VMAC A500248 Multifunction Power System Gasoline Fuel Tank Kit Installation Guide

VMAC A500248 Multifunction Power System Gasoline Fuel Tank Kit

Document: 1901211
Changes and Revisions

Revision

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Revision Details

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Revised by

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Implemented

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Eng.| Tech.| Qual.
Mech.| Elec.
A| Initial release| MSP| NAC| N/A| DSB| LPH| 21 Dec. 2023

Additional Application Information

• For use with the Honda-powered Multifunction Power System GMF0001.
• This equipment meets U.S. Environmental Protection Agency (EPA) evaporative emissions standards when installed on the Honda-powered Multifunction Power System: GMF0001.

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 to the materials. The only warranties for VMAC products and services are those outlined 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 before 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 are 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 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, it means, “Attention, become alert! Your 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; (il) services are completed under 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 1R3

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 log in 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 parts). 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 Products), 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 Products), 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 before 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.
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

ASSY, FUEL TANK, 12GAL COMPLETE, 9500705

ASSY, FUEL TANK, 12GAL COMPLETE, 9500705 (CONTINUED)

ASSY, FUEL TANK, 12GAL COMPLETE, 9500705 (CONTINUED)

PORT)
14| 1700681| 14.0| HOSE, FUEL, 1/4” SAE-30R9 (CANISTER PURGE PORT TO PURGE PORT BARB ADAPTER)
15| 1700681| 12.0| HOSE, FUEL, 1/4” SAE-30R9 (BALL VALVE TO ENGINE FUEL FILTER)
16| 1700680| 48.0| HOSE, FUEL, 7/16” SAE-30R7 (PURGE PORT BARB ADAPTER TO ENGINE PURGE PORT)
| NOT SHOWN|  |  

Maintenance and Repair Safety

• It is impossible to warn of all the possible hazards that may result from operating, servicing, or repairing this system.
• Follow all safety precautions and industry standard “best practices”.
• 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 replacement parts to maintain the system.
• Genuine VMAC replacement parts are designed to work with the high pressure and heat generated by the compressor. Substituting genuine VMAC replacement 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.

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.

Installation

• Read the “Maintenance and Repair Safety” section before performing any work on the system (beginning on page 11).
• Wear appropriate Personal Protective Equipment and follow all industry-standard safety practices.
• Remove both side panels to access the (×4) carriage bolts (installed from the bottom of the pallet). If required, the end panels can be removed to provide better access to the mounting bolts (Figure 1).

Remove and discard the fill port cover and fasteners (Figure 2).

• Feed the hoses and harnesses from the fuel tank into the GMF while lowering the GMF into place on the fuel tank frame.
• While it is possible to reach most of the fasteners from the top of the GMF, the fasteners are easiest to access with the side panels removed.
• Using the (×6) supplied M10×1.5×35 mm fasteners and flange nuts, secure the GMF to the fuel tank (Figure 3).

• Remove the lower nut from the rear of the electrical box and set it aside (Figure 4).

• Route the fuel hose up past the electrical box; using the supplied P-clip and nut retained from the previous step, secure the fuel supply hose to the electrical box (Figure 5).

• Using the supplied gear clamp, connect the fuel supply hose (hose with the fuel shut-off valve) to the fuel filter (Figure 6).

• Using the supplied clamp and cable ties, connect the vapour return hose to the purge port on the Honda engine (Figure 7).

• Route the vapour loop hose up along the vapour return hose to the fuel carbon canister, and then loop it back down to create a P-trap (this line must be routed as high as possible to ensure no fuel can enter the carbon canister) (Figure 8).

• Connect the ring terminals from the fuel light LED to the key-switched power, and ground posts near the control box (Figure 9).

• VMAC supplies pigtails to connect the low-fuel LED (that will be mounted in the display panel) to the LED harness.
• Route the fuel light harness (with the 2-pin connector) out through the harness and pass through near the discharge port (Figure 10).

• Slide the grommet to the rear of the LED (Figure 11).

• Insert the LED into the display panel from the rear (Figure 12).

• Slide the grommet into place and push the LED into the grommet (Figure 13).

• Plug the “LOW FUEL” LED into the LED harness.
• Install the supplied emissions decal beside the System ID plate (Figure 14).

• Do not modify or alter any fuel tank assembly components.
• Modifying or altering any components may void EPA emissions compliance.

General Fuel Tank Safety Information

| •    Do not fill the fuel tank while the engine is running, or while the system is on standby. Stop the engine and allow it to cool before refuelling.

•    Ensure the unit is on level ground before checking the fuel level or filling the fuel tank.

•    Ensure the unit is in a well-ventilated area before refuelling.

•    Do not smoke while filling the fuel tank.

•    Ensure there are no sparks or other sources of combustion near the system before filling the fuel tank.

•    Do not operate the system with the fuel cap removed. The fuel cap must be installed and tight during operation.

•    When installing the fuel cap, tighten it until 3 clicks are heard or felt.

•    Ensure any spills have been wiped up before starting the engine.

•    Allow fuel vapours to dissipate before starting the engine.

•    When operating at angles, the effective fuel capacity will vary. Higher angles of operation may cause the low-fuel LED to illuminate prematurely as the fuel settles away from the fuel pickup tube. Maximum run time will be achieved while the system is on level ground.

•    Do not overfill the fuel tank! The fuel tank has a maximum capacity of 12 USG (45.4 L).

•    The maximum fuel level is marked on the fuel tank. The fuel tank is equipped with a white fuel level sleeve installed in the filler neck. When filling the fuel tank, fill until the fuel level reaches the bottom of the fuel sleeve (Figure 15).

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VMAC – Vehicle Mounted Air Compressors

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

CONTACT

• 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

References

• VMAC Knowledge Base
• Find A Dealer - VMAC
• Find A Dealer - VMAC
• Find A Dealer - VMAC
• Warranty Registration | VMAC

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