Vmac V900094 Installation guide

System V900094

2009-2007 Dodge 2500-3500

5.9L 24 Valve Cummins Diesel

www.vmacair.com

VR70 UNDERHOOD

AIR COMPRESSOR

INSTALLATION MANUAL

VMAC – Vehicle Mounted Air Compressors

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1

Installation Manual for VMAC

System V900094

2009-2007 Dodge 2500-3500

5.9L 24 Valve Cummins Diesel

General Information..................................................................... 3

Before You Start ....................................................................... 3

Part 1: Warranty and System ID ................................................. 4

Part 2: Preparing for Installation ............................................... 7

2.1 Preparing for Installation .................................................... 7

Part 3: Installing the Tank .......................................................... 9

3.1 Assembling and Installing the Brackets ............................. 9

3.2 Installing the Tank Assembly .............................................. 11

Part 4: Installing the Cooler and Compressor ......................... 12

4.1 Installing the Oil Cooler ...................................................... 12

4.2 Installing the Main Bracket and Compressor ..................... 14

4.3 Connecting the Hoses ........................................................ 15

4.4 Completing the Installation ................................................. 16

4.5 Adding Oil to the System .................................................... 20

Part 5: Installing the Control Components .............................. 22

5.1 Installing the Control Box and Throttle Control .................. 23

5.2 Connecting the Wiring ........................................................ 23

5.3 Completing and Testing the Installation ............................. 27

Part 6: Finishing the Installation ................................................ 28

6.1 Before Starting the Engine Checklist.................................. 28

6.2 After Starting the Engine Checklist .................................... 28

6.3 Setup, Performance Testing and Adjustments ................... 29

6.4 Auxiliary Air Receiver ......................................................... 30

Accessory Products from VMAC ............................................... 31

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Document 1930132

Installation Manual for VMAC System V900094

2009-2007 Dodge 2500-3500 5.9L 24 Valve Cummins Diesel

Changes and Revisions

Version

Revision Details

Revised by/date

Checked by/date

Reviewed by/date

Implemented

A

ECN 07-145

IB 10 Nov 2007

SH 23 Nov 2007

N/A

26 Nov 2007

B

ECN 09-038

SL 31 March 2009

RD 29 Mar 2009

N/A

3 April 2009

C

ECN 12-156

SAR 14 Nov 2012

MH 16 Nov 2012

N/A

30 Nov 2012

D

ECN 13-013,

ECN 13-104

SH 18 Jul 2013,

MC 05 Nov 2013

MP/RD 17 Dec 2013

N/A

20 Dec 2013

E

ECN 13-120

JR 22 Apr 2014

MH 22 Apr 2014

DB 24 Apr 2014

01 May 2014

Important Information

The information in this manual is intended for certified VMAC

installers who have been trained in installation procedures and for

people with mechanical trade certification who have the tools and

equipment to properly and safely perform the installation. Do not

attempt this installation if you do not have the appropriate

mechanical training, knowledge and experience.

Follow all safety precautions for underhood mechanical work. Any

grinding, bending or restructuring operations for correct fit in modified

trucks must follow standard shop practices.

These instructions are a general guide for installing this system on

standard production trucks and do not contain information for

installation on non-standard trucks. This system may not fit special

order models or those which have had other changes without

additional modifications. If you have difficulty with the installation,

contact VMAC.

The VMAC 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.

To order parts, contact your VMAC dealer. Your dealer will ask for

the VMAC serial number, part number, description and quantity. To

locate your nearest dealer, call 1-800-738-8622.

All trademarks used in this manual are the property of the respective copyright holder.

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

written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3.

Printed in Canada

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!

General Information

Before You Start

Read this manual before attempting installation so that you can

familiarize yourself with the components and how they fit on the

truck. Identify variations for different model years and different

situations that are listed in the manual. Open the package, unpack

the components and identify them.

All fasteners must be torqued to specifications. Use manufacturers

torque values for OEM fasteners. Apply Loctite 242 or equivalent on

all engine-mounted fasteners. Torque values are with Loctite applied

unless otherwise specified.

STANDARD GRADE 8 NATIONAL COARSE THREAD

Size

1/4

5/16

3/8

7/16

1/2

9/16

5/8

¾

Foot-pounds (ft-lb)

9

18

35

55

80

110

170

280

Newton meter (N•m)

12

24

47

74

108

149

230

379

STANDARD GRADE 8 NATIONAL FINE THREAD

Size

3/8

7/16

1/2

5/8

¾

Foot-pounds (ft-lb)

40

60

90

180

320

Newton meter (N•m)

54

81

122

244

434

METRIC CLASS 10.9

Size

M8

M10

M12

M14

M16

Foot-pounds (ft-lb)

19

41

69

104

174

Newton meter (N•m)

25

55

93

141

236

Hose Information

Depending on other installed equipment, it might be

necessary to move the air/oil separation tank from its

intended location. The hoses used in VMAC

compressor systems have a specific inner liner that is

compatible with our compressor oil. Use of hoses other

than those supplied or recommended by VMAC may

cause compressor damage and may void your

warranty. Please contact VMAC for replacement hoses

and further information.

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Part 1: Warranty and System ID

□ Complete the warranty form. 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.

System Identification and Operating Instructions

The System Identification Number Plate must be attached to the

vehicle at the time of installation. This plate provides information that

allows VMAC to assist in customer inquiries and the ordering of

parts.

□ Mark and drill two 7/64-inch holes in the top of the cross member

in front of the OEM air filter box. Secure the plate with supplied

self- tapping screws

□ Clean cross member beside the number plate and stick the

VMAC belt routing diagram to the cross member.

□ Apply battery warning label to driver side of primary cooling

reservoir.

□ As part of the installation process, ensure that the safety and

operational instruction decal is affixed in an obvious location so

that it can be seen by vehicle operators. A good spot for this is

usually on the inside of the door or on the panel underneath the

steering wheel. (Figure 1.1).

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Figure 1.1

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□ To alert any technicians that may service the vehicle, affix the

servicing caution/contact label in the engine compartment near

the hood latch in a visible location. Thoroughly clean the

selected area before affixing the label (figure 1.2)

Figure 1.2

To order parts, contact your VMAC dealer. Your dealer will ask for

the VMAC serial number, part number, description and quantity. To

locate your nearest dealer, call 1-888-241-2289.

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Part 2: Preparing for Installation

Preparation for installation is very important. Missing an item can

cause problems in the installation or even damage to components.

Check off each item as it is completed so that you do not miss any

preparation steps.

2.1 Preparing for Installation

□ Disconnect the battery terminals.

□ Disconnect the mass air flow sensor, remove the air cleaner

assembly and the passenger side intercooler tube.

□ Drain the coolant and remove the upper and lower radiator

hoses.

□ Disconnect the fan clutch wire and remove it from the mounting

clips

□ Remove the fan shroud from the engine locating brackets.

□ Remove the fan and the OEM belt. Use cardboard to protect the

radiator.

□ Remove the passenger side upper fan shroud mounting bracket

from the front of the engine.

□ Remove the wire harness from the clips on the top front of the

cylinder head.

□ Remove the upper alternator mount and lifting lug, remove the

lower alternator mount bolt and set the alternator aside.

□ Remove the OEM crank pulley and scrape off the clear coat from

the front face.

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□ Place the OEM crank pulley on the front of the crankshaft and

rotate it to align it with the locating pin. Place the VR pulley in

front of the OEM crank pulley and align it with the locating pin.

□ Apply Loctite to the four OEM bolts and install them through the

two pulleys into the crankshaft. Torque the bolts to

specifications.

□ Remove the plug from the passenger side of the cylinder head

(Figure 2.1). Save this plug as it will be re-used later. Use thread

sealant on NPT fittings. Install the supplied pipe nipple, and tee

fitting in the cylinder head port. Face the tee fitting towards the

passenger side of the truck, and install the hose barb in the tee.

Remove this plug

Figure 2.1

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Part 3: Installing the Tank

The tank will mount on the passenger side of the vehicle between

the two cab mounts.

1/4” and 3/16” tubes

Mount bracket

Strap mounts

5/16” bolts and nuts

C-clamps

5/16” nuts and flat washer

3/4” fitting

1/2” fitting

Mounting cable

FRAM

E

Figure 3.1

3.1 Assembling and Installing the Brackets

□ Place the tank on a work bench with the front (oil filter end) of the

tank to your left and remove the oil filter.

□ Remove the two 1/4 inch clamp bolts from the C-clamps. Expand

the clamps slightly and slide them over the front of the tank.

□ Position the front clamp right behind the weld on the filter end of

the tank and the rear clamp approximately 18 inches from the

weld.

□ Place the two L-shaped tank strap mounts under the C-clamps

with the right-angle ends facing you and hanging over the edge

of the work bench.

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□ Apply Loctite and insert 5/16 inch bolts with flat washers into the

bottom hole on each bracket, install the nuts but do not tighten.

□ Install the 1/4 inch clamp bolts into the C-clamps so that the

heads of the bolts face toward you, apply Loctite and install the

nuts but do not tighten.

□ Rotate the tank so that the directional arrow on the end of the

tank is parallel to the work bench and faces toward you.

□ Install a 3/4 inch fitting (not supplied) in the back of the tank.

□ Apply Loctite and insert 5/16 inch bolts through the C-clamps

and the mount brackets, install the nuts but do not tighten.

□ Check tank alignment then tighten the C-clamp bolts.

□ Slide the tank all the way up on the tank mount brackets (away

from you) and tighten the mounting bolts.

Figure 3.2

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3.2 Installing the Tank Assembly

□ Insert the threaded ends of the mounting cable through a hole on

each tank strap flat bar. Route the cables over the top of the

frame so that the flat bars are on the inside of the frame.

□ Support the tank body in position against the frame rail with the

tank strap mounts on the outside of the frame rail and the short

arms over the top of the frame.

□ Route the cable through the cable guide slot at the top of the

tank strap mount, through the guide slot at the bottom of the tank

strap mount and through the bottom hole in the flat bar (Figure

3.1).

□ Install a 3/8 inch nut and washer on each cable, adjust the tank

for best fit between the cab mounts and tighten the nuts. Install

and tighten a second 3/8 inch nut on each cable as a lock.

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Part 4: Installing the Cooler and

Compressor

4.1 Installing the Oil Cooler

□ Remove OEM hose clamps from OEM lower radiator hose. Cut 2

sections out of hose as seen in Figure 3.1.

Figure 4.1

□ Install cooler in engine bay on the passenger side beside engine.

Tab on cooler will be bolted to the top of the body lift tab above

passenger side frame. The cooler tab faces forward with oil ports

facing up (Figure 4.2).

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Figure 4.2

□ Attach short elbow from OEM hose to the radiator and front

spigot of cooler. Attach long section from OEM hose to engine

and rear spigot of cooler (Figure 4.2).

□ Install supplied bolt through cooler with washer and nut on

bottom side of the body lift tab. Secure hoses with supplied hose

clamps and tighten bolt to specifications.

□ Connect the supplied 3/4 inch heater hose to the fitting on the oil

cooler, route it up the passenger side of the engine and connect

it to the 3/4 inch hose barb in the cylinder head. Make sure that

it does not contact any sharp surfaces or interfere with any belts

or moving components by securing with nylon ties and supplied

hose clamps.

□ Disconnect the small rubber hose on the upper passenger side

of the primary radiator. Fill the coolant system at the reservoir

tank, using the disconnected hose as an air bleed. Once coolant

is seen coming out of the hose and/or port on the radiator, re-

connect the hose and finish filling the reservoir to the marked

level.

TO TANK

TO COMPRESSOR

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□ Once the air is purged from the system, install the OEM plug

(from the cylinder head) in the top of the tee fitting installed

during section 2.1 (using thread sealant).

4.2 Installing the Main Bracket and Compressor

□ Remove the belt tensioner assembly and the two idlers from the

VR main bracket.

□ Position the main bracket on the passenger side front of the

engine cylinder head with the idler stubs facing forward and align

holes on passenger side of the bracket with the holes from the

engine lifting lug and the upper alternator mount. Make sure that

the wire harness is clear of the bracket.

□ Apply Loctite and install (Figure 4.3):

 one M8 x 30 mm hex head bolt with flat washer into the top

right passenger side hole in the main bracket

 three M10 x 35 mm hex head bolts with washers in the top

back hole and the two bottom holes on the passenger side of

the bracket

 one M8 x 25 mm socket head bolt into the lower hole on the

front of the bracket

□ Snug all fasteners down equally then torque to specification.

□ Place the compressor on the bracket and fit the two studs into

the engine side holes on the main bracket. Install nuts with

captive serrated lock washers to each stud and hand tighten.

□ Apply Loctite and install the M8 x 30 mm hex head bolt with flat

washer through the bracket and into the front passenger side

hole on the compressor. Torque the fasteners to specifications.

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M10 x 35 mm

M8 x 30 mm

M8 x 25 mm

M8 x 30 mm

Main bracket

Figure 4.3

4.3 Connecting the Hoses

□ Connect the 45 degree end of the 3/4 inch hose to the top front

tank fitting, route it along the frame rail and up the passenger

side of the engine and connect it to the matching fitting on the

back of the compressor.

□ Connect the straight end of the longest 1/2 inch hose to the

matching fitting on the tank. Route the hose along the passenger

side frame rail and attach the 90 degree fitting to the passenger

side fitting on the top of the cooler.

□ Connect the straight end of the remaining 1/2 inch oil hose to the

90 degree fitting on the driver side of the compressor, route it

behind the compressor and down the passenger side of the

engine. Attach the 45 degree fitting to the driver side oil fitting on

the top of the cooler.

□ Insert the 1/4 and 3/16 inch tubes into the fittings on the back of

the tank and cover them with high temperature loom. Route the

tubes through the frame up to the compressor and connect them

to the matching fittings on the compressor inlet valve.

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4.4 Completing the Installation

□ Install the alternator to the VR main bracket using the OEM

fasteners and torque to specifications.

□ Install the OEM belt (Figure 4.4).

Figure 4.4

□ Apply Loctite and install the VR tensioner, smooth idler and the

ribbed idler. Ensure the ribbed idler is installed with the narrow

shoulder towards the bracket. Torque all fasteners to

specifications.

□ Install the VR belt (Figure 4.5).

Figure 4.5

□ Install the fan spacer.

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□ Remove the OEM screws holding the fan to the hub and replace

it with the supplied replacement fan, fastening it in place with the

5/16 x 5/8 inch button-head screws.

□ Install the replacement passenger side upper fan shroud

mounting bracket to the compressor mounting bracket. Attach it

by fitting the M8 x 30 mm socket head bolt through the shroud

mounting bracket, the top front hole of the compressor mounting

bracket and into the engine (Figure 4.3) and with the M8 x 16

mm socket head bolt threaded into the compressor mounting

bracket.

□ Place the supplied template on the fan shroud and align it with

the front edge. Mark and cut the area on the passenger side for

fan clearance.

□ Cut a 2 x 1 inch rectangular hole under the original location on

the driver’s side of the shroud for the fan wire harness.

□ Pry open the steel locking tab in the bottom part of the steel

sheath, pull out some of the harness and reroute it to the other

side of the sheath, above the locator tab.

□ Lay the supplied replacement fan in the centre of the shroud and

pass the fan wire harness and steel sheath through the new hole

in the shroud (Figure 4.5 - viewed from the front).

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Figure 4.6

□ Lower the replacement fan and shroud in front of the engine.

Thread the fan onto the spacer and tighten; then position the

shroud.

□ Install the replacement fan harness attachment bracket on the

back of the lower driver side OEM fan shroud bracket. The

spacer on the attachment bracket should face forward and sit

below the locator (Figure 4.7). Use the OEM fastener.

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Vmac V900094 Installation guide

Vmac V900094 Installation guide

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