Vmac UNDERHOOD 40 Installation Manual
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Vmac UNDERHOOD 40 Installation Manual

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Installation Manual for VMAC
System
V40T033
2023 + Mercedes Sprinter
2.0 L Diesel
www.vmacair.com

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Summary of Contents for Vmac UNDERHOOD 40

  • Page 1 Installation Manual for VMAC System V40T033 2023 + Mercedes Sprinter 2.0 L Diesel www.vmacair.com...

  • Page 3: Table Of Contents

    Accessory Products from VMAC ........54...
  • Page 4 Copyright © 2023 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 products and...

  • 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

    (ii) services are completed in accordance with the Owner’s Manual; (iii) proof of purchase of applicable service kits are made available to VMAC upon request. The VMAC Lifetime Warranty is applicable to new products shipped on or after 1 October, 2015. Warranty Registration The VMAC warranty registration form is located near the back of this manual.
  • Page 7 VMAC will provide direction for repair or replacement of the failed components. 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: Preparing For Installation

    Review the contents of the system using the illustrated parts list to ensure all components are present and in the correct quantity. If any components are missing, have the system ID ready and call VMAC Technical Support. ☐ Remove the driver side step cover and floor mat (Figure 1).
  • Page 11 Determine whether the vehicle is equipped with the dual row crank pulley (Figure 3). Single row crank pulley Figure 3 — Identify crank pulley Vehicles equipped with dual row crank pulley, skip to page 11. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 12: Installing The Dual Row Pulley

    *Step 2: Install (×2) fasteners and washers in the non-counterbored holes. ☐ *Torque the fasteners to 43 ft•lb. ☐ Re-tension the OEM FEAD belt (on the rear row of crank pulley). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 13: Installing The Main Bracket And Compressor

    Using the supplied fasteners, install the main bracket onto the passenger side of the oil pan (Figure 4, Figure 5). M8×1.25×70 M8×1.25×100 Figure 4 — VMAC Main bracket mount location VMAC main bracket Figure 5 — VMAC main bracket installed...
  • Page 14 Install the tensioner (Figure 6). Figure 6 — Install tensioner ☐ Install one of the supplied idlers onto the VMAC main bracket (Figure 7). Figure 7 — Install main bracket idler VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289...
  • Page 15 Using (×3) M8 × 1.25 × 35 mm bolts, mount the compressor assembly, and pressure switch assembly (in the orientation shown) onto the main bracket (Figure 9). Figure 9 — Mount compressor VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 16 (Figure 10). Install idler Figure 10 — Install oil pan idler ☐ Install and tension the VMAC belt (Figure 11). Figure 11 — VMAC belt routing VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289...
  • Page 17 (located in the void beneath the driver side headlight) (Figure 13). VMAC air filter Bumper mounting bolts Front of Front of vehicle vehicle Figure 13 — Install compressor air filter bracket VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 18 ☐ Route the compressor air intake hose from the bottom of the VMAC air filter assembly, along the cross member below the radiator, to the compressor (Figure 13). ☐ Secure the air intake hose to the air filter and compressor using the supplied gear clamps (Figure 14).

  • Page 19: 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 20 18 1/8 in 15 3/8 in 4 1/2 in 5/16 in or M8 mounting holes Figure 15 — Minimum WHASP Tank mounting clearances VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 21 (intake) side of the WHASP Tank to allow fresh, cool air to circulate into the cooler and fan (Figure 17). Front of vehicle Provide minimum 6 in clearance for air flow Figure 17 — WHASP ventilation VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 22: Installing The Bulkhead Fittings

    23 of this manual. Figure 18 — Bulkhead fittings (A700224 Remote Muffler accessory shown) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 23 This kit includes hoses of an adequate length to connect to the location specified in this manual. If installing in an alternate location: • Contact a VMAC dealer to order hose extensions. • If sourcing custom length hoses locally, refer to our knowledge base article (https://kb.vmacair.com/help/required-vmac-hoses ) for hose requirements.
  • Page 24 1/4 in push-to-connect fittings in the bulkhead fitting (Figure 20 and Figure 21). Figure 20 — Bulkhead fittings installed (interior view) (some applications may not include subfloor) Figure 21 — Bulkhead fittings installed (exterior view) VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 25: Hose Requirements

    • 1/4 in (PTFE Tube) × 108 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 26: Connecting The Hoses

    Cut the tube square. Do not use side Slide the collet out once cutters as they will deform the tube the tube is fully inserted O-ring Figure 22 — Push-to-connect fittings VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 27 Use of an air receiver tank (minimum 6 USG) is required with this application. Follow the instructions on page 44 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 28 (Figure 25). Install push-to- connect fitting Figure 25 — Install push-to-connect fitting VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 29 Install the tube into the push-to-connect bulkhead fitting (Figure 27) Figure 27 — 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 30 Route the 3/4 in and 3/8 in hoses, as well as the 1/4 in PTFE tube, over the frame crossmembers and steering rack (Figure 29). PTFE from compressor Pressure switch PTFE 3/4 in hose 3/8 in hose Figure 29 — Install hoses VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 31 Route the hoses along the base of the frame/body, and up to the bulkhead fittings installed earlier (Figure 31, Figure 32, and Figure 33). Secure 3/4 in hose Figure 31 — Route hoses VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 32 (Figure 31, Figure 32, and Figure 33). ☐ Using cable ties, secure the 3/8 in hose and 1/4 in PTFE tube to the 3/4 in hose. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 33: 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 34: Installing The Control System

    Do not use a test light to probe for power on vehicle circuits, the increased current draw of the test light may damage components. • VMAC recommends using only sealed crimp and solder butt connectors for all electrical connections. •...
  • Page 35 Tying into OEM connectors Some OEM connectors may have locking tabs that must be disengaged prior to inserting a crimped connector. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 36 Compressor Control Module Throttle Control WHASP Interface Tank Panel Figure 36 — 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 37 Control Module (Figure 37) The control module serves as the primary input/output interface between the vehicle and the various VMAC components (compressor, throttle control, WHASP Tank, interface panel, etc.). Power, 12 V Clutch, throttle WHASP Compressor (switched), and control, and...
  • Page 38 Figure 39 — VMAC digital throttle control Mechanical Pressure Switch (Figure 40) 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 39 Figure 41 — Electrical schematic 1 VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 40 Bullet connectors Figure 42 — Electrical schematic 2 VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 41 Connect the yellow wire with bullet connector running from the control module to the red wire with bullet connector running from the throttle control (an extension wire has been included to accommodate longer routing options). VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 42 ☐ Connect the ground wires (green wire) running from the throttle control, CAN converter, and control module to a good ground. VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 43 ☐ *White 16 AWG wire from the control module (clutch 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 44 ☐ Route the bundled harnesses through the pass-through in the bulkhead to the cargo bay (Figure 48). Driver seat bracket Passthrough Figure 48 — Bulkhead passthrough VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 45 ☐ 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 46: 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 47: 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 54 for a list of products available for purchase through VMAC.

  • Page 48: 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 49 ☐ Install the VMAC belt routing diagram in a suitable location under the hood (Figure 54). Figure 54 — Belt routing label (actual belt routing label may differ) ☐ As part of the installation process, ensure that the safety and operational instruction decal is affixed in an obvious location so that it can be seen by vehicle operators.

  • Page 50: 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 51 Add oil as necessary to bring the level to the “FULL” line in the sight glass and check for leaks. ☐ Install the VMAC Air Test Tool (P/N: A700052) with the 40 cfm (5/32 in) orifice installed and the ball valve closed. ☐...
  • Page 52 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 53: Performance Testing

    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 56).

  • Page 54: Digital Throttle Control Operation And Adjustments

    The throttle control is configured at the factory for optimum performance at maximum cfm. In applications where maximum cfm is not required, or noise is a concern, the throttle control can be adjusted to reduce the maximum VMAC rpm. Safety features...
  • Page 55 The cfm produced by the system is directly related to engine speed; this system delivers 34.5 cfm at 3,700 rpm. Maximum VMAC rpm can be adjusted between 1,500 rpm and 3,700 rpm (in 50 rpm increments) via the ““ or “” buttons in the “MAX RPM” column.

  • Page 56: 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 57 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 58 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, 170 psi pressure relief valve, and tank drain.
  • Page 59 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 60 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...
  • Page 61 Notes VMAC - Vehicle Mounted Air Compressors VMAC Technical Support: 888-241-2289 VMAC Knowledge Base: kb.vmacair.com...

  • Page 62: 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 64 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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