Vmac 9055 Installation guide

Type
Installation guide
Installation Manual
For The
System #9055
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 19507
1996-2000 GM K20/2500 & K30/3500
6.5 L DIESEL 4-WHEEL DRIVE
Installation Manual
VR7000 Underhood Air Compressor
System Number 9055
Application: 1996-2000 GMC K20/2500, K30/3500 6.5L Diesel, 4-wheel drive
Publication Date: July 2000
Publication Number: 19500
Origination Documents: #19507a - introduction
#19508 - air tank and line installation
#19509 - compressor and oil cooler installation
#19510 - control system installation
#19511 - illustrated parts list
#19130 - warranty registration
Registered Trademarks:
VR7000, 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.
Copyright 2000
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 #9055
1996-2000 GM K20/2500 & K30/3500
6.5 L DIESEL 4-WHEEL DRIVE
UNDERHOOD AIR COMPRESSOR
3
DOCUMENT 19507a
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 19507a
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 VR7000 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
T
y
pe 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 19507a
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 19507a
8
Part 1
Installing the
Air Tank and Lines
System #9055
1996-2000 GM K20/2500 & K30/3500
6.5 L DIESEL 4-WHEEL DRIVE
UNDERHOOD AIR COMPRESSOR
9
DOCUMENT 19508
10
11
DOCUMENT 19508
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 19508
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 19508
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 19508
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 19508
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 #9055
1996-2000 GM K20/2500 & K30/3500
6.5 L DIESEL 4-WHEEL DRIVE
UNDERHOOD AIR COMPRESSOR
17
DOCUMENT 19509
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Vmac 9055 Installation guide

Type
Installation guide

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