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Vmac V900104 Installation Manual

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Installation Manual for VMAC
2007-2009 25-3500 Dodge Cab & Chassis
2008-2010 45-5500 Cab & Chassis 6.7L Cummins Diesel
2007-2008 Sterling Bullet 6.7L Cummins Diesel
General Information..................................................................... 3
Before You Start ....................................................................... 3
Part 1: Preparing for Installation ............................................... 4
1.1 Preparing for Installation .................................................... 4
Part 2: Installing the Tank .......................................................... 6
2.1 Assembling and Installing the Brackets ............................. 6
2.2 Installing the Tank Assembly .............................................. 7
3.1 Installing the Oil Cooler ...................................................... 8
3.3 Connecting the Hoses ........................................................ 14
3.4 Completing the Installation ................................................. 16
3.5 Adding Oil to the System .................................................... 20
Part 4: Installing the Control Components .............................. 21
4.2 Connecting the Wiring ........................................................ 22
4.3 Completing and Testing the Installation ............................. 27
Part 5: Finishing the Installation ................................................ 28
5.1 Before Starting the Engine Checklist.................................. 28
5.2 After Starting the Engine Checklist .................................... 28
5.4 System Identification and Warnings ................................... 30
5.5 Auxiliary Air Receiver ......................................................... 31
Accessory Products from VMAC ............................................... 33
VMAC - Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
System V900104
2007-2009 2500-3500 4X4 Pickup
6.7L Cummins Diesel
System V900106
1

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Summary of Contents for Vmac V900104

  • Page 1: Table Of Contents

    5.2 After Starting the Engine Checklist ........28 5.3 Setup, Performance Testing and Adjustments ....29 5.4 System Identification and Warnings ........30 5.5 Auxiliary Air Receiver ............31 Accessory Products from VMAC ..........33 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 2 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.

  • Page 3: General Information

    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.

  • Page 4: Part 1: Preparing For Installation

    Remove the OEM crank pulley and scrape off the clear coat from the inside front face of the hub. Discard the locking plate. □ Remove the lower fan shroud bracket and cut away the section shown in Figure 1.1. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 5 Face the elbow towards the passenger side of the truck. Use thread sealant on the NPT fittings. □ Remove the sway-bar mounts from the frame and allow the sway bar to drop. Remove this plug Figure 1.2 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 6: Part 2: Installing The Tank

    18 inches from the front weld. □ Place the two formed tank strap mounts under the C-clamps with the ends with threaded holes facing you. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 7: Installing The Tank Assembly

    3/8” bolt into the tank strap mount. □ Adjust the tank for the best fit and install the lower 3/8” tank strap bolts and nuts. Apply Loctite to the lower tank strap bolts. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 8: Part 3: Installing The Cooler And Compressor

    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 3.2). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 9 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. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 10: Installing The Main Bracket And Compressor

    If the bracket does not fit correctly make sure that the dowel pin in the air conditioning mounting bracket against the front of the block is bottomed-out by using a pry-bar to push it into place (Figure 3.4). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 11 Thread the rear M12 bolt into the engine. Tighten both M12 bolts then tighten the bottom AC bolts against the main bracket. □ Apply loctite and install the M6 tensioner stop bolt (Fig 3.5). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 12 □ Place the VR pulley in front of the OEM crank pulley and align it with the locating pin. without air conditioning with air conditioning Figure 3.6 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 13 Main bracket M10 bolt Idler Shroud support bracket Figure 3.7 □ Install the VR compressor belt (Figure 3.8) and remove the M10 tensioner lock bolt from the bracket. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 14: Connecting The Hoses

    Run the hose along the frame rail and connect it to the matching fitting on the front of the tank. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 15 Attach the hose to the supplied oil fill fitting and secure it to the back of the passenger side battery box with the supplied P-clip. Oil fill fitting Drill a hole above the top of the battery Figure 3.9 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 16: Completing The Installation

    3.4 Completing the Installation □ Remove the OEM screws holding the fan to the hub. Use the VMAC tool 5900220 to countersink the holes and install the replacement 5/16 inch screws with Loctite. □ Install the fan spacer, fan, fan shroud and intercooler tube.
  • Page 17 (Figure 3.12). Adjust the position of the filter assembly so that it does not touch any body parts and tighten the bolt. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 18 OEM bolts. Use the 3/4” sway bar spacer between the sway bar and the large sway bar spacer. Attach the sway bar to the sway bar spacer using the supplied flange head bolts (Figure 3.14). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 19 Flexible hose to remote air cleaner Figure 3.13 V900106 LARGE SWAY BAR SPACER OEM SWAY BAR BOLTS FRAME 3/4" SWAY BAR SPACER SUPPLIED BOLTS Figure 3.14 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 20: Adding Oil To The System

    3.5 Adding Oil to the System You must use the VMAC supplied and approved compressor oil in this system. Failure to use this special oil will result in damage to the compressor and will void your warranty. □ Remove the plug or open the outlet of the tank.

  • Page 21: Part 4: Installing The Control Components

    Part 4: Installing the Control Components VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 22: Installing The Control Box And Throttle Control

    If this connection comes apart it will cause drivability problems. Secure the connection using a small nylon tie strap. □ Connect the interface harness to the matching connector from the control box. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 23 37 of connector 1 on the ECM (Figure 4.1). Pin 37 Backside of connector facing driver’s side of engine VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 24 This wire should show 0 Volts in Park or Neutral and approximately 12 V in all other gear selections when tested with a multi-meter. Pin 10 Figure 4.2 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 25 4.2.3 Ignition switched 12V cab chassis 35/45/5500 □ Install a 20 Amp fuse in the Auxiliary Power Distribution Box (Figure 4.4). Insert fuse here Auxiliary PDC box Relays Blunt cut wires located here Figure 4.4 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
  • Page 26 4.2.5 Manual Transmission □ Cut the long blue wire to about 6 inches, strip the end and connect it to the short blue wire with the crimp connector. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 27: Completing And Testing The Installation

    If the truck fails the test, check the wiring to make sure that all the connections are correct and secure. If you require additional assistance, contact your local VMAC dealer. Call 1-888-241-2289 or 250-740-3200. VMAC – Vehicle Mounted Air Compressors...

  • Page 28: Part 5: Finishing The Installation

    □ Repeat this test in all gear selector positions to make sure that the engine does not idle up unless the selector is in Park or Neutral. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 29: Setup, Performance Testing And Adjustments

    (Figure 5.1). Figure 5.1 1. Install the test tool in the tank outlet fitting. If you are using the VMAC test tool, use the correct orifice fitting (small hole for VR70, large hole for VR140). VMAC – Vehicle Mounted Air Compressors...

  • Page 30: System Identification And Warnings

    The System Identification Number Plate must be attached to the truck at the time of installation. This plate provides information which allows VMAC to assist in customer inquiries and the ordering of parts. Mark and drill two 7/64 inch holes to the top surface of the radiator support in front of the battery, then secure the plate with self- tapping screws.

  • Page 31: Auxiliary Air Receiver

    The line from the VMAC tank to the auxiliary air receiver must have a one-way check valve installed to prevent blow back from the auxiliary tank and to stop moisture from entering the VMAC tank (Figure 5.4).
  • Page 32 Auxiliary Tank One-way check valve Install the line as high as VR Tank possible, NOT on the bottom of the auxiliary tank Figure 5.4 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

  • Page 33: Accessory Products From Vmac

    Accessory Products from VMAC The following accessory products for your VR compressor system are available from VMAC. For more information or to order these products, call 1-800-738-8622. Eliminator Aftercooler Removes up to 80% of moisture from compressed air. Quick installation,...
  • Page 34 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...

This manual is also suitable for:

V900106

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