Vmac V900067 Installation guide

DOCUMENT# 1900669

Installation Manual

For The

UNDERHOOD AIR COMPRESSOR

System #V900067

2001–2002 GMC C6500 – C8500

CAT 3126 W/WOAC

1333 KIPP ROAD, NANAIMO, B.C. V9X

1R3

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

Installation Manual Document Number: 1900669

VR70 Underhood Air Compressor

System Number V900067

For trucks with air brakes, system V900067 will require adaptor kit A700043.

Application

2001–2002 GMC C6500 – C8500 CAT 3126 W/WOAC

Publication Date

Original: Revised by S. Large, January / 2002

Current: June 20, 2002

Notice

Manuals and products are subject to change without notice.

Registered Trademarks

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

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

Nylok is a registered trademark of Nylok Fastener Corporation.

GMC C 6500 – C8500 are trademarks of General Motors Corporation.

3126 CAT is a trademark of Caterpillar Engines.

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

permission.

Page 1 June 20, 2002

Contents

PART 1 GENERAL INFORMATION ............................................................................................. 3

1.1 INTRODUCTION............................................................................................................................ 5

1.2 INSTALLATION STEPS................................................................................................................... 5

1.3 TERMS AND SYMBOLS ................................................................................................................. 5

1.4 INSTALLATION NOTES.................................................................................................................. 5

1.5 SYSTEM IDENTIFICATION NUMBER PLATE .................................................................................. 6

1.6 WARRANTY................................................................................................................................. 6

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

1.8 LIST OF TOOLS REQUIRED FOR COMPRESSOR INSTALLATION........................................................ 7

1.9 LIST OF TOOLS REQUIRED FOR THROTTLE COMPONENT INSTALLATION........................................ 7

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

PART 2 PREPARING FOR INSTALLATION............................................................................... 9

2.1 PREPARING FOR INSTALLATION................................................................................................. 11

PART 3 INSTALLING THE AIR TANK AND LINES ............................................................... 13

3.1 INSTALLING THE TANK MOUNTING BRACKETS........................................................................... 15

3.2 INSTALLING THE C-CLAMPS ...................................................................................................... 16

3.3 ATTACHING THE LINES TO THE TANK......................................................................................... 17

PART 4 INSTALLING THE COMPRESSOR AND OIL COOLER ......................................... 19

4.1 COOLER INSTALLATION............................................................................................................. 21

4.2 INSTALLING THE SPACER PLATE AND REMOTE IDLER ............................................................... 22

4.3 INSTALLING THE MAIN BRACKET .............................................................................................. 23

4.4 BRACKET TIGHTENING PROCEDURE........................................................................................... 25

4.5 INSTALLING THE VR70 CRANK PULLEY ................................................................................... 25

4.6 COMPLETING THE INSTALLATION.............................................................................................. 26

PART 5 INSTALLING THE CONTROL COMPONENTS ........................................................ 29

5.1 INSTALLING THE CONTROL UNIT................................................................................................ 32

5.2 CONNECTING THE WIRING ......................................................................................................... 33

5.3 INSTALLING THE THROTTLE CONTROL ...................................................................................... 34

PART 6 ILLUSTRATED PARTS LIST......................................................................................... 37

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

Page 2 June 20, 2002

DOCUMENT #1900669

Page 3 June 20, 2002

Part 1

General Information

System #V900067

2001–2002 GMC C6500 – C8500

CAT 3126 W/WOAC

UNDERHOOD AIR COMPRESSOR

Page 4 June 20, 2002

Page 5 June 20, 2002

1.1 Introduction

This book provides installation instructions for the VMAC underhood air compressor installation kit.

1.2 Installation steps

The installation procedure in this manual has four main steps:

• Preparing for Installation

• Installing the Air Tank and Lines

• Installing the Compressor and Oil Cooler

• Installing the Control Components

1.3 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)

1.4 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 suggestions 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 following

specifications. Torque specifications are in foot pounds (ft-lb) and are only applicable when

Loctite is used. If the threads are dry, add 20% to the torque values. Check that system hoses

are all tight before running the system. Refer to setup procedure in the Owner’s Manual

before attempting to run this air system.

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.

Page 6 June 20, 2002

8. Different frame designations will affect the tank mounting position. You may have to move

the tank rearward from the standard position on your application. If you must move the tank,

the lines may be too short. If this is the case, measure the hose shortfall and order a “Hose

Extender Kit”, P/N (A410XXX)*

*The last three digits in the P/N indicate the length of the extension.

Example: A410055 is a 55-inch hose extender kit.

1.5 System Identification Number Plate

The System Identification Number Plate included with the kit must be attached to the vehicle at

the time of installation. Locate the plate as shown below. Mark and drill two holes using a 7/64”

drill bit. Secure the plate in position using the supplied #6 pan head, self-tapping screws.

1.6 Warranty

The Underhood 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.

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

Page 7 Document June 20, 2002

1.7 Ordering Parts

To order parts, contact VMAC for your nearest dealer.

Telephone: 250-740-3200 Facsimile: 250-740-3201 Toll Free: 800-738-8622

Office Hours: 5:00 AM to 4:30 PM (Pacific Time) 8:00AM to 7:30PM (Eastern Time)

1.8 List of tools required for compressor installation

• 1/2” drive metric socket set

• 1/2” drive SAE socket set

• Allen key sets – metric and SAE

• Mechanic’s screwdriver set

• Nut drivers – 5/16- 3/8 inch.

• 1/2-inch drill with assorted bits up to 1/2-inch

• Hacksaw or zip wheel suitable for cutting metal

1.9 List of tools required for throttle component installation

• Small soldering gun/ Soldering pen

• Wire cutters

• Wire strippers

• Crimping tool

• Digital multimeter – preferably with a frequency (Hz) setting

• Very small Jeweler’s screwdriver set for the adjustment of the throttle control

1.10 Changes and improvements

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

Page 8 June 20, 2002

DOCUMENT #1900669

Page 9 June 20, 2002

Part 2

Preparing for Installation

System #V900067

2001–2002 GMC C6500 – C8500

CAT 3126 W/WOAC

UNDERHOOD AIR COMPRESSOR

Page 10 June 20, 2002

Page 11 June 20, 2002

2.1 Preparing for Installation

1. Disconnect the batteries.

2. Drain the coolant into a suitable container.

3. Remove the upper and lower radiator hoses.

4. Disconnect hoses to the coolant expansion tank and remove the tank.

5. Remove the air cleaner intake ducting.

6. Remove the air cleaner ducting to the turbo inlet.

7. Remove the air cleaner assembly.

8. Remove the air cleaner locating bracket and the three OEM bolts locating the cast mounting

from the cylinder head..

9. Disconnect the alternator wiring.

10. Remove the OEM 8 rib drive belt.

11. Remove the fan.

12. Remove the alternator.

13. Remove the two OEM 10mm bolts locating the upper alternator support strap to the right

side of the fan hub casting. Discard the bolts.

14. Remove the six OEM 8mm bolts holding the fan pulley to the fan hub and remove the pulley.

15. Remove the four 10mm OEM bolts locating the fan hub casting to the cylinder head behind

the fan pulley.

16. Remove the OEM belt tensioner.

17. Remove the four 10mm OEM bolts securing the OEM belt tensioner mounting to the side of

the engine and remove the mounting.

18. Slacken but do not remove the two remaining 10mm bolts locating the fan hub casting, just

behind the OEM belt tensioner. Allow the casting to move forward about 1/2 inch.

19. Disconnect the heater return hose.

20. Remove the eight bolts securing the harmonic balancer on the OEM crank pulley and discard

the bolts.

For trucks with air brakes, system V900067 will require adaptor kit A700043.

Please consult the instructions that come with the adaptor kit and see page 12

of this manual for more instructions concerning the preparation for

installation on trucks equipped with air brake systems.

Page 12 June 20, 2002

Preparation for installation on trucks equipped with air brake systems.

In order to allow for the installation of the main bracket and attachment bracket, both the coolant

supply hose and the coolant return hose screw fittings must be detached from the air brake

compressor housing. This housing is located on the front driver side of the engine block. These

connectors are illustrated in the photographs below. Undo any hose clamps that may secure these

hoses to the front of the engine block. These hoses are to be moved aside during the install process

and will be reattached in the “Completing Installation” section of this manual.

Driver side view of the air brake compressor housing

Disconnect the screw on fittings

Remove the hose clamp

View from above – securing hose clamp

DOCUMENT #1900669

Page 13 June 20, 2002

Part 3

Installing the Air Tank and

Lines

System #V900067

2001–2002 GMC C6500 – C8500

CAT 3126 W/WOAC

UNDERHOOD AIR COMPRESSOR

Page 14 June 20, 2002

Page 15 June 20, 2002

3.1 Installing the tank mounting brackets

1. Measure 15 inches back from the center of the rear cab mount on the under side of the

passengers side frame rail and mark the position, (figure 1)

2. Pass the threaded end of the tank strap cable through the upper of the top holes of the front tank

mount bracket. The pressed out dimple must be towards the frame. Pull the cable right through to

the stop, (figure 2).

3. Hook the cable with the front tank mount bracket over the passengers side frame rail from the

inside and set it at the marked point on the frame rail.

4. Wrap the cable around the frame rail and pass the threaded end back through the hole in the tank

bracket that lines up with the under side of the lower frame rail. Ensure the cable does not foul

on the fuel lines or vehicle-wiring loom, (figure 3 and 4).

5. Adjust the tank mount bracket to allow the pressed out dimple to sit on the upper side of the

lower frame rail edge to secure it in place.

6. Place one thick 5/16 flat washer (supplied) over the threaded end of the cable then fit one 5/16

NC nut on the threaded end of the cable and tighten enough to hold the bracket securely,

(figure 3).

7. Measure the underside of the frame rail 18 inches back from the front tank bracket cable and

mark the frame rail, (figure 1).

8. Repeat the above procedure with the rear tank mount bracket and set this bracket at the marked

position on the frame rail.

Figure 1, marking the tank bracket locations Figure 2, tank strap cable, (tab faces frame rail)

18”

15”

Front Tank Mount Position

Rear Tank Mount Position

Cab Moun

t

Page 16 June 20, 2002

3.2 Installing the C-clamps

1. Remove the 1/4 x 3 and 1/2-inch pinch bolts and nuts from both the supplied C-clamps. Expand

the clamp and slide it over the front of the tank with the flat side facing the oil filter side of the

tank. Place the front C-clamp at three inches from the front of the tank and place the rear C-

clamp at 18 inches from the center of the front C-clamp.

2. Refit the pinch bolts to the C-clamps with the nuts to the bottom and tighten. Before fully

tightening the C-clamps, align the flat mounting sections vertically with the “UP” arrow on the

front of the tank.

3. Insert the threaded end of the 5/16 –inch scavenge line into the fitting at the bottom rear of the

tank. Route the steel pipe section of the scavenge line along the upper frame rail side of the tank

so it will fix to the top C-clamp position.

Figure 4, tank strap cable fitted around frameFigure 3, Tank mount brackets fitte

d

Figure 5, C-clamps fitted on the tan

k

Figure 6, Tank supported ready to install

Clamp positions

18”

Page 17 Document June 20, 2002

4. Follow the above procedure to install the 1/4 - inch oil pressure control line threaded end into the

fitting at the top rear of the tank. Route the steel section of the line along side the 5/16 scavenge

line.

5. Fit the two (supplied ) “P” tube retaining clips over both steel tube sections with the flat side

towards the C-clamp. Position these two “P” clips in line with the upper mounting holes for the

front and rear C-clamps.

6. Support the tank in position under the vehicle using stands or suitable support system and align

the C-clamps lower holes with the lower holes in the tank mounting brackets, (figure 6).

7. Insert two 5/16 x 1 inch bolts with flat washers through the lower holes in the C-clamps and then

through the lower holes in the front and rear tank-mounting brackets. Fit a second 5/16 flat

washer to the bolts and then two 5/16 nylock nuts and tighten, (figure 7).

8. Repeat the above step for the two upper securing 5/16x 1 inch bolts. Do not use a flat washer

under the bolt heads and pass the bolts through the “p” clips first then through the C-clamps and

upper holes in the tank mount brackets. This will secure the two steel lines to the tank bracket,

(figure 7).

9. Align the tank and tighten all bolts securely, tighten the tank bracket securing cables. Fit two

further 5/16 nuts to the cables and jam the nuts together.

3.3 Attaching the lines to the tank.

1. Feed the flexible ends of the 1/4 and 5/16 lines up into the engine compartment.

2. Fit the straight end of the longest 1/2 inch oil return line to the connection at the lower front

of the tank and feed the 90 degree end up into the engine compartment along with the ¼ and

5/16 lines.

3. Fit one end of the 3/4 main air discharge line to the connection at the upper front of the tank.

Feed this hose also up into the engine compartment with the other lines.

Figure 7, steel lines attached at the rear of the tan

k

Figure 8, Main airline securing bracket

P-clip

Page 18 June 20, 2002

4. Install the longest flat end of the main airline-securing bracket to the transmission casting

using the M10 x 25 hex head cap screw. Fit the rubber insulated “P” clip over the main air

line and connect to the other end of the main air line securing bracket using M10 x 25 bolt

with flat washer and Nylock nut. Ensure that the bracket and clip are fitted as shown in figure

6 to enable the airline to be clear of the exhaust system, (figure 8).

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Vmac V900067 Installation guide

Vmac V900067 Installation guide

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