VMAC A500247 Multifunction Power System External Fuel Pump Instruction Manual

VMAC A500247 Multifunction Power System External Fuel Pump

A500247 Multifunction Power System External Fuel Pump (Gas) (Honda IGX800) www.vmacair.com

VMAC – Vehicle Mounted Air Compressors

• VMAC Technical Support: 888-241-2289
• VMAC Knowledge Base: kb.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
B| ECN: 23-143 Update EPA/CARB info| MSP| NAC| N/A| MSP| N/A| 14 Jul. 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.

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 if more information is required, please contact VMAC Technical Support before 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, and 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.

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 per the Owner’s Manual; (iii) proof of purchase of applicable service kits are made available to VMAC upon request. The VMAC Lifetime Warranty applies 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
• warranty@vmacair.com
• 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/

1. Communicate with VMAC Technical Support at 1-888-241-2289 or tech@vmacair.com to help diagnose/troubleshoot the problem before repair. VMAC technical support will require the VMAC System ID and hours on the compressor.
2. VMAC will provide direction for the 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 “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 (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, VMAC endeavours 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 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

Illustrated Parts List

Electrical System Best Practices

• To confirm 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.
• 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 before 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 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.

Installation

• Ensure there is an ABC-rated fire extinguisher within reach.
• 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 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 lines rated for gasoline and that meet EPA and CARB evaporative emissions regulations may be used. It is the installer/customer’s responsibility to ensure compliance with EPA and CARB evaporative emissions regulations are met. For a complete list of approved evaporative components refer to:

• EPA “Nonroad Evaporative Components” certification.
• CARB SORE – Evaporative Component Certification.
• The fuel pump is a pusher pump. It must be mounted within 3 feet of the bottom of the fuel tank.

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 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 labelled “Fuel Pump” (the harness is located among the main harness 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*:

• The red wire running from the fuel pump to the red wire on the fuel pump harness.
• The black wire running from the fuel pump to the black wire on the fuel pump harness.

Note: Depending 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 877-740-3202 www.vmacair.com
  • tech@vmacair.com warranty@vmacair.com kb.vmacair.com
  • 1333 Kipp Road, Nanaimo, B.C., V9X 1R3 Canada

References

• VMAC Knowledge Base
• Find A Dealer - VMAC
• Find A Dealer - VMAC

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