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
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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
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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.
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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.
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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 (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.
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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.
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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
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