Vmac VR70 Bedienungsanleitung

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

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

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

VMAC –Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

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

ECN 07-145

IB 10 Nov 2007

SH 23 Nov 2007

N/A

26 Nov 2007

ECN 09-038

SL 31 March 2009

RD 29 Mar 2009

N/A

3 April 2009

ECN 12-156

SAR 14 Nov 2012

MH 16 Nov 2012

N/A

30 Nov 2012

ECN 13-013,

ECN 13-104

SH 18 Jul 2013,

MC 05 Nov 2013

MP/RD 17 Dec 2013

N/A

20 Dec 2013

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

VMAC –Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

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

Foot-pounds (ft-lb)

110

170

280

Newton meter (N•m)

108

149

230

379

STANDARD GRADE 8 NATIONAL FINE THREAD

Size

3/8

7/16

1/2

5/8

Foot-pounds (ft-lb)

180

320

Newton meter (N•m)

122

244

434

METRIC CLASS 10.9

Size

M10

M12

M14

M16

Foot-pounds (ft-lb)

104

174

Newton meter (N•m)

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.

VMAC –Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

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).

VMAC –Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Figure 1.1

VMAC –Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

□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.

VMAC –Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

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.

VMAC –Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

□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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