Vmac UNDERHOOD 40 Series, Installation Manual

Page 1: ...www vmacair com Installation Manual for VMAC System V400013 2019 Mercedes Sprinter 2019 Freightliner Sprinter 3 0 L Diesel ...

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Page 3: ...alling 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 49 Recommended Accessories 50 Completing the Installation 51 Testing the Installation 52 Performance Testing 55 Digital Throttl...

Page 4: ...st 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 ...

Page 5: ...ure 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 c...

Page 6: ...ducts 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 s...

Page 7: ...ours 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 Us...

Page 8: ...he 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 t...

Page 9: ... 6 25 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 manufac...

Page 10: ...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 V...

Page 11: ... 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 ...

Page 12: ...ox elbow Front mounts Electrical plugs Hose clamp Figure 4 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 Disconnect the fan clutch plug and remove the stator fastener using an E11 Torx socket Figure 5 Disconnect fa...

Page 13: ...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 t...

Page 14: ...sher 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 7 Remove and discard the OEM washer ...

Page 15: ...Figure 8 Figure 8 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 9 M8 1 25 25 mm M8 1 25 50 mm M8 1 25 55 mm Figure 9 VMAC Main bracket mount location Apply Loctite 242 blue to all engine mounted fasteners Installing the Compressor ...

Page 16: ...teners and install the VMAC main bracket onto the engine Figure 10 Figure 10 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 11 Figure 11 Install idler idler spacer and tensioner Idler spacer ...

Page 17: ...9 VMAC Knowledge Base kb vmacair com 15 Apply Loctite 242 blue and mount the compressor onto the bracket using the 3 supplied fasteners Figure 12 Install the VMAC compressor belt Figure 13 Figure 13 VMAC belt routing Figure 12 Mount compressor M8 1 25 100 mm M8 1 25 35 mm ...

Page 18: ...on each side of the belt Figure 14 Remove the shipping pin in the tensioner to tension to the belt Verify the belt is properly seated on all of the pulleys Figure 14 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 15 Do not over tighten the debris shield fasteners Figure 15 Install compres...

Page 19: ...ompressor Figure 16 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 17 Figure 16 Install compressor air filter bracket Cab air filter box VMAC air filter bracket VMAC air filter bracket fasteners Compressor air intake hose VMAC ...

Page 20: ...888 241 2289 VMAC Knowledge Base kb vmacair com 18 Reconnect the stator to the engine Figure 17 Reinstall the air box including the related hoses and electrical connectors Figure 18 Air box elbow Front mounts Electrical plugs Hose clamp Figure 18 Remove air box ...

Page 21: ...e 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 proper...

Page 22: ...ical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 20 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 19 Minimum WHASP Tank mounting clearances 12 in Fan out 20 7 16 in ...

Page 23: ...te air flow and so that the fan is blowing out toward the cargo door During operation the door should be kept open to ensure there is a constant supply of cool air to prevent the system from overheating Figure 20 Figure 20 WHASP ventilation Front of vehicle Provide adequate space for inspection and service Front of vehicle Figure 21 WHASP ventilation Provide a minimum of 6 in of clearance for air ...

Page 24: ...of the vehicle 1 bulkhead fitting is used to locate the blowdown muffler outside of the vehicle This kit includes hoses of a fixed length to run from the compressor to the bulkhead fittings and from the fittings to the WHASP Tank 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 ...

Page 25: ...khead fittings and from the bulkhead fittings to the WHASP Tank Also ensure that there are no wires hoses or other components on the other side of the panel that may be damaged when drilling holes For best fit ensure the bulkhead fittings are centered on the top of the structural ribs From the chassis member mark a location 5 in from the front of the vehicle Figure 23 and 4 in from the driver side...

Page 26: ...lkhead fitting holes using a drill step drill or hole saw Leave enough room between the fittings to allow access for a wrench Figure 25 Figure 26 Figure 27 Discharge from the compressor ø1 1 8 in Oil return ø9 16 in Oil scavenge ø5 8 in Remote blowdown ø5 8 in Figure 25 Bulkhead fitting location ø1 1 16 in ø5 8 in ø9 16 in ...

Page 27: ...macair com 25 Fit the bulkhead fittings through the top of the hole and secure from the bottom with the supplied nuts Apply Loctite 567 thread sealant when installing the 1 4 in push to connect fittings in the bulkhead fittings Figure 26 and Figure 27 Figure 27 Exterior View Figure 26 Interior view ...

Page 28: ...used VMAC recommends shortening these hoses as a preferred alternative to coiling up and securing the excess Shorter hose length will maximize system performance Avoid using 90 fittings wherever possible as they cause flow restrictions and negatively impact performance The following hoses are included with this compressor kit From the compressor to the bulkhead fittings 3 4 in 118 in 3 8 in 118 in...

Page 29: ...ontaminants do not get in the line Take care when routing hoses as a hose failure may damage the compressor and or cause injury Ensure there is sufficient slack in the hose routing to allow for normal engine movement PTFE Tubing Loom and Push To Connect Fittings PTFE tubing should only be cut using proper tubing cutters Side cutters utility knives etc will deform the tube preventing a proper seal ...

Page 30: ...an Figure 34 Connect the 90 fitting on the 3 8 in 30 in hose to the 6 JIC fitting oil return fitting beneath the oil filter on the tank Figure 34 Connect the 1 4 in PTFE tube to the 1 4 in push to connect oil scavenge fitting near the coalescing filter Figure 29 Connect the discharge fitting 8 male JIC to the customer s air system hose not supplied Secure all hoses tubes and wires with P clips and...

Page 31: ...utside of the vehicle Remove the blowdown muffler from the side of the WHASP Tank below the coalescing filter Figure 30 Ensure no debris enters the WHASP Tank manifold Contamination of the assembly may cause erratic performance Separate the PTFE tube from the fittings Apply the supplied 1 4 in split loom to the 1 4 in PTFE tube Apply Loctite 567 thread sealing compound to the 1 4 in push to connec...

Page 32: ...FE tube to the bulkhead fitting ensuring the tube will not kink and cut the hose to length Install the tube into the push to connect bulkhead fitting Figure 33 Secure the tube with the supplied cable ties Ensure the tube is cut square and that there are no sharp edges Do not use side cutters as this will deform the hose Figure 33 Tubing Installation Remote Blowdown Muffler assembly Figure 32 Tubin...

Page 33: ...e 35 Install P clip mount Connect the Exterior Hoses Apply loom not supplied to the 3 4 in 118 in and 3 8 in 118 in hoses as well as the 1 4 in 140 in PTFE tube Connect the 1 4 in 140 in PTFE tube to the 90 push to connect fitting on the compressor Ensure the tube fully seats in the fitting Connect the 3 4 in 118 in and 3 8 in 118 in hoses to the compressor Route the 3 4 in 118 in and 3 8 in 118 i...

Page 34: ...ing to allow for normal engine movement Route all 3 hoses through the P clip then position the hoses towards the rear of the vehicle Figure 36 Remove the lower OEM bolt from the shift bracket mounted on the driver side of the bell housing Figure 37 Spacer M8 1 25 100 mm bolt P clip Nut Figure 36 Install P clip mount Figure 37 Remove shift linkage bolt OEM bolt ...

Page 35: ...owledge Base kb vmacair com 33 Route the hoses toward vehicle s battery box and install the supplied P clip using the OEM bolt Figure 38 Figure 38 Install P clip Remove and discard the OEM M6 bolt on the rear of battery box Figure 39 OEM bolt location Figure 39 Remove battery bolt ...

Page 36: ...ied M6 1 0 16 mm fastener Locate the M6 OEM stud on the driver side of the underbody approximately 8 inches in front of the fuel filler Figure 40 Route the PTFE tube and 2 hoses through the P clip and secure the P clip using the M6 nut Feed the PTFE tube and hoses through the lower portion of the OEM aluminum shield around the fuel filler Figure 41 Figure 41 Hose routing Aluminum shield OEM stud l...

Page 37: ...heet metal Drill a 1 4 in hole in the rear lip of the fuel filler bodywork in the location shown Figure 42 Secure the hose bundle using the supplied P clip M6 1 0 16 mm bolt and nut 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 Figure 42 Install P clip Drilled hole ...

Page 38: ... with oil can flood the sight glass window and make the system appear empty Remove the fill cap on the WHASP Tank above the sight glass Figure 43 Using a funnel pour oil into the tank until the oil level in the sight glass reaches the MAX line The system capacity is 4 L Figure 43 Reinstall the fill cap and tighten it securely Ensure the fill port remains accessible as it will be necessary to check...

Page 39: ...wledge Base kb vmacair com 37 Remove the driver side step cover and floor mat Figure 44 Remove the driver side lower dashboard panels Figure 45 Figure 44 Remove step cover and mat Step cover fasteners Figure 45 Remove lower dashboard panels Dashboard fasteners Interior Panel Removal ...

Page 40: ...ve the driver seat Remove the hatch from the driver side floorboard Figure 46 Figure 46 Remove driver side hatch 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 The driver seat is heavy use care when lifting it to prevent injury ...

Page 41: ...uding the park brake mechanism steering column and pedals Before drilling any holes ensure there are no OEM wires hoses or components that may be damaged 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 To ensure a durabl...

Page 42: ... from rain snow mud direct sunlight etc e g inside the cab service body or cabinet Keep the rear of the Interface Panel protected Ensure the control module and throttle control are mounted away from the pedals park brake mechanism or where they could be inadvertently knocked by occupants Control Components Overview Figure 47 General component overview Actual installation locations may vary Compres...

Page 43: ... Control WHASP Tank Control Interface etc Power 12 V switched and WHASP fan Clutch Throttle Control and Interface Panel WHASP pressure switch Compressor temperature sensor Figure 48 Control Module Interface Panel Figure 49 The Interface Panel serves as the operator s control panel and contains the ON OFF switch compressor status light and the compressor hour meter Figure 49 Interface Panel ON OFF ...

Page 44: ...Control Mechanical pressure switch Figure 51 WHASP Tank pressure switch Throttle Control Figure 50 The throttle control responds to signals from the control module and commands the vehicle s throttle to increase or decrease engine speed in response to air demand The throttle control also allows the operator to configure the vehicle s engine speed when air is demanded to their needs maximum cfm spe...

Page 45: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 43 Figure 52 Electrical schematic 1 ...

Page 46: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 44 Figure 53 Electrical schematic 2 ...

Page 47: ... wires populating pins 6 and 14 are a twisted pair violet with white stripe and violet wires Locate the violet wire with white stripe connected to pin 6 of the OBD II port Figure 54 Figure 54 OBD II connector Cut the violet wire with white stripe approximately 2 in from the back of the OBD II connector Strip approximately 3 8 in from the end of both wires Twist the light blue wire from the throttl...

Page 48: ...Control over to the center console and down to the battery hatch Splice the black wire from the Throttle Control to the brown wire with green strip wire running to the park brake Figure 55 Control Module Plug the 4 harnesses into the Control Module Mount the Control Module under the dashboard up and out of the way of the pedals steering column and the park brake mechanism Locate the 3 terminal stu...

Page 49: ...h in the bulkhead to the cargo bay Figure 58 Figure 57 Tying into vehicle power Key switched 12 V Constant 12 V supply Figure 58 Bulkhead passthrough Passthrough Driver seat bracket If the interface panel will be mounted in the cargo bay route its harness through the bulkhead passthrough Route the following wires from the Throttle Control and Control Module through the grommet in the floor beneath...

Page 50: ...he pressure switch on the WHASP Tank not polarity dependent Figure 60 Ensure all wires and harnesses are protected with loom and routed away from sharp hot or moving components and away from high traffic areas The WHASP Tank harnesses are made to a generic length Any excess harness should be coiled up and secured out of the way There are 2 extra ring terminals included with the pressure switch har...

Page 51: ...pressor system will automatically depressurize when it is shutdown The WHASP Tank has a built in check valve which prevents blow back and moisture from the receiver tank entering the WHASP Tank Installation of an additional check valve will cause erratic performance While the air receiver tank can be installed at any height in relation to the WHASP the discharge hose running from the WHASP must be...

Page 52: ...wering the duty cycle of the compressor system This application requires a minimum air receiver tank size of 6 USG Pressure Gauge While not critical to system performance a pressure gauge is important for fine tuning the system and simplifies any potential troubleshooting Install a 200 psi pressure gauge downstream of the air discharge valve Pressure Regulator and or Lubricator or FRL The compress...

Page 53: ...n of the vehicle Secure all wiring with rubber coated P clips cable ties and loom as required Check all VMAC and OEM hoses and tubes to ensure that they will not contact any hot sharp or moving components and will not interfere with the operation of the vehicle Secure all hoses and tubes with rubber coated P clips cable ties and loom as required Replace all dashboard panels Replace the driver seat...

Page 54: ...f the compressor outlets are closed Ensure the parking brake is engaged and the transmission is in PARK Start the engine After Starting the Engine Checklist Allow the vehicle to reach operating temperature Turn on the compressor The compressor clutch should engage and the engine speed should increase in response to the throttle control The vehicle s tachometer should indicate approximately 2 200 r...

Page 55: ...l will turn off Close the ball valve Turn off the compressor Reapply the park brake 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 Start the engine Assistance may be required for the next steps Ensure any stored air is drained from the syst...

Page 56: ...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 Road test the vehicle for approximately 20 km 14 miles Observe the compressor while it is operating to ensure the belts rotate properly pulleys rotate smoothly and nothing is rubbing or contacting hot pa...

Page 57: ... with the 40 cfm 5 32 in orifice Ensure the ball valve is closed Place the transmission in PARK and fully apply the park brake Allow the engine to run until it is at operating temperature Turn on the air compressor system and allow it to operate until the oil is warm Observe the pressure gauge Pressure should be approximately 150 psi Open the ball valve on the test tool and observe the engine tach...

Page 58: ...aged If an unsafe condition is detected the STATUS LED will turn off and engine speed will return to idle Once all unsafe conditions have been removed the system must be cycled off then on again to reset it Once the system powers up the STATUS LED will illuminate and the system will operate normally Figure 63 Throttle control If the vehicle is placed into gear or the park brake disengaged the STAT...

Page 59: ...on inside the throttle control box Using a paper clip or similar object push and hold the factory reset button for 5 seconds All of the LED lights will illuminate for several seconds while the settings revert to their defaults Once the LED s return to their normal state the system is ready for use again Figure 64 In order to perform a factory reset or adjust the MAX RPM the throttle needs to be ac...

Page 60: ... body panels 3 4 in JIC bulkhead fitting P N 4900170 3 8 in JIC bulkhead fitting P N 4900209 1 8 in NPT bulkhead fitting P N 5000178 2 45 1 4 push to connect fittings P N 5000158 Hose Fittings 45 1 4 push to connect fitting P N 5000158 1 4 in push to connect fitting For PTFE scavenge tube 90 1 4 push to connect fitting P N 5000020 1 4 in push to connect fitting For PTFE scavenge tube Straight 1 4 ...

Page 61: ... 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 Max pressure up to 150 psi Dimensions 32 in 81 3 cm L 8 in 20 3 cm D Weight 23 lb 10 4 kg 10 Gallon Air Receiver T...

Page 62: ...n reduce air pressure going to tools lubricator adds atomized tool oil to the air stream to lubricate air tools Tool oil not included Max air flow up to 70 cfm 150 psi Port size 3 4 in NPT inlet and outlet 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 Remote...

Page 63: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 61 Notes ...

Page 64: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 62 Notes ...

Page 65: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 63 Notes ...

Page 66: ... by VMAC within 3 months of receiving the vehicle or 200 hours of operation whichever occurs first VMAC s Warranty policy and registration can be viewed online at www vmacair com warranty Warranty Registration Owner End User Information Company Name City State Province Phone Email Address Date vehicle was put into service Day Month Year Submitted by Name Phone Email Vehicle Information Optional Un...

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Page 68: ...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 Manufactured by ...