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- Page 1 DOCUMENT 19295 Installation Manual For The System #9014 UNDERHOOD AIR COMPRESSOR 1996-1999 GMC CK2500, CK3500 & HD3500 454 W/WOAC TEL: 250-754-6997 FAX: 250-754-6972 TOLL FREE: 800-738-8622 1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3...
- Page 2 #19299 - control unit installation #19300 - illustrated parts list #19130 - warranty registration Registered Trademarks: VR7000, VMAC and Throttle Commander are registered trademarks of VMAC, a division of Mangonel Corporation. GMC, CK2500, CK3500 and HD3500 are registered trademarks of General Motors Corporation Loctite, Prime N’...
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Page 3: Table Of Contents
Contents GENERAL INFORMATION ..................3 .......................5 NTRODUCTION ...................... 6 NSTALLATION OTES ......................7 RDERING ARTS ......................... 7 ARRANTY ...................7 HANGES AND IMPROVEMENTS PART 1: INSTALLING THE COMPRESSOR, FILTER, REGULATOR AND OIL COOLER ..................9 1.1 P ................... 11 REPARING FOR INSTALLATION 1.2 I ..............13 NSTALLING THE BRACKET AND COMPRESSOR 1.3 I... -
Page 5: General Information
DOCUMENT 19295a General Information System #9014 1996-1999 GMC CK2500, CK3500 & HD3500 454 W/WOAC UNDERHOOD AIR COMPRESSOR... -
Page 7: Introduction
DOCUMENT 19295a General Information Introduction This book provides installation instructions for: VMAC underhood air compressor installation kit VMAC Throttle Commander This kit has been designed for: 1996-1999 GMC CK2500, CK3500 & HD3500 454 W/WOAC Installation steps The installation procedure in this manual has four main steps:... -
Page 8: Installation Notes
DOCUMENT 19295a Installation Notes 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. Follow all safety precautions for underhood mechanical work. Use Loctite 242 or equivalent on all engine-mounted fasteners. 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. -
Page 9: Ordering Parts
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. -
Page 11: Part 1: Installing The Compressor, Filter, Regulator And Oil Cooler
DOCUMENT 19296 Part 1 Installing the Compressor, Filter Oil Cooler System #9014 1996-1999 GMC CK2500, CK3500 & HD3500 454 W/WOAC UNDERHOOD AIR COMPRESSOR... -
Page 13: Preparing For Installation
DOCUMENT 19296 Part 1: Installing the Compressor, Filter, Regulator and Oil Cooler 1.1 Preparing for installation Disconnect the battery. Drain the coolant from the cooling system and remove the OEM radiator hoses. Remove the upper radiator cowling . Remove the OEM belt, then remove the cooling fan. Remove the lower radiator cowling. - Page 14 Remove the OEM fasteners holding the OEM pulley in place on the crankshaft. Install the VR7000 pulley in place over the OEM crankshaft pulley. Install and tighten the three (3) supplied 3/8 x 3-1/2 inch NF hex head cap screws and one...
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Page 15: Installing The Bracket And Compressor
DOCUMENT 19296 1.2 Installing the bracket and compressor Apply Loctite to the five (5) 7/16 x 1-1/4 hex head cap screws and fasten the VR7000 bracket in place of the OEM air conditioning and power steering mounting bracket (Figure 1.3). -
Page 16: Installing The Remote Filter And Regulator
(2) supplied 8 mm hex head cap screws in the front holes. 1.3 Installing the remote filter and regulator Mount the remote filter assembly to the inside of the VR7000 mounting bracket in the location between the air conditioning compressor and the alternator (Figure 1.4) using three (3) 1/4 x 3/4 inch hex head cap screws with serrated washers. - Page 17 Nylok nuts. Tighten the fasteners securely. Drill These Two Holes For Heavy Duty Installation Use These Two Existing Holes For Heavy Duty Radiator Installation Vehicle Body Use These Three Holes Crossmember For Standard Model Installation VR7000 Oil Cooler Mount Bracket VR7000 Oil Cooler Figure 1.5...
- Page 18 DOCUMENT 19296 1.4.3 All models Slide a hose clamp over the ends of the VR7000 coolant hoses. Insert the hoses on the radiator fitting and the water pump fitting. Tighten all of the clamps securely. HS28 Clamp TO WATER PUMP...
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Page 19: Completing The Installation
DOCUMENT 19296 Hose To Lower Radiator Connection Hose To Water Pump Connection Cross-Member In Front Of The Radiator Figure 1.7 1.5 Completing the installation Lower the radiator back into place and install the OEM fasteners which hold it in place. Tighten the fasteners. - Page 20 WITHOUT AIR CONDITIONING Figure 1.8 Install the VR7000 belt following the belt routing shown in Figure 1.9. For units without air conditioning, remove the OEM idler from the OEM bracket and mount it onto the pad on the front of the VR7000 bracket. Figure 4 shows the belts and idlers in place.
- Page 21 Adjust the hose for a proper fit and tighten the hose clamps. Install the hose retainer on the top of the VR7000 compressor air intake using the back left fastener (Figure 1.10) and tighten the hex head cap screw securely.
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Page 23: Part 2: Installing The Air Tank And Lines
DOCUMENT 19297 Part 2 Installing the Air Tank and Lines System #9014 1996-1999 GMC CK2500, CK3500 & HD3500 454 W/WOAC UNDERHOOD AIR COMPRESSOR... -
Page 25: Installing The Tank Mounts And The Tank
DOCUMENT 19297 Part 2: Installing the Air Tank and Lines 2.1 Installing the tank mounts and the tank The tank mounts supplied with this system are designed so that they can be mounted on the frame without drilling holes. They are also adjustable so that the tank can be positioned more precisely. Figure 11 shows the components of the tank mounts. - Page 26 DOCUMENT 19297 Clean all dirt and debris from the frame on the driver’s side, between the two cab mounts (Figure 12) Front Bracket Rear Bracket Front Cab Mount Rear Cab Mount Figure 12 Look at the frame under the cab on the driver’s side of the truck to determine if there are any obstructions that require clearance, such as emergency brake cables or brake lines.
- Page 27 DOCUMENT 19297 Insert, then Rotate 90 Frame Rail Figure 14 Install the inner coupling nut on the inner side upper tank bracket in the same manner as with the outer nut. Insert a long hex head cap screw into the bracket and thread it into the coupling nut Repeat these procedures with the rear tank bracket.
- Page 28 DOCUMENT 19297 Remove the retaining nuts and washers from the end of the tank retaining cables and remove the threaded end from the tank cradle. Install the tank on the cradles, insert the retaining cables and install the washers and nuts, but do not tighten the cables.
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Page 29: Connecting The Air And Oil Lines
DOCUMENT 19297 2.2 Connecting the air and oil lines 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 This procedure will follow the installation of each individual line, show the location on each component and describe the complete process. - Page 30 DOCUMENT 19297 Connect the 45 degree swaged fitting of the main air line (part #17311) to the “ x “ compressor fitting (Figure 18) and to the air tank at location 1 (Figure 16). Route the lines to clear the exhaust manifold, along the frame and past the body mount to the tank (Figure 20).
- Page 31 DOCUMENT 19297 Connect the pressure control line (part #17313) to the tank fitting at location 2 “ x “ (Figure 16) and to the 90 degree fitting at the pressure regulator (Figure 22). Route this line above the body mount and across the fender liner to the regulator. Make sure the lines do not contact the exhaust manifold.
- Page 32 DOCUMENT 19297 Connect the oil return line (Part #17316) to the passenger side fitting on the oil “ x “ cooler. Connect the end with the 45 degree elbow to the 90 degree elbow fitting on the alternator side of the remote filter (Figure 24). Oil Return Line Cooler to Filter 1/2"...
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Page 33: Adding Oil To The System
DOCUMENT 19297 2.3 Adding oil to the system Make sure that the vehicle is level. If equipped, remove the filler plug from the top of the inlet control valve (Figure 26). If there is no filler plug, remove the four socket head cap screws retaining the inlet control valve and remove the inlet control valve from the compressor Pour six (6) litres (1.6 US Gal.) of the supplied compressor oil into either the fill hole or the large air intake opening. -
Page 34: Completing The Installation
Also note that this type of installation will result in a delay in the actuation of the mechanical throttle by approximately 30 seconds. 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. -
Page 35: Part 3: Installing The Throttle Controller
DOCUMENT 19298 Part 3 Installing the Throttle Controller System #9014 1996-1998 GMC CK2500, CK3500 & HD3500 454 W/WO AC, W/WO A.I.R. UNDERHOOD AIR COMPRESSOR... -
Page 37: Installing The Throttle Control
DOCUMENT 19298 Part 3: Installing the Throttle Controller 3.1 Installing the Throttle Controller Remove the two (2) 8 x 60 front socket head cap screws and the 8 x 45 socket head cap screw from left rear of the inlet control valve as shown in Figure 27. Remove and discard the 8 flat washers from right front cap screw. - Page 38 OEM bracket). Remove the nut and washer from the end of the controller cable, insert it through the drilled hole at the top of the fitted VR7000 bracket, reinstall the washer and nut and tighten them.
- Page 39 DOCUMENT 19298 Fit the inner throttle controller cable through the throttle pull bracket nipple, install the cable stop nipple, pull the inner cable tight and adjust the nipple so that there is between the “ nipple and the pull bracket. This distance may need to be adjusted if engine speed exceeds 2200 RPM when the system is operated at full flow.
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Page 41: Part 4: Installing The Control Unit
DOCUMENT 19299 Part 4 Installing the Control Unit System #9014 1996-1999 GMC CK2500, CK3500 & HD3500 454 W/WOAC UNDERHOOD AIR COMPRESSOR... -
Page 43: Installing The Control Unit
DOCUMENT 19299 Part 4: Installing the Control Unit 4.1 Installing the control unit Locate a suitable location for the control unit. One recommended location is behind the seat on the driver’s side of the vehicle (Figure 4.1). Locate and drill two (2) holes through the plastic trim panel to match the control unit brackets. -
Page 44: Connecting The Wires
Connect the green wire to a good ground. Route the white wire along the firewall and along the right-side valve cover to the VR7000 compressor. Connect this wire to the compressor clutch connection. - Page 45 DOCUMENT 19299 Connect the black wire from the Drive Disable Circuit with the piggyback connector to the connector on the park brake switch. Connect the OEM wire to the piggyback connector at the park brake switch. Route the blue wire into the engine compartment along the same route as the other wires. Locatethe light green wire at cavity B in the 7 pin connector at the transmission (Figure 4.2).
- Page 46 DOCUMENT 19299 In-line Fuse To switched power source To ground Green To OEM park brake switch and Black OEM park brake switch wire Black To female quick-connector at the Blue harness on top of the engine To Matching AUTOMATIC TRANSMISSION ONLY Connector on Harness From To compressor clutch...
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Page 47: Part 5: Illustrated Parts List
DOCUMENT 19300 Part 5 Illustrated Parts List System #9014 1996-1999 GMC CK2500, CK3500 & HD3500 454 W/WOAC UNDERHOOD AIR COMPRESSOR... - Page 49 DOCUMENT19307 ILLUSTRATED PARTS LIST FOR SYSTEM 9014 - 1996-1999 GMC CK2500, CK3500 & HD3500 454 W/WOAC ITEM UNIT DESCRIPTION 1225 AIR COMPRESSOR 2035 CLUTCH ASSEMBLY 6 GROOVE 50060 1/2 NPT X 1/2 SAE CONNECTOR 35363 TEMPERATURE PROBE 92103 FILTER BLANK PLATE FITTING 58045 3/4 ID VITON O RING 92104...
- Page 50 13008 IDLER 6 RIB 14148 TENSIONER SPACER 13007 BACK IDLER 26106 TENSIONER 11125 VR7000 BRACKET 50075 1/2 NPT X 1/2 SAE 45 DEGREE ELBOW 45089 REMOTE FILTER ADAPTOR 50074 1/2 NPT X 1/2 SAE 90 DEGREE ELBOW 92039 OIL FILTER...
- Page 51 DOCUMENT19300 ILLUSTRATED PARTS LIST FOR SYSTEM 9014 - 1996-1999 GMC CK2500, CK3500 & HD3500 454 W/WOAC ITEM UNIT DESCRIPTION 15049 3/8 NC X 3/4 FLANGE LOCK BOLTS 22093 BOTTOM FRAME CLAMP 22092 TANK CRADLE 22095 TANK CABLE 18121 CRANK PULLEY 15044 3/8 SAE PLAIN W ASHERS 15188...
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Page 53: Warranty Registration
Warranty Registration This form must be fully completed and returned to VMAC at the time of installation. Warranty will be void if this form is not received by VMAC within 30 days by mail or fax. Installer Information Company Name:... - Page 54 1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3 TEL: 250-754-6997 FAX: 250-754-6972 TOLL FREE: 800-738-8622...
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