Installation Manual
Low Profile Air Receiver Tanks
(Accessory Kit A500183/A520003)
VMAC – Vehicle Mounted Air Compressors
Toll Free: 1-888-241-2289
Fax: 1-250-740-3201
1
Document: 1901041
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.
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®, Loctite® 242 and are registered trademarks of Henkel AG &
Company KGaA.
Notice
Manuals are subject to change without notice.
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
Copyright 2019
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 Global Technology, Inc., 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 16-123
RAR
CJH
N/A
GB
AMG
08 Dec 2016
D
ECN 17-159 Safety relief valve change
MSP
JKR
N/A
GB
AWG
10 Nov 2017
E
ECN 19-125 Add note re crossover tube
MSP
JKR
N/A
MSP
N/A
1 Oct 2019
VMAC – Vehicle Mounted Air Compressors
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2
General Information
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. 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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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
Minimum Pressure Check Valve
The WHASP tank has a built-in Minimum Pressure Check Valve (MPCV) to
maintain a minimum pressure of approximately 60 psi (410 kPa) in the
WHASP tank. This ensures compressor lubrication and cooling, as well as oil
separation in the coalescing filter. Air will not flow out of the WHASP tank
until around 60 psi of air pressure is reached. The MPCV is factory set and
requires no adjustment or servicing.
A separate check valve is not recommended or required when
connecting the WHASP tank to the receiver tanks.
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.
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Parts List
Item
Part #
QTY
Description
1
A300049
1
ASSY, TANKS, AIR RECEIVER
2
3600047
1
GAUGE, BACK MOUNT 200PSI, 2 1/2
3
5000047
1
BUSHING, BRASS, 3/8 X 1/4
4
5000221
1
ELBOW, BRASS MNPT 1/4
5
3600159
1
VALVE, BALL, NPT-NPT, 1/2-1/2
6
3600188
1
VALVE, SAFETY REL, 3/8"NPT 170PSI
7
5000188
2
PLUG, HEX HEAD, 1/2 NPT
8
1520591
4
BOLT, HHCS, M8-1.25 X 25, G10.9 FL PL
9
1560515
6
NUT, M8 X 1.25 FL PL
10
1520525
2
BOLT, FLAT HEAD SOCKET, M8 X 25
11
4900027
1
ELBOW, STEEL NPT-TUBE, 1/2-1/2
12
4900218
1
CAP, #6 JIC
13
4900242
1
TEE, STL, JIC-NPT-JIC, 3/8-1/4-3/8
14
4900241
1
ELBOW, STEEL, 90DEG, 1/4NPT-3/8JIC
15
4900167
1
CONN, 1/2 SWIVEL – 1/2 MALE NPT
16
4900016
1
CONN, STEEL NPT-TUBE, 1/2 – 1/2
17
1750024
1
HOSE, CRIMPED, 1/2” X 24”
18
1810010
1
HOSE, CRIMPED, 3/8” X 10”
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Safety Precautions
Compressor Air and Oil Hazard
• The compressor system is under sufficient
pressure that a leak could force the air/oil mixture
through the skin directly into your bloodstream.
This could cause serious injury or death.
• Ensure the system is completely depressurized
before attempting maintenance or repair.
• Do not use compressor air to clean off clothing or
skin, compressed air can penetrate the skin
causing serious injury or death.
• Do not move or service the compressor while it is
pressurized or operating.
• Do not move the compressor by pulling on any
hoses.
• Components and hoses under pressure could
separate suddenly, fly out and cause serious injury
or death. If equipped, the auxiliary air tank must be
drained before servicing any components in the
compressor system.
• Never adjust or attempt to make any repairs to the
system while the engine is running. Components
and hoses under pressure could fail and cause
serious injury or death.
Burst Hazard
• Serious injury or death may result from an air tank
explosion.
• Never exceed manufacturer’s maximum air
pressure rating.
• Do not repair components, only replace with
approved parts.
• Do not tamper with or disable factory safety
equipment.
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.
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Remove the ball valve and adaptor. Set aside to install later as per
instructions in this manual (Figure 3).
Figure 3 - Remove Ball Valve and Adaptor
Disconnect the negative battery cable. Loosen off the restraining strap
and move strap off the battery (Figure 4).
Figure 4 - Battery Hold Down
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Pull the battery out of the front of the unit, once it is clear, disconnect the
positive battery terminal (Figure 5).
Figure 5 - Battery Removal
Remove the 5X bolts holding the belt guard and remove the belt guard.
(Figure 6).
Figure 6 - Belt Guard
VMAC – Vehicle Mounted Air Compressors
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6X fasteners are included to mount the Gas Drive to the
A500183/A520003 4X M8 x 25 bolts with M8 flange nuts on the outside,
and 2X flat head M8 x 25 bolts with M8 flange nuts on the inside
(Figure 7).
Figure 7 - Mounting Fasteners
(Dependent upon manufacture date, tank crossover tube may not be installed)
The gas drive base plate has 6X holes which will be used for mounting
to the A500183/A520003. 4X holes on the outside and 2X on the inside.
(Figure 8).
Figure 8 - Base Plate Mounting Holes
Locate a suitable mounting position for the Gas Drive and
A500183/A520003. Place the unit and check clearances to any other
objects (Figure 9).
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Figure 9 - G30 and A500183/A520003 External Dimensions
(Dependent upon manufacture date, tank crossover tube may not be installed)
There are 4X holes near the four corners of the A500183/A520003
which can be used as mounting bolt locations (Figure 10).
Drill 4X 1/2 in holes in the surface that the unit will be mounted to and
secure the A500183/A520003. Use a minimum of 4X 3/8 in bolts. Use
bolts, washers and locknuts or Loctite. Fasteners are not supplied.
(Figure 10).
Figure 10 - A500183/A520003 Bolt Hole and Overall Dimensions
15 in
24 in
16.5 in
42.25 in
35.25 in
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The G30 Gas Drive compressor is extremely heavy,
take all precautions when lifting to prevent injury.
Place the gas drive on top of the receiver tank pack. (Figure 11)
Figure 11 – Mounting the Gas Drive
(Dependent upon manufacture date, tank crossover tube may not be installed)
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Apply Loctite 242 (blue) and secure the outside of the
A500183/A520003 to the Gas Drive base plate with the 4 supplied M8 x
25 bolts and 4 x M8 flange nuts. Do not torque fasteners at this time.
(Figure 12 / Figure 13).
Figure 12 - Side Mounting Bolts
Figure 13 - Side Mounting Bolts
(Dependent upon manufacture date, tank crossover tube may not be installed)
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Apply Loctite 242 (blue) and install the supplied 2 x M8 x 25 flat head
bolts with the 2 x M8 flange nuts through the base plate center holes into
the A500183/A520003 (Figure 14) .
Figure 14 - Center Fasteners
Torque all mounting fasteners to specification.
Apply Loctite 242 (blue) and install the belt guard with the 5 bolts.
Connect spark plug wire.
Install and reconnect the battery.
Apply Loctite 242 (blue) and install the shroud.
Connect the 1/2 in hose to the WHASP outlet elbow (Figure 15).
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Figure 15 - Connecting the Discharge Hose
The G30 Gas Drive Air Compressor has a built in Minimum Pressure
Check Valve so a secondary check valve is not required (Figure 16).
Figure 16 - Minimum Pressure Check Valve
Install the ball valve and adaptor that were previously removed. Use
Loctite 567 on NPT threads (Figure 17).
Figure 17 - Install ball valve & adaptor
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System Testing
Start the G30 Gas drive and allow it to build to pressure.
Ensure the system is operating normally. When the G30 is shut off, the
WHASP tank should vent out of the blowdown muffler; the pressure in
the receiver tanks should hold and maintain a steady pressure reading.
If system does not operate normally ensure lines are connected correctly
and that there are no air leaks. If the problem still persists, contact
VMAC Technical Support at 1-888-241-2289 or tech@vmacair.com.
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Operation and Maintenance
When the compressor is no longer needed, shut the compressor system
down, and open the manual drain valve (located on the bottom of the
receiver tanks). This will drain moisture out of the tanks, and will help prevent
rust or contaminants from getting into the air line or tools (Figure 1.14).
Figure 18 - Draining the Tanks
(Dependent upon manufacture date, tank crossover tube may not be installed)
Do not operate the compressor with the ball valve wide open
and no tool attached, this may cause oil-carry over (Figure
19).
Figure 19 - Ball Valve
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