VMAC A700247 Multifunction Power System External Fuel Pump Installation Guide
- October 30, 2023
- VMAC
Table of Contents
Installation Manual for VMAC
Accessorywww.vmacair.com
A700247
Multifunction Power System External Fuel Pump (Gas)
(Honda IGX800)
www.vmacair.com
Document: 1901208
Changes and Revisions
Revision
|
Revision Details
|
Revised by
| Checke| d 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 GMF0001 Multifunction Power System (Honda IGX800).
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 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 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 © 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
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.
| 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.
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| 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.**
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: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: h t t p s : / / ww w . v m a c a i r . c o m / d e a l e r – l o c a t o r /
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- Communicate with VMAC Technical Support at 1-888-241-2289 or tech@vmacair.com 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.
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VMAC Product Warranty Policies & Warranty Registration can be found on the VMAC website (see previous page for URL).
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,
VMACendeavors 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.
| Apply Loctite 242 (blue) to all fasteners (except nylon lock nuts)
unless otherwise stated. Damage Table
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Torque values are with Loctite applied unless otherwise specified.
Standard Grade 8 National Coarse Thread
Size (in)| 1/4| 5/16| 3/8| 7 / 1 6|
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 / 1 6| 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
Illustrated Parts List
| Item # | Part # | QTY | Description |
|---|---|---|---|
| 1 | 9500675 | 1 | FUEL PUMP, ELEC, 12V |
| 2 | 3550900 | 1 | FUEL PUMP HARNESS |
| 3 | 2200164 | 3 | CABLE TIES |
| 4 | 3501441 | 2 | CONN,BUTT,CRIMP-SOLDER-SEAL,20-18GA |
| 5 | 9500676 | 1 | FUEL FILTER |
| 6 | 5000239 | 1 | CONNECTOR, BRASS, 1/8NPT X 1/4 BARB |
Electrical System Best Practices
- To confirm a good ground, use an ohm meter to measure the resistance between the ground point and the negative battery terminal. Resistance should be less than 1 Ω.
- Route all wires to ensure they will not contact hot, sharp or moving parts (including the park brake mechanism, steering column, and pedals).
- Before drilling any holes ensure there are no OEM wires, hoses, or components that may be damaged.
- Do not use a test light to probe for power on vehicle circuits, the increased current draw of the test light may damage components.
- VMAC recommends using only sealed crimp and solder butt connectors for all electrical connections.
- To ensure a durable connection, use only good quality crimping tools.
- Apply loom to all wiring:
- Use high temperature loom in areas where high temperatures may be expected.
- Use spiral loom in areas with high vibration.
In-line Butt Splice Connections
- Cut the wire approximately 2 in from the connector.
- Strip approximately 3/8 in from the end of both sides of the cut wire, as well as from the end of the wire being spliced in-line.
- Twist the wire to be spliced in-line, together with the “live” side of the wire (not the wire attached to the connector).
- Slide the butt connector onto the twisted wires and crimp it.
- Insert the “connector side” of the wire into butt connector and crimp it.
- Lightly tug the wires to ensure they are properly crimped.
- Using a heat gun, carefully apply heat to the butt connectors to seal the connection.
Tying into OEM connectors
Some OEM connectors may have locking tabs that must be disengaged prior to
inserting a crimped connector.
Maintenance and Repair Safety
| Prior to performing any service, ensure the transmission in “PARK” with the
parking brake applied and the wheels chocked.
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| 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.
| 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.
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Installation
| Ensure there is an ABC rated fire extinguisher within reach.
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Mounting Parameters
- This is a pusher pump and must be mounted within 3 feet of the bottom of the fuel tank (Figure 1).
- Ensure the fuel pump is mounted where the temperature will not exceed 140° F (60° C).
- If tying in to the vehicle’s fuel tank, do not tap into the lower portion of the tank.
- The fuel pump can be mounted Vertically, at a 45° angle, or horizontally (Figure 2).
| Only fuel line rated for gasoline, and that meets EPA and CARB evaporative
emission regulations (Executive Order Number Q-19-011) may be used. The fuel
pump is a pusher pump. It must be mounted within 3 feet of the bottom of the
fuel tank.
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| All wires and hoses that are installed, rerouted or shifted during the
installation must be secure so that they do not contact any hot, sharp or
moving parts. Use rubber coated P-clips or cable ties wherever possible.
Mounting the Fuel Pump
-
Ensure the key switch is in the OFF position and remove the service panel.
-
Disconnect the negative battery terminal.
-
Using the fuel pump as a jig, mark and drill (×2) 7/32 in holes into the frame in the desired location (Figure 3).
-
Mount the fuel pump in the selected location (fasteners not included) (Figure 3).
-
Install the supplied fuel filter on the inlet side of the pump (Figure 4).
-
Install the supplied fuel line fitting on the outlet side of the pump (Figure 5).
-
Using gasoline compatible fuel hose (not included), connect the fuel filter to the fuel tank, and Gas MF.
-
Locate the 2 pin fuel pump connector on the GMF wire harness labeled “Fuel Pump” (the harness is located among the main harnesses bundle near the air discharge).
-
Connect the supplied blunt cut harness to the fuel pump connector.
-
Cut the blade and ring connectors from the fuel pump. Using the supplied butt connectors, connect the following wires*:
-
*Red wire running from the fuel pump to the red wire on the fuel pump harness.
-
*Black wire running from the fuel pump to the black wire on the fuel pump harness.
Note: Dependant upon the fuel pump location, the harness wires may need to be extended in order to reach the fuel pump connector. -
Reconnect the negative battery terminal.
*Prime the Fuel System:** -
*Turn the key switch to the “ON” position. The fuel pump will click while the system is being primed.
-
*Once the fuel pump stops clicking, the system has been primed. Turn the key switch to the “OFF” position.
-
*Turn the key switch to the “ON” position.
-
*Press the “ENTER” button to start the engine and allow it to reach normal operating temperature.
-
Check the system for any leaks.
-
888-241-2289
tech@vmacair.com
877-740 -3202
warranty@vmacair.com
www.vmacair.com
kb.vmacair.com
1333 Kipp Road, Nanaimo, B.C., V9X 1R3 Canada
VMAC – Vehicle Mounted Air Compressors
VMAC Technical Support: 888-241-2289
VMAC Knowledge Base: kb.vmacair.com
References
- VMAC Knowledge Base
- VMAC - Vehicle Mounted Air Compressors | VMACAIR.com
- Find A Dealer - VMAC
- VMAC Warranty Policies & Warranty Registration
- Find A Dealer - VMAC
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