VMAC iGX800 Multifunction Power System Installation Guide

: October 30, 2023
: VMAC

Table of Contents

VMAC iGX800 Multifunction Power System
Product Information
Product Usage Instructions
Additional Application Information
Safety
Warranty
General Information
Maintenance and Repair Safety
General Service Information
Service (Engine)
Manufactured by
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

VMAC iGX800 Multifunction Power System

Product Information

VMAC Accessory Multifunction Power System (Honda iGX800) engine service kit

The VMAC Accessory Multifunction Power System (Honda iGX800) engine service kit is designed for use with the Honda powered Multifunction Power System (GMF). It comes in two variants – A500251 100 hour / 6 month service kit and A500253 300 hour / 1 year service kit. The kit is manufactured by VMAC, a leading manufacturer of vehicle-mounted air compressors. The product is covered under VMAC Standard Warranty (Limited) and VMAC Lifetime Warranty (Limited), details of which can be found on their website.

Product Usage Instructions

Before starting any service operations, it is important to read and understand the safety instructions provided in the manual. 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. 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.

The kit comes in two variants – A500251 100 hour / 6 month service kit and A500253 300 hour / 1 year service kit. It is important to select the appropriate kit based on the hours of usage of the engine. The kit contains all the necessary components required for servicing the Honda powered Multifunction Power System (GMF).

Follow the instructions provided in the manual to carry out the servicing of the engine. The 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. Pay attention to the symbols used in the manual to call attention to instructions concerning personal safety, instructions on a specific procedure that if not followed may damage or reduce the useful life of the compressor or other equipment, and additional instructions or special emphasis on a specific procedure. After completing the servicing, verify that the equipment is functioning properly before using it. If there are any issues, please contact VMAC Technical Support for assistance.

Document: 1901214
Changes and Revisions

Revision| Revision Details| Revised by| Checked| by| | Implemented
---|---|---|---|---|---|---
Eng.| Tech.| Qual.
Mech.| Elec.
A| Initial release| MSP| NAC| N/A| MSP| LPH| 25 Apr. 2023

Additional Application Information

For use with the Honda-powered Multifunction Power System (GMF).

Registered Trademarks

All trademarks mentioned in this manual are the property of their respective owners. MAC’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 is a registered trademark 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 VAC 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 © 2023 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

VMAC – Vehicle Mounted Air Compressors

VMAC Technical Support: 888-241-2289
VMAC Knowledge Base: kb.vmacair.com

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.

Attention: 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.

Warning: 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.

Attention: This symbol is used to call attention to additional instructions or special emphasis on a specific procedure.

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

Warranty registration for VMAC systems can be completed online or by filling in the form at the back of each system installation manual. Warranty registration must be completed and sent to VMAC at the time the system is put into service for any subsequent warranty claim to be considered valid.

There are 4 ways the warranty can be registered with VMAC:

www.vmacair.com/warranty
[email protected]
(877) 740-3202
VMAC – Vehicle Mounted Air Compressors
1333 Kipp Road, Nanaimo, BC, Canada V9X 1R3LIFETIME

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/

Communicate with VMAC Technical Support at 1-888-241-2289 or [email protected] to help diagnose/troubleshoot the problem prior to repair. VMAC technical support will require the VMAC System ID, hours on the compressor.
VMAC will provide direction for repair or replacement of the failed components.
If requested, failed parts must be returned to VMAC for evaluation.
Dealers may login to the VMAC website to view the “VMAC Labour Time Guide” (under “Agreements”) to see the allowable warranty labour times.
Warranty invoices must include the Service Ticket number, VMAC System ID#, hours on the compressor, and a detailed description of the work performed.
VMAC Warranty does not cover consequential damages, overtime charges, mileage, travel time, towing/recovery, cleaning or shop supplies.
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 “Standard” 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.

General Information

Optional Equipment Compatibility

While VMAC strives to design systems compatible with optional OEM equipment (such as running boards), it is impractical to develop systems that accommodate every OEM and aftermarket option or add-on. Whenever possible, VMAC endeavors to advise of compatibility issues in the “Additional Application Information” section of the manual. Even when specific optional equipment is determined by VMAC to be incompatible, it does not preclude the vehicle upfitter or end user from modifying the optional equipment to make it compatible with the installed VMAC system. VMAC does not warrant or accept responsibility or liability for the fitment, function, or safety of any products modified in any way not expressly outlined in the installation manual.

Before Starting

Read this manual prior to beginning the installation to ensure familiarity with the components and how they will fit on the vehicle. Identify any variations from the application list such as vehicle model, engines, or optional equipment (e.g., dual alternator, active steering assist, etc.). Open the package, unpack the components and identify them using the Illustrated Parts List (IPL) included in the Fastener Pack.

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.

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.

Special Tools Required

None

All fasteners must be torqued to specifications. Use manufacturers’ torque values for OEM fasteners. The torque values supplied in Table 1 are intended for VMAC supplied components, or for use as a guide in the absence of a torque value provided by an OEM.

Warning: Apply Loctite 242 (blue) to all fasteners (except nylon lock nuts) unless otherwise stated.

Torque values are with Loctite applied unless otherwise specified.

Standard Grade 8 National Coarse Thread

Size (in)| 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 (in)| 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 (mm)| 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

Maintenance and Repair Safety

Warning

Prior to performing any service, ensure the transmission in “PARK” with the parking brake applied and the wheels chocked.
It is impossible to warn of all the possible hazards that may result from operating, servicing, or repairing this system. Wear all appropriate Personal Protective Equipment and follow all industry standard safety practices.
Confirm that the system is depressurized and has cooled prior to performing any service work.
Never use flammable solvents to clean any components. If a flammable solvent has been used, rinse the component thoroughly with water and dry it before reinstalling it to prevent the possibility of explosion.
Use only genuine VMAC parts to maintain the system. Genuine VMAC parts are designed to work with the high pressure and heat generated by the compressor. Substituting genuine VMAC parts may void the warranty and could cause equipment damage, injury, or death.
This information is intended for people with mechanical trade certification who have the tools and equipment to properly and safely perform the service or repair. Do not attempt to service or repair this system without the appropriate mechanical training, knowledge and experience. Follow all safety precautions and industry standard “best practices”.

Safety Check List

Open the ball valve or connect an air tool to the system to ensure all the stored air is released.
Gently pull up on the ring on the pressure relief valve to confirm the system is depressurized.

Warning: Do not use the pressure relief valve as a means of depressurizing the compressor system. Doing so will prematurely wear the internal spring or the seat, preventing the valve from maintaining normal system pressure.

General Service Information

Warning: Read the “Maintenance and Repair Safety” section prior to performing any work on the system (beginning on page 8). Wear appropriate Personal Protective Equipment and follow all industry standard safety practices.

If the system is cold, bring the engine to operating temperature and then operate the compressor system for a few minutes to bring the compressor oil to operating temperature. Warming the system will improve oil flow and will allow the oil to flow better and will also help to suspend contaminants in the oil, so that they can be removed from the system with the old oil.
Shutdown the compressor.
Shutdown the engine.
Ensure the system is fully depressurized prior to beginning any service work.
Observe all safety procedures relating to moving belts, hot oil and compressed air. Use all appropriate Personal Protective Equipment and follow all industry standard safety practices.
Check the old oil for any evidence of metal filings or contamination. If any metal filings are found, flush the hoses and the AOST using the VMAC flushing kit (P/N: A700214).

Push-To-Connect Fittings

Lubricate the tube and firmly push it into the fitting so that the tube fully seats in the fitting.
Slide the collet out, away from the body of the fitting to lock the tubing in place.
Ensure the tube does not have any “play” to prevent the O-ring from wearing.

Inspecting the Drive Belt

Warning

Read the “Maintenance and Repair Safety” section prior to performing any work on the system.
Wear appropriate Personal Protective Equipment and follow all industry standard safety practices.

Check the Front End Accessory Drive (FEAD) belt for evidence of glazing, cracks, missing or damaged ribs or damage to the belt edges and surface. If the FEAD belt is damaged, install a new FEAD belt. Inspect the pulley(s), idler(s), and tensioner for damage. If any of the components show cracks, chipping, impact damage or any other indications of physical damage, replace the component. If the damage indicates possible misalignment, check the pulley/idler/tensioner alignment. If the pulleys are not properly aligned, check all fasteners to ensure that they are properly torqued and that there are no loose or worn components. See the system specific Illustrated Parts List (IPL) for VMAC supplied part numbers.

VMAC Belt Routing

Service (Engine)

100 Hour / 6 Month Service (Engine)

Warning

Read the “Maintenance and Repair Safety” section prior to performing any work on the system (beginning on page 8). Wear appropriate Personal Protective Equipment and follow all industry standard safety practices.
The 100-hour / 6 month HONDA iGX800 Engine Service Kit (P/N: A500251) is intended to provide the components required to perform a basic engine service. These instructions are not comprehensive and are intended to supplement the HONDA iGX800 Owner’s manual (P/N: 1901216). See the HONDA iGX800 Owner’s Manual for a complete list of maintenance recommendations and the service interval.

Attention: A clean engine and generator compartment, in addition to being more efficient, make detecting issues (i.e. oil leaks, hose or electrical harness wear, etc.) easier. VMAC recommends cleaning the Gas MF as part of regular servicing.

Run the system for a few minutes to warm the engine oil.
Remove the engine oil fill cap (Figure 3).
Clean the area around the engine and the oil filter to prevent contamination (Figure 4).
Place appropriate absorbent material under the filter to collect oil spills.
Connect a drain hose (3/8 in ID) to the drain petcock.
Open the oil drain petcock and drain the oil into a container with a capacity of at least 1/2 USG (2 L).
Remove the oil filter.
Once the oil has drained completely, close the oil drain petcock.
Apply a thin coat of engine oil to the rubber gasket on the oil filter.
Spin the filter onto the threaded nipple until the gasket contacts the sealing surface on the engine, then tighten the filter an additional 3/4 to 1 turn to seat the gasket.
Using a funnel, pour oil into the oil fill until the oil level on the dipstick is within the acceptable range. The engine holds 1.9 US qt (1.8 L) of oil.
Reinstall the oil fill cap and dipstick securely.
Inspect all wire harnesses for signs of wear. If signs of wear are present, apply protective loom as necessary and secure with rubber coated P-clips or cable ties.
Inspect all hoses for signs of wear. If signs of wear are present, take appropriate action to prevent further wear.
Refer to the Honda iGX8000 Owner’s Manual to complete the remainder of the recommended maintenance.

There is no way to clear the engine service reminder. Engine service reminders are displayed for 2 hours prior to the service being due, and for an additional 2 hours after the service was due.

300 Hour / 1 year Service (Engine)

Warning

Read the “Maintenance and Repair Safety” section prior to performing any work on the system (beginning on page 8). Wear appropriate Personal Protective Equipment and follow all industry standard safety practices.
The 300 hour / 1 year HONDA iGX800 Engine Service Kit (P/N: A500253) is intended to provide the components required to perform a basic engine service. These instructions are not comprehensive and are intended to supplement the HONDA iGX800 Owner’s Manual (P/N: 1901216). See the HONDA iGX800 Owner’s Manual for a complete list of maintenance recommendations and the service interval.

Attention: A clean engine and generator compartment, in addition to being more efficient, make detecting issues (i.e. oil leaks, hose or electrical harness wear, etc.) easier. VMAC recommends cleaning the Gas MF as part of regular servicing.

Run the system for a few minutes to warm the engine oil.
Remove the engine oil fill cap (Figure 5).
Clean the area around the engine and the oil filter to prevent contamination (Figure 6).
Place appropriate absorbent material under the filter to collect oil spills.
Connect a drain hose (3/8 in ID) to the drain petcock.
Open the oil drain petcock and drain the oil into a container with a capacity of at least 1/2 USG (2 L).
Remove the oil filter.
Once the oil has drained completely, close the oil drain petcock.
Apply a thin coat of engine oil to the rubber gasket on the oil filter.
Spin the filter onto the threaded nipple until the gasket contacts the sealing surface on the engine, then tighten the filter an additional 3/4 to 1 turn to seat the gasket.
Using a funnel, pour oil into the oil fill until the oil level on the dipstick is within the acceptable range. The engine holds 1.9 US qt (1.8 L) of oil.
Reinstall the oil fill cap and dipstick securely.
Install the (×2) supplied spark plugs.
Place appropriate absorbent material under the fuel filter to collect fuel spills (Figure 7).
Replace the fuel filter.
Inspect all wire harnesses for signs of wear. If signs of wear are present, apply protective loom as necessary and secure with rubber-coated P-clips or cable ties.
Inspect all hoses for signs of wear. If signs of wear are present, take appropriate action to prevent further wear.
Refer to the Honda iGX8000 Owner’s Manual to complete the remainder of the recommended maintenance.

Prime the Fuel System

Turn the key switch to the “ON” position, and listen for the high pressure fuel pump to turn off (approximately 10 seconds).
Once the high pressure fuel pump stops, turn the key switch to the “OFF” position.

Attention: There is no way to clear the engine service reminder. Engine service reminders are displayed for 2 hours prior to the service being due, and for an additional 2 hours after the service was due.