Installation Manual
For The
System #9059
TEL: 250-754-6997
FAX: 250-754-6972
TOLL FREE: 800-738-8622
1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3
DOCUMENT 19573
UNDERHOOD AIR COMPRESSOR
2000 OTTAWA TRUCK
5.9 CUMMINS 24 VALVE DIESEL
(with or without air conditioning)
Installation Manual
VR7000 Underhood Air Compressor
System Number 9059
Application: 2000 Ottawa Truck with Cummins 5.9 24 valve diesel engine with or without
air conditioning
Publication Date: December 2000
Publication Number: 19573
Origination Documents: #19573a - general information
#19574 - installing the tank, oil cooler and lines
#19575 - installing the control and electrical components
#19576- installing compressor, mounting bracket
#19577 - illustrated parts list
#19130 - warranty registration
Registered Trademarks:
VR7000, VMAC and Throttle Commander are registered trademarks of VMAC.
Ottawa is the registered trademark of Kalmar Industries and Ottawa Truck
Cummins is a registered trademark of Cummins Motor Company
Loctite, Prime N’ Clean, 242 and PST are registered trademarks of Loctite Corporation.
Nylok is a registered trademark of Nylok Fastener Corporation.
Notice:
Manuals and products are subject to change without notice.
Copyright 2000
The contents of this manual may not be reproduced in any form without the express written
permission of VMAC
Contents
GENERAL INFORMATION ................................................................................................. 3
INTRODUCTION ........................................................................................................................ 5
INSTALLATION NOTES ................................................................................................................ 6
ORDERING PARTS ...................................................................................................................... 7
WARRANTY ............................................................................................................................. 7
CHANGES AND IMPROVEMENTS ................................................................................................... 7
PART 1: INSTALLING THE AIR TANK , OIL COOLER AND LINES .......................... 9
1.0 PREPARING FOR INSTALLATION ......................................................................................... 11
1.1 INSTALLING THE BRACKETS AND TANK .............................................................................. 11
1.2 INSTALLING THE LINES .................................................................................................... 13
1.3 INSTALLING THE BLOWDOWN SOLENOID ............................................................................ 13
1.4 INSTALLING THE OIL COOLER ......................................................................................... 14
PART 2: INSTALLING THE CONTROL AND ELECTRICAL COMPONENTS ........ 15
2.0 INSTALLING THE CONTROL UNIT ....................................................................................... 17
2.1 INSTALLING THE SWITCHING BOX ...................................................................................... 17
2.2 CONNECTING THE WIRING ............................................................................................... 18
PART 3: INSTALLING THE COMPRESSOR AND OTHER COMPONENTS ........... 19
3.0 INSTALLING THE MOUNTING BRACKET ............................................................................... 21
3.1 INSTALLING THE ALTERNATOR BRACKET ........................................................................... 22
3.2 INSTALLING CRANK PULLEY AND BELT .............................................................................. 22
3.3 INSTALLING THE COOLING SYSTEM HOSES ........................................................................... 23
3.4 INSTALLING THE COMPRESSOR AND LINES .......................................................................... 23
3.5 INSTALLING THE VR 7000 BELT TENSIONER AND DRIVE BELT ............................................. 24
3.6 FILLING THE SYSTEM WITH OIL ........................................................................................ 25
3.7 COMPLETING THE INSTALLATION ...................................................................................... 25
PART 4: ILLUSTRATED PARTS LIST ............................................................................. 27
WARRANTY REGISTRATION .......................................................................................... 33
1
2
General Information
System #9059
2000 OTTAWA TRUCK
5.9 CUMMINS 24 VALVE DIESEL
(with or without air conditioning)
UNDERHOOD AIR COMPRESSOR
3
DOCUMENT 19573A
4
This symbol indicates that there is additional information or special emphasis
on a specific procedure.
This symbol indicates that there is a possibility of personal injury or damage to
the equipment if the indicated warning is not followed.
General Information
Introduction
This book provides installation instructions for:
VMAC underhood air compressor installation kit
This kit has been designed for:
2000 Ottawa Truck equiped with a 5.9 cummins 24 valve diesel engine with or without air
conditioning.
Installation steps
The installation procedure in this manual has three main steps:
Part 1: Installing the Air tank, Oil Cooler and lines
Part 2: Installing the control and electrical components
Part 3: Installing the compressor mounting bracket, Alternator bracket and connecting the lines
Terms and symbols
This manual uses the following terms and symbols:
•OEM - Original Equipment Manufacturer
•HHCS - Hex Head Cap Screw (also called a hex bolt)
•SHCS - Socket Head Cap Screw (also called an Allen head bolt)
5
DOCUMENT 19573A
NOTE
WARNING
!
Installation notes
1. It is important that you complete all the installation steps before operating the system.
2. Follow all safety precautions for underhood mechanical work.
3. Use Loctite 242 or equivalent on all engine-mounted fasteners.
4. All hoses, tubes and wires which are re-routed or shifted during installation must be
secured so that they do not contact excessively hot areas or sharp edges. Where
possible, follow the routing suggestions in this manual.
5. These installation instructions are intended as a general guide. In some instances, due
to variations in vehicle manufacture or if prior modifications have been made to the
vehicle, it may be necessary to carry out grinding, bending or rearranging operations
for correct fit. These operations must follow sound, standard shop practices.
6. Left and right definitions in this manual are determined when sitting in the driver’s
seat, facing forward.
7. All fasteners must be of the correct size and torqued according to the specifications
shown below. Torque specifications are in foot pounds (ft-lb).
The above fastener torque values are applicable when Loctite is used.
If the threads are dry, add 20% to the torque values.
6
DOCUMENT 19573A
STANDARD GRADE 8 NATIONAL COARSE THREAD
Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4
Foot-pounds 9 18 35 55 80 110 170 280
STANDARD GRADE 8 NATIONAL FINE THREAD
Size 3/8 7/16 1/2 5/8 3/4
Foot-pounds 40 60 90 180 320
METRIC CLASS 10.9
Size M8 M10 M12 M14 M16
Foot-pounds 19 41 69 104 174
WARNING
!
Ordering parts
To order parts, contact VMAC at:
Telephone 250-754-6997
Facsimile 250-754-6972
Office Hours 8:00 AM to 4:30 PM Pacific Time
Please quote the VMAC part number, the description and the quantity.
Warranty
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.
The enclosed System Identification Number Plate must be attached to the vehicle at the time of
installation. Locate the plate on the dash near the control box (Figure 1) . Drill the two hole
locations using a 7/64” drill bit. Place the plate in position and fix in place with the two supplied
#6 pan head self tapping screws.
This plate provides information, which allows VMAC to assist in customer inquiries and
ordering parts. It is important that this plate is affixed to the vehicle.
Figure 1 Location of System Identification Number Plate
Changes and improvements
These products and documents are subject to changes or improvements without notice.
7
DOCUMENT 19573A
NOTE
S/N
8
Part 1
Installing the
Air Tank, Oil Cooler and
Lines
System #9059
2000 OTTAWA TRUCK
5.9 CUMMINS 24 VALVE DIESEL
(with or without air conditioning)
UNDERHOOD AIR COMPRESSOR
9
DOCUMENT 19574
10
1.0 Preparing for installation
1. Disconnect the batteries.
2. Drain the cooling system.
3. Remove the following components:
• air cleaner assembly
• air cleaner mounting bracket
• turbo-to-intercooler pipes and hoses
• cooling fan (disconnect the fan wire
flexible support strap from the cylinder
head bracket)
• drive belt
• drive belt tensioner
• alternator (disconnect the wiring and
discard the lower alternator strap)
• clamps holding the alternator wiring to
the front of the cylinder head
• crankshaft pulley bolts
4. Remove the 1 inch radiator coolant hose
from the fitting on the engine and the 5/8
inch heater return hose from the engine
lower radiator hose connection.
5. Remove the lower radiator hose at the
radiator and at the OEM cast housing
attached to the engine block.
6. Remove the 3 OEM bolts that locate the
cast housing for the lower rad hose to the
engine. These bolts also locate(sandwich)
the OEM belt tensioner cast mount/
coolant housing. This tensioner/coolant
housing gets discarded, but keep the 2
sealing rings for later use during the
VR7000 installation process.
1.1 Installing the brackets and tank
1. Securely clamp the OEM right hand front
air tank mounting bracket to prevent it
from springing open.
11
DOCUMENT 19574
Part 1: Installing the Air Tank and Lines
Clamp the OEM bracket to remove the pinch bolt
Slide the VR7000 C-clamps over the tank
Brackets in place on the tank
12
DOCUMENT 19574
2. Remove the OEM 3/8 pinch bolt and nut.
Install one (1) small, right-angle VR 7000
tank support brackets (with the welded 5/
16 x 1 inch bolts pointing downwards and
facing the center of the vehicle) on the
pinch bolt.
3. Install the OEM air tank pinch bolt and
place the second bracket (facing in the
same direction) on the bolt and install the
nut. Repeat the procedure for the right
rear OEM air tank bracket. Align the
brackets so they are level, then snug the
pinch bolts and nuts.
4. Remove the 1/4 NC x 3-1/2 inch pinch
bolts from the VR7000 tank C- clamps
and slide both C-clamps over the front of
the tank.
5. Position the front C-clamp approximately
6 inches back from the front of the tank
and rotate the C-clamp to the top of the
tank so it is horizontal. Install the pinch
bolt and tighten it just enough to keep the
C-clamp in place.
6. Install the pinch bolt in the rear C-Clamp,
but leave the clamp loose enough so that
it can be positioned easily.
7. Pull the vehicle hydraulic hoses down and
place the VR7000 tank in position on the
tank support brackets (above the vehicle
hydraulic hoses) with the front C-clamp
over the 5/16 inch bolts welded to the
installed brackets. Front C clamp should
be approximately 6” from front of tank.
8. Place a flat washer and 5/16 inch nut on
each of the bolts and hand tighten them
9. Position the rear C-clamp on the 5/16
inch bolts welded to the rear tank support
brackets attached to the OEM pinch bolt.
Place a flat washer and 5/16 inch nut on
each of the bolts and hand tighten them.
Pinch bolts and 5/16 inch mounting nuts
Pressure control (upper) and Scavenge (lower)
Line routing
13
DOCUMENT 19574
Main discharge (lower) and oil return (upper)
10. Check the tank to make sure that the “UP”
arrow on the tank is vertical and that the
tank is level.
11. Tighten the OEM pinch bolts, then the
VR7000 pinch bolts and then the two (2)
inner 5/16 inch nuts on the bracket bolts.
1.2 Installing the lines
1. Thread the fitting on the steel tube attached
to the end of the 1/4 inch pressure control
line into the upper threaded fitting on the
rear of the tank. Leave the fitting hand-
tight. Route the end of the flexible line up
to the right side of the engine.
2. Thread the fitting on the steel tube attached
to the 5/16 inch oil scavenge line into the
lower threaded fitting in the rear of the
tank. Leave the fitting hand-tight. Route
the end of the flexible line up to the right
side of the engine.
3. Align the 1/4 inch steel line and the 5/16
inch steel line. Place the two small P-clips
over the two lines.
4. Remove the two (2)outer 5/16 inch nuts
from the mounting brackets, place the P-
clips over the 5/16 inch welded bolts and
install the washers and nuts. Tighten the
two (2) outer mounting nuts.
5. Thread the straight end of the 1/2 x 56
inch oil return line into the lower fitting on
the front of the VR7000 tank and route the
other end up to the engine along with the
1/4 and 5/16 inch lines. Leave the fitting
hand-tight
6. Thread one end of the 3/4 inch main
discharge line into the upper fitting on the
front of the VR7000 tank and route the
hose up to the front of the vehicle with the
other hoses. Leave the fitting hand-tight.
1.3 Installing the blow down solenoid
1. Remove the plastic blanking plug from the
rear of the VR7000 tank.
Blow-down solenoid in position
Detail of Direction Indicator(Up)
DOCUMENT 19574
14
2. Apply PST sealant to the threads on the
3/4 inch NPT male end of the solenoid
tee assembly. Thread it into the rear of
the VR 7000 tank and tighten it so that
the solenoid is at the top.
1.4 Installing the oil cooler
1. Remove the coolant cover plate with the
blanking plug from the rear of the engine
cylinder block.
2. Remove the blanking plug from the cover
plate. Do not disconnect the air brake
compressor line from theplate, it is only
removed to allow the 90 degree elbow
to be fitted
3. Apply PST sealant to the 1/2 inch NPT
threads on the 5/8 inch hose elbow and
thread it nto the coolant plate. Point the
elbow to the right side of the engine.
4. Make sure the OEM sealing ring is still in
place, then install the coolant plate to the
rear of the engine using the OEM bolts.
5. Locate the four (4) 12 mm mounting
holes on the right side of the engine
block under the turbo. The two front
holes are next to the oil dipstick.
6. Fasten the oil cooler to the four (4) holes
in the engine block using the four (4)
M12 x 25 bolts and flat washers from
the cooler fastener pack.
7. Place clamps on the longest 5/8 inch
heater hose and install it between the 90
degree elbow on the top of the cooler
and the elbow in the coolant cover plate
on the rear of the engine block. Tighten
the hose clamps.
8. Install the short length of 5/8 inch heater
hose on the 90 hose barb elbow on the
bottom of the cooler. Place an HS 10
hose clamp on the connection and tighten
it securely.
Rear coolant plate hose to oil cooler fitting
Installing the upper oil cooler hose
Cooler in position
Part 2
Installing the Control
and
Electrical Components
System #9059
2000 OTTAWA TRUCK
5.9 CUMMINS 24 VALVE DIESEL
(with or without air conditioning)
UNDERHOOD AIR COMPRESSOR
15
DOCUMENT 19575
16
17
DOCUMENT 19575
2.0 Installing the control unit
1. Position the control unit on the right side
of the dash panel and mark the drilling
locations for the L-bracket mounting
holes.
2. Mark a point about 1” behind the control
unit to provide a route for the wiring.
3. Drill two7/32 inch holes for the mounting
brackets.
4. Check under the dash panel to ensure that
there are no obstructions for the wiring
hole or any components that could be
damaged during drilling. If it is not clear,
relocate the position of the hole.
5. Drill a pilot hole, then enlarge the hole with
a 19/32 inch drill bit.
6. Mount the control unit to the dash panel
using the two (2) supplied self-tapping
screws.
7. Feed the control unit cable through the
hole and install the rubber grommet into
the hole to protect the wiring.
8. Route the control unit wiring along the
vehicle wire harness and secure it to the
flexible link that allows the cab to tilt
without fouling the vehicle harness.
9. Route the wiring back along the vehicle
harness towards the rear cab cross-
member.
2.1 Installing the switching box
1. Mount the switching box on the left front
of the rear cab cross-member, using the
OEM fastener for the vehicle electrical
box.
Part 2: Installing the Control and Electrical
Components
Recommended location for the control unit
Control unit mounted in position
Switching box in position
Mounting holes
18
DOCUMENT 19575
2.3 Connecting the wiring
1. Connect the short cable with the green 7
pin connector from the switching box to
the matching connector from the control
panel. Secure the cable inside the left
frame rail with the vehicle harness. Leave
enough slack in the cable for the cab to
tilt.
2. Connect the white 4 wire connector to
the matching connector on the interface
cable. Remove the lid on the vehicle
electrical box and feed the green wire
with the ring terminal up through the
drain hole in the box. Connect this wire
to one of the common ground rail
connections inside the box.
3. Locate the yellow wire (with weather-
pack connector) in the OEM harness
near the electrical box. Remove the
male weather-pack blank plug. Test to
make sure that there is battery voltage
present when the ignition switch is in the
“ON” position.
Interface
connection
to switching
box
To OEM 12 V ignition po
wer
T
o compressor clutch
OEM 12 V replacem
ent
Ground
To blowdown solenoid
Interface Cable
4. Connect the red wire with the weather pack
connector to the yellow wire. An additional
connector is also provided for alternate
power sources. The additional connector is
part of our interface cable and is a
replacement for OEM yellow.Fit the male
weather-pack blank plug to the additional
connector
5. Route the gray two-core cable with the
square cap plug along the cross member and
under the vehicle to the back of the VR7000
tank Connect it to the blow-down solenoid
on the back of the tank. Make sure that the
rubber gasket is in place and fasten it to the
solenoid with the screw. Secure the cable to
the vehicle harness or other components.
6. Route the white single wire and the gray 4 pin
cable along the cross member, follow the
vehicle harness and hoses and route them
inside the right hand frame rail towards the
radiator. The white wire will be connected to
the VR7000 compressor clutch and the gray
cable to the compressor temperature probe.
Gray 7-core cable
Green 7-pin
connector Gray 4-core cable
Control
Panel
Switching Box
Male weatherpack
OEM female weatherpack
Green 4-pin
connector Compressor
clutch
Red
White
OEM 12 V yellow
Gray 3-core cable
Blow down
solenoid
Green
OEM common ground rail
Wiring Schematic and Interface Cable
Interface Cable
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