Vmac V900104 User manual

VMAC –Vehicle Mounted Air Compressors
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Installation Manual for VMAC
System V900104
2007-2009 25-3500 Dodge Cab & Chassis
2007-2009 2500-3500 4X4 Pickup
6.7L Cummins Diesel
System V900106
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
Part 3: Installing the Cooler and Compressor......................... 8
3.1 Installing the Oil Cooler ...................................................... 8
3.2 Installing the Main Bracket and Compressor ..................... 10
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
4.1 Installing the Control Box and Throttle Control .................. 22
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
5.3 Setup, Performance Testing and Adjustments................... 29
5.4 System Identification and Warnings................................... 30
5.5 Auxiliary Air Receiver ......................................................... 31
Accessory Products from VMAC ............................................... 33

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Document 1930141
Installation Manual for VMAC System V900104/V900106
Dodge 2007- 2010 6.7L Cummins diesel
Changes and Revisions
Version
Revision Details
Revised by/date
Approved
Implemented
L
ECN 09-093
SL 09 Sept 2009
TG 17 Sep 2009
23 Sep 2009
M
ECN 10-035
SH 30 Aug 2010
TG 30 Aug 2010
1 Sep 2010
N
ECN 11-127
SAR 19 OCT 2011
SC 20 Oct 2011
20 Oct 2011
P
ECN 12-140
SAR 02 Oct 2012
MH 10 Oct 2012
12 Oct 2012
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.
All hoses, tubes, and wires that are rerouted or shifted
during installation must be secure so that they do not
contact excessively hot areas or sharp edges. Where
possible, use rubber coated P-clips. Follow the routing
suggestions in this manual and cover all hoses with the
supplied plastic loom.
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 that 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.
Copyright 2009
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: 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.
□Remove the air cleaner assembly and the passenger side
intercooler tube.
□Drain the coolant and remove the lower radiator hose (save for
use later).
□Disconnect the fan clutch wire and remove it from the mounting
clips
□Remove the fan and the fan shroud from the engine locating
brackets.
□Loosen the OEM crank pulley bolts but do not remove them.
Now release the OEM belt from the OEM tensioner. Remove the
OEM belt.
□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.

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Cut off here
Figure 1.1
□Remove the plug from the passenger side of the cylinder head
(Figure 1.2) and install the supplied 1/2 inch NPT nipple, NPT
elbow and NPT to 3/4 inch hose barb in the cylinder head port.
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

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Part 2: Installing the Tank
The tank will mount on the passenger side of the vehicle between
the two cab mounts.
Figure 2.1
2.1 Assembling and Installing the Brackets
□Place the tank on a workbench with the front (oil filter end) of the
tank to your left and remove the oil filter.
□Remove the two 1/4 inch pinch 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
front weld.
□Place the two formed tank strap mounts under the C-clamps with
the ends with threaded holes facing you.

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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 pinch 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 workbench 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.
2.2 Installing the Tank Assembly
□Insert 3/8” bolt through the tank flat bar backing strap and route
the bolt over the top of the frame so that the flat bar is on the
inside of the frame rail (Figure 2.1).
□Support the tank body in position against the frame rail with the
tank strap mounts on the outside of the frame rail and thread the
top 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.

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Part 3: Installing the Cooler and
Compressor
3.1 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 3.1
□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 3.2).

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Figure 3.2
□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 3.2).
□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.

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3.2 Installing the Main Bracket and Compressor
□Lock the tensioner in the loaded position with an M10 (Figure
3.5).
□Remove the idler from the VR main bracket.
□Loosen the two bottom bolts on the side of the air conditioning
compressor.
□Install M12 washers on M12 bolts.
□Insert the short M12 bolt through the rear mount. Place the
bracket in position on the engine so that you can see how it will
mount once the compressor has been attached (Figure 3.3.
Angle the front of the bracket up during installation to hook the
front stud over the oil pan on the front of the engine.
Compressor, idler and tensioner left off for clarity
Short M12 bolt
M12washer
M12washer
LongM12bolt
Air conditioning
compressor bolt
mount locations
Figure 3.3
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).

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Pin Pry-bar
Oil pan
Figure 3.4
□Install the M12 bolts just finger tight (longest in the front and
shortest in the rear) and check to make sure that the bracket is
flush against the block. Once you have checked the fit, remove
the bracket.
□Install the compressor on the bracket using the two hex head
bolts and the countersunk bolt. Use Loctite and tighten securely.
□Ensure that the supplied 5/16” washer is installed on the hex
head bolt that is closest to the front of the compressor and
engine.
□Apply Loctite and insert the rear M12 bolt through the bracket, lift
the compressor-bracket assembly up under the AC compressor
and angle the front of the bracket over the front of the oil pan so
that the bracket is “hung” in position.
□Apply Loctite and insert the front M12 bolt, lift the bracket into
position and thread the bolt into the engine.
□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).

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The tensioner stop bolt must be installed after the
bracket is mounted on the engine.
Figure 3.5
□Place the OEM crank pulley on the front of the crankshaft and
rotate it to align it with the locating pin. Route the belt as per
(Figure 3.6) but leave the belt loose.
Do not tension the OEM belt before the OEM crank bolts
are torqued.
□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
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□Apply Loctite to the four OEM bolts and install them through the
two pulleys into the crankshaft. Torque the crank pulley bolts to
69 ft-lbs.
□Check the OEM belt routing diagram for the correct installation
(Figure 3.6).
□Tension the OEM belt.
□Place the idler on the main bracket and install the fan shroud
bracket so that it points toward the passenger side of the truck
(Figure 3.7). Apply Loctite and fasten it in position with the M10
bolt.
Idler
Shroud support bracket
M10 bolt
Main bracket
Figure 3.7
□Install the VR compressor belt (Figure 3.8) and remove the
M10 tensioner lock bolt from the bracket.

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Figure 3.8
3.3 Connecting the Hoses
V900104 Only
□Connect straight end of the 3/4 inch hose to the top front
tank fitting, route it between the suspension arms, over the
engine cross-member, along the frame rail and connect it to
the matching fitting on the back of the compressor. Route
the hose as far as possible from the engine cross-member.
V900106 Only
□Connect the straight end of the 3/4-inch hose to the back of
the compressor. Route the hose up and over the engine
cross-member, and the engine mount, then down between
the inner fender and frame. Run the hose along the frame
rail and connect it to the matching fitting on the front of the
tank.

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□Connect the 1/2 inch oil fill hose with the straight ends to the
fitting on the bottom of the inlet control valve and route it up
behind the passenger side battery box.
□Connect the straight end of the longest 1/2 inch hose (with the
90 degree fitting) to the matching fitting (furthest from frame) 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 shortest 1/2 inch oil hose to the matching fitting on
the compressor and the fitting on the top of the cooler. If needed,
loosen the locknut on the fitting and rotate it to attach the hose.
Tighten the locknut and make sure the hose clears all objects.
□Insert the 1/4 and 3/16 tubes into the fittings on the back of the
tank and cover them with high temperature loom. Route them to
clear any moving or high temperature components and connect
them to the matching fittings on the inlet control valve.
□Drill a hole in the battery box just above the battery to secure the
oil fill hose and fitting (Figure 3.9).
□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.
Drill a hole
above the top
of the battery
Oil fill fitting
Figure 3.9

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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.
□Install the driver’s side of the cut fan shroud bracket to the
engine using the supplied bolt and spacer (Figure 3.10). Make
sure that there is sufficient clearance between the bracket and
the OEM belt. Use Loctite on the bolt. Install the fan shroud nuts.
□Install the fan clutch wire bracket using the supplied bolt, washer,
and spacer (Figure 3.10).
Fan Shroud
Bracket Spacer
Fan Clutch Wire
Bracket Spacer
Figure 3.10
□Attach fan wiring harness to the fan shroud bracket. Ensure
there is at least a 0.3" gap between the fan wire and the radiator.
□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.

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V900104 Only
□Remove the bolt holding the exhaust hanger to the transmission
bell housing and install the supplied L-bracket with the horizontal
part of the bracket facing the passenger side (Figure 3.11).
□Install a P-clip around the hoses and fasten it to the bracket to
hold the hoses secure and away from the exhaust and
suspension components.
Transmissionbell-housing
Engine oil pan
Bracket and hoses
Front
Figure 3.11
□Remove the cab mount bolt behind the passenger side of the
front bumper. Insert the OEM bolt through the hole in the filter
assembly mount bracket and install the filter assembly with the
hose connection fitting pointing down (Figure 3.12). Adjust the
position of the filter assembly so that it does not touch any body
parts and tighten the bolt.

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Front bumper
Body
Body mount
OEM bolt and washer
Figure 3.12
□Remove three bolts from the inlet valve on the compressor and
install the intake guard plate using the three bolts (Figure 3.13).
Position it so that the short end of the hose will attach to the
intake and the long end to the remote filter. Tighten the inlet
valve bolts and secure the hoses with the supplied clamps.
V900104 Only
□Insert the supplied spacers between the frame and the sway bar
mount and fasten the sway bar in place with the supplied flange
head bolts (Figure 3.13).
V900106 Only
□Attach the large supplied sway bar spacer to the frame using the
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).

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Attach the intake
guard plate using
these three fasteners Flexible hose to remote
air cleaner
Sway bar
spacer
Compressor
Figure 3.13
SUPPLIED BOLTS
FRAME
V900106 LARGE
SWAY BAR SPACER
OEM SWAY
BAR BOLTS
3/4" SWAY
BAR SPACER
Figure 3.14

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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.
□Remove the plug from the fill tube and slowly pour oil into the
opening using a funnel.
□Continue adding oil until the level is correct.
□Install the fill plug in oil fill fitting and tighten it securely.
Do not overfill the system. Overfilling the system with
oil can flood the sight glass window and make the
system appear empty.
V900106 Only
□Rotate the clutch clockwise during oil fill to speed up the oil fill
time.
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