Vmac 9039 Installation guide

Type
Installation guide
Installation Manual
For The
System #9039
UNDERHOOD AIR COMPRESSOR
1996-2000 GMC C2500 & C3500
5.0L (305) & 5.7L (350)
TEL: 250-754-6997
FAX: 250-754-6972
TOLL FREE: 800-738-8622
1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3
DOCUMENT 19622
Installation Manual
VR7000 Underhood Air Compressor
System Number 9039
Application: 1996-1999 GMC C2500 & C3500 5.0L (305) & 5.7L (350)
Revision Date: February 2001
Publication Number: 19620
Origination Documents: #19620a - introduction
#19620b - compressor and oil cooler installation
#19620c - air tank and line installation
#19620d - throttle controller installation
#19620e - control unit installation
#19621 - illustrated parts list
#19130 - warranty registration
Registered Trademarks:
VR7000, VMAC and Throttle Commander are registered trademarks of VMAC.
GMC, C2500 and C3500 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.
Copyright 1999
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 PREPARING FOR INSTALLATION .......................................................................................... 11
1.2 INSTALLING THE BRACKETS AND TANK ............................................................................... 12
PART 2: INSTALLING THE COMPRESSOR AND COOLER ...................................... 17
2.1 INSTALLING THE BRACKET AND THE COMPRESSOR ................................................................ 19
2.2 INSTALLING THE CRANK PULLEY ....................................................................................... 20
2.3 INSTALLING THE OIL COOLER ............................................................................................ 21
2.4 CONNECTING THE HOSES .................................................................................................. 22
2.5 COMPLETING THE INSTALLATION ...................................................................................... 23
PART 4: INSTALLING THE CONTROL UNIT ................................................................25
3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 27
3.2 CONNECTING THE WIRING HARNESS ................................................................................... 28
PART 4: INSTALLING THE THROTTLE CONTROLLER ........................................... 31
4.1 INSTALLING THE THROTTLE CONTROLLER ASSEMBLY ........................................................... 33
4.2 CONNECTING THE CABLE ................................................................................................. 34
4.3 ADJUSTING THE CABLE ..................................................................................................... 35
ILLUSTRATED PARTS LIST .............................................................................................. 37
WARRANTY REGISTRATION ..............................................................................................
1
2
General Information
System #9039
1996-1999 GMC
C2500 & C3500
5.0L (305) & 5.7L (350)
UNDERHOOD AIR COMPRESSOR
3
DOCUMENT 19622
4
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:
1996-1999 GMC C2500 & C3500 with a 5.0L (305) or a 5.7L (350)
Installation steps
The installation procedure in this manual has four main steps:
Part 1: Installing the Compressor, Filter, Regulator and Oil Cooler
Part 2: Installing the 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
!
5
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.
DOCUMENT 19622
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).
The above fastener torque values are applicable when Loctite is used .
If the threads are dry add 20% to the torque values.
DANGER
Never operate the system unless the vehicle transmission is in neutral (standard
transmission) or park (automatic transmission) with the park brake fully applied. A
sudden increase in engine RPM when the system is engaged will cause the vehicle to
move suddenly if the transmission is left in drive.
6
DOCUMENT 19622
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 9 18 35 55 80 110 170 280
STANDARD GRADE 8 NATIONAL FINE THREAD
Size 3/8 7/16 1/2 5/8 3/4
Foot-pounds 40 60 90 180 320
METRIC CLASS 10.9
Size M8 M10 M12 M14 M16
Foot-pounds 19 41 69 104 174
WARNING
!
Ordering Parts
To order parts, contact VMAC at:
Telephone 250-754-6997
Facsimile 250-754-6972
Customer Service 800-736-8622
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.
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 19622
8
DOCUMENT 19622
Special installation notes
If you intend to use an auxiliary air receiver with this system you must observe the following
installation procedure (Figure 2) . Failure to observe this procedure will result in damage to the
system.
1. The line from the VR7000 tank to the auxiliary air receiver must have a one-way check
valve installed to prevent blowback from the auxiliary tank and to prevent moisture from
entering the VR7000 tank.
2. The line to the auxiliary tank must not be installed in the bottom of the tank, but must be
installed as high as possible to prevent water from clogging the line.
VR7000 Tank
Auxiliary Receiver
One-way check valve
Install the line as high as
possible, NOT on the
bottom of the tank
Figure 2
Part 1
Installing the
Air Tank and Lines
System #9039
1996-1999 GMC
C2500 & C3500
5.0L (305) & 5.7L (350)
UNDERHOOD AIR COMPRESSOR
9
DOCUMENT 19622
10
11
DOCUMENT 19622
Part 1: Installing the Air Tank and Lines
1.1 Preparing for installation
1. Disconnect all battery cables, then undo the battery hold down and remove the
battery from the passenger side of the vehicle.
2. Drain the coolant from the cooling system and remove the lower radiator hose.
3. Remove and discard the rock guard from under the radiator. Keep the OEM
fasteners for use with the replacement rock guard.
4. Disconnect the top radiator hose from the radiator end but not from the engine.
5. Disconnect and remove the air inlet box.
6. Remove the positive battery cable from its position on the fan shroud.
7. Remove the upper and lower sections of the fan shroud and the fan.
8. Remove the OEM belt and the fan.
9. Disconnect the transmission and vehicle oil cooler lines from the radiator. Undo the
upper radiator support bolts, then lift out the radiator.
10. On vehicles with or without air conditioning, the OEM idler on the alternator bracket
is discarded with the bracket.
11. Disconnect and remove the wiring from the alternator.
12. Remove the OEM retaining bolts from the alternator and remove the alternator.
13. Remove the heater hoses, air conditioning line and alternator cable from the plastic
locating bracket fastened to the alternator mounting castings (Figure 1.1).
14. Remove the OEM belt tensioner from the alternator mounting bracket (Figure 1.1).
15. Remove and discard the OEM cast aluminum alternator mounting bracket (Figure
1.1).
16. Remove and discard the heater hose (complete with metal S-shaped pipe) from
between the water pump and the firewall (Figure 1.1).
Do not disconnect the heater return hose quick-coupler at the manifold as it may
leak if removed and refitted.
NOTE
OEM Alternator Bracket
Bracket Holding Heater Hoses,
Air Conditioning Line And
Alternator Cable
OEM Heater Hose With Metal S-shaped Pipes
On Vehicles With Or Withoutout A/C Discard
The Idler Which Is Attached Here
On Vehicles
With A/C, Fit The
Supplied Aluminum
Idler To The Cast
AluminumBracket At
This Location
1.2 Installing the brackets and tank
The tank mounts supplied with this system are designed so that they can be mounted on the
frame without drilling holes. The tank is secured to the frame using two L-brackets that
hook over the chassis rail and are secured with wire cables and backing straps. The tank
and clamps then locate on the L-brackets
1. Remove the two (2) 1/4 inch bolts from both of the C-clamps supplied. Expand the clamps
and fit them over the front of the tank. Position the first C-clamp at seven (7) inches from
the rear of the tank and rotate it so the flat mounting section is aligned with the “up” arrow
on the rear of the tank. Locate the front C-clamp at three (3) inches from the front of the
tank and rotate to the same position as the rear C-clamp. Tighten both clamps untill they
hold the tank. Do not over tighten.
2. Connect the swivel nut on the end of the steel line coupled to the 1/4inch pressure control
line, to the upper location on the rear of the tank. Run the steel line along the inside of the
tank. (See figure 1.2)
Figure 1.1
3. Connect the swivel nut on the end of the steel line coupled to the 5/16 scavenge line, to the
lower connection at the rear of the tank. Route the steel line down the inside of the tank
alongside the 1/4 pressure control line. (See figure 1.2)
12
DOCUMENT 19622
4. Fit the two (2) supplied “P” clips over the 1/4 and 5/16 inch steel lines and postion them to
align with the upper fixing slots on both C-clamps.
5. Attach the L-shaped tank brackets to the C-clamps on the tank using the supplied 5/16 x
1/2 inch cap screws. Two 5/16 washers are used on the lower bolts and the “P” clips with
the upper bolts. Use locktite on the bolts.
Connections at the rear of the tank Connections at the front of the tank
6. Make sure that the brackets are at their lowest point on the adjustment
slots (the tank will mount as high as possible). Tighten the cap screws.
7. Remove the two (2) 5/16 inch nuts and washer from the threaded ends of the wire cable
and remove the threaded ends from the backing strap.
9. Place the two backing straps in position on the inside of the frame, one in front of the
transmission crossmember mount and one behind the mount, with the cables over the top of
the frame. (See figure 1.4)
10. Support the tank on adjustable jackstands or a suitable support system (so that you can
locate the tank and lift it into position) under the body on the passenger side of the truck
between the two body mounts.
11. Route the 1/4 inch and 5/16 inch lines between the body mount and the body, up over the
frame rail on the passenger side and up towards the front of the engine compartment.
12. Raise the tank into position along the side of the frame (between the two body mounts) with
the top of the L-bracket over the top of the frame.
13. Fit the cable into the two slots on each of the L-shaped brackets and insert the threaded
end through the bottom holes of each backing strap.
13
Figure 1.2 Figure 1.3
DOCUMENT 19622
14. Slide the flat washers onto the threaded ends of each wire cable and install one of the 5/16
inch nuts on each cable. Do not tighten until all the hoses are installed.
15. Slide the tank rearward on the frame to provide clearance for attaching the remaining lines.
14
DOCUMENT 19622
Figure1.5 Figure 1.6
Figure 1.4
DOCUMENT 19622
15
It is recommended that you leave the tank loose in the clamps until all of the lines are
connected to allow you to adjust tank position during the line connection process.
NOTE
Figure 1.8
Figure 1.7
DOCUMENT 19622
16
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.
WARNING
!
16. Connect the 45 degree fitting end on the 3/4 inch main air hose to the upper fitting on the
front of the tank. Angle the hose to route up and over the cab mount and along the frame rail
towards the front of the engine compartment.
17. Fit the 90 degree fitting end of the longer 1/2 inch oil return hose to the lower fitting on the
front of the tank. Angle the hose up over the cab mount with the 3/4 hose and the two hoses
from the rear of the tank.
20. Move the tank forward on the frame until there is 7 inches between the front of the tank and
the cab mount
21. Tighten the 5/16 inch nut on the cable clamps to hold the tank in position, then install a
second 5/16 inch nut on each clamp and tighten them to lock the nuts and prevent them
from loosening.
22. Tighten all hoses on the tank securely.
Part 2
Installing
the Compressor,
and
Oil Cooler
System #9039
1996-1999 GMC
C2500 & C3500
5.0L (305) & 5.7L (350)
UNDERHOOD AIR COMPRESSOR
17
DOCUMENT 19622
18
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40
  • Page 41 41
  • Page 42 42
  • Page 43 43
  • Page 44 44
  • Page 45 45
  • Page 46 46

Vmac 9039 Installation guide

Type
Installation guide

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI