UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS Installation Manual UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS System # V910001 2001 2002 GMC C6500 C8500 CAT 3126 W/WOAC UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS TM UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS UNDERHOOD AIR COMPRESSORS 1333 KIPP ROAD NANAIMO B.C. V9X 1R3 TEL: (250)-740-3200 FAX: (250)-740-3201 Visit us at... underhoodair THE BENCHMARK IN INNOVATION TOLL FREE: 800-738-8622 www..com
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. Copyright 2003 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
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DOCUMENT #1930038 Part 1 General Information System #V910001 2001 2002 GMC C6500 C8500 CAT 3126 W/WOAC UNDERHOOD AIR COMPRESSOR Page 3
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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
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. 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 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. Page 6
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 7
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
DOCUMENT #1930038 Part 2 Preparing for Installation System #V910001 2001 2002 GMC C6500 C8500 CAT 3126 W/WOAC UNDERHOOD AIR COMPRESSOR Page 9
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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. Page 11
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. Disconnect the screw on fittings Driver side view of the air brake compressor housing Remove the hose clamp View from above securing hose clamp 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
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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). 15 18 Rear Tank Mount Position Front Tank Mount Position Cab Mount Figure 1, marking the tank bracket locations Figure 2, tank strap cable, (tab faces frame rail) Page 15
Figure 3, Tank mount brackets fitted 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). 18 Figure 5, C-clamp mounting positions Figure 6, P clip mounting detail 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 8, steel lines attached at the rear of the tank Figure 9, Main airline securing bracket 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
DOCUMENT #1930038 Part 4 Installing the Compressor and Oil Cooler System #V910001 2001 2002 GMC C6500 C8500 CAT 3126 W/WOAC UNDERHOOD AIR COMPRESSOR Page 19
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4.1 Cooler Installation 1. Identify the four cooler mounting holes in the passenger side of the cylinder head behind the air cleaner OEM cast mounting bracket for the air cleaner, (figure 10). 2. Install the cooler assembly facing outwards to these mounting holes using the 4 supplied M10 x 30 bolts and washers, (figure 10). 3. Remove the 3/4 NPT OEM plug from the passenger side of the thermostat housing and install the supplied 3/4 NPT x 3/4 hose barb 45 degree fitting using Loctite PST sealant, (figure 11). 4. Fit the 32-inch long 3/4-inch heater hose supplied, to the lower 90-degree coolant hose fitting in the cooler. Route the other end of the hose around the air intake and connect it to the 45- degree hose fitting just installed in the thermostat housing. Fit the two supplied HS10 hose clamps and tighten securely. 5. Mark and cut a 1-inch long section out of the OEM lower radiator hose to allow the cooler return tee to be fitted into the hose, (Shown in figure 12 in mounted position for clarity). 6. Install the cooler return tee into the radiator section of the lower radiator hose with the supplied hose clamp. Refit the radiator end of the hose to the lower radiator connection. 7. Rotate the tee to allow it to clear the drive belt fan and in a suitable position to allow the cooler return 3/4-inch hose to be fitted. 8. Fit the engine section of the lower radiator hose to the other end of the cooler return tee with the supplied hose clamp. Reconnect the hose to the engine and tighten all clamps. 9. Fit the supplied 48-inch length of 3/4-inch heater hose between the top cooler fitting and the cooler return tee installed in the OEM lower radiator hose. Fit the supplied hose clamps and tighten. Ensure that the hose is routed away from the turbo and any moving parts. The passenger side of the thermostat housing Figure 10, Cooler mounting bolt locations, (Passenger side of engine) Figure 11, Cooler supply spigot installed Page 21
UP To Rad Cut here 1 Front Engine Figure 13 Cooler return tee Figure 12 Hose cutting detail 4.2 Installing the Spacer Plate and Remote Idler Spacer plate Figure 14, Installing the spacer plate Figure 15, Fitting the fan pulley 1. Insert the supplied spacer plate in behind the fan hub on the cylinder head with the large hole sitting around the shouldered bolt behind the fan hub. Locate the OEM cast fan hub and alternator bracket in position using the four OEM bolts behind the fan pulley. Use Loctite on the threads, (figure 14). 2. Refit the fan hub pulley with the 6 OEM bolts, (figure 15). 3. Refit the OEM upper alternator support strap in place. Remove the small idler from the remote idler bracket and install the remote idler bracket in place where the alternator strap secures to the OEM casting. Use the two supplied M10 x 60 hex head cap screws and two 3/8-inch flat washers, (figure 16 Table A, feature A). Refit the idler, bolt, and spacer using Loctite and torque to specifications. Page 22
A Figure 16, Remote idler installed Figure 17, Alternator refitted 4. Torque the remaining two OEM10 mm bolts on the fan hub casting loosened earlier, (figure 16 and 17). 5. Refit the alternator using the OEM bolts and connect the wiring. Torque to specification, (figure 17). 4.3 Installing the Main Bracket 1. Fit the bracket brace attachment for the main VR140 mounting bracket behind the thermostat housing with the OEM air filter cast mount. This is located in front, on the top right side of the cylinder head used to mount the OEM air filter cast mount. Use the three supplied M10 x 35mm socket head cap screws with three flat washers. Only hand tighten at this time. Use Loctite on the threads, (figure 18 Table A, Page 20, feature B). 2. Refit the OEM belt tensioner using the OEM bolt and torque to specifications. 3. Refit the OEM 8 rib belt. Follow the belt routing shown later in this section. B Figure 18, Fitting the Bracket Brace Figure 19, Fitting the Bracket Brace Page 23
C D E F Figure 20, Fitting the Three Bracket Bolts Figure 21, Main Bracket in Place 4. Fit one M10 x 25 hex head cap screw with flat washer to the small machined section of the VR140 mounting bracket, (bottom right corner of the bracket) hand tighten only, (figure 20). Fit the remaining two M10 x 25 hex head cap screws to mount the main bracket to the bracket brace attachment. Hand tighten only and apply Loctite to the threads, (figure 23 Table A, Page 20, feature G). 5. Align the remaining bolt holes in the mounting bracket with the holes in the aluminum casting on the top of the timing cover. Fit only the two M10 x 40 hex head cap screws with flat washers to the left side upper and lower holes in the bracket to the aluminum casting. Only hand tighten at this time and apply Loctite to the threads, (figure 21 Table A, Page 20, feature D). 6. Remove the six-rib idler from the idler attachment bracket. 7. Fit the idler attachment bracket to the larger machined area of the main bracket. Use the two M10 x 45 bolts screwed into the aluminum casting through the main bracket and the M10 x 30 bolt into the cylinder head,(figure 22 Table A, Page 20, feature E & F). E F G Figure 22, Idler Attachment Bolt Locations Figure 23, VR Belt tensioner on Main Bracket Page 24
E F Detail A Idler attachment bracket fasteners Feature Letter Bracket Fastener Description A Remote Idler 2 x M10 x 60 HHCS, 2 x 3/8 flat washers B Bracket Brace 3 x M10 x 35 HHCS, 3 x 3/8 flat washers C Main Bracket 1 x M10 x 25 HHCS, 1 x 3/8 flat washer D Main Bracket 2 x M10 x 40 HHCS, 2 x 3/8 flat washers E Main Bracket 1 x M10 x 30 HHCS, 1 x 3/8 flat washer F Attachment Bracket 2 x M10 x 45 HHCS, 2 x 3/8 flat washers G Bracket Brace 2 x M10 x 25 HHCS, 2 x 3/8 flat washers Bracket fastener details 4.4 Bracket Tightening Procedure 1. Tighten the front two M10 hex head cap screws on the front fastening to the cylinder head first. Tighten the four remaining M10 hex head cap screws fastening the front of the main bracket and idler attachment bracket to the aluminum casting on the top of the timing cover. Tighten the two M10 hex head cap screws fastening the bracket brace to the main bracket. Tighten the three M10 hex head cap screws that locate the bracket brace attachment to the cylinder head. Torque all bolts, (figures 20, 21, 22 and 23) to the specifications shown in the chart at the front of the manual. 2. Refit the two idlers to the two stubs on the VR140 bracket with the idler bolt spacers and 1/2- inch bolts using Loctite. Fit the eight-rib idler to the idler attachment bracket idler stub and install the 1/2-inch bolts and bolt spacers. Apply Loctite to the threads then torque to specifications. Page 25
3. Locate and fit the VR140 belt tensioner in position on the large boss on the front of the VR140 mounting bracket. Use the supplied M10 x 80 hex head cap screw and flat washer, (figure 23). Torque to specifications. 4. Lift the compressor into position on the VR140 main bracket. Be sure to line up the four mounting holes on the compressor with the four threaded mounts on the main bracket. Apply loctite to the threaded ends of the supplied M8 x 110 socket head cap screws and install them by inserting them through the bolt holes in the compressor and threading them into the mounts on the main bracket horizontal deck. 2- M10 x 25 Figure 24, Bracket Brace Attachment Figure 25, Compressor Installation 4.5 Installing the VR140 Crank Pulley 1. Clean off the paint from the outside lip of the OEM crank pulley to allow a good fit for the VR pulley. Install the VR140 eight-rib pulley over the lip of the OEM crank pulley and refit the harmonic balancer. Align the bolt holes and ensure the pulley is sitting flush. Fit the eight supplied M10 x 50 hex head cap screws to secure using Loctite and torque to specification, (figure 26 and 27). Figure 26, Installing the VR Pulley Figure 27, Installing the OEM Harmonic Balancer Page 26
2. Install the VR140 eight- rib drive belt following the routing shown. Ensure that the belt sits correctly in the grooves and alignment looks good. BACK IDLER VR 140 CLUTCH TENSIONER REMOTE IDLER BACK IDLER RIBBED IDLER CRANK PULLEY 4.6 Completing the Installation 1. Refit the fan. Figure 28, Belt Routing Detail 2. Refit the OEM air cleaner mounting bracket to the cast locating mount on the cylinder head using OEM bolts and torque to specifications. 3. Install the air filter assembly and refit the intake trunking. 4. Refit the air cleaner to the turbo duct. Ensure the cooler 3/4-inch coolant hoses are routed around the ducting and clear of the exhaust manifold or turbo. 17 11 4 11 Discard Figure 29, Rad hose shown before cutting Figure 30, Rad tube with rad hoses in place Page 27
1. Mark the OEM upper radiator hose as shown in figure 29 & 30 and cut. Discard the middle section and the short end piece. 2. Fit the longer 90-degree hose section to the 90-degree end of the replacement upper radiator tube, (figure 30). 3. Fit the short 90 degree section of the OEM hose to the other end of the upper radiator tube and fit the assembly to the vehicle with the tube lying along the top of the radiator, ( figure 31). Fit all clamps and tighten securely. Figure 31, Rad tube with rad hoses installed 4. Connect the end of the 1-inch main airline to the rear of the compressor and tighten using two wrenches to prevent hose twist. 5. Connect the shorter 5/8-inch oil return line 90-degree end to the lower cooler fitting. Route the hose over the cooler and connect it to the 90-degree elbow fitting on the drivers side of the compressor. Use two wrenches when tightening. 6. Connect the end of the 5/16 oil scavenge line to the fitting on the driver side of the inlet control valve. 7. Connect the 1/4-inch pressure line to the 90-degree fitting on the passenger side of the inlet control valve. 8. Connect the 90-degree end of the 5/8 oil return line from the tank to the upper 90-degree elbow fitting supplied on the top of the cooler. 9. Check that all VR140 system hoses are fully tightened. Remove the oil fill plug in the top of the VR140 compressor inlet control valve, (figure 32). Using a small funnel, pour the 9 liters, (1.62 US gal.) of supplied compressor oil slowly into the system. Rotate the compressor clutch clockwise using a 1/2-inch socket as you fill the system to pump the oil to the tank. Page 28
Oil fill plug Figure 32 You must use the supplied VMAC certified and approved synthetic compressor oil in this system. Failure to use this special oil will result in damage to the compressor and will void your warranty. 10. Allow 5 minutes for the oil to settle then look under the vehicle at the sight glass on the front of the tank to check the level is between the Fill and Max marks. If you have a system with the air brake option, reconnect the air compressor coolant hose screw fittings that you removed in the Preparation for Installation section of this manual. These fittings attach to the air brake compressor housing on the driver side of the engine block. Try to relocate any of the original hose clamps for the air brake compressor coolant hoses. This will help to secure the hoses and give further support. Ensure that the hoses do not rest in a position where they can foul with any moving parts or come in contact with any sharp surfaces or obstructions. Refill the compressor coolant to the recommended level. 11. Install the coolant expansion tank. Reconnect the coolant fill hose to the tank. Reconnect the overflow hose. 12. Check that all coolant hoses are connected and tight. Refill cooling system with the manufacturers recommended coolant. 13. Conduct a tidy up of all VR140 hoses and wiring. Use plastic loom for protection on sharp edges or chaffing against body, engine, or other braided hoses. Use tie wraps to secure all loose components. Use the supplied stainless steel ties to secure a bulk of hoses together to the frame or in hot areas. Page 29
14. Allow the cooling system to vent air thoroughly when running the engine before operation of the VR140 system. 15. Follow the setup procedure in the owner s manual before commencing using the system. Page 30
DOCUMENT #1930038 Part 5 Installing the Control Components System #V910001 2001 2002 GMC C6500 C8500 CAT 3126 W/WOAC UNDERHOOD AIR COMPRESSOR Page 31
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CLUTCH CLUTCH 16GA WHT PRESSURE SENSOR INLET VALVE COMPRESSOR TEMPERATURE PROBE 7 PIN CONNECTOR (GREEN) 3 PIN CONNECTOR (BLACK) FIREWALL BULKHEAD CONTROL PANEL 3550404 OEM BREAKER PANEL IGNITION OFF: NO VOLTAGE IGNITION ON: BATTERY VOLTAGE PARK BRAKE HOURS SWITCHING BOX 3550412 TAP-IN CONNECTOR RED 4 PIN CONNECTOR (GREEN) BLK ACCELERATOR PEDAL RED 16GA WHT XXXX XXXX XXXX GRN OEM HARNESS (UNPLUGGED FROM ACCELERATOR PEDAL) WIRE LABEL WHT LEGEND THROTTLE T510085 CHASSIS GROUND GRY THROTTLE CONTROL 12 VOLTS RED RED GROUND PARKING BRAKE 12 VOLTS CURTIS 1/10 BLUE BLACK PRESSURE SENSOR Figure 1 Page 33
Part 5: Installing the Control Components 5.1 Installing the control unit See figure 1 for wiring diagram 1. Mount the control unit inside the cab, on the panel behind and beside the driver s seat. 2. Tighten the brackets on the control unit and using the assembled control unit as a template, locate and drill two (2) 3/32 holes for the mounting brackets. 3. Mount the control unit using the supplied self-tapping screws (Figure 2). Figure 2 Figure 3 4. Remove the doorsill trim and locate the plastic tube containing the OEM wiring. 5. Feed the wire harness from the control unit through the plastic tube up to the park brake, (figure 3). 6. Remove the kick panel at the park brake. Page 34
Figure 4 7. Install the switch box underneath the dash near the heater core. Secure it to the support runner, on its side with the wires facing the driver s side foot-well. Use three black nylon ties (Figure 4). 8. Route the cable from the control unit to the matching connector at the switch box. 9. Connect the wire harness with the large white interface connector to the matching white connector on the switch box. 10. Locate the square opening in the firewall near the heater core in the driver s foot well that is sealed by a rubber plug. Remove the rubber plug and install a grommet. 11. Route the gray cable with green connectors from the switch box, and the white compressor wire from the interface cable, through the grommet and into the engine compartment. 5.2 Connecting the wiring 1. Route the black wire and the green wire (with the ring connector) to the park brake. 2. Locate the small white switch at the park brake. Remove the two-pin plug and separate the wires coming from the plug. 3. Attach the black wire from the interface cable to the blue wire from the plug using the supplied Tap-In connector, and then reconnect the plug to the switch. 4. Fasten the connector on the green wire to ground using the top bolt on the park brake assembly that holds it to the cab frame. 5. Replace the kick panel over the park brake and the doorsill trim. Page 35
6. Locate a breaker in the breaker panel that has a 12 volt, ignition key operated power source. Test with a voltmeter to determine if it is ignition controlled and which side of the breaker is connected to power. One possible location is the 3rd breaker from the top on the right side row. 7. Remove the breaker, install the jumper connection, bend the jumper 90 degrees. Replace the breaker (Figure 5). Figure 5, jumper connection detail 8. Connect the red wire with the inline fuse from the interface cable to the jumper at the breaker panel. 9. In the engine compartment, route the gray cable with the green 7 pin connector to the compressor and connect it to the matching gray cable with connector on the compressor. 10. Also route the white wire to the compressor and connect it to the compressor clutch. 11. Check all wiring to ensure that it is secured and will not contact any hot areas or moving parts. 5.3 Installing the Throttle Control 1. Mount the Throttle Control under the dashboard. Ensure that the harness connectors on the Throttle Control will reach the OEM accelerator connectors. Use supplied nylon ties to hold it in place. Maintain access to the adjustment screws. 2. Unplug the OEM cable from the accelerator pedal and plug it into the male connector on the Throttle Control. 3. Plug the cable from the throttle control with the female connector into the connector on the accelerator pedal. Page 36
4. Route the gray pressure sensor cable through a suitable opening in the firewall through to the engine compartment. 5. Route the gray pressure sensor cable to the VR140 compressor and connect it to the pressure sensor. 6. Cover the wire with the supplied 1/4-inch plastic loom. Refer to figure 1 for drawing of the electrical connection 7. Route the 18 gauge red wire from the interface connector to the throttle control. Connect it to the red wire from the throttle control. Page 37
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DOCUMENT #1930038 Part 6 Illustrated Parts List System #V910001 2001 2002 GMC C6500 C8500 CAT 3126 W/WOAC UNDERHOOD AIR COMPRESSOR Page 39
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ILLUSTRATED PARTS LIST FOR SYSTEM V910001 2001 2002 GMC 6500 C8500 CAT 3126 W/WOAC ASSY. ITEM UNIT QTY PART# DESCRIPTION 1.0 4800321 Main Bracket Assembly 1.1 ea 1 1100142 Main Bracket 1.2 ea 3 1300010 Back Idler 1.3 ea 4 1400051 Spacer, Idler 1.4 ea 4 1510161 Bolt, fl, G8 1/2 x 1 1/4 1.5 ea 1 1200314 Idler Attachment Bracket 1.6 ea 1 1300023 Idler, Serp 8 Rib Groove 1.7 ea 1 1520210 Bolt, HHCS G10.9, M10 X 1.5 X 80 1.8 ea 1 1570044 Washer, Alloy, pl, SAE, 3/8 1.9 ea 1 3300024 Tensioner 1.10 ea 1 1200295 Bracket Brace 1.11 ea 1 1200312 Mount, Remote Idler 1.12 ea 1 1800164 Crank Pulley VR140 1.13 ea 8 1570044 Washer, Alloy, pl, SAE, 3/8 1.14 ea 8 1520106 Bolt, HHCS G10.9 M10, 1.5 X 50 1.15 ea 1 1640001 VR140 Belt 2.0 P140003 Compressor Assembly 2.1 ea 1 P140001 VR140 Compressor 2.2 ea 1 P200036 Clutch, Complete, 8 Groove 2.3 ea 1 3550682 Temp Probe Assembly 2.4 ea 1 5830091 O-Ring, Viton, 3 3/8 ID X 1/8 2.5 ea 1 9210025 Inlet Control Valve 2.6 ea 1 5000064 Elbow, Brass Pipe-Tube, 1/4-1/8 2.7 ea 1 3500288 Pressure Sensor 2.8 ea 1 5000081 Elbow, Brass NPT-Tube, 1/8-5/16 2.9 ea 1 3600072 Air filter 2.10 ea 1 1550514 Nut, Flange Torq lock NC, 1/4-20 2.11 ea 1 1500532 Rod, Threaded 1/4 x 5.62 2.12 ea 1 3600068 Filter Cover 2.13 ea 1 1570038 Flat Washer 1/4 2.14 ea 1 1550029 Nylock nut NC 1/4 2.15 ea 1 4900002 Elbow, Steel JIC/O-Ring, 1/2 3/4-16 2.16 ea 1 5830072 O-Ring, Viton, 5/8 ID X 1/16 2.17 ea 2 1540287 Bolt, SHCS, M10 x 1.5 x 100 2.18 ea 2 1540171 Bolt, SHCS, M10 x 1.5 x 30 Page 41
ILLUSTRATED PARTS LIST FOR SYSTEM V910001 2001 2002 GMC 6500 C8500 CAT 3126 W/WOAC ASSY. ITEM UNIT QTY PART# DESCRIPTION 3.0 9210024 Tank Assembly 3.1 ea 1 9210007 Main Tank Body 3.2 ea 1 4900065 Plug, Hex Head Steel Allen, 5 3.3 ea 1 5830008 O-ring, Viton, 1 15/16 ID X 3/32 3.4 ea 1 3600077 Sight Glass Window 3.5 ea 1 1500385 Ring Retaining, 2 1/8 3.6 ea 1 9200039 Oil Filter,VR140 3.250 short 3.7 ea 1 5000089 Connector, Brass NPT-SAE, 3/8-1/2 3.8 ea 1 4900074 Connector, 1" Pipe TO 1" JIC 3.9 ea 1 5830100 O-ring, Viton, 6 1/2 ID X 1/8 3.10 ea 1 5840068 Compression Spring 3.11 ea 1 3600036 Coalescing Filter Element 3.12 ea 1 3600075 Seal, Tank Rear Cap 3.13 ea 1 1500077 10-32 Button Head SHCS 3.14 ea 1 4800241 Scavenge Screen Barb Assembly 3.15 ea 1 3200326 Discharge Cap 3.16 ea 1 3600073 Valve, Safety, 3/8, 200 PSI 3.17 ea 1 3200227 Ring, window 3.18 ea 2 2200105 Cable Clamps 3.19 ea 1 4100358 Coalescer Spring Plate 3.20 ea 1 5830104 O-ring, Viton, 1 3/8 ID x 1/16 3.21 ea 1 5830055 O-ring, Viton, 1 5/16 x 3/32 3.22 ea 1 3200231 Cover, sight glass 4.0 Hose Kit 4.1 ea 1 1781072 Hose, crimped 1 x 72 4.2 ea 1 1762047 Hose, crimped 5/8 x 47 4.3 ea 1 1762067 Hose, crimped 5/8 x 67 4.4 ea 1 1741110 Hose, crimped 5/16 X 109.75 4.5 ea 1 1731109 Hose, crimped 1/4 X 108.5 4.6 ea 1 1710592 Hose, Heater, 3/4 x 48 (1700177) 4.7 ea 1 1710593 Hose, Heater, 3/4 X 32" (1700177) 4.8 ea 1 1710589 Hose, Green Stripe 11 (1700387) 4.9 ea 1 1720541 Tube, Rad 4.10 ea 1 1720552 Tube, Rad 90 Deg 4.11 ea 2 2200027 Clamp, Hose HS32 4.12 ea 1 4900078 Elbow Steel, 45Deg, 3/4 NPT 3/4 HB 4.13 ea 4 2200029 Hose Clamps, HS10 4.14 ea 1 1720553 Cooler Return Tee 5.0 T510085 Throttle Controls 5.1 ea 1 T510085 Throttle Control Page 42
ILLUSTRATED PARTS LIST FOR SYSTEM V910001 2001 2002 GMC 6500 C8500 CAT 3126 W/WOAC ASSY. ITEM UNIT QTY PART# DESCRIPTION 6.0 4800319 Tank Bracket Assembly 6.1 ea 2 1200319 Strap 6.2 ea 4 1510527 Bolt, HHCS NC G8 PL, 1/2 X 5 1/2 6.3 ea 8 1570102 Washer, flat 1/2 6.4 ea 4 1550103 Nut, Prevailing Torque NC, 1/2 6.5 ea 2 2200149 Clamp, mounting bracket 6.6 ea 2 1200327 Bracket, tank mount 7.0 4800325 Cooler Assembly 7.1 ea 1 9210027 Cooler Assembly 7.2 ea 2 5000016 Connector, 3/4 Hose Barb 8.0 Electrical 8.1 ea 1 3550659 Interface Cable 8.2 ea 1 3550404 Control Box Assembly 8.3 ea 1 3550412 Switch Box 9.0 Miscellaneous 9.1 ea 1 1200308 Spacer plate Page 43