Vmac VR70 User manual

System V900077
2004.5 Dodge
5.9L Cummins Diesel
www.vmacair.com
VR70 UNDERHOOD
AIR COMPRESSOR
INSTALLATION MANUAL

VMAC – Vehicle Mounted Air Compressors
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Installation Manual for VMAC
System V900077
Dodge 2004.5 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 Pneumatic Throttle Controller................. 17
4.2 Installing the Control Box................................................ 24
4.3 Connecting the Wiring..................................................... 26
4.4 Completing and Testing the Installation........................ 28
Part 5: Finishing the Installation................................................ 30
5.1 Before Starting the Engine Checklist............................. 30
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

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2
Document 1930066
Installation Manual for VMAC System V900077
Dodge 2004.5 5.9L 24 valve Cummins diesel
Changes and Revisions
Version Revision Details Revised by/date Approved Implemented
00 new format IB 16 June 2006 SM 19 June 2006 22 June 2006
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.
Copyright 2005
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
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Fax: [phone]
General Information
System V900077
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 Coding
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. The following table
shows the color code used by VMAC to identify hose diameters.
Hose Diameter Colour-Coded Label
1/4 inch
5/16 inch
1/2 inch
5/8 inch
3/4 inch
1 inch
Yellow
Orange
Blue
Blue
Green
Green

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4
Part 1: Preparing for Installation
System V900077
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.

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□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

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6
Part 2: Installing the Tank
System V900077
The tank will mount on the passenger side of the vehicle between
the two cab mounts.
Steel lines
Mount bracket
Strap mounts
5/16” bolts and nuts
C-clamps
P-clip
5/16” nuts and flat washer
3/4” fitting
1/2” fittin
g
Mounting cable
FRAME
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 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
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.

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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 work bench and faces toward you.
□Install a 3/4 inch fitting (not supplied) in the back of the tank.
□Thread the 1/4 and 5/16 inch fittings on the steel lines to the
matching fittings on the back end of the tank, but do not tighten
the fittings. Route the lines along the top of the tank across the
two C-clamps.
□Place the two insulated tube clips over the steel lines with the
mounting holes upward and align them with the top C-clamp
mounting holes (Figure 2.2).
□Apply Loctite and insert 5/16 inch bolts through the clips, the 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.
□Tighten the 1/4” and 5/16” fittings on the back of the tank, then
bend the two securing P-clips outward just enough to provide
clearance between the lines and the tank mount brackets for the
cable straps.
You may have to bend the steel lines at the back of the
tank to clear the rear cab mount.

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8
1/4” lin
e
5/16” line
T
an
k
mount
b
rac
k
et
Tube clip
Figure 2.2
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, behind the steel lines, 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 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.

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Part 3: Installing the Cooler and
Compressor
System V900077
3.1 Installing the Oil Cooler
□Place the cooler on the passenger side frame rail so that the
brackets fit around the anti-roll bar bracket and the vertical inside
face of the cooler bracket is flush with the frame rail.
□Loop the retaining cables from the bottom holes around the
frame and back through the top holes (Figure 3.1).
□Install a washer and spacer on the cable closest to the rear of
the truck and a washer on the cable closest to the front of the
truck. Thread nuts on each cable and tighten them. Install and
tighten a second nut to act as a lock.
To Radiator
To Engine
Cable straps
Spacer
Anti-roll bar
bracket
Passenge
r
side frame
rail
Front
Figure 3.1

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□Connect the short radiator hose from the oil cooler to the bottom
radiator spigot and secure with clamps.
□Connect the long radiator hose from the passenger side rear of
the oil cooler to the coolant intake on the side of the engine
below the alternator and secure with clamps.
□Connect the supplied 5/8 inch heater hose to the fitting on the oil
cooler, route it up the passenger side of the engine and connect
it to the 5/8 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.
3.2 Installing the Main Bracket and Compressor
□Remove the belt tensioner assembly and the two idlers from the
VR main bracket.
□Position the main bracket on the passenger side front of the
engine cylinder head with the idler stubs facing forward and align
holes on passenger side of the bracket with the holes from the
engine lifting lug and the upper alternator mount. Make sure that
the wire harness is clear of the bracket.
□Apply Loctite and install (Figure 3.2):
•one M8 x 30 mm hex head bolt with flat washer into the top
right passenger side hole in the main bracket
•three M10 x 35 mm hex head bolts with washers in the top
back hole and the two bottom holes on the passenger side of
the bracket
•two M8 x 25 mm socket head bolts into the front of the bracket
□Snug all fasteners down equally then torque to specification.
□Place the compressor on the bracket and fit the two studs into
the engine side holes on the main bracket. Install nuts with
captive serrated lock washers to each stud and hand tighten.
□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.

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M10 x 35 mm
M10 x 35 mm
M8 x 30 mm
M8 x 25 mm
Main bracket
Figure 3.2
3.3 Connecting the Hoses
□Connect the 45 degree end of the 3/4 inch hose to the top front
tank fitting, route it along the frame rail and up the passenger
side of the engine and connect it to the matching fitting on the
back of the compressor.
□Connect the straight end of the longest 1/2 inch hose to the
matching fitting 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 straight end of the remaining 1/2 inch oil hose to the
90 degree fitting on the driver side of the compressor, route it
behind the compressor and down the passenger side of the
engine. Attach the 45 degree fitting to the driver side oil fitting on
the top of the cooler.
□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.

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3.4 Completing the Installation
□Install the alternator to the VR main bracket using the OEM
fasteners and torque to specifications.
□Install the OEM belt (Figure 3.3).
Figure 3.3
□Apply Loctite and install the VR tensioner, smooth idler and the
ribbed idler. Torque all fasteners to specifications.
□Install the VR belt (Figure 3.4).
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.

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□Install the replacement passenger side upper fan shroud
mounting bracket to the compressor mounting bracket with two
supplied M8 socket head bolts.
□Place the supplied template on the fan shroud and align it with
the front edge. Mark and cut the area on the passenger side for
fan clearance.
□Cut a 2 x 1 inch rectangular hole under the original location on
the driver’s side of the shroud for the fan wire harness.
□Pry open the steel locking tab in the bottom part of the steel
sheath, pull out some of the harness and reroute it to the other
side of the sheath, above the locator tab.
□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

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□Lower the fan and shroud in front of the engine. Thread the fan
onto the spacer and tighten; then position the shroud.
□Install the replacement fan harness attachment bracket on the
back of the lower driver side OEM fan shroud bracket. The
spacer on the attachment bracket should face forward and sit
below the locator (Figure 3.6). Use the OEM fastener.
Fanshrou
d
Hole cut for
fan wiring
Fan wiring connector
Bracket
Metal wiring
sheath
Figure 3.6
□Attach the metal wiring sheath to the spacer on the new bracket
with the supplied M6 x 40 mm bolt. Route the wire around the
back of the sheath and mount bracket to allow enough length
harness to connect the wiring.
□Align the metal wiring sheath with the hole on the new bracket,
install the supplied 1/4 inch bolt and nut and tighten.
□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.

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□Connect the fan clutch wire and make sure it is clear of the fan
and all moving parts. There must be at least 5/8 inch clearance
between the wire and the fan blade tips to prevent damage to the
wiring.
□Install the two OEM fasteners holding the fan shroud and the
radiator to the radiator support. One of these fasteners also
holds the radiator expansion tank.
□Install the upper radiator hose and intercooler tube.
□Drill an 11/16 inch hole in the air box and install the filter gauge
into the new hole. Plug the original hole that held the filter gauge
with the supplied plastic grommet (Figure 3.7).
5
”
Figure 3.7
□Install the air box in its original mounting position. Secure the air
box and connect the intake ducting and the mass air sensor.
□Insert the engine wire harness to clips where possible. Reroute
the harness so that it is clear of the compressor and moving
parts. Secure it as required.
□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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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. Turn the center of the
compressor clutch clockwise to speed the fill process.
□Allow 5 minutes for the oil to drain into the tank, then check the
level at the sight glass at the front of the tank. Continue adding
oil until the level is correct.
□Install the fill plug in the inlet control valve 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.
!
!

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Part 4: Installing the Control
Components
System V900077
4.1 Installing the Pneumatic Throttle Controller
4.1.1 Automatic Transmission
□Remove the two OEM bolts (Figure 4.1) and mount the throttle
bracket with the vertical section of the bracket facing the
passenger side of the vehicle using the OEM bolts.
R
emove an
d
use t
h
ese
two bolts
Figure 4.1
□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).

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Figure 4.2
□Drill a 3/8 inch hole in the rear of the OEM throttle bracket
(Figure 4.3).
Figure 4.3
□Insert the throttle cable through the hole, install a serrated
washer and thread on the securing nut (Figure 4.4).
□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.