Vmac G300004 Installation, Owners And Service Manual Download Page 44

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VMAC - Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289

VMAC Knowledge Base: kb.vmacair.com

Cold Climate Kit

Part number: A500044; A520004 (factory

installed)

Cold climate heater package for operating the

G300004 in cold climates; proven at temperatures of

-30 °C (-22 °F);
(×2) 120 V AC Heaters; requires 600 W total power.

600 W Power Inverter

Part number: A500181

600 W, 12 V power inverter; required to power the

G300004 Cold Climate Kit.

Remote Control Panel

Part number: A500042

Remote control panel with a 10 ft (304.8 cm)

extension for key switch, hour meter, choke and

unloader valve.

Accessory Products from VMAC

Compressor Service Kits

200 Hour or 6 Month Service Kit -

Part number: A700219

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: A700220

Includes 4 L VMAC high performance compressor oil,

oil filter, air filter, spin-on oil separator, safety valve,

muffler, and next service due decal.

Honda Engine Service Kit

Part number: A500045

300 hour Honda engine tune-up kit includes 2 L

10W30 oil, dual element air filter and spark plug.

Using OEM service products will extend the life of

the system.

Summary of Contents for G300004

Page 1: ...www vmacair com www vmacair com Gas Engine Driven 30 CFM Air Compressor G300004 Installation Owner and Service Manual...

Page 2: ......

Page 3: ...0004 31 Starting and Stopping the Engine 32 Recommended Accessories 38 Air Receiver Tank 39 Setup Performance Testing and Adjustments 40 Engine rpm Adjustment 41 Accessory Products from VMAC 42 Genera...

Page 4: ...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...

Page 5: ...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...

Page 6: ...scribed in this service manual are effective methods of service and repair Some procedures may require the use of tools specially designed for a specific purpose Anyone using a replacement part servic...

Page 7: ...can cause death Do not start or operate this compressor in an enclosed area Always use the appropriate personal protective equipment particularly eye and hearing protection when operating air powered...

Page 8: ...se serious injury or death If equipped the air receiver tank must be drained prior to servicing the system Never adjust or attempt to make any repairs to the system while the engine is running Compone...

Page 9: ...use The compressor may operate anytime the engine is running Avoid contact with the compressor hoses or engine during operation Keep hoses and wiring away from hot sharp or moving components Use only...

Page 10: ...ther 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...

Page 11: ...ket 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 reco...

Page 12: ...mpressor 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 war...

Page 13: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 11 G300004 Installation Manual...

Page 14: ......

Page 15: ...e exhaust is routed to open air and not orientated in a way that will fill with rain The unit is protected from damage and excessive exposure to the elements The unit is away from heat sources such as...

Page 16: ...ure there is a minimum of 6 in of clearance between the engine air intake the recoil starter area and any other components mounted on the vehicle The WHASP cooler fan should have a minimum of 12 in of...

Page 17: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 15 Figure 1 Airflow diagram some frame components removed for clarity...

Page 18: ...best access to cool fresh air Maintain a minimum of 6 in between the sides of the G300004 and 1 ft in front of the WHASP cooling fan and all other solid objects Figure 2 Mounting the G300004 in an enc...

Page 19: ...ed Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 17 Figure 2 Mounting locations Not recommended Top mounted Enclosure mounted Not recommended unless mounted on...

Page 20: ...b vmacair com 18 External dimensions with the base plate Locate a suitable mounting position for the G300004 Place the unit in its intended location and check for clearances to any other objects Figur...

Page 21: ...the base plate for mounting the G300004 Figure 4 Drill 4 holes in the surface that the G300004 will be mounted to Use a minimum of 4 3 8 in or M10 fasteners Ensure washers are used in addition to loc...

Page 22: ......

Page 23: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 21 G300004 Owner s Manual...

Page 24: ......

Page 25: ...ure unload with manual override when the system is unloaded engine speed can be reduced decreasing engine noise emissions and wear and tear while increasing fuel efficiency Engine oil drain Fuel shuto...

Page 26: ...blowdown which depressurizes the system when it is shut down Compressor Discharge Valve Compressor oil drain Compressor overtemperature switch shuts down the engine Discharge valve Compressor WHASP Ta...

Page 27: ...cated inside the OEM key start enclosure 15 A fuse protects the fan s electrical system located in the wiring harness next to the starter The engine will not be able to be restarted until the system h...

Page 28: ...ocated on the frame near the oil drain extension Figure 8 An alternative method of identifying the system is via the compressor serial number which is found on a plate attached to the compressor This...

Page 29: ...The hot air oil mixture from the compressor enters the cooler at the top of the WHASP Tank where the mixture is cooled and the majority of the oil separates from the air and settles into the reservoi...

Page 30: ...e valve Use a Filter Regulator Lubricator FRL to regulate downstream pressure to the tools System Pressure Unload Internal system pressure is controlled via a mechanical unloader valve When downstream...

Page 31: ...e The system s components must all be at or above 0 C 32 F Starting the system while any of the components are below 0 C 32 F may result in excessive engine cranking while starting the engine failing...

Page 32: ...es above 40 C 104 F refer to the Honda GX390 Owner s Manual supplied with the system VMAC P N 1901066 Failure to follow the information supplied in the Honda Owner s Manual may result in poor engine p...

Page 33: ...the Honda Owner s Manual Check the engine oil level and condition See the Honda Owner s Manual Check the fuel level Do a final inspection to ensure that all fasteners and connections are tight Check...

Page 34: ...tions Once system has built to full system pressure 2 400 rpm 100 rpm Starting the engine with the key switch Starting and Stopping the Engine The G300004 is designed to operate at an elevated low idl...

Page 35: ...Actuate the unloader valve by pulling out the handle Figure 12 Figure 13 Key switch If the engine fails to start within 5 seconds release the key and wait at least 10 seconds before operating the star...

Page 36: ...s reached normal operating temperature release the tension on the unloader valve Figure 15 6 Once the engine is running gradually open the choke by moving the choke lever to the right as the engine wa...

Page 37: ...e kit is turned off 2 Close the choke by moving the choke lever all the way to the left Figure 16 4 Actuate the unloader valve by pulling out the handle Figure 17 The G300004 is designed to operate at...

Page 38: ...unloader valve to allow the system to build to full system pressure Unloader valve 6 Once the engine is running gradually open the choke by moving the choke lever to the right as the engine warms up F...

Page 39: ...ressor air filter Ensure the fuel shut off valve is closed all the way to the left when the unit is not being run or before moving to a different site Failure to do this may allow fuel to overfill the...

Page 40: ...rtant 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 com...

Page 41: ...when it is shut down The WHASP Tank has a built in check valve which prevents the compressed air and any moisture in receiver tank from traveling back into the WHASP Tank Installation of an additional...

Page 42: ...e system outlet with the 30 cfm 1 8 in orifice Ensure that the ball valve on the test tool is closed Start the compressor system and allow the engine to run until it is at operating temperature Ensure...

Page 43: ...zed engine rpm adjustment will not be covered under warranty Lowering the engine rpm will decrease the cfm output and will cause the engine to stall while increasing the engine rpm may damage the engi...

Page 44: ...rol panel with a 10 ft 304 8 cm extension for key switch hour meter choke and unloader valve Accessory Products from VMAC Compressor Service Kits 200 Hour or 6 Month Service Kit Part number A700219 In...

Page 45: ...owering compressor duty cycle and removing water from compressed air Recommended for optimum operation of VMAC Hydraulic Air Compressors VMAC Diesel Driven Air Compressors UNDERHOOD40 UNDERHOOD70 incl...

Page 46: ...ap Part number A700136 Heavy duty compressor air filter for moderate dust environments Heavy Duty Air Filter w Pre cyclonic Filter Part number A700138 Heavy duty compressor air filter for moderate and...

Page 47: ...aspect of maintenance is proper air filtration and clean oil If any particles enter the compressor they can score the rotors and contaminate the roller bearings in the compressor Any contamination wil...

Page 48: ...ues are with Loctite applied unless otherwise specified Apply Loctite 242 blue to all fasteners except nylon lock nuts unless otherwise stated Table 1 Torque Table Standard Grade 8 National Coarse Thr...

Page 49: ...the possibility of explosion This information is intended for people with mechanical trade certification who have the tools and equipment to properly and safely perform the service or repair Do not a...

Page 50: ...up on the ring on the pressure relief valve to confirm the system is depressurized Figure 24 Do not use the pressure relief valve as a means of depressurizing the compressor system Doing so will prem...

Page 51: ...AC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 49 Disconnect the spark plug wire Figure 26 Disconnect spark plug wire Figure 26 Spark plug wi...

Page 52: ...nge compressor oil filter Change compressor air filter Inspect pressure relief valve Components Part Number Interval Extreme Conditions Air filter 3600037 200 hours 6 months 100 hours Compressor oil 4...

Page 53: ...ght glass and ensure that it is between the MAX arrow and the ADD arrow If the level is below the ADD arrow Remove the fill cap on the tank above the sight glass Using a funnel pour oil into the fill...

Page 54: ...l occurs first Visually inspect the blowdown muffler for evidence of corrosion or loss of functionality Ensure the muffler allows the blowdown to pressurize the system To test the blowdown system and...

Page 55: ...ect the valve and ensure it is not corroded and that the vent holes are not plugged Turn the system on and allow it reach full system pressure factory setting 140 psi Ensure that air does not leak out...

Page 56: ...tainer knob the air filter cover and the air filter element Immediately cover the compressor opening with tape or with a clean cloth to prevent contamination Do not use compressed air or perform any o...

Page 57: ...ponents show cracks chipping impact damage or any other indications of physical damage replace the component If the damage indicates possible misalignment check the pulley alignment If the pulleys are...

Page 58: ...ard air brake hose is not a suitable replacement PTFE tubing should only be cut using proper tubing cutters Side cutters utility knives etc will deform the tube preventing a proper seal or leave sharp...

Page 59: ...nates to enter the compressor system Always replace the air filter element during this service Do not overfill the system Overfilling the system with oil can flood the sight glass window and make the...

Page 60: ...nipple thoroughly clean the threads and apply Loctite 242 blue to the end with the short threads and replace it in the AOST Figure 34 Clean the gasket sealing surface on the front of the tank and ins...

Page 61: ...inates to enter the compressor system Always replace the air filter element during this service Do not overfill the system Overfilling the system with oil can flood the sight glass window and make the...

Page 62: ...s To reinstall the nipple thoroughly clean the threads and apply Loctite 242 blue to the end with the short threads and replace it in the AOST Figure 36 Clean the gasket sealing surface on the front o...

Page 63: ...level is correct Reinstall the fill cap Clean the WHASP Tank around the coalescing filter to prevent contamination Remove the spin on coalescing filter by turning it counterclockwise Figure 38 Remove...

Page 64: ...lescing filter Spin the new filter onto the threaded nipple until the gasket contacts the sealing surface on the tank then tighten the filter an additional 3 4 to 1 turn to seat the gasket Start the e...

Page 65: ...lied with the system VMAC P N 1901066 Failure to follow the instructions in the Honda Owner s Manual could result in poor engine performance engine damage and may void the Honda engine warranty For al...

Page 66: ...am customer supplied equipment If the G300004 is still within the warranty period contact VMAC prior to commencing any diagnostics or repairs Problem diagnosis should follow sound recognized practices...

Page 67: ...ivated Manually disengage unloader valve Excessive leakage through blowdown muffler Replace blowdown shuttle valve Plugged or dirty compressor air filter Replace air filter Drive belt slipping Check b...

Page 68: ...tom Possible Cause Corrective Action Compressor overheat Low compressor oil level Check oil level with equipment on level ground Wrong compressor oil used Flush and replace with VMAC approved compress...

Page 69: ...charge valve Throttle actuator failure Replace actuator Symptom Possible Cause Corrective Action Engine overheat High ambient temperatures Reduce duty cycle Low engine oil level Check engine oil level...

Page 70: ...g gap Replace spark plug Engine air intake restricted Remove restriction replace air filter Engine exhaust system plugged or restricted Clean or replace exhaust spark arrester Fuel bowl filter plugged...

Page 71: ...red Figure 39 For testing and diagnosis install the 30 cfm 1 8 in orifice Figure 39 A700052 VMAC Air Test Tool Install orifice here Orifice Ball valve JIC Adapters PTFE Test Tool A PTFE test tool can...

Page 72: ...mum of 3 minutes or until the WHASP Tank fan turns on as all adjustments must be made while the system at operating temperature System Adjustments The G300004 is tuned at the factory for optimum perfo...

Page 73: ...ate removed for clarity Connect the VMAC Air Test Tool P N A700052 to the discharge fitting of the WHASP Tank or receiver tank With the ball valve on the test tool closed run the system and note the m...

Page 74: ...145 psi See page 70 The following steps require working on the system while it is at normal operating temperature special care must be taken to prevent injury from burns as the surfaces of the unit a...

Page 75: ...system and repeat the steps above if necessary until the system unloads at 140 psi Pressure Adjustment Screw Pressure Adjustment Locknut While securely holding the Pressure Adjustment Screw loosen th...

Page 76: ...re to the throttle actuator and the discharge valve blue arrows Once air pressure at the ball valve and unloader valve downstream pressure reaches 140 psi the throttle actuator closes the throttle red...

Page 77: ...2289 VMAC Knowledge Base kb vmacair com 75 Figure 46 Throttle operation Steady system pressure to inlet regulator 0 140 psi downstream pressure System pressure once discharge valve diaphragm opens at...

Page 78: ...48 Throttle actuator tube Throttle actuator Unloader valve Discharge valve Unloader valve Scavenge Tube A 1 4 in PTFE tube shown in navy blue connects the WHASP Tank to the compressor inlet valve Vac...

Page 79: ...Figure 50 Figure 50 1 4 in Pressure control tube 1 4 in PTFE pressure control tube Discharge valve 1 4 in compressor fitting and air bleed muffler A 3 16 in PTFE tube shown in green connects the disch...

Page 80: ...cate 0 psi and the throttle will be wide open Once downstream pressure reaches 140 psi it will actuate the unloader valve which opens the discharge valve The PTFE test tool gauge will indicate 140 psi...

Page 81: ...d the engine rpm should decrease If the throttle actuator rod does not move diagnose or replace the throttle actuator 3 When the system pressure indicated on the VMAC test tool reaches 140 psi the pre...

Page 82: ...rize and may cause a compressor oil leak When the inlet valve poppet is closed the compressor will not build air pressure Figure 55 Air pressure generated by the compressor is controlled mechanically...

Page 83: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 81 Figure 56 VMAC electrical harness schematic Electrical Components and Testing...

Page 84: ...er amperage fuse may damage components and will void the warranty Figure 57 WHASP Tank cooling fan A 15 A fuse protects the G300004 s fan electrical system The fuse holder is located in the wiring har...

Page 85: ...tch should drop to 0 Compressor Temperature Switch If the compressor s oil temperature exceeds 140 C 284 F the thermostatic switch located in the compressor discharge cap will disable the engine ignit...

Page 86: ...precautions and industry standard best practices Read the Maintenance and Repair Safety section prior to performing any work on the system beginning on page 47 Wear appropriate Personal Protective Equ...

Page 87: ...888 241 2289 VMAC Knowledge Base kb vmacair com 85 Tilt the battery up and slide a back a few inches Figure 61 Figure 61 Remove battery Rotate the battery and pull it out of the frame Figure 62 Instal...

Page 88: ...d remove the belt guard Figure 63 Figure 63 Inspecting the drive belt Remove fasteners 4 Using a 3 8 in drive remove tension from the drive belt Remove the belt and set it aside for later Disconnect t...

Page 89: ...the bolt from the side of the compressor Figure 64 Remove the 4 bolts securing the compressor to the belt guard Figure 65 Figure 64 Remove compressor Remove compressor mounting bolt Figure 65 Remove c...

Page 90: ...1 2289 VMAC Knowledge Base kb vmacair com 88 Pull the compressor out from the side of the unit to remove it Figure 66 Figure 66 Remove compressor Install the compressor in the reverse order Do not rem...

Page 91: ...ts are 55 mm long and the shorter ones are 50 mm long Ensure the bolts are installed in the correct position Installing the inlet bolts in the wrong location could severely damage the compressor Figur...

Page 92: ...ear appropriate Personal Protective Equipment and follow all industry standard safety practices Fan Switch Replacement Figure 68 Disconnect the temperature switch from the harness Remove the temperatu...

Page 93: ...t the temperature switch from the harness Remove the temperature switch from the compressor discharge cap Apply Loctite 567 thread sealant to the new temperature switch and install it into the WHASP T...

Page 94: ...ces Drain the compressor oil from WHASP Tank Remove the coalescing filter from the WHASP Tank Remove the air filter from the compressor Disconnect the 3 4 in and 1 2 in hoses from the WHASP Tank Disco...

Page 95: ...rt 888 241 2289 VMAC Knowledge Base kb vmacair com 93 Shift the WHASP Tank forward and rotate the rear of the tank out of the frame Figure 72 Figure 72 Remove instruction plate Pull the WHASP Tank out...

Page 96: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 94 G300004 Illustrated Parts List IPL...

Page 97: ......

Page 98: ...10 1 1201106 MOUNT HOUR METER 11 2 1520629 BOLT HHCS GR10 9 PL FL M10 X 1 5 X 16 12 1 3501094 BATTERY GROUP 51 13 1 4800832 ASSEMBLY UNLOADER 14 1 3200587 POST IDLER 15 6 1560512 NUT FLANGE PL M10 X 1...

Page 99: ...X 1 43 1 1510049 BOLT HHCS NC G5 FL LK PL 3 8 X3 4 44 1 4800782 ASSEMBLY THROTTLE PNEUMATIC 45 1 1570484 WASHER FLAT SS M5 46 1 1500729 SCREW PH PHILLIPS M5 X 16 NYLO 47 1 1570488 WASHER NYLON 3 16 4...

Page 100: ...IGH TEMP 73 10 5 1700581 LOOM SPLIT PLASTIC 1 4 HIGH TEMP 74 9 1700581 LOOM SPLIT PLASTIC 1 4 HIGH TEMP 75 12 1700581 LOOM SPLIT PLASTIC 1 4 HIGH TEMP 76 19 1700581 LOOM SPLIT PLASTIC 1 4 HIGH TEMP 77...

Page 101: ...28 27 7 56 12 30 33 4X 32 4X 31 2X 55 57 15 14 6 16 17 4 19 16 29 11 2X 8 5 52 53 2X 13 43 28 27 26 18 24 20 54 23 2 44 1 51 36 2X 38 2X 37 2X 10 34 4X 50 2X 32 2X 42 4X 40 3X 61 2X 15 5X 9 45 55 67 6...

Page 102: ...540530 BOLT SHCS M8 X 1 25 X 55 G12 9 PLT 5 2 1540550 BOLT SHCS M8 X 1 25 X 50 G12 9 PLT 6 1 5000090 ELBOW BRASS EXTR D 90 STREET 1 8 7 1 5000121 TEE STREET EXTRUDED 1 8 8 1 3600185 ASSEMBLY MUFFLER R...

Page 103: ...SSORY PACK REGULATOR ASSEMBLY 2 1 4900045 PLUG 8ORB INTERNAL HEX 3 1 5830002 O RING VITON 2 3 8 ID X 3 32 4 1 5830130 O RING VITON 1 5 16 ID X 3 16 5 1 A700049 OVAL FILTER CAP KIT 5 1 1 3600066 COVER...

Page 104: ...10 2X DETAIL D BELT GUARD CLIP NUT DETAIL 10 ITEM QTY PART DESCRIPTION 1 34 1520591 BOLT HHCS M8 1 25 X 25 G10 9 FL PL 2 32 1560515 NUT M8 X 1 25 FL PL 3 1 1201100 PLATE ENGINE 4 1 1201102 MOUNT PLAT...

Page 105: ...1 4900175 FTG STR 6MJIC 8MORB VITON 10 1 4900117 FTG 90 6FJIC 6MJIC 11 1 3550958 FAN PULLER 7 5 GT280 12 4 1520590 BOLT HHCS M6X1 0X14 FL PL 13 1 4900128 FTG STR 12MORB 12MJIC VITON 14 1 1200852 PLATE...

Page 106: ...ted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 104 Figure 77 WHASP Tank 13 1 16 17 11 12 4X 2 3 15 2X 14 10 9 4 5 6 7 23 21 8 24 20 19 21 18 25 22 26 Item 3...

Page 107: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 105 Notes...

Page 108: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 106 Notes...

Page 109: ...VMAC Vehicle Mounted Air Compressors VMAC Technical Support 888 241 2289 VMAC Knowledge Base kb vmacair com 107 Notes...

Page 110: ...not received 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...

Page 111: ......

Page 112: ...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...

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