Vmac V910001 Installation guide

UNDERHOOD AIR COMPRESSORS

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1333 KIPP ROAD NANAIMO B.C. V9X 1R3

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UNDERHOOD AIR COMPRESSORS

TM

2001–2002 GMC C6500 – C8500

CAT 3126 W/WOAC

System # V910001

Installation Manual

Installation Manual Document Number: 1930038

VR140 Underhood Air Compressor

System Number V910001

For trucks with air brakes, system V910001 will require adaptor kit A700043.

Application

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

Publication Date

Revised by S. Large, February 5, 2003

Notice

Manuals and products are subject to change without notice.

Registered Trademarks

Underhood, VR140, 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 C6500 – 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.

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................................................................................................................................. 7

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 VR140 CRANK PULLEY ................................................................................. 26

4.6 COMPLETING THE INSTALLATION.............................................................................................. 27

PART 5 INSTALLING THE CONTROL COMPONENTS ........................................................ 31

5.1 INSTALLING THE CONTROL UNIT................................................................................................ 34

5.2 CONNECTING THE WIRING ......................................................................................................... 35

5.3 INSTALLING THE THROTTLE CONTROL ...................................................................................... 36

PART 6 ILLUSTRATED PARTS LIST......................................................................................... 39

WARRANTY..................................................................................................................................... 45

Page 1

DOCUMENT #1930038

Part 1

General Information

System #V910001

2001–2002 GMC C6500 – C8500

CAT 3126 W/WOAC

UNDERHOOD AIR COMPRESSOR

Page 3

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)

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.

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.

Page 5

Page 6

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. 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.

Table 1 – Torque values

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.

Hose diameter Color coded label Part number prefix

1/4” Yellow 173

5/16” Orange 174

1/2” & 5/8” Blue 175 & 176

3/4” & 1” Green 177 & 178

Table 2 – Hose color codes.

9. Table 2 above illustrates the color code used by VMAC to define the different hose

diameters. 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.

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.

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

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.

1.7 Ordering Parts

Contact your nearest VMAC dealer.

Be sure to include the part number, description and quantity of parts when ordering.

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

Page 8

• 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.

DOCUMENT #1930038

Part 2

Preparing for Installation

System #V910001

2001–2002 GMC C6500 – C8500

CAT 3126 W/WOAC

UNDERHOOD AIR COMPRESSOR

Page 9

Page 11

2.1 Preparing for Installation

1. Disconnect the batteries.

2. Drain the coolant into a suitable container.

3. Remove the upper radiator hose.

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. 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.

18. Disconnect the heater return hose.

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

the bolts.

For trucks with air brakes, system V910001 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.

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.

View from above – securing hose clamp

Remove the hose clamp

Disconnect the screw on fittings

Driver side view of the air brake compressor housing

Page 12

DOCUMENT #1930038

Part 3

Installing the Air Tank and

Lines

System #V910001

2001–2002 GMC C6500 – C8500

CAT 3126 W/WOAC

UNDERHOOD AIR COMPRESSOR

Page 13

3.1 Installing the tank mounting brackets

1. Measure 15 inches back from the rear of the front spring hanger and mark the lower edge of

the passenger side frame rail, (Figure 1).

2. Measure 18 inches back along the rail from the previous mark and mark the lower edge of

the passenger side frame rail, (Figure 1).

3. Pass the threaded end of the 1/2 x 5 1/2 inch supplied tank bracket bolt through the lower of

the top holes in the tank mount backing strap from the outside of the frame rail, (figure 2).

4. Hold the backing strap in place at the 15 inch mark on the outside of the frame rail. Pass the

threaded end of the bracket bolt with washer through the second hole from the top on the

tank mount bracket. The frame rail will become sandwiched between the backing strap and

the tank mount bracket. Make sure that the tab on the tank mount bracket is facing towards

the frame rail so that it will slot into the top edge of the lower frame rail lip.

5. Install another 1/2-inch flat washer and Nylock nut and thread until hand tight. In a similar

fashion, pass the next 1/2 x 5 1/2 inch bolt through the lowest hole on the backing strap and

through the hole just below the tab on the tank mount bracket. Install the supplied 1/2-inch

flat washer and Nylock nut. Tighten both nuts on the assembly to specification, (figure 2).

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

marked position on the frame rail, (figure 4).

18”

15”

Rear Tank Mount Position

Front Tank Mount Position

Cab Mount

Figure 1, marking the tan

k

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

Page 15

Figure 3, Tank mount brackets fitte

d

Figure 4, Tank supported ready to install

3.2 Installing the C-clamps

1. Remove the 3/8 x 1 1/2 inch pinch bolts and nuts from both the supplied tank mount C-

clamps. Line up the four holes in each clamp half section, with the mounting holes in the

tank mount brackets. Install the four 3/8 x 1 inch bolts with washers in each C-clamp. Install

the four supplied 3/8 inch nuts and tighten to specification, (figure 5 & 6).

2. Lift the tank into position using a suitable support system to hold the tank so that the first

clamp is six inches from the front of the tank. Resting on the curved half sections of the

installed C-clamps, set the tank so that it sits horizontal with the arrow on the front of the

tank pointing up. Refit the other half of the C-clamps with the 3/8 x 1 1/2 inch pinch bolts

and Nylock nuts. tighten enough just to loosely grip the tank, (figure 5).

Figure 6, “P” clip mounting detail

Figure 5, C-clamp mounting positions

18”

Page 16

2 x 5 1/2 x 1/2” NC

4 x 1 ” NC HHCS

2 x 1 1/2” NC

Figure 7, C-clamp mounting detail

3.3 Attaching the lines to the tank.

1. 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 along the upper, (middle) of the tank, (figure 8).

2. Insert the threaded end of the 1/4-inch pressure control line into the fitting at the top rear of

the tank. Route the steel pipe section along the upper, (middle) of the tank alongside of the

scavenge line, (figure 8).

3. Spring open the two small insulated “P” clips and fit them over the two steel sections of the

scavenge and pressure control line.

4. Use the threads that extend past the nut on the top 1 1/2” bolt of the first C-clamp as a

mounting point for the “P” clip. Insert the threaded end of this bolt through the “P” clip that

holds the steel lines. Install a second supplied Nylock nut to secure the “P” clip and tighten

to specifications, (Figure 6).

5. Follow the same procedure outlined in steps three and four to install a “P” clip on the

second C-clamp located 18 inches further forward on the tank, (figure 5).

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

7. Fit the 45-degree connector end of the 1-inch main air discharge hose to the top fitting on

the front of the tank. Route the flexi hose up into the engine compartment with the 1/4 and

5/16 hoses.

8. Fit the straight end connector of the longest 5/8-inch oil return hose to the lower fitting on

the front of the tank. Route the hose up into the engine compartment.

Page 17

P-clip

Figure 9, Main airline securing bracketFigure 8, steel lines attached at the rear of the tan

k

9. 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 9 to enable the airline to be clear of the exhaust system.

Page 18

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Vmac V910001 Installation guide

Vmac V910001 Installation guide

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