooler tube, remove all retaining fasteners

and remove the intercooler tube from the engine. This tube will be modified and installed in

the final steps.

5. Remove the coolant expansion bottle.

6. Remove the upper radiator hose and support bracket.

7. Remove the fan from the engine.

8. Remove the fan shroud.

9. Loosen both clamps on the lower radiator hose, but only remove the end that is attached to

the engine.

10. Remove the harmonic balancer.

11. Remove and discard the fastener from the retainer which holds the electrical harness in

place on the top front driver’s side of the timing cover casting.

12. Similarly, remove but keep the hose retainer from the front of the timing cover casting, as the

compressor mounting bracket must be fitted behind the hoses.

13. Clean the engine block in the area where the compressor bracket will be mounted to ensure

that it mounts properly. If there is any contamination behind the bracket, the pulleys may

not line up correctly.

1.2 Installing the bracket and compressor

1. Remove the idler and tensioner from the VR7000 mounting bracket (Figure 1).

2. Shift the electrical harness so that it will be behind the VR7000 bracket when the bracket is

placed on the engine.

DOCUMENT 19282

NOTE

Check the engine to see if there is an oil filler tube on the timing cover. If the engine is

equipped with a filler tube, you will have to remove the tube assembly and replace it with

the VR7000 cover plate (part #32096).

DOCUMENT 19282

Figure 1

Figure 2

4. Install the idler on the VR7000 mounting bracket. Use Loctite and torque the M12 hex

head cap screw to 80 ft-lbs.

3. Fasten the compressor bracket to the engine block (Figure 2) using five (5) 10 x 30 mm hex

head cap screws and 7/16” flat washers. Use Loctite and torque them to 45 ft-lb. Fasten

the hose retainer back in place using the mounting bolt behind the tensioner (Figure 3).

Make sure that the hose does not interfere with any moving parts.

Install the VR7000 Bracket

Using these Five Holes

Tensioner Mounting Cap Screw

And Washer

Idler Mounting Cap Screw

Mount Bracket Here

Using 10 x 30 mm HHCS

DOCUMENT 19282

5. Install the tensioner on the VR7000 mounting bracket. Use Loctite and torque the M12

hex head cap screw to 80 ft-lb.

6. Place the compressor on the mounting bracket (Figure 3). Apply Loctite to the three (3)

8mm nuts. Install the washers and nuts and torque them to 25 ft-lbs.

Figure 3

7. Place the VR7000 crankshaft pulley in place on the end of the crankshaft and line up the

holes with those in the crankshaft.

8. Place the OEM harmonic balancer over the VR7000 pulley. Apply Loctite to the eight (8)

10 x 60 mm supplied hex head cap screws. Place the 3/8” flat washers over the bolts,

thread them in snug and then torque to 45 ft-lbs.

9. Install the VR7000 belt. Figure 4 shows the correct belt routing.

Figure 4

VR7000 Crankshaft

Pulley

VR7000 Idler

VR7000 Adjuster

VR7000 Compressor

Fasten the Hose

Clip Outside the

VR7000 Bracket

at This Location

DOCUMENT 19282

1.4 Installing the oil cooler

1. Fasten the oil cooler on the outside of the frame rail on the passenger side of the truck.

Figure 6 shows the location of the mounting holes on the frame.

2. Use three (3) 3/8” x 11/2” hex head cap screws, 3/8” flat washers and 3/8” Nylock nuts.

Torque them to 45 ft-lb.

1.3 Installing the regulator

1. Remove the two (2) OEM hex head cap screws from the right front side of the cylinder

head and install the regulator/throttle controller bracket assembly (Figure 5) using the OEM

fasteners.

2. Tighten the OEM hex head cap screws and make sure that the cap screws holding the

regulator assembly and throttle controller are also tight.

Figure 5 shows the bracket installed without any components and with the regulator and

throttle controller in place.

Figure 5

10. Remove the six (6) 5/16” NC cap screws holding the fan on the viscous coupling and install

the VR7000 fan spacer ring (part# 34039). Install the six (6) cap screws and tighten them.

11. Install the fan spacer (part# 34025) on the fan pulley and install the fan blades. Make sure

to install the fan shroud at the same time. Tighten the spacer and fan nut.

DOCUMENT 19282

Mount The Cooler Using These Three Holes

Figure 6

Hose Connection

To Engine Block

Using OEM Hose

Mounting Holes For

3/8" x 1-1/2" HHCS

Hose Connection

To Lower Radiator

Fitting

Figure 7

3. Place the OEM lower radiator hose (with hose clamps installed) onto the forward fitting of

the cooler (Figure 7) and the fitting on the engine.

4. Rotate the OEM hose as necessary to ensure that it clears all moving parts. Tighten the

clamps.

5. Install the 14” green stripe straight coolant hose (part #17236) between the rear cooler

fitting and the lower radiator fitting (complete with hose clamps). Tighten the clamps.

Figure 8 shows the tank installed on the frame.

6. Install the fan shroud and the fan.

7. Install the coolant expansion bottle.

8. Fill the cooling system with the OEM recommended coolant to the correct level.

DOCUMENT 19282

When operating the engine for the first time following installation, be sure to allow the

engine to reach full operating temperature and ensure that the cooling system level is

correct. Failure to do so could result in an overheat condition and possible engine

damage.

Figure 8

WARNING

Part 2

Installing the

Air Tank and Lines

System #9028

1990-1996 GMC C5500, C6500, C7500 & C8500

CATERPILLAR 3116 W/WOAB

UNDERHOOD AIR COMPRESSOR

DOCUMENT 19283

Part 2: Installing the Air Tank and Lines

2.1 Installing the tank mounts and the tank

1. Install the tank brackets on the inside of the frame, between the center crossmembers on the

driver’s side of the truck using four (4) 1/2” x 18” threaded rod, eight (8) 1/2” flat washers

and eight (8) 1/2” Nylok nuts.

2. Install the front air tank mounting bracket approximately 2” - 3” behind the forward

crossmember (Figure 9).

3. Install the rear air tank mounting bracket approximately 8” in front of the rear crossmember

(Figure 9).

4. Install the air tank into the brackets and install the supplied hex head cap screws, washers

and nuts in the tank clamp straps.

5. Position the air tank in the brackets so that the air outlet on the rear of the tank is

approximately 1” from the rear crossmember.

6. Rotate the tank until it is aligned as shown in Figure 10. Tighten the tank clamp straps onto

the tank.

Figure 9

This alignment is extremely important. Improper installation can result in damage to the

equipment, personal injury or death.

DOCUMENT 19283

FRONT

Approximately 8 Approximately

2” - 3”

Tank Brackets (part #12178)

Two Center Crossmembers

NOTE

Make sure that the rear tank bracket is positioned so that it does not clamp over the weld

on the back of the air tank.

WARNING

Figure 10

2.2 Connecting the air and oil lines

1. Figure 10 shows the locations of all lines at the air tank. Use Figure 10 to locate the correct

line fittings on the tank and the individual diagrams shown with each step for the correct

location, size and part number of each line.

This procedure will follow the installation of each individual line, show the location

on each component and describe the complete process.

2. Route all lines so that they are clear of moving parts. Secure all lines using the

appropriate tie-wrap or chassis clip to keep them in place. Do not allow lines to

contact hot engine components or exhaust components. Stainless steel tie clips are

provided for hot oil hoses or for extra strength securing.

3. Connect the 3/4” x 132” main air line (part #17260) to the compressor fitting (Figure 11) and

to the air tank at location 1 (Figure 10).

4. Connect the 1/4” x 145” pressure control line (part #17264) between the tank at position 2

(Figure 10) and the regulator (Figure 12).

The lines must be installed in the correct locations or the system will not function

properly. In addition, a hazardous situation may develop from oil spray, potential

fire or explosion.

OIL LEVEL

(check cold)

MAX

ADD

THIS

WAY

IMPORTANT

Check Oil

Level Here

3/4 JIC Main Air Line

1/4 SAE Pressure Control Line

5/16 SAE Oil Scavenge Line

1/2 SAE Oil Return Line

DOCUMENT 19283

WARNING

Keep the VR7000 lines clear of all OEM hoses, as motion of the lines due to changes

in pressure can cause rubbing, resulting in rapid abrasion and wear of all lines. If you

are grouping the VR7000 lines, wrap the individual lines with rubber insulating material

to prevent damage.

Main Air Line 3/4" x 132"

Part #17260

Pressure Control Line

1/4" x 145" Part #17264

DOCUMENT 19283

Figure 11

Figure 12

Main Air Line 3/4" x 132"

Part #17260

Main Air Line 3/4" x 132"

Part #17260

Pressure Control Line

1/4" x 145" Part #17264

Scavenge Line 5/16" x 141"

Part #17263

DOCUMENT 19283

5. Connect the 5/16” x 141” scavenge line (part #17263) to the fitting on the compressor

control valve (Figure 13) and to the air tank at location 3 (Figure 10). Figure 14 shows the

line routing from the tank through the frame members.

Figure 13

Figure 14

Main Air Line 3/4" x 132"

Part #17260

Pressure Control Line

1/4" x 145" Part #17264

Scavenge Line 5/16" x 141"

Part #17263

Oil Return Line - Cooler to Compressor

1/2" x 68" Part #17262

Main Air Line 3/4" x 132"

Part #17260

Pressure Control Line

1/4" x 145" Part #17264

Scavenge Line 5/16" x 141"

Part #17263

Oil Return Line - Tank to Cooler

1/2" x 194" Part #17261

Oil Return Line - Cooler to Compressor

1/2" x 68" Part #17262

DOCUMENT 19283

6. Connect the 1/2” x 68” cooler to compressor oil return line (part #17262) to the fitting on the

bottom of the compressor and to the rearward cooler fitting (Figure 15). Route this line

under the engine, through the front cross-member (Figure 17).

Figure 15

7. Connect the 1/2” x 194” tank to cooler oil return line (part #17261) to the forward cooler

fitting (Figure 16) to the tank fitting at location 4 (Figure 10). Follow the same route as with

the previous line (Figure 17).

Figure 16

DOCUMENT 19283

Figure 17

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Vmac 9028 Installation guide

Brand: Vmac

Model: 9028

Category: Air compressors

Type: Installation guide

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Vmac 9028 Installation guide

Vmac 9028 Installation guide

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