Vmac VR70 Manuale utente

System V900084

2005 - 2006 Doge

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 1

Installation Manual for VMAC

System V900084

Dodge 2005 - 2006

5.9L 24 Valve 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.............................................. 8

Part 3: Installing the Cooler and Compressor......................... 9

3.1 Installing the Oil Cooler ...................................................... 9

3.2 Installing the Main Bracket and Compressor ..................... 10

3.3 Connecting the Hoses........................................................ 11

3.4 Completing the Installation................................................. 12

3.5 Adding Oil to the System.................................................... 16

Part 4: Installing the Control Components .............................. 17

4.1 Installing the Control Boxes................................................ 18

4.2 Connecting the Wiring ........................................................ 19

4.3 Completing and Testing the Installation ............................. 23

Part 5: Finishing the Installation................................................ 24

5.1 Before Starting the Engine Checklist ................................. 24

5.2 After Starting the Engine Checklist..................................... 24

5.3 Setup, Performance Testing and Adjustments................... 26

5.4 System Identification and Warnings................................... 27

5.5 Auxiliary Air Receiver ......................................................... 28

Accessory Products from VMAC............................................... 29

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Document 1930079

Installation Manual for VMAC System V900084

Dodge 2005-2006 5.9L 24 valve Cummins diesel

Changes and Revisions

Version Revision Details Revised by/date Approved Implemented

000 new format IB 15 Dec 2004 SM/BC 18 Jan 2005 18 Jan 2005

A 2006 update IB 24 Oct 2005 SM 25 Oct 2005 31 Oct 2005

B install modification IB 17 Feb 2006 SC 20 Feb 2006 24 Feb 2006

C ECN#06-117 IB 22 May 2006 SM 23 May 2006 26 May 2006

D ECN 06-123 IB 27 May 2006 SM 29 May 2006 01 Jun 2006

E ECN 06-277 fastener change IB 05 Jan 2007 BC 08 Jan 2007 11 Jan 2007

F ECN 07-145 IB 05 Nov 2007 SH 23 Nov 2007 26 Nov 2007

G ECN 08-037 SL 20 Feb 2008 SH 22 Feb 2008 22 Feb 2008

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 1-888-241-2289.

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 3

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

Different frame designations will affect the tank mounting position. If

you have to move the tank, the lines may be too short. Measure the

hose shortfall and order a Hose Extender Kit.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Part 1: 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.

1.1 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.

□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 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: 1-888-241-2289

Fax: 1-250-740-3201 5

Part 2: 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” fittin

Mounting cable

FRAM

Figure 2.1

2.1 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.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

□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.

3/16” tube

1/4” tube

Figure 2.2

□Apply Loctite and insert 5/16 inch bolts through C-clamp 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.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201 7

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

2.2 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

2.1).

□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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