ECN16-037: Engineering Release 5 July 2016 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.
Warranty for full details. http://vmacair.com/support/warranty/ Warranty Registration The VMAC warranty form is located at the back of this manual. This warranty form must be completed and sent to VMAC at the time of installation for any subsequent warranty claim to be considered valid.
Page 6
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.
If fuel is spilled clean area and wait for it to dry before starting the engine. Never place objects against or on top of the compressor. Never expose the tank or compressor to extreme heat. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 8
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. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 9
Never adjust or attempt to make any repairs to the compressor system while the engine is running. Components and hoses under pressure could fail and cause serious injury or death. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 10
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 replacement parts; do not use any substitutes. The procedures described in this service manual are effective methods of service and repair.
“On” position. The engine will not be able to be restarted until the system has cooled and the temperature switch has closed. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Operating Principles Air Compression The Gas Drive uses a VMAC designed and manufactured flooded-lobe, rotary screw compressor. The oil-filled compressor housing contains two rotors. Compression occurs when inlet air (at normal atmospheric pressure) enters a chamber where it is trapped between meshing rotor lobes.
Page 13
Filtration VMAC rotary screw compressors are designed and machined to exacting tolerances. Foreign particles entering the compressor can damage system components such as seals, bearings, rotors, and the inside of the housing resulting in efficiency and performance losses and reduced system life expectancy.
For engine oil recommendations in temperatures below 0 °C (32 °F) refer to the “Subaru Engine Manual” supplied with the system. (VMAC part number: 1901022). Not following the Subaru Engine manual supplied can result in poor engine performance or engine damage.
Page 15
For engine oil recommendations in temperatures above 35 °C (90 °F) refer to the “Subaru Engine Manual” supplied with the system. (VMAC part number: 1901022). Not following the “Subaru Engine Manual" supplied can result in poor engine performance or engine damage.
For operation above 2500 feet lowering the compressor air pressure to 100 psi is recommended. For further information, please contact VMAC Technical Support at 1-(888) 241-2289. For information regarding high altitude operation refer to the “Subaru Engine Manual”...
Figure 3 - Serial number plate and location Support and Parts To order parts call at 1-(800) 738-8622 or email sales@vmacair.com For technical support call 1-(888) 241- 2289 or email tech@vmacair.com VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
“Run” position, whether the engine is running or not. There are two options for the control panel: Control Panel Figure 5 - Control panel Remote Control Panel Figure 6 - Remote Control Panel (Optional Accessory) VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 20
Compressor depressurization on shut down (blowdown system). The electric fan on the WHASP tank will run anytime the key switch is in the “On” position. This is normal operation. Figure 7 - Control overview VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Exhaust can be routed away to open air and not orientated in a way that it will fill up with rain (or exhaust flapper installed). Figure 8 - Installation considerations VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Locate a suitable mounting position for the Gas Drive. Place the unit and check for clearances to any other objects (Figure 11). All dimensions are in inches. 33.6 20.8 25.0 21.0 14.0 Figure 11 - External dimensions VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 25
There are two optional M8 Bolt holes, shown by the grey outlines (Figure 12). All dimensions are in inches. 24.0 6.00 8.25 6.00 12.00 Figure 12 - Mounting with base plate VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 26
90 degree fittings will be used, this will ensure optimal performance. See the hose requirements on the following page. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
There are two different types of hoses used with the Gas Drive compressor: Braided oil hoses VMAC braided hoses have an AQP elastomer liner for compatibility with the compressor oil. Two braided hoses are used: #12 (3/4 in ID) x 19 in discharge hose ...
Electronic Fuel Pump The use of an electronic fuel pump is not recommended or supported by VMAC. Contact a Subaru Industrial Power Product dealer for information regarding external fuel pumps. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289...
As the engine warms push the choke in. If the system has been run, ensure the compressor system has depressurized. The engine will not be able to start if the system is still under pressure VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
While the unloader valve is actuated the system will only build to 40 psi. Once the engine has warmed up, close the unloader valve to allow the system to build to full system pressure. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 31
3) Once running, push the choke to the “OFF” position (Figure 20). Figure 20 - Choke The choke may not be required if the ambient air temperature is high or if the engine has already been warmed up. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 32
Figure 22 – Choke 3) Pull the recoil starter handle gently until resistance is felt, allow the handle to return to its original position then pull swiftly. Do not pull VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 33
(Figure 23). Figure 23 - Recoil starter 4) Once running, push the choke to the off position (Figure 24). Figure 24 - Choke VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 34
Failure to do this may allow fuel to overfill the carburetor float bowl and flow into the engine’s crank case and/or cylinder causing the engine to hydraulically lock. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
7) With the ball valve fully open, the pressure should stabilize at approximately 100 psi (this simulates a tool operating at 30 cfm). 8) Close the ball valve to allow the system pressure to rise. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 36
No operator input is required on the throttle lever. Figure 26 - Throttle Actuator VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
While not critical to system performance, a pressure gauge is important for fine tuning the system and simplifies any potential troubleshooting. Install a 200 psi pressure gauge downstream of the VMAC tank outlet. Pressure regulator and/or lubricator The compressor can produce air pressures up to approximately 150 psi (1205 kPa).
Air Receiver Tank WHASP Tank Figure 27 - Receiver Tank The VMAC WHASP tank has a built-in check valve at the outlet port, an additional check valve is not required for use with an air receiver tank. Use of an additional check valve may cause erratic performance.
Exhaust Resonator Part number: A500035 Is available Eliminator Aftercooler Part number: A800070 Removes up to 80% of moisture from compressed air. Quick installation, automatic drain and compact design. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 40
The A700224 WHASP remote mount muffler kit is designed to relocate the blowdown muffler to an external location to reduce operating noise and to ensure that any oil vapor will be safely discharged. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 41
Remote heavy duty air filter body with cyclone pre-filter, compressor adapter and flexible intake hose. Test Tool Part number: A700052 Tool to test the output of VMAC air compressor systems, comes with adapter fittings, hose, 200 psi gauge and orifice fittings. Hose Reel...
Maintenance Information Routine Maintenance In order to maintain the VMAC warranty the maintenance schedule must be followed. In addition, only genuine original VMAC replacement parts can be used to maintain the system. The compressor system does not contain reed-valves or other easily fouled, fatigue-prone components.
Page 44
Compressor and engine oil may cause skin irritation. 10) Fill out the appropriate maintenance and repair section of this manual. 11) Test the system after completing any repair or service. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Maintenance Schedule Use only VMAC recommended service or replacement components. To ensure good performance and long service life, the following maintenance schedule should be adhered to. The hours indicated are those displayed on the hour meter. Service should be performed at whichever interval occurs first.
Page 46
Do not attempt to change the oil filter until the oil has cooled. Hot oil can cause severe burns. VMAC supplied and approved compressor oil must be used in this system. Failure to use this oil may result in damage to the compressor and will void the warranty.
Page 47
Figure 32 - Belt and cover Description Part Number Tensioner (Ford part number 7C3Z-6B209-D) 3300036 Belt (Gates part number K040438) 1620365 Table 6 - Belt part numbers and tension VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 48
2) Turn the system off and listen for the pressurized air to blow-down through the muffler. 3) If the muffler is showing signs of blockage, contact a local authorized VMAC dealer for a replacement part. A replacement blow-down muffler is included with the VMAC 400 hour service kit.
Page 49
150 psi). Ensure that no air leaks out of the valve. 3) If the pressure relief valve is showing loss of functionality, contact a local authorized VMAC dealer for a replacement part. A replacement pressure relief valve is included with the VMAC 400 hour service kit.
Page 50
6) Replace the cover and secure it with the cover bolt (rotate clockwise). Do not over-tighten the bolt. Figure 35 - Compressor air filter and cover VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 51
Do not attempt to change the oil filter until the oil has cooled. Hot oil can cause severe burns. Always use a VMAC oil filter. VMAC oil filters are designed to work properly at system pressure. Standard automotive oil filters are NOT capable of withstanding system pressure.
Page 52
Figure 37 - Compressor oil filter 4) Apply a thin coating of compressor oil to the filter-sealing gasket and fill the filter with VMAC compressor oil. 5) Spin the filter clockwise 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 sealing gasket.
Page 53
Do not attempt to change the oil until the oil has cooled. Hot oil can cause severe burns. VMAC certified and approved compressor oil must be used. Failure to use this oil may result in damage to the compressor and will void the warranty.
Page 54
6) Remove the filler cap by turning it counter-clockwise to remove it from the fill fitting and pour VMAC compressor oil into the oil fill fitting on the tank. The air compressor system holds approximately 3 liters of oil (including enough to fill the oil filter). The filter holds 0.3 liters of oil.
Page 55
Read the “Maintenance and Repair” safety section before working on the system. Ensure the new filter is a VMAC filter, part # 3600088. This is a high-pressure filter. Use of other filters not rated to the required pressure may cause the filter to rupture.
Page 56
Every 100 hours: Change engine oil. Change spark plug. Change air filter. VMAC sells a 100 hour engine tune-up kit (Part number A500039). See Table 7 for contents. Description Part Number Quantity Engine oil 10W30 1L 5400729...
Page 57
5) Remove the cloth or masking and install a new air filter. 6) Replace the cover and secure it with the two latches. Figure 42 - Engine air filter VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 58
1) Locate the oil fill cap. The oil fill cap is located adjacent to the oil drain. 2) Clean the area around the fill cap to prevent contamination. 3) Add Oil, using an accordion funnel (engine oil capacity is 1.2L). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Performing proper post-repair testing to ensure that the repairs were effective. Electrical testing should be performed according to the processes described in the troubleshooting charts and in conjunction with the manuals provided by VMAC. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 61
POSSIBLE CAUSE CORRECTIVE ACTION Scavenge tube frozen, Clean tube. plugged or obstructed. Blowdown does not Blowdown muffler Replace muffler. function plugged or obstructed. Blowdown valve Replace blowdown valve. failure. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 62
WHASP Cooling fan Repair or replace. not functioning. High ambient Reduce duty cycle. temperatures. Oil temperature Replace if defective. switch failure. Check for kinked or pinched Restricted oil lines. lines. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 63
Fuel switch left on Remove spark plug. Use during transport, fuel recoil starter to drain Engine will not crank. flooded crank case and cylinder. Change oil and cylinder filter. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Testing VMAC Test Tool To properly diagnose the system a VMAC test tool (part number A700052) or equivalent is required. Use a 1/8 in orifice to test the gas drive, the purpose of this orifice is to simulate a tool operating at 30 cfm.
(Figure 46). Start the gas drive, and monitor both pressure gauges: 5) As the pressure indicated on the VMAC test tool gauge reaches 150 psi, the gauge connected to the1/4 in PTFE tube should read 150 psi. If the pressure on the gauge connected to the1/4 in PTFE tube does not rise, confirm the manual unloader valve has not been adjusted.
Page 66
To better familiarize yourself with compressor components, completely read through this section of the manual. Figure 46 - Test equipment installed (Air Receiver Tank not shown) Compressor Connections Figure 47 - Compressor connections VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 67
Vacuum from the compressor pulls the separated oil from the coalescing filter, recirculating the oil in the system (Figure 48). Figure 48 – Pressure control and scavenge tube VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 68
150psi, the unloader valve sends a signal to open the discharge valve, closing the air intake poppet and allowing the throttle control to reduce the engine speed accordingly. Figure 50 - Throttle actuator VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 69
(Figure 51). Figure 51 - Poppet valve open If the poppet valve is closed the compressor will not build air pressure (Figure 52). Figure 52 - Poppet valve closed VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
A 15 A fuse protects the Gas Drive electrical system; the fuse holder is located in the wiring harness behind the over-temperature relay next to the battery (Figure 57). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 71
Temperature switch The temperature switch on the VMAC gas drive is normally closed and becomes an open circuit at 140 °C (290 °F). The temperature switch is located in the top of the WHASP tank cooler (Figure 54). If the compressor oil temperature exceeds 140 °C (290 °F), the thermostatic switch will disable the engine ignition system, but the cooling fan will remain running as long as the key switch is in the “On”...
Page 72
3) With the key switch on the blue wire should have battery voltage (+12 4) Measure resistance on the green wire yellow stripe to the battery negative terminal, resistance should be 0 Ω or extremely low resistance. Figure 56 - Electric fan VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 73
There is only one relay on the Gas Drive located next to the battery, this is used for the over temperature protection circuit. The temperature switch on the VMAC gas drive is normally closed and becomes an open circuit at 140 °C (290 °F).
Figure 58 - Battery hold down 2) Pull the battery out of the front of the unit, once it is clear, disconnect the positive battery terminal (Figure 59). Figure 59 - Battery removal VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 75
4) Disconnect the 1/2 in hose from the side of the compressor. 5) Disconnect the 3 clear PTFE tubes from the compressor. When disconnecting hoses, plug the ends so that contaminants do not enter the system during the repair. VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 76
8) Remove 4 compressor bolts from the belt guard (Figure 62). Figure 62 - Compressor front bolts 9) Lift the compressor back and up to remove it (Figure 63). VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 77
1) Remove and place the compressor assembly on a bench. 2) Remove 4 socket head bolts. 3) Ensure O-ring is not defective or damaged. Figure 64 - Inlet valve VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 78
2) Remove 4 bolts. 3) Use blue Loctite and install the new fan with the 4 bolts. 4) Reconnect fan electrical connector. 5) Test system. Figure 65 - WHASP fan removal VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 79
3) Apply thread sealing compound to the new temperature switch. 4) Reconnect the 2 spade terminals to the new temperature switch. 5) Connect battery. 6) Test system. Figure 66 - Temperature switch removal VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 80
5) Disconnect the 3/16 in and 1/4 in PTFE tubes. 6) Disconnect fan and temperature switch electrical connectors. 7) Remove 4 nuts from bottom of WHASP brackets. 8) Remove WHASP tank. Figure 67 - WHASP removal VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Maintenance and Repair Records System Installation System ID number: Compressor Serial Number: System Installed by: Address: Date Installed: 20 Hour Inspection Date: Performed by: Address: Parts replaced: or notes: 50 Hour Inspection VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 82
Date: Performed by: Address: Parts replaced or notes: 400 Hour or 12 month service Date: Performed by: Address: Parts replaced or notes: 600 Hour or 18 month service Date: VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 83
Date: Performed by: Address: Parts replaced or notes: See note in the Subaru Engine manual supplied with the system. (VMAC P/N: 1901022) at 1000 Engine hours. Additional service log VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 84
Additional service log Date: Hours: Performed by: Address: Parts replaced or notes: Additional service log Date: Hours: Performed by: Address: Parts replaced or notes: Additional service log VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 85
Address: Parts replaced or notes: Additional service log Date: Hours: Performed by: Address: Parts replaced or notes: Additional service log Date: Hours: Performed by: Address: Parts replaced or notes: VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Record #2 Date: Performed by: Part or Adjustment: Reason: Record #3 Date: Performed by: Part or Adjustment: Reason: Record #4 Date: Performed by: Part or Adjustment: Reason: Record #5 VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 87
Record #6 Date: Performed by: Part or Adjustment: Reason: Record #7 Date: Performed by: Part or Adjustment: Reason: Record #8 Date: Performed by: Part or Adjustment: Reason: Record #9 Date: VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Page 88
Part or Adjustment: Reason: Record #10 Date: Performed by: Part or Adjustment: Reason: Record #11 Date: Performed by: Part or Adjustment: Reason: Record #12 Date: Performed by: Part or Adjustment: Reason: VMAC – Vehicle Mounted Air Compressors Toll Free: 1-888-241-2289 Fax: 1-250-740-3201...
Warranty Registration This form must be fully completed and returned to VMAC at the time of installation. Warranty may be void if this form is not received by VMAC within 30 days of installation. VMAC’s Warranty policy and registration can be viewed online at: http://vmacair.com/support/warranty/...
Need help?
Do you have a question about the RAPTAIR-G30 and is the answer not in the manual?
Questions and answers