Vmac G300004 User manual

www.vmacair.comwww.vmacair.com
Gas Engine Driven 30 CFM Air
Compressor
G300004
Installation, Owner and Service
Manual
®

VMAC - Vehicle Mounted Air Compressors
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Table of Contents
Safety ..............................................................3
Safety Precautions..................................................4
Warranty ...........................................................8
General Information ...............................................10
G300004 Installation Manual .................................. 11
Installation Requirements ..........................................13
Ventilation Requirements...........................................14
Mounting Locations................................................16
Mounting the Compressor..........................................18
G300004 Owner’s Manual ..................................... 21
System Overview ................................................. 23
Safety Features................................................... 25
Identifying Your System........................................... 26
Operating Principles ...............................................27
Extreme Climates and Elevation................................... 29
Operating the G300004 ...........................................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
General Maintenance Information................................. 45
Maintenance and Repair Safety ....................................47
Maintenance Schedule ............................................ 50
Regular Inspection Instructions.....................................51
200 Hour / 6 Month Service ...................................... 57
400 Hour / 1 year Service......................................... 59
Engine Maintenance and Warranty Information ................... 63
Diagnostics and Trouble Shooting ................................. 64
System Adjustments .............................................. 70
Compressor Regulation and Throttle Actuator Testing ..............74
Electrical Components and Testing.................................81
Component Repair / Replacement ................................ 84
G300004 Illustrated Parts List (IPL)............................94
Illustrated Parts List .............................................. 96
Warranty Registration ........................................... 108

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Document: 1930423
Changes and Revisions
Revision Revision Details Revised by
Checked by
Implemented
Eng. Tech. Qual.
Mech. Elec.
AInitial Release MSP NAC N’A DSB AWM 17 Apr. 2020
B ECN: 20 146 Update startup procedure and cold climate kit info MSP NAC N/A MSP LPH 17 July 2020
CECN: 20-176 Compr. removal and unloader adjustment instructions MSP NAC N/A MSP N/A 4 Sept. 2020
Additional Application Information
• VMAC recommends installing the Cold Climate Kit (P/N: A500044) if this unit
will be used in temperatures below 0 °C (32 °F).
• Refer to the Honda GX390 Owner’s Manual (VMAC P/N: 1901066) for engine
specific information.
Registered Trademarks
All trademarks mentioned in this manual are the property of their respective
owners. VMAC’s use of manufacturers’ trademarks in this manual is for
identification of the products only and does not imply any affiliation to, or
endorsement of said companies.
Loctite®, Loctite®242 and Loctite®567 are registered trademarks of Henkel AG &
Company KGaA.
Honda®is a registered trademark of Honda Motor Co., Ltd.
Important Information
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 tools and equipment to properly and
safely perform the installation or service. Do not attempt installation or service
without the appropriate mechanical training, knowledge and experience.
Follow all safety precautions. Any fabrication for correct fit in modified vehicles
must follow industry standard “best practices”.
Notice
Copyright © 2020 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. Printing or copying of any page
in this document in whole or in part is only permitted for personal use. 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

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This symbol is used to call attention to instructions concerning
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 aware
of the possibility of personal injury or death. As it is impossible
to warn of every conceivable hazard, common sense and industry
standard safety practices must be observed.
This symbol is used to call 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 attention to additional instructions or
special emphasis on a specific procedure.
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, service
techniques and running OEM changes. If a discrepancy is found in 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, who proceeds to perform 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 ensure that their safety and
that of others is not being compromised, and that there will be no adverse effects
on the operational safety or performance 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 anyone
to properly adhere to the procedures set out in this manual or standard safety
practices.
Safety should be the first consideration when performing any service operations.
If there are any questions concerning the procedures in this manual, or more
information is required, please contact VMAC Technical Support prior to beginning
work.
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.

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As it is impossible to warn of every possible hazard that may result
from operating this system, common sense and industry standard
safety practices must be observed.
Safety Precautions
Read this information before operating the compressor for the first time. Follow
the information and procedures in this manual for operation, maintenance and
repair. Observe the following items to reduce the chance of personal injury or
equipment damage.
Follow all safety precautions for mechanical work. Moving belts and rotating
components are an extreme hazard. Stay clear of all moving parts when the
system is operating. Only qualified personnel should perform maintenance and
repair on system components and only while the system is properly shut down.
Proper service and repair are important to the safety of the service technician and
the safe, reliable operation of the equipment. Always use genuine VMAC and/or
Honda replacement parts.
The procedures described 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, service procedure or tool must
first determine that neither their safety nor the safe operation of the equipment
will be compromised by the replacement part, service procedure or tool selected.
Harmful Vapours
Breathing fuel vapours or engine exhaust can expose you to chemicals
known to the State of California to cause cancer and birth defects or
other reproductive harm.
• Always start and operate the engine in a well ventilated area.
• Do not breathe engine exhaust. Internal combustion engines
produce carbon monoxide, a poisonous odorless gas which can
cause death. Do not start or operate this system in an enclosed
area.
• If in an enclosed area, vent the exhaust to the outside and ensure
there is adequate access to fresh breathable air.
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 prior to
performing service.
• Avoid contact with the engine or compressor components until the
system has cooled sufficiently.

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Lead Acid Battery Hazard
Working near lead acid batteries is dangerous. Batteries may generate
sulphuric acid and explosive gases 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 overcharge a battery.
Personal Safety
• Do not breathe the compressor air as vaporized oil is a respiratory
hazard.
• Do not breathe engine exhaust, internal combustion 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.
Fire and Explosion Hazard
• Vaporized oil propelled by high pressure air is an explosive mixture.
• Fire in the compressor can cause an explosion and flame projection.
Should this occur, there is potential for serious injury or death.
• Operate the compressor in a well ventilated area free of flammable
vapors, dust, or other combustible materials.
• Do not refuel the engine while the system is running or hot.
• Do not refuel the engine in an enclosed space or area with poor
ventilation.
• If fuel is spilled, clean the area and wait for it to dry before
starting the engine.
• Never place objects against or on top of the compressor.
• Never expose the system to extreme heat.

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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 compressed air to clean off clothing or skin, compressed
air can penetrate the skin causing serious injury or death.
• Do not move or service the system while it is pressurized or
operating.
• Components and hoses under pressure could separate suddenly
and cause 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. Components and hoses under pressure could
fail and cause serious injury or death.
Burst Hazard
This system is designed to generate air pressure up to 150 psi during
normal operation (factory default: 140 psi):
• 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
• Prior to performing service, disconnect the spark plug lead to
prevent unexpected engine start.
• Do not operate the system without guards in place. If the guards
are damaged or missing, replace them before operating the
equipment.

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General Warnings
• Disconnect the spark plug lead prior to attempting any repair or
service.
• Be attentive for unexplained changes in operation parameters and
record any changes.
• Check the engine and compressor oil levels and condition prior to
starting the system.
• Do not add or change oil while the system is running.
• Use only approved oils.
• Inspect the equipment before every 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 approved hoses and replacement parts.
• Do not modify the equipment.
• Do not operate this system unless this manual has been read in its
entirety.
• Do not operate this system when fatigued or under the influence of
alcohol or drugs.
• Never bypass or disable any of the safety equipment.
• Never adjust or attempt to make any repairs to this system while
the engine is running unless expressly instructed to do so.
• Components and hoses under pressure could fail and cause serious
injury or death.

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Warranty
VMAC Standard Warranty (Limited)
For complete warranty information, including both VMAC Standard
Warranty (Limited) and VMAC Lifetime Warranty (Limited)
requirements, please refer to our current published warranty located
at: www.vmacair.com/warranty
If you do not have access to a computer, please contact us and we will be happy
to send you our warranty.
VMAC’s warranty is subject to change without notice.
VMAC Lifetime Warranty (Limited)
A VMAC Lifetime Limited Warranty is offered
on the base air compressor only and only on
UNDERHOOD™, Hydraulic Driven, Transmission
Mounted, Gas and Diesel Engine Driven Air
Compressors, Multifunction Power Systems, and
other 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) services are completed in accordance with the Owner’s
Manual; (iii) proof of purchase of applicable service kits are made available to
VMAC upon request.
The VMAC Lifetime Warranty is applicable to new products shipped on or after
1 October, 2015.
Warranty Registration
The VMAC warranty registration form is located near the back of this manual. This
warranty registration form must be completed and sent to VMAC at the time of
installation for any subsequent warranty claim to be considered valid.
There are 4 ways the warranty can be registered with VMAC:
www.vmacair.com/warranty
[e-mail]
[phone]
VMAC - Vehicle Mounted Air Compressors
1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3
LIFETIME
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WARRANTY

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VMAC Warranty Claim Process
VMAC warranty work must be pre-authorized by VMAC. Claims are
processed via our dealer network. If you are not a VMAC dealer,
please select one to work with via our Dealer Locator:
https://www.vmacair.com/dealer-locator/
1. Communicate with VMAC Technical Support at 1-888-241-2289 or
[e-mail] to help diagnose/troubleshoot the problem prior to repair.
VMAC technical support will require the VMAC System ID, hours on the
compressor and mileage on the vehicle.
2. VMAC will provide direction for repair or replacement of the failed components.
3. If requested, failed parts must be returned to VMAC for evaluation.
4. Dealers may login to the VMAC website to view the "VMAC Labour Time Guide"
(under “Agreements”) to see the allowable warranty labour times.
5. Warranty invoices must include the Service Ticket 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/recovery, cleaning or shop supplies.
7. Dealers submit warranty claims on behalf of the Vehicle Owner/End User
affected by the defective part(s). The dealer ensures that all warranty credits
are refunded back to the Vehicle Owner/End User who made the initial warranty
claim.
In order to qualify for Lifetime Warranty (Limited), the completed
warranty registration form must be received by VMAC within 3
months of the buyer receiving the Product(s), or 200 hours of
operation, whichever occurs first.
If the completed warranty registration form has not been received
by VMAC within 3 months of the buyer receiving the Product(s),
or 200 hours of operation, the warranty period will be deemed to
commence 30 days from the date of shipment from VMAC.
Failure to follow the warranty claim process may result in denial of
the warranty claim.
VMAC Product Warranty Policies & Warranty Registration can be found on the
VMAC website (see previous page for URL).

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Before Starting
Read this manual as well as the Honda Owner’s Manual prior to installing or
operating the Gas Engine Driven 30 CFM Air Compressor (G300004) to ensure
familiarity with the components, installation requirements and how to operate the
unit.
Open the package, unpack the components and identify them using the included
Illustrated Parts List (IPL).
Hose Information
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.
Ordering Parts
To order parts, contact a VMAC dealer. The dealer will ask for the VMAC serial
number, part number, description and quantity. Locate the nearest dealer online at
www.vmacair.com/dealer-locator or call 1-877-912-6605.
General Information
Technical Support
For technical support visit VMAC’s Knowledge Base or contact the technical
support team.
Knowledge Base: http://kb.vmacair.com/
Toll free: 1-(888) 241- 2289
Email: [e-mail]

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G300004
Installation Manual
®

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When determining a mounting location for the G300004, ensure the following
conditions are met (see Figure 1 on page 15):
• The fuel shut off valve is easily accessible (the fuel valve must be shut off
when the unit is not in use, including during transport).
• The sight glass, oil drain and filters on the WHASP Tank are easily accessible
for service.
• The belt guard is accessible and can be removed for service.
• The engine oil drain, oil fill, fuel fill, and air filter are easily accessible for
service.
• There is adequate access to cool fresh air for optimum engine performance.
• There is sufficient clearance around the unit for good air circulation and
effective cooling.
• The unit is mounted in a position where hot air and exhaust will not recirculate
back into the system.
• The 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 engines, exhaust systems or other
components that generate heat.
• The unit is not in a location where it will be exposed to high contamination
levels, including combustible gases.
The information in this section is very important for proper
operation of the compressor. Read these requirements prior to
beginning the installation.
Installation Requirements
Read pages 2 – 10 of this manual prior to proceeding.
See page 23 of this manual for an overview of the various
components.
Enclosed mounting must incorporate one of the following to ensure an
adequate supply of cool fresh air to the engine, and to remove all of
the engine exhaust and heat generated from the system:
• The unit must be mounted on a pull out tray that is extended
anytime the unit is run. In general, this is the simplest method.
• The cabinet must be designed with features such as ducting and
intake/exhaust fans.

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Adequate ventilation is vital for safety as well as proper operation
of the engine. Systems without adequate cooling may experience
stalling, premature oil deterioration, increased oil consumption,
power loss, and reduced life or failure of the engine and/or
compressor.
If the compressor overheats, the temperature switch will shut down
and disable the engine until the oil temperature drops below 140 °C
(284 °F).
During operation, the G300004 generates a considerable amount of heat that
must be evacuated away from the unit for it to run efficiently. The engine is air
cooled and requires an adequate supply of cool fresh air to cool the engine and
allow proper fuel combustion.
Ensure 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 clearance in front of it, however
unobstructed venting to open atmosphere is preferred.
The engine exhaust must be vented away from the G300004 and toward a
safe location (the exhaust tip can be rotated to change the exhaust direction if
needed). If mounted in an enclosure (such as a cabinet, or the bed of a pickup
truck box), the exhaust must be vented outside of the vehicle to prevent the gas
engine from ingesting its exhaust and overheating or stalling (Figure 1).
Exhaust and waste heat from the G300004 system must be vented
away from the system to prevent the gas engine from ingesting its
exhaust and stalling.
Ventilation Requirements
If mounted in an enclosure, special consideration must be made to
ensure adequate ventilation. See “Enclosed Mounting” on page 16
for more information.

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Figure 1 — Airflow diagram
(some frame components removed for clarity)

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When selecting a top mount location, ensure the fuel shut off valve
is easily accessible. The fuel valve must be shut off when the unit is
not in use, including during transport.
Ensure the engine exhaust and hot air generated by the gas engine
and WHASP Tank cooler are routed in such a way as to prevent
recirculation back into the unit.
Note that the fan on the WHASP Tank is a “puller” fan.
Minimum considerations for mounting in an enclosure
Supply cool fresh air to: Exhaust and heat:
• Engine air intake.
• Compressor air intake.
• WHASP Tank.
• Duct the engine exhaust outside of the
vehicle / enclosure.
• Install an exhaust fan to remove hot air
from the enclosure.
Mounting Locations
VMAC does not recommend mounting the unit at the back of the
vehicle as the drag created when the vehicle is moving causes debris
to be deposited (and accumulated) inside the unit.
Top Mounting
Top mounted is the preferred mounting location. Placing the unit on top of the
service body provides the 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 enclosure will limit access to cool fresh air, restrict
the escape of hot air from around the unit and have an adverse effect on cooling,
engine performance and reduce the unit’s duty cycle. Ensure adequate ventilation
is provided for cooling and to evacuate the exhaust. If mounting in an enclosure,
VMAC strongly recommends mounting the unit on a pullout drawer and extending
the drawer any time the unit is run.
While it is not possible to make absolute recommendations regarding ventilation
due to the widely differing circumstances that are possible, duty cycle, ambient
temperature and enclosure shape are some of the important variables that must
be considered.
Enclosed Mounting
Enclosed mounting must incorporate one of the following to ensure an
adequate supply of cool fresh air to the engine, and to remove all of
the engine exhaust and heat generated from the system:
• The unit must be mounted on a pull out tray that is extended
anytime the unit is run. In general, this is the simplest method.
• The cabinet must be designed with features such as ducting and
intake/exhaust fans.

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Figure 2 — Mounting locations
Not recommended
Top mounted
Enclosure mounted
(Not recommended unless
mounted on a pull out drawer)

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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 (Figure 3).
All dimensions are in inches.
Figure 3 — External dimensions
Mounting the Compressor
20
38
18