Vmac UNDERHOOD 40 Series User manual

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

VMAC - Vehicle Mounted Air Compressors
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Table of Contents
Safety .........................................................................3
Warranty ......................................................................4
General Information ...........................................................6
System Identification, Warranty Registration and Warning Labels..............8
Preparing for Installation .....................................................10
Installing the Pulley ........................................................... 12
Installing the Compressor..................................................... 13
Installing the Waste Heat Air Separator Package (WHASP) Tank.............. 19
Installing the Bulkhead Fittings ...............................................22
Hose Requirements ...........................................................26
Connecting the Hoses .......................................................27
Adding Oil to the System .....................................................36
Interior Panel Removal ........................................................37
Installing the Control System .................................................39
Air Receiver Tank ............................................................ 50
Recommended Accessories ...................................................51
Completing the Installation ...................................................52
Testing the Installation ...................................................... 53
Performance Testing and System Adjustments ............................... 56
Accessory Products from VMAC ............................................. 58
Warranty Registration ....................................................... 64

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Document: 1930336
Changes and Revisions
Revision Revision Details Revised by
Checked by
Implemented
Eng. Tech. Qual.
Mech. Elec.
AInitial Release MSP KRM AJH GB AWG 14 Feb 2018
B ECN 19-141 Model year update MSP CAM N/A BDJ TK 27 Aug 2019
CECN: 20-210 Receiver tank requirement MSP MRH N/A MSP N/A 26 Oct. 2020
Additional Application Information
• Use of an air receiver tank (minimum 6 USG) is required with this application.
• 2010 –2018 Mercedes Sprinter 3.0 L Diesel.
• 2010 –2018 Freightliner Sprinter 3.0 L Diesel.
Important Information
The information in this manual is intended for certified VMAC installers who
have been trained in installation and service procedures and/or for anyone with
mechanical trade certification who has the tools and equipment to properly and
safely perform the installation or service. Do not attempt installation or service
without the appropriate mechanical training, knowledge and experience.
Follow all safety precautions. Any fabrication for correct fit in modified vehicles
must follow industry standard “best practices”.
Notice
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
products and services are those set forth in the express warranty statements
accompanying such products and services, if any, and nothing herein shall be
construed as constituting an additional warranty. Printing or copying of any page
in this document in whole or in part is only permitted for personal use. All other
use, copying or reproduction in both print and electronic form of any part of this
document without the written consent of VMAC is prohibited. The information
contained herein may be changed without prior notice.
Printed in Canada
Registered Trademarks
All trademarks mentioned in this manual are the property of their respective
owners. VMAC’s use of manufacturers’ trademarks in this manual is for
identification of the products only and does not imply any affiliation to, or
endorsement of said companies.
Loctite®, Loctite®242 and Loctite®567 are registered trademarks of Henkel AG &
Company KGaA.
Eaton Aeroquip® is a registered trademark of EATON AEROQUIP INC.
Torx® is a registered trademark of Acument Intellectual Properties, LLC
Mercedes® and Sprinter® are registered trademark of DAIMLER AG.

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Important Safety Notice
The information contained in this manual is based on sound engineering principles,
research, extensive field experience and technical information. Information
is constantly changing with the addition of new models, assemblies, service
techniques and running OEM changes. If a discrepancy is found in this manual,
contact VMAC Technical Support prior to initiating or proceeding with installation,
service or repair. Current information may clarify the issue. Anyone with knowledge
of such discrepancies, who proceeds to perform service and repair, assumes all
risks.
Only proven service procedures are recommended. Anyone who departs from the
specific instructions provided in this manual must first ensure that their safety and
that of others is not being compromised, and that there will be no adverse effects
on the operational safety or performance of the equipment.
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.
Safety should be the first consideration when performing any service operations.
If there are any questions concerning the procedures in this manual, or more
information is required, please contact VMAC Technical Support prior to beginning
work.
Safety Messages
This manual contains various warnings, cautions and notices that must be
observed to reduce the risk of personal injury during installation, service or repair
and the possibility that improper installation, service or repair may damage the
equipment or render it unsafe.
This symbol is used to call attention to instructions concerning
personal safety. Watch for this symbol; it points out important
safety precautions, it means, “Attention, become alert! Your
personal safety is involved”. Read the message that follows and
be aware of the possibility of personal injury or death. As it is
impossible to warn of every conceivable hazard, common sense and
industry standard safety practices must be observed.
This symbol is used to call attention to instructions on a specific
procedure that if not followed may damage or reduce the useful life
of the compressor or other equipment.
This symbol is used to call attention to additional instructions or
special emphasis on a specific procedure.
Safety

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VMAC Standard Warranty (Limited)
For complete warranty information, including both VMAC Standard
Warranty (Limited) and VMAC Lifetime Warranty (Limited)
requirements, please refer to our current published warranty located
at: www.vmacair.com/warranty
If you do not have access to a computer, please contact us and we
will be happy to send you our warranty.
VMAC’s warranty is subject to change without notice.
VMAC Lifetime Warranty (Limited)
A VMAC Lifetime Limited Warranty is offered
on the base air compressor only and only on
UNDERHOOD, Hydraulic Driven, Transmission
Mounted, Gas and Diesel Engine Driven Air
Compressors, Multifunction Power Systems, and
other products as defined by VMAC, provided that
(i) the purchaser fully completes and submits a
warranty registration form within 3 months of purchase, or 200 hours of operation,
whichever occurs first; (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. 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.
There are 4 ways the warranty can be registered with VMAC:
www.vmacair.com/warranty
[e-mail]
(877 ) 740-3202
VMAC - Vehicle Mounted Air Compressors
1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3
LIFETIME
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WARRANTY
Warranty

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VMAC warranty work must be pre-authorized by VMAC. Claims are
processed via our dealer network. If you are not a VMAC dealer,
please select one to work with via our Dealer Locator:
https://www.vmacair.com/dealer-locator/
1. Communicate with VMAC Technical Support at 1-888-241-2289 or
[e-mail] to help diagnose/troubleshoot the problem prior to repair.
VMAC technical support will require the VMAC System ID, hours on the
compressor and mileage on the vehicle.
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.
5. Warranty invoices must include the Service Ticket number, VMAC System ID#,
hours on the compressor, and a detailed description of the work performed.
6. VMAC Warranty does not cover consequential damages, overtime charges,
mileage, travel time, towing/recovery, cleaning or shop supplies.
7. Dealers submit warranty claims on behalf of the Vehicle Owner/End User
affected by the defective part(s). The dealer ensures that all warranty credits
are refunded back to the Vehicle Owner/End User who made the initial warranty
claim.
In order to qualify for Lifetime Warranty (Limited), the completed
warranty registration form must be received by VMAC within 3
months of the buyer receiving the Product(s), or 200 hours of
operation, whichever occurs first.
If the completed warranty registration form has not been received
by VMAC within 3 months of the buyer receiving the Product(s),
or 200 hours of operation, the warranty period will be deemed to
commence 30 days from the date of shipment from VMAC.
Failure to follow the warranty claim process may result in denial of
the warranty claim.
VMAC Product Warranty Policies & Warranty Registration can be found on the
VMAC website (see previous page for URL).
VMAC Warranty Claim Process

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General Information
Optional Equipment Compatibility
While VMAC strives to design systems compatible with optional OEM equipment
(such as running boards), it is impractical to develop systems that accommodate
every OEM and aftermarket option or add-on. Whenever possible, VMAC
endeavors to advise of compatibility issues in the “Additional Application
Information” section of the manual. Even when specific optional equipment is
determined by VMAC to be incompatible, it does not preclude the vehicle upfitter
or end user from modifying the optional equipment to make it compatible with
the installed VMAC system. VMAC does not warranty or accept responsibility or
liability for the fitment, function or safety of any products modified in any way not
expressly outlined in the installation manual.
Before Starting
Note and label all parts that are removed from the vehicle as many
of the OEM parts will be reused during the installation of the VMAC
system.
Read this manual prior to beginning the installation to ensure familiarity with the
components and how they will fit on the vehicle. Identify any variations from the
application list such as vehicle model, engines, or optional equipment (e.g., dual
alternator, active steering assist, etc.).
Open the package, unpack the components and identify them using the Illustrated
Parts List (IPL) included in the Fastener Pack.
Hose Information
Depending on other installed equipment, it might be necessary to move the air/oil
separation tank from its intended location. The hoses used in VMAC compressor
systems have a specific inner liner that is compatible with VMAC compressor oil.
Use of hoses other than those supplied or recommended by VMAC may cause
compressor damage and may void your warranty. 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.

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Table 1 — Torque Table
Standard Grade 8 National Coarse Thread
Size (in) 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4
Foot pounds (ft•lb) 918 35 55 80 110 170 280
Newton meter (N•m) 12 24 47 74 108 149 230 379
Standard Grade 8 National Fine Thread
Size (in) 3/8 7/16 1/2 5/8 3/4
Foot pounds (ft•lb) 40 60 90 180 320
Newton meter (N•m) 54 81 122 244 434
Metric Class 10.9
Size (mm) M6 M8 M10 M12 M14 M16
Foot pounds (ft•lb) 4.5 19 41 69 104 174
Newton meter (N•m) 625 55 93 141 236
Special Tools Required
• Pneumatic fan wrench (Lisle 43300 or equivalent) or a manual fan pulley
holder (such as KD3900).
• Pulley Counter Rotation Tool: VMAC part number 5900252 / 5900254, or
Mercedes part number A1260.
• Internal and external Torx socket sets.
• Trim Removal Tool (such as Harbor Freight Tools®67021).
Torque Specifications
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.
Torque values are with Loctite applied unless otherwise specified.
Apply Loctite 242 (blue) to all fasteners (except nylon lock nuts)
unless otherwise stated.

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Preparation for installation is very important. Missing a step
or an item can cause problems in the installation or damage to
components.
☑
Check off each item as it is completed so that no steps are
missed.
☐ 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 at
[phone].
The VMAC warranty form must be completed and returned to VMAC
at the time of installation for any subsequent warranty claim to be
considered valid.
☐ 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. This plate provides information that allows
VMAC to assist with parts and repairs.
☐ Mark and drill 2 × 7/64 in holes in the top of the cross member in front of the
hood support. Secure the plate with the supplied self-tapping screws (Figure 1).
Figure 1 — System Identification Plate
☐ Install the VMAC belt routing diagram in a suitable location under the hood.
System Identification, Warranty
Registration and Warning Labels

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☐ 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. A good spot for this is usually on the inside of the door or on
the panel underneath the steering wheel (Figure 2).
Figure 2 — Operating Instruction label
☐ 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

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☐ Disconnect the battery by pressing down on the red tab and pulling back on
the quick release located next to throttle pedal (Figure 4).
Battery quick
release
Figure 4 — Disconnect battery
☐ Remove the airbox located in the center of the engine bay. Remove the 2
electrical plugs, the hose clamp, airbox elbow and pull the 2 front mounts
straight up. Move the assembly out of the way (Figure 5).
Air box elbow
Front
mounts
Electrical
plugs
Hose clamp
Figure 5 — Remove air box
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).
Preparing for Installation

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☐ Disconnect the fan clutch plug and remove the stator fastener using an E11 Torx
socket (Figure 6).
Disconnect
fan harness
Figure 6 — Disconnect fan clutch
Remove
stator
fastener
☐ Leave the upper coolant line from the radiator in place during the installation.
☐ Push in the clips on either side of the radiator to release the shroud from the
radiator frame. Gently lift up to keep the clips unlocked (Figure 7).
☐ Loosen the fan nut; the fan has reverse thread (left hand thread) so it must
be rotated clockwise to loosen. A counter rotating tool may be required
(Mercedes part # 8930).
If using a pneumatic fan removal tool, the nut size is 36mm.
Alternatively a 1-7/16” wrench and Mercedes fan tool (Part number
906589004000) can be used.
☐ Remove the fan and shroud at the same time, through the top of the engine
compartment. Manipulate the assembly to get it past the upper coolant line.
☐ Store the fan in a vertical position to prevent damage to the viscous clutch.
☐ 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.
☐ Remove the washer from the OEM crank pulley bolt.
Figure 7 — Shroud clip locations
Shroud clips

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• Prior to installing the VMAC pulley, ensure any surface rust or
dirt inside the OEM pulley has been removed.
• Do not use an impact tool to tighten pulley bolt. Use a torque
wrench and follow the recommended torque values.
• Do not remove the OEM stretch belt. The VMAC crank pulley
may have to be removed during stretch belt service.
☐ Remove and discard the OEM washer from the OEM Crank Pulley bolt.
☐ 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.
☐ Install the OEM fastener with the supplied washer (Figure 8).
Remove and discard the OEM washer from the OEM Crank Pulley
bolt. The VMAC washer must be used.
☐ Use a counter rotating tool (VMAC P/N# 5900252 / 5900254 or Mercedes
P/N# A1260) to stop the pulley from rotating, and torque the main fastener to
147 (ft•lb).
Figure 8 — Crank pulley installation
Installing the Pulley

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☐ Remove the idler and tensioner from the VMAC main bracket (Figure 9).
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).
M8 × 1.25 ×
25 mm
M8 × 1.25 ×
50 mm
M8 × 1.25 ×
55 mm
Figure 10 — VMAC Main bracket mount location
Apply Loctite 242 (blue) to all engine mounted fasteners.
Installing the Compressor

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☐ Apply Loctite 242 (blue) to the 5 supplied fasteners and install the VMAC main
bracket onto the engine (Figure 11).
Figure 11 — Main bracket mounting fasteners
M8 × 1.25 ×
55 mm
M8 × 1.25 ×
50 mm
M8 × 1.25 ×
25 mm
☐ Apply Loctite 242 (blue) and install the idler, idler spacer and tensioner onto the
main bracket. Torque the fasteners to specification (Figure 12).
Figure 12 — Install idler, idler spacer and tensioner
Idler spacer

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☐ Apply Loctite 242 (blue) and mount the compressor onto the bracket using the
3 supplied fasteners (Figure 13).
☐ Install the VMAC compressor belt (Figure 14).
Figure 14 — VMAC belt routing
Figure 13 — Mount compressor
M8 × 1.25 ×
100 mm
M8 × 1.25 ×
35 mm

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☐ Ensure the 6 rib belt is centered on the 8 rib compressor clutch. One clutch rib
should be visible on each side of the belt (Figure 15).
☐ Remove the shipping pin in the tensioner to tension to the belt. Verify the belt is
properly seated on all of the pulleys.
Figure 15 — Align belt on clutch
One rib
visible on
each side
☐ Apply Loctite 242 (blue) to the 3 supplied fasteners and install the debris shield
onto the compressor (Figure 16).
Do not over tighten the debris shield fasteners.
Figure 16 — Install compressor shield

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☐ Install the compressor air filter bracket behind the radiator overflow bottle. Use
the supplied M8 × 18 mm fasteners with lock nuts in the 2 existing holes located
toward the engine below the cab air filter box (Figure 17).
Figure 17 — Install compressor air filter bracket
Cab air
filter box
VMAC air
filter
VMAC air filter
bracket
Compressor air
intake hose
VMAC air
filter bracket
fasteners
☐ 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.
☐ Reinstall the fan and shroud onto the engine, ensuring the radiator shroud tabs
click into place.
☐ Reconnect the fan harness (Figure 18).
Connect fan
harness
Figure 18 — Disconnect fan clutch
Connect
stator
fastener

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☐ Reconnect the stator to the engine (Figure 18).
☐ Reinstall the air box, including the related hoses and electrical connectors
(Figure 19).
Air box elbow
Front
mounts
Electrical
plugs
Hose clamp
Figure 19 — Remove air box