G30 Honda Gas Drive Stalling - Conditions and Solutions

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Technical Support Subject G30 Honda Gas Drive Stalling – Conditions and Solutions Document Version Department Revision Details Revised by Tech Engineering Implemented EXT-G30-002 A Tech Document Release BDJ 25 June 2018 GB 25 June 2018 N/A 26 June 2018 Knowledge Base Email: tech@vmacair.com : www.kb.vmacair.com Page 1 of 3 Web: www.vmacair.com Technical Support: 1(888)241-2289 Toll Free:1(800)738-8622 Fax: 1(877)740-3201 System or Parts affected • G300003 Gas Drive Compressor, powered by Honda Index System or Parts affected .............................................................1 Overview .......................................................................................1 Conditions that can create a stall...............................................1 Unloader activates, engine RPM drops too low, stalls. ............1 Stalling as pressure builds to 150 psi .......................................2 Overview • Following are the common conditions that will create a stalling situation in the G30003, and the remedy for each condition. Conditions that can create a stall Unloader activates, engine RPM drops too low, stalls. • Solution: Increase the engine base idle rpm. 1. Turn the engine off and drain the air from system. 2. Locate the black plastic Phillips head idle speed adjustment screw on the side of the carburetor. (Figure 1) 3. Gently turn the idle speed screw clockwise until it bottoms out. The engine idle speed should increase by approximately 150rpm. Over-tightening the idle adjustment screw will snap the screw. Figure 1 Idle speed screwTechnical Support Subject G30 Honda Gas Drive Stalling – Conditions and Solutions Document Version Department Revision Details Revised by Tech Engineering Implemented EXT-G30-002 A Tech Document Release BDJ 25 June 2018 GB 25 June 2018 N/A 26 June 2018 Knowledge Base Email: tech@vmacair.com : www.kb.vmacair.com Page 2 of 3 Web: www.vmacair.com Technical Support: 1(888)241-2289 Toll Free:1(800)738-8622 Fax: 1(877)740-3201 Stalling as pressure builds to 150 psi • Solution: Adjustment of the unloader valve to bring the system pressure down slightly and adjustment of the inlet regulator to ensure the regulated air pressure is above the unloader pressure. The unloader valve controls the maximum system air pressure. Reduce the air pressure just enough so that the engine doesn’t stall. 1. Toggle the manual unloader lever to the engaged (on) position, the lever will be straight out, and the system will build low pressure, to approximately 40 psi. (Figure 2) Figure 2 2. Start the engine and allow it to warm up for 2 minutes. 3. Turn the engine off and drain the air from the system. 4. Remove the compressor air cleaner to provide easier access to the inlet regulator. 5. Loosen the regulator jam nut and turn the regulator adjustment bolt counter-clockwise 1.5 turns. (Figure 3) Figure 3 Regulator adjuster bolt Jam nutTechnical Support Subject G30 Honda Gas Drive Stalling – Conditions and Solutions Document Version Department Revision Details Revised by Tech Engineering Implemented EXT-G30-002 A Tech Document Release BDJ 25 June 2018 GB 25 June 2018 N/A 26 June 2018 Knowledge Base Email: tech@vmacair.com : www.kb.vmacair.com Page 3 of 3 Web: www.vmacair.com Technical Support: 1(888)241-2289 Toll Free:1(800)738-8622 Fax: 1(877)740-3201 6. Toggle the manual unloader lever to the disengaged (off) position. The lever will be at 90° to the unloader body. 7. Start the engine and allow the system to build air. The regulator adjuster bolt may turn on its own, so hold it in place with a wrench. The system will not build to the 150 psi that would activate the unloader valve, so the engine speed will remain high after system stops building air. 8. Slowly turn the regulator adjuster clockwise bolt until the unloader activates and the engine speed drops to its idle. 9. Turn the inlet regulator adjuster bolt clockwise an additional 3/8 turn and tighten the jam nut. 10. Turn the engine off and drain the air from the system. 11. Restart the engine. The engine should rev to its maximum rpm and build to an air pressure of approximately 150psi. The unloader should activate and lower the engine rpm to below idle speed briefly, then increase to the correct base idle. • If the engine stalls after performing steps 1-11, an unloader valve adjustment may be necessary to reduce the system pressure to approximately 145psi. 12. Remove the main discharge hose from the WHASP tank, which would go to an air receiver tank and/or to air tools. Install a 160psi gauge and a ball valve in the discharge port of the WHASP tank where the hose was previously. 13. Following Knowledge Base article EXT-G30-001 Adjusting the Unloader Valve , adjust the unloader valve (Figure 4) to 145 psi. 14. Repeat the Regulator adjustment as in steps 1-11, above. 15. Remove the air pressure gauge and ball valve, and reinstall the discharge hose. 16. Restart and re-test the compressor. • If the unit stalls again, repeat unloader valve adjustment steps 12-16 to reduce the maximum pressure by another 5psi. Repeat until the unit no longer stalls. Figure 4