Vmac V300003 Installation guide

Installation Manual for VMAC

System V300003

2010 - 2015 Mercedes Sprinter

2010 - 2015 Freightliner Sprinter

3.0L Diesel

www.vmacair.com

TM

COMPACT. POWERFUL.

VMAC – Vehicle Mounted Air Compressors 
Toll Free: 1-888-241-2289 
Fax: 1-250-740-3201 
1 
Installation Manual for VMAC 
System V300003 
2010 - 2015 Mercedes Sprinter 
2010 - 2015 Freightliner Sprinter 
3.0L Diesel 
General Information.......................................................................... 3 
Before You Start ................................................................................... 3 
Torque Specifications ........................................................................... 3 
Special Tools Required ........................................................................ 3 
Hose Information .................................................................................. 3 
Important Safety Notice ................................................................... 4 
Safety Messages .................................................................................. 4 
Ordering Parts ...................................................................................... 5 
Warranty Registration ........................................................................... 5 
Part 1: System Identification, Warranty and Warnings ................. 6 
Part 2: Preparing for Installation ..................................................... 8 
Part 3: Installing the Pulley ............................................................ 11 
Part 4: Installing the Compressor ................................................. 12 
Part 5: Installing the Tank and Hoses........................................... 22 
5.1 Installing the hoses .................................................................. 22 
5.2  Installing the Tank ................................................................... 34 
5.3  Connecting the Hoses ............................................................. 37 
5.4  Remote Muffler Installation ...................................................... 40 
Part 6: Interior Panel removal ........................................................ 44 
6.1  Dash Panel Removal ............................................................... 44 
Part 7: Installing the Control Components .................................. 49 
7.1  Installing the Control Box ......................................................... 50 
7.2  Installing the Relay Harness .................................................... 54 
7.3 Connecting the Throttle Control ............................................... 56 
Part 8: Adding oil to the system .................................................... 60 
Part 9: Completing and Testing the Installation .......................... 61 
9.1  Completing and Testing the Installation .................................. 61 
9.2  Safety Test ............................................................................. 61 
9.3  Final Testing ............................................................................ 63 
Part 10: Setup, Performance Testing and Adjustments ............. 64 
10.1  Throttle Control Adjustment ................................................. 65 
Part 11: Recommended Accessory Installation .......................... 66 
Part 12: Auxiliary Air Receiver ...................................................... 67 
Part 13: Accessory Products from VMAC .................................... 68 
Part 14: Warranty Registration ...................................................... 69 
 

VMAC – Vehicle Mounted Air Compressors

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Fax: 1-250-740-3201

2

Installation Manual for VMAC System V300003

2010 - 2015 Mercedes Sprinter

2010 - 2015 Freightliner Sprinter

3.0L Diesel

Document 1930251

Changes and Revisions

Important Information

The information in this manual is intended for certified VMAC installers

who have been trained in installation procedures and for people with

mechanical trade certification who have the tools and equipment to

properly and safely perform the installation. Do not attempt this

installation if you do not have the appropriate mechanical training,

knowledge and experience.

Follow all safety precautions for mechanical work. Any grinding,

bending or restructuring operations for correct fit in modified trucks must

follow standard shop practices.

Notice

Manuals are subject to change without notice.

Registered Trademarks

All trademarks mentioned in this manual are the property of their

respective owners. Their use by VMAC is for identification of the

manufacturers’ products only and does not imply any affiliation or

endorsement by said companies.

Loctite, Klean N’ Prime, 242 and PST are registered trademarks of

Henkel AG & Company KGaA.

PTFE is a registered trademark of E. I. du Pont de Nemours and

Company or its affiliates.

Nylok is a registered trademark of Nylok Fastener Corporation.

All trademarks used in this manual are the property of the respective copyright holder.

The contents of this manual may not be reproduced in any form without the express

written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3.

Printed in Canada

Revision

Revision Details

Revised

by

Checked by

Implemented

Eng.

Tech.

Qual.

Mech.

Elec.

C

ECN 15-105

REF

KRM

N/A

BDJ

N/A

10 Nov 2015

D

ECN 16-140 – Park interlock update

MSP

N/A

AJH

GB

AMG

24 Nov. 2016

E

ECN 17-094 Improved safety testing

MSP

N/A

AJH

GB

SM

28 June 2017

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General Information

Before You Start

Read this manual before attempting installation so that you can

familiarize yourself with the components and how they fit on the vehicle.

Identify variations for different engine models and different situations that

are listed in the manual. Open the package, unpack the components and

identify them.

Torque Specifications

All fasteners must be torqued to specifications. Use manufacturers

torque values for OEM fasteners. Apply Loctite 242® or equivalent on

all engine-mounted fasteners. Torque values are with Loctite applied

unless otherwise specified.

STANDARD GRADE 8 NATIONAL COARSE THREAD

Size

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

Foot-pounds (ft-

lb)

9

18

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

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

M8

M10

M12

M14

M16

Foot-pounds (ft-lb)

19

41

69

104

174

Newton meter (N•m)

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

5900252/5900253, or Mercedes part number A1260

• Internal and external Torx® socket sets

• Trim Removal Tool (such as Harbour Freight 67021)

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 our 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.

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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 and service techniques. If a discrepancy is noted in

this manual, contact VMAC prior to initiating or proceeding with service.

Current information may clarify the issue. Any person with knowledge of

such discrepancies who performs 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 assure

that their safety and that of others is not being compromised and that

there will be no adverse effects on performance or the operational safety

of the equipment.

VMAC will not be held responsible for any liability, injuries, loss or

damage to individuals or to equipment as a result of the failure of any

person to properly adhere to the procedures set out in this manual or

standard safety practices. Safety should be your first consideration in

performing service operations. If you have any questions concerning the

procedures in this manual or require any more information on details that

are not included in this manual, please contact VMAC before beginning

repairs.

Safety Messages

This manual contains various warnings, cautions and notices that must

be observed to reduce the risk of personal injury during service or repair

and the possibility that improper service or repair may damage the

equipment or render it unsafe.

This symbol is used to call your attention to instructions

concerning your 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 alert to the possibility of personal

injury or death. Be alert; your safety is involved. While it is

impossible to warn about every conceivable hazard, let good

common sense be your guide.

This symbol is used to call your attention to instructions on a

specific procedure that if not followed may damage or reduce

the useful life of the compressor.

This symbol is used to call your attention to additional

instructions or special emphasis on a specific procedure.

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Ordering Parts

To order parts, contact your VMAC dealer. Your dealer will ask for the

VMAC serial number, part number, description and quantity. To locate

your nearest dealer, call 1-800-738-8622 or online at www.vmacair.com

Warranty Registration

The VMAC warranty form is located at the back of this manual. This

warranty form must be completed and sent to VMAC at the time of

installation for any subsequent warranty claim to be considered valid.

There are four ways warranty forms can be submitted to VMAC:

Online

http://vmacair.com/support/warranty/

Email

[email protected]

Fax

(250) 740-3202

Mail

VMAC - Vehicle Mounted Air Compressors

1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

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Part 1: System Identification,

Warranty and Warnings

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 you do not miss

any preparation steps.

□ Check through the illustrated parts list, ensure that no components

are missing, and that they are in the correct quantity. If any

components are missing, have the system ID ready and call VMAC

tech support at (888) 241-2289.

□ Complete the warranty form. The VMAC warranty form is located at

the back of this manual, as well as online at:

http://vmacair.com/support/warranty/

This warranty form must be completed and mailed or faxed to

VMAC at the time of installation for any subsequent warranty claim

to be considered valid.

The System Identification Number Plate must be attached

to the vehicle at the time of installation. This plate

provides information that allows VMAC to assist in parts

and repairs.

□ Mark and drill two 7/64-inch holes in an appropriate location, close

to the compressor. Secure the plate with supplied self- tapping

screws (Figure 1.1).

Figure 1.1 – System Identification Plate

□ Install the VMAC belt routing diagram in a suitable location

under the hood.

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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 1.2).

Figure 1.2

□ 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. Thoroughly clean the

selected area before affixing the label (Figure 1.3).

Figure 1.3

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Part 2: Preparing for Installation

□ Remove the battery terminal from the quick release post located

next to throttle pedal. Press down on the red tab and pull back

(Figure 2.1).

Figure 2.1

□ Remove the air box located in the center of the engine bay. Remove

the two electrical plugs, the hose clamp, air box elbow and pull the

front two legs straight up to release the air box. Move the assembly

out of the way (Figure 2.2).

Figure 2.2

Hose Clamp

Air box Elbow

Electrical

plug x2

Front legs

Quick

Release

Terminal

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□ Remove the fan clutch electrical plug, and use an E11 Torx socket

to remove the stator fastener (Figure 2.3).

Figure 2.3

□ The upper coolant line from the radiator can be left in place during

the installation.

□ Push in on 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 2.4).

Figure 2.4 – Shroud clip location

□ 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).

Shroud Clips

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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, carefully remove both

out 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 27mm socket and the counter rotating tool VMAC part

number 5900252/5900253, or Mercedes part number A1260 to

remove the center fastener from the crank pulley.

□ Remove the washer from the OEM crank pulley bolt.

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Part 3: Installing the Pulley

• Before installing the VMAC pulley, ensure there is

no surface rust or dirt inside the OEM pulley.

• Do not use an impact tool to tighten pulley bolt.

Use 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

□ Insert the VMAC pulley into the OEM crank pulley and rotate the

VMAC pulley counter-clockwise until the tabs seat inside the

spokes of the OEM pulley.

□ Install the OEM fastener with the supplied washer (Figure 3.1).

Remove the OEM washer from the OEM Crank Pulley

bolt. Use the supplied VMAC washer only.

□ Use the counter rotating tool VMAC part number

5900252/5900253, or Mercedes part number A1260 to stop the

pulley from rotating, and torque the main fastener to 200N.m (147

ft/lbs).

Figure 3.1 – Crank pulley installation

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Part 4: Installing the Compressor

□ Connect the straight fitting on the 3/4” x 118” discharge line to the

compressor (Figure 4.1).

□ Connect the straight fitting on the 3/8” x 118” oil line to the side of

the compressor (Figure 4.1).

Figure 4.1 – Compressor hose connections

3/8” Oil Line

3/4" Discharge Line

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□ Remove the idler and tensioner from the VMAC main bracket

(Figure 4.2).

Figure 4.2 – VMAC main bracket assembly

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□ The VMAC main bracket will bolt into five holes on the engine oil

pan, there are four holes on the side, and one hole on the front

(Figure 4.3).

Figure 4.3 – OM642 Engine

M8 X 25MM

M8 X 50MM

M8 X 55MM

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□ Apply blue Loctite® to the five supplied fasteners, and install the

VMAC main bracket onto the engine (Figure 4.4).

Figure 4.4 – Main bracket mounting fasteners

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□ Using blue Loctite®, install the idler and tensioner onto the main

bracket and torque bolts to specifications.

□ Ensure the idler spacer is installed (Figure 4.5).

Figure 4.5

M10 X 35MM

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□ Use blue Loctite® and mount the compressor onto the bracket using

the three supplied fasteners (Figure 4.6).

Figure 4.6

□ Install the supplied compressor belt (Figure 4.7).

Figure 4.7

M8 X 45MM

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□ The compressor clutch is 8 rib, install the 6 rib belt so that it is

centered on the clutch. You should see one clutch rib on each side

of the belt (Figure 4.8).

Figure 4.8

□ Remove the shipping pin in the tensioner, this will apply tension to

the belt. Ensure belt is properly seated on all pulleys.

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Vmac V300003 Installation guide

Vmac V300003 Installation guide

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