Vmac Underhood 40 Installation Manual
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Vmac Underhood 40 Installation Manual

For 2010-2018 mercedes sprinter; 2010-2018 freightliner sprinter
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Installation Manual for VMAC
System
V400003
2010 – 2018 Mercedes Sprinter
2010 – 2018 Freightliner Sprinter
3.0 L Diesel
www.vmacair.com

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Summary of Contents for Vmac Underhood 40

  • Page 1 Installation Manual for VMAC System V400003 2010 – 2018 Mercedes Sprinter 2010 – 2018 Freightliner Sprinter 3.0 L Diesel www.vmacair.com...

  • Page 3: Table Of Contents

    Accessory Products from VMAC ........
  • Page 4 Copyright © 2020 VMAC Global Technology Inc. All Rights Reserved. These materials are provided by VMAC for informational purposes only, without representation or warranty of any kind, and VMAC shall not be liable for errors or omissions with respect to the materials. The only warranties for VMAC...

  • Page 5: Safety

    VMAC will not be held responsible for any liability, consequential damages, injuries, loss or damage to individuals or to equipment as a result of the failure of anyone to properly adhere to the procedures set out in this manual or standard safety practices.

  • Page 6: Warranty

    1 October, 2015. Warranty Registration The VMAC warranty registration form is located near the back of this manual. This warranty registration form must be completed and sent to VMAC at the time of installation for any subsequent warranty claim to be considered valid.
  • Page 7 2. VMAC will provide direction for repair or replacement of the failed components. 3. If requested, failed parts must be returned to VMAC for evaluation. 4. Dealers may login to the VMAC website to view the "VMAC Labour Time Guide" (under “Agreements”) to see the allowable warranty labour times.

  • Page 8: General Information

    Please contact VMAC for replacement hoses and further information. Ordering Parts To order parts, contact a VMAC dealer. The dealer will ask for the VMAC serial number, part number, description and quantity. Locate the nearest dealer online at www.vmacair.com/dealer-locator or call 1-877-912-6605.
  • Page 9 All fasteners must be torqued to specifications. Use manufacturers’ torque values for OEM fasteners. The torque values supplied in Table 1 are intended for VMAC supplied components, or for use as a guide in the absence of a torque value provided by an OEM.

  • Page 10: System Identification, Warranty Registration And Warning Labels

    ☐ Complete the warranty form. The VMAC warranty form is located at the back of this manual, as well as online at: www.vmacair.com/warranty The System Identification Plate must be attached to the vehicle at the time of installation.
  • Page 11 To alert any technicians that may service the vehicle, affix the servicing caution/contact label in the engine compartment near the hood latch in a visible location (Figure 3). Figure 3 — Advisory label VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 12: Preparing For Installation

    Preparing for Installation Ensure the VMAC Warranty Registration has been filled out and the System Identification Plate and Operating Instruction Label are installed prior to proceeding (Please see page 8 for details). ☐ Disconnect the battery by pressing down on the red tab and pulling back on the quick release located next to throttle pedal (Figure 4).
  • Page 13 Install cardboard (or similar protection) over the radiator core to prevent damage to the fins when installing components. ☐ Use a 27 mm socket and a counter rotating tool (VMAC P/N# 5900252 / 5900254 or Mercedes P/N A1260) to remove the center fastener from the crank pulley.

  • Page 14: Installing The Pulley

    Scrape the clear coat (or any corrosion) from the inside front face of the crank pulley hub and ensure the surface is clean. ☐ Insert the VMAC pulley into the OEM crank pulley and rotate the VMAC pulley counterclockwise until the tabs seat inside the spokes of the OEM pulley. ☐...

  • Page 15: Installing The Compressor

    Figure 9 — VMAC main bracket assembly ☐ The VMAC main bracket is secured to the engine via 5 threaded holes on the engine oil pan (4 threaded holes on the side and 1 threaded hole at the front) (Figure 10).
  • Page 16 ☐ Apply Loctite 242 (blue) to the 5 supplied fasteners and install the VMAC main bracket onto the engine (Figure 11). M8 × 1.25 × 50 mm M8 × 1.25 × M8 × 1.25 × 25 mm 55 mm Figure 11 — Main bracket mounting fasteners ☐...
  • Page 17 100 mm M8 × 1.25 × 35 mm Figure 13 — Mount compressor ☐ Install the VMAC compressor belt (Figure 14). Figure 14 — VMAC belt routing VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 18 ☐ Apply Loctite 242 (blue) to the 3 supplied fasteners and install the debris shield onto the compressor (Figure 16). Figure 16 — Install compressor shield VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 19 Figure 17 — Install compressor air filter bracket ☐ Route the compressor air intake hose from the bottom of the VMAC air filter, down between the engine and the frame, to the compressor (Figure 17). ☐ Secure the air intake hose to the air filter and compressor using the supplied gear clamps.
  • Page 20 Reinstall the air box, including the related hoses and electrical connectors (Figure 19). Air box elbow Hose clamp Electrical plugs Front mounts Figure 19 — Remove air box VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 21: Installing The Waste Heat Air Separator Package (Whasp) Tank

    Illustrated Parts List (IPL). If the WHASP Tank or bulkhead fitting location requires longer hoses, contact a local VMAC dealer. See page 6 for ordering information . VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289...
  • Page 22 18 1/8 in 15 3/8 in 4 1/2 in 5/16 in or M8 mounting holes Figure 20 — Minimum WHASP Tank mounting clearances VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 23 (Figure 22). Front of vehicle Provide a minimum of 6 in of clearance for air flow Figure 22 — WHASP ventilation VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 24: Installing The Bulkhead Fittings

    To maximize compressor performance, hose lengths should be kept as short as possible; if longer hoses are required please follow the hose requirements listed on page 26 of this manual. Figure 23 — Bulkhead fittings VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 25 Front of vehicle Driver side Figure 24 — Measure from front of vehicle Front of vehicle Driver side Figure 25 — Measure from driver side of vehicle VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 26 Oil scavenge: 5/8 in. • ø Remote blowdown: 5/8 in. ø 1 1/16 in ø 5/8 in ø 9/16 in Figure 26 — Bulkhead fitting location VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 27 Apply Loctite 567 (thread sealant) when installing the 1/4 in push-to-connect fittings in the bulkhead fittings (Figure 27 and Figure 28). Figure 27 — Interior view Figure 28 — Exterior View VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 28: Hose Requirements

    • 1/4 in (PTFE Tube) × 25 in. If longer hoses are required: To order parts, contact a VMAC dealer. The dealer will ask for the VMAC serial number, part number, description and quantity. See page 6 for ordering information.

  • Page 29: Connecting The Hoses

    Cut the tube squarely, using only proper tubing cutters as side cutters the tube is fully inserted will deform the tube. O-ring Figure 29 — Push-to-connect fittings VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 30 Use of an air receiver tank (minimum 6 USG) is required with this application. Follow the instructions on page 50 of this manual to prevent damage to the system. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 31 (Figure 32). Install push-to- connect fitting Figure 32 — Install push-to-connect fitting VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 32 Install the tube into the push-to-connect bulkhead fitting (Figure 34) Figure 34 — Tubing Installation Remote Blowdown Muffler assembly ☐ Secure the tube with the supplied cable ties. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 33 Insert the supplied M8 × 1.25 × 100 mm bolt and washer through the hole in the vehicle sub frame (Figure 36). M8 × 1.25 ×100 mm bolt and washer Figure 36 — Install P-clip mount VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 34 Remove the lower OEM bolt from the shift bracket mounted on the driver side of the bell housing (Figure 38). OEM bolt Figure 38 — Remove shift linkage bolt VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 35 Figure 39 — Install P-clip ☐ Remove and discard the OEM M6 bolt on the rear of battery box (Figure 40). OEM bolt location Figure 40 — Remove battery bolt VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 36 Feed the PTFE tube and hoses through the lower portion of the OEM aluminum shield around the fuel filler (Figure 42). Aluminum shield Figure 42 — Hose routing VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 37 Continue routing the 1/4 in PTFE tube and the 3/4 in, 3/8 in hoses toward the bulkhead fittings installed earlier. ☐ Connect the hoses to the appropriate bulkhead fittings. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 38: Adding Oil To The System

    Adding Oil to the System The VMAC supplied and approved compressor oil must be used in this system. Failure to use this special oil will result in damage to the compressor and will void warranty. Do not overfill the system. Overfilling the system with oil can flood the sight glass window and make the system appear empty.

  • Page 39: Interior Panel Removal

    Figure 45 — Remove step cover and mat ☐ Remove the driver side lower dashboard panels (Figure 46). Dashboard fasteners Figure 46 — Remove lower dashboard panels VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 40 To remove the cover from the park brake: • Pull the cover toward the passenger seat to release the latch. • Pull back on the cover to separate it. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 41: Installing The Control System

    Strip the wire at the desired location and solder the VMAC wire into place. Slide the shrink tube up to the soldered joint and seal it. Finally, replace the pin in the connector, taking special care to ensure the pin is fully inserted and the locking tabs are engaged.
  • Page 42 Control Components Overview Compressor Control Module Throttle Control WHASP Interface Tank Panel Figure 51 — General component overview (Actual installation locations may vary) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 43 Control Module (Figure 52) The Control Module serves as the primary input/output interface between the vehicle and the various VMAC components (compressor, Throttle Control, WHASP Tank, Control Interface, etc.). Power, 12 V Clutch, Throttle WHASP Compressor (switched), and Control, and...
  • Page 44 “SPEED1” adjusting screw (under side) Figure 54 — VMAC Throttle Controls Mechanical Pressure Switch (Figure 55) The mechanical pressure switch is mounted on the side of the WHASP Tank and limits the maximum pressure to a safe amount by disengaging the clutch once system pressure is achieved.
  • Page 45 Figure 56 — Electrical schematic VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 46 Grey cable Grey cable Figure 57 — Wire schematic VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 47 Splice the blue wire from the Throttle Control (Park Signal) into the brown wire (front pin) on the shift module (Figure 59). Brown wire (front pin) Figure 59 — Splice into shift module VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 48 Locate the electrical access point under the driver seat and open the black cover over the 3 terminal studs (Figure 61). Cover Terminal studs Figure 61 — Electrical access point VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 49 White 16 AWG wire from the Control Module (clutch wire). ☐ White wire from the Throttle Control (tachometer signal wire). ☐ Grey cable with the green connector from the Control Module (Temperature sensor). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 50 Module to the bullet connector on the black wire running from the compressor. ☐ Connect the green connector on the grey cable running from the Control Module to the matching connector on the compressor. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 51 ☐ Ensure all wires and harnesses are protected with loom and routed away from sharp, hot, or moving components and away from high traffic areas. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 52: Air Receiver Tank

    This is normal operation. Prior to performing any service work on the system, discharge any stored air in the air receiver tank. The VMAC WHASP Tank has a built-in check valve. Use of an additional check valve is not required and may cause erratic performance.

  • Page 53: Recommended Accessories

    Recommended Accessories While the compressor system will function without the following accessories, VMAC strongly recommends their use for optimal performance. See the “Accessory Product” section of this manual on page 58 for a list of products available for purchase through VMAC.

  • Page 54: Completing The Installation

    Completing the Installation ☐ Check all VMAC and OEM wiring to ensure that it will not contact any hot, sharp or moving components and will not interfere with the operation of the vehicle. Secure all wiring with rubber coated P-clips, cable ties and loom as required.

  • Page 55: Testing The Installation

    If the vehicle fails the test, ensure the wiring to all of the connections are correct and secure. If additional assistance is required, contact your local VMAC dealer or call VMAC Technical Support 1-888-241-2289 or 250-740-3200. Safety Test Ensure the following has been completed: ☐...
  • Page 56 The second person will actuate the compressor switch and ball valve as necessary ☐ Install the VMAC Air Test Tool (P/N: A700052) with the 40 cfm (5/32 in) orifice installed and the ball valve closed. ☐ With the engine running and the vehicle in “PARK”, release the parking brake.
  • Page 57 Ensure the following has been completed: ☐ Operate the system with an air tool (or the VMAC Air Test Tool with the appropriate orifice installed) for at least 1/2 hour (1 hour preferred). The WHASP Tank cooling fan is thermostatically controlled, and may start or stop without warning.

  • Page 58: Performance Testing And System Adjustments

    Try turning the engine speed down and observe the performance. When testing the system or adjusting the VMAC Throttle Control, ensure the system does not exceed 2,500 engine rpm. Exceeding this speed will cause erratic system performance and in extreme cases may also cause long term damage to the compressor.
  • Page 59 Control. System operation can be tested using the tools that will be operated by the system or by using the VMAC Test Tool (A700052) with the 40 cfm (5/32 in) orifice in the outlet to simulate tool use (Figure 69).

  • Page 60: Accessory Products From Vmac

    Compressor Service Kits 200 Hour or 6 Month Service Kit - Part number: A700263 Includes 4 L VMAC high performance compressor oil, oil filter, air filter, and next service due decal. 400 Hour or 1-Year Service Kit - Part number: A700264...
  • Page 61 Air receiver tanks are used for lowering compressor duty cycle and removing water from compressed air; recommended for optimum operation of all VMAC Gas Driven, Diesel Driven, Hydraulic, and UNDERHOOD40 air compressors. Manufactured to FMVSS 121 standard; includes fittings, 160 psi pressure relief valve, and tank drain.
  • Page 62 Interface Harness Extension Part number: A700265 This interface harness extension provides an additional 10 ft of cable which allows for greater flexibility in locating the Interface Panel. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 63 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 64 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 65 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 66: Warranty Registration

    Warranty Registration This form must be fully completed and returned to VMAC at the time the vehicle is put into service. Warranty may be void if this form is not received by VMAC within 3 months of receiving the vehicle, or 200 hours of operation, whichever occurs first.
  • Page 68 Manufactured by ® 888-241-2289 tech@vmacair.com 877-740-3202 warranty@vmacair.com www.vmacair.com kb.vmacair.com 1333 Kipp Road, Nanaimo, B.C., V9X 1R3 Canada...

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V400003

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