THE BENCHMARK IN INNOVATION

1333 KIPP ROAD NANAIMO B.C. V9X 1R3TEL: (250)-740-3200FAX: (250)-740-3201TOLL FREE: 877-912-6605

www. .comthrottlecommanderVisit us at...

DODGE 1998.5 - 2003 5.9L CUMMINS ISB DIESEL 2500 - 3500 (2003.5 automatic transmission only)

Throttle # T500055

Installation Manual

Manufactured by

Installation Manual � Document Number: 1900439

Throttle Commander Throttle Control Application:

Dodge 1998.5 - 2003 5.9L Cummins ISB Diesel 2500 � 3500 (2003.5 automatic transmission only)

Revision History:

Version Revision Details Revised by/date Approved by/date Implemented

00 Complete review of originating document content, revisions and updating

Dec 22/03 Jan 13/04 Jan 14/04

Registered Trademarks:

VR70, VMAC and Throttle Commander are registered trademarks of VMAC. Notice:

Manuals and products are subject to change without notice.

Copyright 2004 The contents of this manual may not be reproduced in any form without the express written

permission of VMAC Printed in Canada

Contents

General Information.......................................................................................................................... 3

Ordering Parts ............................................................................................................................... 3

Warranty ....................................................................................................................................... 3

1.0 Preparing for Installation ............................................................................................................ 3

2.0 Installing the Throttle Commander............................................................................................. 4

2.1 1998.5 � 2002 Connecting the White Wire ............................................................................ 5

2.2 2003 Connecting the White Wire............................................................................................ 7

2.3 Connecting the Black Wire..................................................................................................... 7

3.0 Completing and Testing the Installation..................................................................................... 9

3.1 Operational and Safety Test.................................................................................................... 9

4.0 Auxiliary Equipment Connections............................................................................................ 10

4.1 Single Speed Control ............................................................................................................ 10

4.2 Multiple Speed Control......................................................................................................... 10

5.0 Setting up the Throttle .............................................................................................................. 12

5.1 Changing Speed 1 ................................................................................................................. 13

5.2 Changing Speed 2 ................................................................................................................. 13

5.3 Changing Speed 3 ................................................................................................................. 13

6.0 Troubleshooting ........................................................................................................................ 14

Appendix A � Soldering ................................................................................................................. 15

Warranty Registration..................................................................................................................... 17

1

LE

GE

ND

WIR

ELA

BE

L

XX

XX

XX

XX

XX

XX

CH

AS

SIS

GR

OU

ND

OEM

HA

RN

ES

S(U

NP

LUG

GE

DFR

OM

TP

S)

SO

LDE

R A

ND

SE

AL

THIS

CO

NN

ECTI

ON

(GRY/BLK)

TRA

NS

MIS

SIO

NC

ON

TRO

LM

OD

ULE

C1-

PIN

8TP

SC

ON

NE

CTO

R( U

ND

ER T

PS

MO

DU

LELO

CK

ING

TA

B T

O

FRO

NT

OF

TRU

CK

)

WH

ITE

TACHLINEWHITEWIRE

WH

ITE

PAR

K B

RA

KE

SW

ITC

H/D

DC

THR

OTT

LEC

OM

MA

ND

ER

BLACK

PU

RP

LE

SP

EE

D 2

RE

D

SP

EE

D 1

SE

E A

PP

RO

PR

IATE

INS

TRU

CTI

ON

SIN

MA

NU

AL

FOR

TRA

NS

MIS

SIO

N T

YP

E

FWD

Figure 1

2

General Information Ordering Parts

To order parts, contact your nearest VMAC dealer. 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.

1.0 Preparing for Installation

1. Disconnect the batteries, positive terminal first, then negative terminal.

2. Undo the Phillips-head fasteners holding the OEM TPS cover in place and pry the fasteners out of the cover with a regular screwdriver. Remove the TPS cover (Figure 2).

Figure 2

3. Depress the lock tab on the front of the TPS connector and remove the OEM connector

(Figure 3).

3

Figure 3

2.0 Installing the Throttle Commander

1. On 1998.5 � 2002 models, mount the Throttle Commander on the driver-side of the vehicle near the firewall using the OEM body bolt (Figure 4).

Figure 4

2. On 2003 models, mount the Throttle Commander on the driver-side of the vehicle using the

hood hinge bolt (Figure 5).

4

Figure 5

3. Route the wiring from the Throttle Commander to the TPS.

4. Connect the TPS cable to the matching connector on the Throttle Commander wiring

harness.

5. Connect the matching Throttle Commander connector to the TPS.

6. Make sure that all connectors are fully seated and that the locking tabs are engaged.

2.1 1998.5 � 2002 Connecting the White Wire

1. Remove the air box cover and the air filter element.

2. Remove the air box from the right inner fender.

3. Locate the innermost connector on the firewall, squeeze both lock tabs together and unplug the connector (Figure 6).

5

Figure 6

4. Locate the grey wire with the black stripe at cavity 8 on the connector (Figure 7).

5. Solder and seal the white throttle wire to the grey with black stripe wire using the

supplied heat shrink.

32222112111

Gray/Black wireCavity #8

Figure 7

6

2.2 2003 Connecting the White Wire

1. Locate the Transmission Control Module (TCM) on the passenger side firewall behind the battery (Figure 8).

C1

Figure 8

2. Unplug the bottom connector.

3. Locate the grey with black stripe wire on the bottom connector.

4. Solder and seal the white throttle wire to the grey with black stripe wire using the

supplied heat shrink.

2.3 Connecting the Black Wire

The black wire from the Throttle Commander is attached to the park brake to prevent operation of the throttle control unless the park brake is engaged. This is a safety interconnect feature.

1. On vehicles with an automatic transmission, cut a small slit in the rubber cover over the unused clutch rod hole in the firewall and route the black wire from the Throttle Commander into the cab.

7

2. On vehicles with a manual transmission, cut a small slit in the rubber grommet surrounding the hood latch actuator cable and route the black wire from the Throttle Commander into the cab.

!

IF THE VEHICLE HAS AN AUTOMATIC TRANSMISSION, THE THROTTLE COMMANDER MUST BE CONNECTED SO THAT IT WILL NOT FUNCTION UNLESS THE TRANSMISSION IS IN PARK OR NEUTRAL. FAILURE TO PROPERLY INSTALL AND VERIFY THE FUNCTION OF THIS SAFETY FEATURE CAN RESULT IN INJURY OR DEATH. IF YOU REQUIRE A SAFETY INTERCONNECT TO PERFORM THIS TASK, ORDER THE VMAC DRIVE DISABLE CIRCUIT PART NUMBER 3550665. BE SURE TO PERFORM THE SAFETY TEST IN THE DDC INSTALLATION INSTRUCTIONS BEFORE PROCEEDING.

3. Remove the electrical connector from the switch at the park brake (Figure 9).

4. Connect the black wire from the Throttle Commander to the OEM park brake wire and protect the connection with electrical tape.

5. Plug the assembled wiring back onto the switch at the park brake.

OEMPARK BRAKE

WIREPARK BRAKE

PA

RK

BRA

KE

COMMANDERTHROTTLE

Figure 9

8

3.0 Completing and Testing the Installation

1. Install the TPS cover and tighten the screws.

2. Check all wiring to ensure that it will not contact any hot or moving components and will not interfere with the operation of the vehicle. Secure all wiring with nylon ties and the supplied loom as required.

3. Connect the batteries, positive terminal first, then the negative terminal. 4. Temporarily route an 18 gauge test wire from the positive battery terminal into the cab. This

wire will be used to activate the Throttle Commander for the operational and safety tests.

3.1 Operational and Safety Test

1. Place the vehicle in a safe operating position and block the wheels. Ensure that there are no people around the vehicle before beginning the test.

2. Sit in the driver�s position with the automatic transmission in Park, manual

transmission in neutral and the park brake fully engaged.

3. Start the vehicle engine and wait for the idle to stabilize. Engine temperature should be in the normal operating range.

4. Test the operation of the Throttle Commander. Momentarily activate the throttle by

quickly connecting and disconnecting the temporary wire from the battery positive post to the red wire on the Throttle Commander. The engine should start to idle up.

5. Firmly apply the service brake pedal and hold it down.

6. Release the park brake and momentarily activate the throttle as before. The engine

should not idle up.

7. Apply the park brake and shift the automatic transmission into gear with your foot on the service brake pedal. Momentarily activate the throttle as before. The engine should not idle up.

8. Shift the transmission back into Park and shut down the engine.

If the vehicle fails the test, check the wiring to make sure that all the connections are correct and secure. If you require additional assistance, contact your local VMAC dealer.

!

9

4.0 Auxiliary Equipment Connections The Throttle Commander has three (3) possible speed settings. These settings are obtained by providing battery power to the red wire and the purple wires. Factory default settings provide the following speeds:

Speed Selection Red wire Purple wire Factory settingOff 0 Volts 0 Volts 0 RPM Speed 1 12 Volts 0 Volts 1,400 RPM Speed 2 0 Volts 12 Volts 1,800 RPM Speed 3 12 Volts 12 Volts 1,800 RPM

4.1 Single Speed Control

1. Connect the red wire from the Throttle Commander through a suitable switch to an

ignition activated 12-volt power source using an 18 gauge or heavier wire. Coil and insulate the purple wire with tape.

2. Install a 1-amp inline fuse between the switch and the red wire.

4.2 Multiple Speed Control

1. Make the single speed connection using the red wire.

2. Connect the purple wire from the Throttle Commander through a second switch to an

ignition activated 12-volt power source using 18 gauge or heavier wire.

3. Install a 1-amp inline fuse between the switch and the purple wire. The following diagrams show options for connecting the red wire from the Throttle Commander so that it is activated by auxiliary equipment. Figure 10 shows switch activation and Figure 11 shows relay activation.

10

NOTEWHEN ENGINE OFF, 12V GOING TO

THROTTLE MUST BE OFF.DO NOT REACTIVATE THROTTLEUNTIL ENGINE HAS RESTARTED

AND RPM HAS STABILIZED.

CONTROL

THROTTLEREDPURPLE

SPEED 2 SPEED 1

Figure 10

NOTEWHEN ENGINE OFF, 12V GOING TO

THROTTLE MUST BE OFF.DO NOT REACTIVATE THROTTLEUNTIL ENGINE HAS RESTARTED

AND RPM HAS STABILIZED.

CONTROL

THROTTLE

SPEED 1SPEED 2

REDPURPLE

5-PRONG RELAY(BOSCH TYPE)

Figure 11

11

5.0 Setting up the Throttle Factory speed settings can be changed by using the VMAC RPM setting tool, part number A700035 (Figure 12).

Figure 12

1. Plug the RPM setting tool into the port on the back of the Throttle Commander. Make sure

that you push the connector in all the way.

! Make sure that the speed control and engine are turned off before plugging or unplugging the RPM setting tool.

2. To increase speed, press the �+� button on the RPM setting tool and hold it for at least one second, the LED will turn off, then release. The LED will turn back on and the speed setting will increase by 100 RPM. Each time you press, hold and release the button you will increase the speed by 100 RPM.

3. To decrease the speed, press the �-� button on the RPM setting tool and hold it for at least

one second, the LED will turn off, then release. The LED will turn back on and the speed setting will decrease by 100 RPM. Each time you press, hold and release the button you will decrease the speed by 100 RPM.

Before making any speed changes, make sure that the vehicle is in a safe operating condition, in neutral or park with the park brake engaged and that all speed switches are in the OFF position.

!4. Start the engine and allow the idle to stabilize.

12

5.1 Changing Speed 1

1. Activate speed 1 by turning on the switch which connects power to the red wire.

2. Use the RPM setting tool to increase or decrease speed.

5.2 Changing Speed 2

1. Activate speed 2 by turning on the switch which connects power to the purple wire.

2. Use the RPM setting tool to increase or decrease speed.

5.3 Changing Speed 3

1. Activate both speed 1 and speed 2 by turning on both switches.

2. Use the RPM setting tool to increase or decrease speed.

The park brake or transmission shift selector must not be used as an ON/OFF switch.

! When the engine is turned off, the Throttle Commander must also be turned off. Do not reactivate the Throttle Commander until the engine has been restarted and the RPM has stabilized.

13

6.0 Troubleshooting

Problem Possible Cause Corrective Action

Engine stays at base idle and the green LED on the Throttle Commander blinks steadily on for one second and off for one second.

No voltage applied to either the red or purple wires.

Check for 12 volts at the red wire and the purple wire with the appropriate switch turned on.

Engine stays at base idle and the green LED on the Throttle Commander flashes once quickly with a long pause between flashes.

No tachometer signal. Make sure that the white wire is connected properly.

Engine stays at base idle and the green LED on the Throttle Commander flashes twice quickly with a long pause between groups of flashes.

Park brake not engaged. Black wire not connected properly.

Set the parking brake. Check the connections.

Engine stays at base idle and the green LED on the Throttle Commander flashes three times quickly with a long pause between groups of flashes.

Engine over speed condition (3,000 RPM or above) has been sensed by the Throttle Commander. Intermittent connection at the white wire.

Turn off throttle and engine. Wait for LED to go out and stay out. Restart engine and engage Throttle Commander. If problem continues, check all connections.

Vehicle �CHECK ENGINE� light comes on and/or throttle pedal does not have authority when the Throttle Commander is not engaged.

Bad plug connections between the Throttle Commander and the TPS.

Make sure that all connectors are properly engaged, fully seated and latched.

If you are unable to effectively troubleshoot operational problems, call your local VMAC dealer for technical support.

14

Appendix A � Soldering 1. Cut the OEM wire and strip approximately 1/2 inch from

each end and from the VR70 wire.

2. Slide the provided heat shrink onto one OEM wire and one

VR wire. Twist all three wires together.

3. Heat all 3 wires at the joint with a soldering gun or pen,

then apply the supplied solder. Ensure the solder �flows� into the joint to bond the wires together.

4. Once the joint has cooled, slide the heat shrink over the

joint and heat it with a heat gun. Make sure the shrink is heated until the liner melts and makes a good seal.

15

16

Warranty Registration This form must be fully completed and returned to VMAC at the time of installation. Warranty will be void if this form is not received by VMAC within 30 days by mail or fax.

Installer Information Company Name:

Installer Name:

City: State/Prov.

Zip/Postal Code Telephone:

Installation Date: / / Day month year

Owner Information Owner Name:

Address:

City: State/Prov.

Zip/Postal Code: Telephone:

Purchase Date: / / day month year

Purchased From:

Application Vehicle Make: ________________ Year: ________ Engine type/size: ______________

Vehicle Identification Number (VIN#):

Product Information

System Identification Number: V _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Compressor Number: P _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Tank Serial Number: 9 __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Throttle Control Serial Number: T5 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

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

TEL: 250-740-3200

FAX: 250-740-3201

TOLL FREE: 877-912-6605

www.throttlecommander.com