Vmac VR70 Installation Manual
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Vmac VR70 Installation Manual

Underhood air compressor
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V R 7 0 U N D E R H O O D
A I R C O MP R E S S O R
I N S T A L L A T I O N MA N U A L
S y s t e m V 9 0 0 0 7 7
2 0 0 4 . 5 D o d g e
5 . 9 L C u mmi n s D i e s e l
w w w . v ma c a i r . c o m

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  • Page 1 V R 7 0 U N D E R H O O D A I R C O MP R E S S O R I N S T A L L A T I O N MA N U A L S y s t e m V 9 0 0 0 7 7 2 0 0 4 .

  • Page 3: Table Of Contents

    5.2 After Starting the Engine Checklist........ 30 5.3 Setup, Performance Testing and Adjustments ..... 31 5.4 System Identification and Warnings ......32 5.5 Auxiliary Air Receiver ............33 Accessory Products from VMAC ..........34 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 4: Installation Manual For Vmac

    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 5: System V900077

    Measure the hose shortfall and order a Hose Extender Kit. The following table shows the color code used by VMAC to identify hose diameters. Hose Diameter Colour-Coded Label...

  • Page 6: Part 1: Preparing For Installation

    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. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 7 Remove the plug from the cylinder head (Figure 1.1) and install the supplied 1/2 inch NPT to 5/8 inch hose barb in the cylinder head port. Remove this plug Figure 1.1 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 8: Part 2: Installing The Tank

    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. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 9 You may have to bend the steel lines at the back of the tank to clear the rear cab mount. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 10: Installing The Tank Assembly

    Install a 5/16 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 5/16 inch nut on each cable as a lock. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 11: Part 3: Installing The Cooler And Compressor

    Thread nuts on each cable and tighten them. Install and tighten a second nut to act as a lock. To Engine Spacer To Radiator Front Passenger Anti-roll bar side frame bracket rail Cable straps Figure 3.1 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 12: Installing The Main Bracket And Compressor

    Apply Loctite and install the M8 x 25 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. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 13: Connecting The Hoses

    □ Route the 1/4 and 5/16 hoses up from the tank to the compressor and connect them to the matching fittings on the inlet control valve. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 14: Completing The Installation

    Figure 3.4 □ Install the fan spacer. □ Remove the OEM screws holding the fan to the hub and replace them with the 5/16 x 5/8 inch button-head screws. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 15 Lay the fan in the centre of the shroud and pass the fan wire harness and steel sheath through the new hole in the shroud (Figure 3.5 - viewed from the front). Figure 3.5 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 16 Locate the fan shroud on the remaining three OEM mount brackets and install the OEM nuts, then install the two supplied M6 bolts to the upper passenger side mounting bracket. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 17 Route all hoses so that they do not interfere with any moving components and are not exposed to excessive heat or abrasive surfaces. Secure them with nylon ties and use plastic loom as required. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 18: 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 from the fill tube and slowly pour oil into the inlet control valve using a funnel.

  • Page 19: Part 4: Installing The Control Components

    □ Mount the throttle to the bracket using 1/4 x 5/8 inch screws, with the VMAC logo to the top and the throttle pull cable facing towards the rear of the truck (Figure 4.2). VMAC – Vehicle Mounted Air Compressors...
  • Page 20 Remove the OEM cruise cable retaining clip from the inner end of the throttle spindle and remove the OEM cruise cable. □ Insert the wide end of the VR throttle pull bracket over the spring and over the spindle. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 21 Tighten the setscrew on the cable nipple, leaving a 1/4 inch gap between the pull bracket swivel and the cable nipple (Figure 4.7). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 22 Cut out a section of the throttle arm plastic cover to allow for movement of the throttle pull (Figure 4.7). Red polyline connection Black polyline connection Figure 4.6 Leave a 1/4” gap Figure 4.7 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 23 □ Mark the lid of the throttle actuator (Figure 4.9) and cut out the marked section with a small zip wheel or similar tool. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 24 Figure 4.9 □ Remove the bracket from the VMAC throttle controller and mount the VMAC throttle controller to the mounting bracket using the correct holes (Figure 4.10). Use the four 1/4 NC x 1/2 inch bolts with Loctite on the threads.
  • Page 25 Remove the outer cable end nut from the VMAC throttle control. Thread the outer cable through the brass nipple on the end of the VMAC throttle pull arm and secure it with the end nipple removed earlier. Leave a gap of about 1/4 inch between the brass nipple and the securing nipple.

  • Page 26: Installing The Control Box

    Route the cables from the control box along the doorsill, under the trim panel, behind the kick panel and up under the dash. Replace the doorsill trim and the kick panel. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 27 GROUND THROTTLE GROUND CONTROL VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 28: Connecting The Wiring

    Remove the plastic fastener above the firewall on the driver’s side of the engine. Mount the relay using the supplied bracket and fasteners (Figure 4.13). Relay Ground Connector C1 Figure 4.13 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 29 Route the blue wire from the DDC to the transmission range sensor on the driver side of the transmission above the oil pan. Solder the blue wire to the yellow wire with the black stripe. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 30: Completing And Testing The Installation

    Check all gear selector positions to make sure that the light does not come on unless the selector is in Park or Neutral. □ Turn the ignition key “OFF”. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...
  • Page 31 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 1-800-738-8622 or 250-740-3200. VMAC – Vehicle Mounted Air Compressors...

  • Page 32: Part 5: Finishing The Installation

    Check the coolant level after the engine has been operated. □ Check the compressor oil level after the engine has been shut down and the oil level has had time to stabilize. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-800-738-8622 Fax: 1-250-740-3201...

  • Page 33: Setup, Performance Testing And Adjustments

    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). 2. Make sure that the ball valve is closed.

  • Page 34: 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 35: Auxiliary Air Receiver

    The line from the VMAC tank to the auxiliary air receiver must have a one-way check valve installed (part #3600078) to prevent blow back from the auxiliary tank and to stop moisture from entering the VMAC tank (Figure 5.4).

  • Page 36: 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 37 DE-ICING HEATER System Testing Tool Simulates tool use to provide for accurate system adjustments. Orifice fittings included for both VR70 and VR140 systems. VR Service Kits Using OEM service products will extend the life of your system. Includes oil, filters, seals and O-rings.
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  • Page 40 Ma n u f a c t u r e d b y P H 2 5 0 - 7 4 0 - 3 2 0 0 F X 2 5 0 - 7 4 0 - 3 2 0 1 T F 1 - 8 0 0 - 7 3 8 - 8 6 2 2 1 3 3 3 K i p p R o a d , N a n a i mo , B C , V 9 X 1 R 3 C a n a d a w w w .

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