Vmac V900055 Installation guide

Installation Manual

For The

System #V900055

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 1900507

1996-2000 GM K20/2500 & K30/3500

6.5 L DIESEL 4-WHEEL DRIVE

Installation Manual

VR70 Underhood Air Compressor

System Number V9000055

Application: 1996-2000 GMC K20/2500, K30/3500 6.5L Diesel, 4-wheel drive

Publication Date: July 2000

Publication Number: 1900500

Origination Documents: #1900507a - introduction

#1900508 - air tank and line installation

#1900509 - compressor and oil cooler installation

#1900510 - control system installation

#1900511 - illustrated parts list

#1900130 - warranty registration

Registered Trademarks:

VR70, VMAC and Throttle Commander are registered trademarks of VMAC.

GMC, K20/2500, K30/3500 are registered trademarks of General Motors Corporation

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

Nylok is a registered trademark of Nylok Fastener Corporation.

Notice:

Manuals and products are subject to change without notice.

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

permission of VMAC

Contents

GENERAL INFORMATION ........................................................................................3

INTRODUCTION ........................................................................................................................ 5

INSTALLATION NOTES ............................................................................................................... 6

ORDERING PARTS ..................................................................................................................... 7

WARRANTY ............................................................................................................................. 7

CHANGES AND IMPROVEMENTS ................................................................................................... 7

PART 1: INSTALLING THE AIR TANK AND LINES ................................................9

1.1 INSTALLING THE TANK MOUNTS ........................................................................................ 11

1.2 INSTALLING THE TANK ..................................................................................................... 12

1.3 CONNECTING THE AIR AND OIL LINES ................................................................................ 13

PART 2: INSTALLING THE BRACKET, COMPRESSOR AND COOLER ............17

2.1 PREPARING FOR INSTALLATION .......................................................................................... 19

2.2 CONNECTING THE WHITE WIRE ......................................................................................... 21

2.3 INSTALLING THE BRACKET, COMPRESSOR AND COMPONENTS ................................................. 22

2.4 INSTALLING THE COOLER .................................................................................................. 24

2.5 CONNECTING THE LINES ................................................................................................... 26

2.4 COMPLETING THE INSTALLATION ...................................................................................... 27

2.5 ADDING OIL TO THE SYSTEM ............................................................................................ 28

PART 3: INSTALLING THE CONTROL COMPONENTS ......................................29

3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 31

3.2 CONNECTING THE WIRING HARNESS ................................................................................... 33

PART 4: ILLUSTRATED PARTS LIST...................................................................37

WARRANTY REGISTRATION .................................................................................43

1

2

General Information

System #V900055

1996-2000 GM K20/2500 & K30/3500

6.5 L DIESEL 4-WHEEL DRIVE

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 1900507a

4

General Information

Introduction

This book provides installation instructions for:

VMAC underhood air compressor installation kit

VMAC Throttle Commander

This kit has been designed for:

1996-2000 GMC CK2500, CK3500 & HD3500 6.5 L Diesel

Installation steps

The installation procedure in this manual has four main steps:

Part 1: Installing the Air Tank and Lines

Part 2: Installing the Bracket, Compressor and Cooler

Part 3: Installing the Control Components

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)

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.

5

NOTE

WARNING

!

DOCUMENT 1900507a

Installation Notes

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

Refer to the Owner’s Manual before operating the system for the first time.

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).

Warning

Do not operate the VR70 system unless the vehicle transmission is in PARK

(automatic transmissions) or NEUTRAL (manual transmissions) and the park

brake is firmly engaged.

8. The photographs in this manual show an installation on a 1997 HD3500 with a reinforced

frame.

6

Type Grade 8 plated Class 10.9 unplated

Size In Cast or

Steel

In

Aluminum

In Cast or

Steel

In

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 1900507a

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, Monday-Friday

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.

The enclosed System Identification Number Plate must be attached to the vehicle at the time of

installation. This plate provides information, which allows VMAC to assist in customer inquiries and

ordering of parts. It is important that this plate is affixed to the vehicle.

Instructions

Locate the plate on the front body support on the passenger side of the in front of the hood stop

(Figure 1). Drill the two hole locations using a 7/64” drill bit. Place the plate in position and fix in

place with the two #6 pan head self tapping screws provided.

Figure 1

Changes and improvements

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

7

DOCUMENT 1900507a

8

Part 1

Installing the

Air Tank and Lines

System #V900055

1996-2000 GM K20/2500 & K30/3500

6.5 L DIESEL 4-WHEEL DRIVE

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 1900508

10

11

DOCUMENT 1900508

1.1 Installing the tank mounts

1. Clean the frame on the driver side of

the truck to remove any dirt or debris

that will interfere with the installation of

the tank brackets.

2. Remove the two (2) 5/16 nuts from the

retaining cables on each of the tank

brackets, then remove the backing

strap and cables from the bracket.

There are two different lengths of

tank backing strap and two different

lengths of cable.

There are four spacers included for

different applications. Observe the

combinations shown in the diagram

for the different frame sizes

3. Remove the retaining cable from one of

the short backing straps.

4. Place the backing strap on the inside of

the frame, just behind the front spring

hanger. The top of the strap must be

inserted under the brake line and wire

harness that run along the frame.

5. Insert the threaded end of the retaining

cable through the top hole of the

backing strap and make sure that the

end of the cable is seated in the strap.

Make sure that the retaining cable

fits under the OEM cable that runs

along the top of the frame so that it

does not get pinched when the cable

is tightened.

Part 1: Installing the Air Tank and Lines

Tank mounting combinations

2500 Series

2 short backing straps

2 short cables

2 spacers, top & bottom

on each strap

3500 Series

2 short backing straps

2 short cables

2 spacers top & bottom (front)

1 spacer bottom (rear)

Heavy Duty Series

1 short backing strap (front)

1 long backing strap (rear)

1 short cable (front)

1 long cable (rear)

no spacers

FRONT REAR

Rear backing strap in place

Front backing strap in place

12

DOCUMENT 1900508

6. Place the rear backing strap on the inside

of the frame behind the transmission

cross-member with the cable over the

top of the frame.

Use the short backing strap for the

C models and the long backing

strap on the HD models. Photos

show positions of backing straps

for HD model.

1.2 Installing the tank

1. Remove the pinch bolts from the c-

clamp, expand the clamps and slide

over the front of the tank. Refit the

pinch bolts. Fit the two (2) C-clamps to

the front and rear of the tank, just

behind the end welds. Make sure the

clamps are fitted with the flat

attachments facing inboard when

looking at the front of the tank. Hand

tighten clamps only at this point.

2. Fit the 1/4 and 5/16 inch steel tube and

hose assemblies to the rear of the tank.

Thread the fittings securely in place, but

do not tighten them yet (1/4 inch tube

fits upper most). Then fit the two small

insulated double tube clips over the

tube.

3. Attach the L-brackets to the C-clamps

on the tank using four (4) 5/16 x 1/2

inch hex head cap screws according to

the following sequence:

a. Insert two (2) of the cap screws

through the two (2) small insulated

double tube clips.

b. Install these two cap screws into

the top mounting holes on the L-

bracket.

c. Install the two remaining cap

screws complete with flat

washers into the bottom mounting

holes on the L-bracket.

Tank shown without L-brackets

Installing the L-brackets

Installing the 1/4 inch tube

DOCUMENT 1900508

13

4. Adjust the position of the L-brackets

on the tank C-clamps before tightening

the cap screws. This will ensure that

the tank is level once it is installed.

On C models, make sure that both

brackets are all the way up, then

tighten the cap screws.

Tank must sit level and rotated so

that the “UP” arrow at rear of tank

is upright (90 degrees to ground).

On HD models, push the front

bracket down until you can just get

a thin-wall 1/2 box wrench on the

cap screw. Move the rear bracket

all the way up, then tighten the cap

screws.

5. Select the spacer and cable

combinations for your application and

place the tank in position on the frame

with the short angle part of the L-

brackets over the top of the frame.

6. Place the retaining cable over the L-

bracket, making sure that the cable fits

into the slots on the bracket.

7. Insert the threaded end of the cable

through the hole in the bottom of the

backing strap.

8. Install a flat washer or spacer and a

5/16 nut on the cable. Thread the nut

on sufficiently to hold the tank in place.

9. Repeat this process with the rear tank

bracket.

10. Tighten the cable nuts until the bracket

is tight against the frame. Do not over-

tighten, as this could damage the

threads or the cable.

11. Install a second 5/16 nut on the

threaded end of the cable and tighten it

against the first nut to prevent the cables

from loosening.

Attaching the L-brackets to the C-clamps

Cap screws retaining small insulated double tube clip

Tubes in place

DOCUMENT 1900508

14

1.3 Connecting the air and oil lines

1. Route the 5/16 scavenge line along the

frame, over the front body mount and

up into the engine bay.

2. Route the 1/4 pressure control line

along the frame, over the front body

mount up into the engine bay alongside

the 5/16 inch line.

3. Tie the 5/16 and 1/4 lines together with

nylon ties. The lines can also be

protected with 1/2 inch loom.

4. Install the 1/2 inch 45 degree swivel on

the lower fitting on the front of the tank.

5. Route the straight end of the 1/2 x 83

inch tank to cooler oil return line from

the engine compartment, along the

frame and around the outside of the

front body mount to the tank.

11. Connect the line to the swivel fitting on

the bottom front of the tank and tighten

the fitting.

12. Route the end of the 3/4 inch main

discharge line with the 45 degree fitting

along the frame from the engine

compartment and around the outside of

the front body mount to the tank.

13. Connect the fitting to the matching fitting

on the top front of the tank and tighten

the fitting.

14. Check the tank bracket retaining cables

to make sure that they are tight.

Rear of tank

Tank installed

DOCUMENT 1900508

15

15. Check all fittings at the tank to make sure

that they are tight.

16. Make sure all lines are secured to the

frame or brackets and will not contact

any moving parts.

Additional views of line routing and

connections are shown below

3/4" Main discharge fitting

1/2" Oil return line to cooler

Line fittings at the front of the tank

Line routing over the frame

1/2 and 3/4 lines around the mount

1/2 and 3/4 connections at the tank

16

Part 2

Installing

the

Bracket, Compressor

and

Oil Cooler

System #V900055

1996-2000 GM K20/2500 & K30/3500

6.5 L DIESEL 4-WHEEL DRIVE

UNDERHOOD AIR COMPRESSOR

17

DOCUMENT 1900509

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Vmac V900055 Installation guide

Vmac V900055 Installation guide

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