installation manual for vmac accessory manual for vmac accessory ... a production release msp jkr...

Installation Manual for VMAC Accessory

A500187

Remote Control Panel for G300002

Installation Manual for VMAC A500187 Remote Control Panel

Safety ................................................................................................. 3

Safety Precautions ............................................................................ 4

General Information .......................................................................... 5

Installation ......................................................................................... 6

Operation ........................................................................................... 18

VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289

Fax: 1-250-740-3201 2

Document: 1901054 Changes and Revisions

Additional Application Information A500187: Remote Control Panel for G300002

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 to, or endorsement of said companies.

Loctite®, Loctite® 242 and are registered trademarks of Henkel AG & Company KGaA.

Ford® is registered trademark of Ford Motor Company.

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 vehicles must follow standard shop practices.

Notice Copyright © 2017 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. You may print or copy for your personal use any whole page or pages in this document. 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

Revision Revision Details Revised

by

Checked by

Implemented Eng. Tech. Qual.

Mech. Elec.

A Production Release MSP JKR AJH GB AMG 19 Jan 2017

VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201

3

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 and service techniques. If a discrepancy is noted in this manual, contact VMAC prior to initiating or proceeding with installation, service or repair. 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, consequential damages, 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 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 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. As 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 or other equipment.

This symbol is used to call your attention to additional instructions or special emphasis on a specific procedure.


Fax: 1-250-740-3201 4

Safety Precautions

Moving Parts Hazard Before performing service, disconnect the battery

and disconnect the spark plug wire to prevent unexpected engine start.

Do not operate the compressor without guards in place. If the guards are damaged or missing, replace them before operating the equipment.

Burn Hazard The engine, exhaust and the compressor system

get very hot during operation, contact with the components or the oil can cause serious injury. Allow sufficient time for the system to cool before performing service.

Never allow any part of your body to contact the engine or compressor components.

Personal Safety Do not breathe the compressor air. Vaporized oil is

a respiratory hazard.

Do not breathe engine exhaust, gasoline engines produce carbon monoxide, a poisonous odorless gas which 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 equipment.

Lead Acid Battery Hazard Working near Lead-acid batteries is dangerous. Batteries may generate sulphuric acid and explosive gasses during regular operation. Lead-acid batteries may explode if exposed to a spark.

Follow all safety precautions when jump starting or charging a battery.

Never attempt to jump-start a frozen battery.

Never over-charge a battery.


5

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 (blue) 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 M6 M8 M10 M12 M14 M16

Foot-pounds (ft•lb) 4.5 19 41 69 104 174

Newton meter (N•m) 6 25 55 93 141 236

Table 1 – Torque Table

Special Tools Required None

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 1-877-912-6605 or online at www.vmacair.com.

http://www.vmacair.com/


Fax: 1-250-740-3201 6

Installation

Disconnect the negative battery cable (Figure 1).

Figure 1 – Battery hold down

Disconnect the spark plug wire (Figure 2).

Figure 2 – Spark plug wire

The remote control panel is weather resistant, not weather proof. Mount the control panel inside of a cabinet or cover to protect it from the elements.

The choke cable cannot operate if it is bent at too extreme of an angle.

Negative battery cable

Retaining strap

Spark plug wire


7

Locate a suitable mounting position for the A500187 Remote Control Panel with considerations for weather protection, wire length and routing (Figure 3) (Figure 4) (Figure 5).

Figure 3 – Panel, front dimensions

Figure 4 – Panel, top dimensions

Figure 5 – Wire & choke cable length

11 1/2 in

10 1/2 in

3 1/2 in

4 1/2 in

2 3/8 in

3

3 in 1 in

130 in

132 in

132 in

120 in


Fax: 1-250-740-3201 8

Remove the air filter and filter cover, cover the intake opening with a clean cloth or tape (Figure 6).

Figure 6 – Air filter cover

Use a 10 mm socket and 10 mm wrench to remove the P-clip bolt and nut. Expand the P-clip and retain for installation onto the new choke cable (Figure 7).

Figure 7 – Choke cable & fasteners

Undo latches

Remove cover

Cable hold

Locking block

P-clip bolt


9

Use a Phillips screwdriver to loosen the cable hold screw (Figure 8).

Figure 8 – Remote choke connections

Use a Phillips screwdriver to loosen the choke actuating rod locking block screw (Figure 9).

Figure 9 – Remote choke connections

Slide the old choke actuating cable rod from the locking block, and pull the cable through the hold down. Leave the cable loose, it will be secured later.

Cable hold

Actuating rod

Locking block

screw


Fax: 1-250-740-3201 10

Ensure the choke is pushed in before installing the choke cable

(Figure 10).

Figure 10 – Choke pushed in

Slide the new throttle cable assembly through the cable hold down, while sliding the actuating rod through the locking block (Figure 11).

Figure 11 – Choke cable installation

Cable hold Locking block

Actuating rod


11

Position the new cable so that 4 ribs on the sheathing are protruding from the cable hold. Do not tighten the locking screw. (Figure 12).

Figure 12 – Choke cable sheathing

Tighten the locking block screw (Figure 13).

Figure 13 – Actuating rod lock screw

Tighten the cable hold screw (Figure 14).

Figure 14 – Choke cable hold screw

4 ribs

Cable hold

screw

Locking block

screw

Cable hold


Fax: 1-250-740-3201 12

Use a pair of side cutters to cut the excess actuating rod length off near the locking block (Figure 15).

Figure 15 – Choke actuating rod

Route the old choke cable down along the 1/4 in loom and secure with 2 cable ties (not supplied) (Figure 16).

Apply Loctite 242 (blue) and install the P-clip, bolt and nut onto the new choke cable (Figure 16).

Figure 16 – Securing the choke cables

Throttle Control

(May be different than shown)

Locking block

Actuating rod

P-clip

Cable ties


13

Locate and disconnect the white, 6 wire electrical connector (above the relay, to the left of the battery) (Figure 17).

Figure 17 – Electrical connector

The remote control box will plug into the female connector (Figure 18).

Figure 18 – G30 female connector

Electrical connector

Female connector


Fax: 1-250-740-3201 14

Connect the male connector from the remote control panel into the female connector on the G30 (Figure 19).

Figure 19 – Remote electrical connector

Secure all wiring and cables with cable ties.

Reinstall the engine air filter and filter cover.

Reconnect the spark plug wire.

Locate the unloader valve on the outboard side of the WHASP tank (Figure 20).

Figure 20 – Unloader valve

Bracket fasteners

Unloader valve


15

Remove the 2 bolts and the bracket supporting the unloader valve.

Disconnect the PTFE tube running from the unloader valve to the tee at the base of the WHASP tank, near the battery (Figure 21).

Figure 21 – Unloader PTFE tee

Remove the unloader valve from the 90° fitting in the WHASP tank.

Install the supplied push-connect fitting into the unloader valve and rotate the existing 90° fitting so that it is oriented as shown (Figure 22).

Figure 22 – Push connect fitting (Remote panel)

Remove PTFE tube running from

unloader valve

Push-connect fitting

Rotate fitting


Fax: 1-250-740-3201 16

Install the supplied push-connect fitting onto the 90° fitting on the WHASP tank (Figure 23). Route the supplied PTFE tube from the straight push connect fitting on the unloader valve to the push connect fitting on the WHASP.

Figure 23 – Push connect fitting (WHASP)

Connect the other supplied PTFE tube from the 90° fitting on the unloader valve to the tee at the base of the WHASP tank.

Mount the unloader valve to the remote panel as shown in Figure 19 using the supplied fastener through the remote box (temporarily open the plastic box on the panel, then reassemble after the unloader has been tightened).

Cover both PTFE tubes with loom and route them to the remote panel. Ensure that the PTFE tube coming from the tee goes to the 90° fitting on the side of the unloader valve and the one from the WHASP tank goes to the straight fitting in the bottom of the valve.

Reconnect the negative battery cable.

Push-connect fitting


17

System Testing After the installation of the A500187 remote control panel, the original choke, hour meter and key switch on the engine will not function, only the remote controls can be used.

Gently pull the remote choke out and push back in to verify it properly moves the choke linkage.

Use the remote key switch to start the G30 Gas drive and allow it to build to pressure. Once it has built to system pressure, turn the system off.

The system pressure unloader pilot valve can also be activated manually to aid in cold weather start up. This will allow the compressor to not build to full system pressure resulting in less load on the engine during warm up.

If the system does not operate normally, ensure the electrical connection is fully seated, and that the choke cable and PTFE tubes are installed properly. If the problem still exists, contact VMAC technical support at 1-888-241-2289.


Fax: 1-250-740-3201 18

Operation 1) Pull the choke out to the “ON” position (Figure 24).

Figure 24 – Choke out

2) Turn the key switch to the “START” position (Figure 25).

Figure 25 – Key switch

3) Once running, push the choke in to the “OFF” position (Figure 26).

Figure 26 – Choke in


19

Do not operate the electric starter continuously for more than 5 seconds, even if the engine does not start. If the engine fails to start wait 10 seconds before trying to restart.

The choke may not be required based on the ambient air temperature or if the engine has already been warmed up.

The system pressure unloader pilot valve can also be activated manually to aid in cold weather start up. This will allow the compressor to not build to full system pressure resulting in less load on the engine during warm up.

installation manual for vmac accessory manual for vmac accessory ... a production release msp jkr...

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