Vmac UNDERHOOD 40 Series User manual

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

VMAC - Vehicle Mounted Air Compressors
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Table of Contents
Safety ..............................................................3
Warranty ...........................................................4
General Information.................................................6
Preparing for Installation ............................................8
Installing the Dual Row Pulley ......................................10
Installing the Main Bracket and Compressor ........................ 11
Installing the Waste Heat Air Separator Package (WHASP) Tank .... 17
Installing the Bulkhead Fittings.................................... 20
Hose Requirements ............................................... 23
Connecting the Hoses ............................................ 24
Adding Oil to the System ..........................................31
Installing the Control System...................................... 32
Air Receiver Tank.................................................. 44
Recommended Accessories ....................................... 45
Completing the Installation ....................................... 46
Testing the Installation............................................ 48
Performance Testing ...............................................51
Digital Throttle Control Operation and Adjustments ............... 52
Accessory Products from VMAC................................... 54
Warranty Registration............................................. 60

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Document: 1930495
Changes and Revisions
Revision Revision Details Revised by
Checked by
Implemented
Eng. Tech. Qual.
Mech. Elec.
AInitial release MSP MRH TDF N/A N/A 4 Oct. 2023
Additional Application Information
• Use of an air receiver tank (minimum 6 USG) is required with this application.
• 2023+Mercedes Sprinter 2.0 L Diesel, L4 OM654.
ǛVehicle should be equipped with either prep option code N62 (preferred)
or N63 (This will equip the vehicle with the Mercedes OEM dual row
pulley).
ǛVehicles equipped with single row crank pulley will need to install the
VMAC auxiliary pulley (supplied in kit).
Notice
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
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.
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”.

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Safety
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.

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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 Gas 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]
[phone]
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, and hours on the
compressor.
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.
VMAC Warranty Claim Process
VMAC Product Warranty Policies & Warranty Registration can be found on the
VMAC website (see previous page for URL).
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 “Standard” 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.

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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
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.
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.

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Special Tools and Parts Required
• Recommended: Right angle impact wrench (such as Milwaukee M12,
P/N: 2565-20).
• May be required: Pulley Counter Rotation Tool: Mercedes
P/N: 654-589-00-40-00.
• 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.
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
Apply Loctite 242 (blue) to all fasteners (except nylon lock nuts)
unless otherwise stated.

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☐ 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).
Preparing for Installation
Figure 1 — Remove step cover and mat
Step cover
fasteners
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.
When dissembling engine components, cover the openings to
prevent debris from entering the system.

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☐ Remove the driver seat.
☐ Remove the hatch from the driver side floorboard (Figure 2).
Figure 2 — Remove driver side hatch
The driver seat is heavy, use care when lifting it to prevent injury.
☐ Disconnect the battery(ies).
☐ Determine whether the vehicle is equipped with the dual row crank pulley
(Figure 3).
Figure 3 — Identify crank pulley
Single row
crank pulley
Vehicles equipped with dual row crank pulley, skip to page 11.

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Installing the Dual Row Pulley
This chapter applies only to vehicles equipped with a single row
crank pulley. If the vehicle is equipped with a dual row crank pulley,
skip to the next chapter (page 11).
☐ Remove tension from OEM FEAD belt.
☐ Using a right angle counter rotating tool, remove the crank pulley (E12 Torx) and
discard the fasteners.
Do not reuse the OEM fasteners as they are “torque to yield”.
☐ Apply Loctite 242 (blue) to (×4) supplied crank pulley fasteners.
Using the supplied fasteners and washers, install the dual row crank pulley:*
☐ *Step 1: Install (×2) fasteners and washers in the counterbored holes.
☐ *Torque the fasteners to 43 ft•lb.
☐ *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).

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☐ Using the supplied fasteners, install the main bracket onto the passenger side
of the oil pan (Figure 4, Figure 5).
Figure 4 — VMAC Main bracket mount location
Installing the Main Bracket and
Compressor
Figure 5 — VMAC main bracket installed
(idler installed in later step)
VMAC main
bracket
M8×1.25×100
M8×1.25×70

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☐ 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

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☐ Slide the pressure sensor assembly into the P-clip and mount it to the bracket
using the supplied M6 × 1.0 × 14 mm fastener (Figure 8).
Figure 8 — Install pressure switch
☐ 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

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☐ Using the supplied bolt, washer, and spacer, Install the remaining idler into the
tapped hole in the oil pan (Figure 10).
Figure 10 — Install oil pan idler
Install idler
☐ Install and tension the VMAC belt (Figure 11).
Figure 11 — VMAC belt routing

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☐ Verify the belt is properly seated on all of the pulleys.
☐ 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 12).
One rib
visible on
each side
Figure 12 — Align belt on clutch
☐ Using the supplied M8 lock nuts, secure the air filter bracket to the driver side
bumper mounting bolts (located in the void beneath the driver side headlight)
(Figure 13).
VMAC air
filter
Bumper
mounting bolts
Figure 13 — Install compressor air filter bracket
Front of
vehicle
Front of
vehicle

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☐ 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).
Figure 14 — Install remote intake hose
Air intake hose

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WHASP Tank location guidelines
• Adequate supply of fresh air and venting for the cooling fan.
• Minimum of 12 in of clearance at the front of the cooling fan.
• Minimum of 6 in clearance at the rear of the unit.
• Hose connections and wiring are accessible.
• Mounted on a level surface.
• Impact protection.
• The oil level sight glass is easily accessible.
• The oil fill and drain ports are accessible for servicing.
• Minimize the hose lengths to maximize performance.
Mounting the WHASP Tank
Refer to (Figure 15) for mounting dimensions.
Special consideration must be made to ensure the WHASP Tank will be protected
from damage and to ensure that it has adequate ventilation.
In some cases, it may be necessary to fabricate a mounting bracket to position the
tank in an appropriate location.
Secure the WHASP Tank by bolting the mounting feet to the installation surface,
use M8 or 5/16 in fasteners (not supplied).
Mounting in an Enclosure or Body
Mounting the WHASP Tank in an enclosure will limit access to cooling air or restrict
the escape of hot air from around the unit and will have an adverse effect on
cooling.
Ensure adequate ventilation is provided for the cooling system to function properly.
It is not possible to make absolute recommendations regarding ventilation because
of the widely differing configurations that are possible. Duty cycle, ambient
temperature and enclosure shape are some of the important variables that need to
be taken into account when determining the suitability of enclosure mounting.
Cool air ducted to the cooler and installing an exhaust fan to remove hot air is
recommended.
Installing the Waste Heat Air Separator
Package (WHASP) Tank
Confirm the hose lengths included in this kit when determining the
location of the WHASP Tank and bulkhead fittings. Hose lengths
can be found in the 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.
When determining a mounting location for the WHASP Tank, ensure
the following conditions are met:

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20 1/14 in
18 1/8 in
Maintain adequate
clearance for servicing
15 3/8 in
4 1/2 in
5/16 in
or M8
mounting
holes
Figure 15 — Minimum WHASP Tank mounting clearances
12 in Fan out
20 7/16 in