Vmac V900059 Installation guide

Installation Manual

For The

System #V900059

TEL: 250-740-3200

FAX: 250-740-3201

TOLL FREE: 800-738-8622

1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3

DOCUMENT 1900684

UNDERHOOD AIR COMPRESSOR

2000 OTTAWA TRUCK

5.9 CUMMINS 24 VALVE DIESEL

(with or without air conditioning)

Installation Manual

VR70 Underhood Air Compressor

System Number V9000059

Application: 2000 Ottawa Truck with Cummins 5.9 24 valve diesel engine with or without

air conditioning

Publication Date: Revised by S. Large, August / 2002

Publication Number: 1900684

Origination Documents: #1900684a - General information

#1900684b - Installing the tank, oil cooler and lines

#1900684c - Installing the control and electrical components

#1900684d- Installing compressor, mounting bracket

#1900664e - Illustrated parts list

#1900130 - warranty registration

Registered Trademarks:

VR70, 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.

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 .................................................................................................... 12

1.3 INSTALLING THE BLOWDOWN SOLENOID ............................................................................ 13

1.3 INSTALLING THE OIL COOLER ......................................................................................... 14

PART 2: INSTALLING THE CONTROL AND ELECTRICAL COMPONENTS ........ 15

2.1 INSTALLING THE CONTROL UNIT....................................................................................... 17

2.2 INSTALLING THE SWITCHING BOX ...................................................................................... 17

2.3 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 70 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 #V900059

2000 OTTAWA TRUCK

5.9 CUMMINS 24 VALVE DIESEL

(with or without air conditioning)

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 1900684

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

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

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

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 Standard 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

NOTE

S/N

8

Part 1

Installing the

Air Tank, Oil Cooler and

Lines

System #V900059

2000 OTTAWA TRUCK

5.9 CUMMINS 24 VALVE DIESEL

(with or without air conditioning)

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 1900684

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 with the

cast OEM housing, leaving the hose

attached to the housing.

6. Remove the cast OEM coolant / tensioner

housing and discard but keep the 2

rubber sealing rings. The OEM bolts that

locate the cast OEM lower rad hose

housing also locate"sandwich" the coolant

/ tensioner housing.

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

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

2. Remove the OEM 3/8 pinch bolt and nut.

Install one (1) small, right-angle VR 70

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 VR70 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 VR70 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.

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.

10. Check the tank to make sure that the

“UP” arrow on the tank is vertical and

that the tank is level.

Pinch bolts and 5/16 inch mounting nuts

Pressure control (upper) and Scavenge (lower)

Line routing

13

Main discharge (lower) and oil return (upper)

11. Tighten the OEM pinch bolts, then the

VR70 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 VR70 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 VR70 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 VR70 tank.

Blow-down solenoid in position

Cooler in position

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 70 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 turned for fitting to the plate.

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 #V900059

2000 OTTAWA TRUCK

5.9 CUMMINS 24 VALVE DIESEL

(with or without air conditioning)

UNDERHOOD AIR COMPRESSOR

15

DOCUMENT 1900684

16

17

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

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 power

To compressor clutch

OEM 12 V replacement

Ground To blowdown solenoid

4. Connect the red wire with the weather pack

connector to the yellow wire. An additional

connector is also provided for alternate

power sources if the yellow wire is not

available. 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 VR70

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 VR70 compressor clutch and the gray

cable to the compressor temperature probe.

Gra

y

7-core cable

Green 7-pin

connector Gra

y

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

g

round rail

Wiring Schematic and Interface Cable

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Vmac V900059 Installation guide

Vmac V900059 Installation guide

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