INSTALLATION MANUAL. with ILLUSTRATED PARTS LIST. covering. Fuel Tank Replacement Kit. Part Number

Size: px

Start display at page:

Download "INSTALLATION MANUAL. with ILLUSTRATED PARTS LIST. covering. Fuel Tank Replacement Kit. Part Number"

Eustace Darren Powers
5 years ago
Views:

1 TO INSTALLATION MANUAL with ILLUSTRATED PARTS LIST covering Fuel Tank Replacement Kit Part Number manufactured by HOBART BROTHERS COMPANY Ground Power Division TROY,OHIO45373 U.S.A.

2 This page intentionally left blank

3 Instructions for Installing Plastic Fuel Tank Part Number On Series 7003B Jet-Ex 4D Generator Sets TO General These installation instructions explain the procedure for removing a metal fuel tank from a Series 7003B generator set to replace it with a plastic fuel tank (Hobart Part No ). These instructions include a list of the parts which comprise the fuel tank replacement kit, identified by Hobart Part. No These instructions also include a schematic and connection diagram for wiring the fuel gage to the sender installed in the plastic fuel tank. 2. Removing the Old Fuel Tank a. Disconnect negative battery cable, at the battery. b. Remove the 8 hex-head bolts and washers which mount to 2 rear side panels, and remove these panels. c. Remove the 15 self-tap screws which mount the canopy top to the generator set. d. Remove the mounting hardware from the fuel tank mounting straps, and remove the straps. Discard or put away these items. They won t be needed for installation of the new tank. e. Remove the 4 screws which secure the tank to the support tray at the front and rear of the tank. f. Close the shutoff valve and disconnect the supply fuel line from the valve by loosening the hose clamp and removing the hose from the valve. g. Using a funnel and a container of sufficient size, open the fuel shutoff valve and drain the fuel tank. h. Close the shutoff valve and loosen the hose clamp which attach the return hose to the fuel tank. Then disconnect the hose from the fuel tank. i. Remove the fuel tank and set it aside. j. Locate the engine wiring harness. k. Tag the leads on the engine wiring harness at the control panel terminal strip. l. Disconnect the engine wiring harness at the terminal strip, (the harness will be rerouted under the support tray). 3. Mounting the New Fuel Tank Set the new plastic fuel tank on the fuel tank support tray. As you will notice, at its base, the plastic tank has 5 feet, each with a hole. To mount the fuel tank, it will be necessary to drill 5 new holes in the in the fuel tank support tray. Proceed as follows to mount the fuel tank: April 1/96 Page 1

4 TO-237 a. Position the tank on the support tray such that the shutoff valve and drain sump will center themself through the existing holes in the tray. It is approximately 3-3/16 inches in from the front of the tray and 5/8-inch in from the left edge of the tray. b. With a sharp pencil, place a mark through the center of the slot in each foot at the base of the tank and onto the fuel tank support tray, such that the marks can be clearly seen when the tank is lifted from the tray. c. With the fuel tank removed, drill accurately a 7/32-inch hole where each of the marks appear. d. Set the fuel tank back on the fuel tank support tray, and mount it to the tray using the 1/4-inch self-tapping screws and 3/4 X 3 inch mounting plates provided in this kit. e. Route engine wiring harness under the support tray. f. Hold harness up into position using the clamps (Hobart Part No ). Mount clamps using the old holes that had been used by the metal fuel tank straps. g. Reconnect harness to terminal strip. 4. Mounting the New Fuel Gage on Left Rear Side Panel In the fuel tank replacement kit there is a round mounting ring, 6 inches in diameter (Hobart Part No ) into which the new electric fuel gage (Hobart Part No ) must be fastened before the fuel gage assembly is mounted on the exterior of the left rear side panel of the generator set. a. Place the new electric fuel gage in the large hole in the center of the 6-inch diameter mounting ring that is included in the installation kit. b. Attach the fuel gage to the mounting ring by putting the bracket on the back of the gage, and installing the washers and nuts provided with the gage. Make certain that the gage is securely fastened to the mounting ring. c. Place the mounting ring with gage attached on the left rear side panel such that the gage is centered in the existing hole in the panel. d. With the mounting ring in this position, and using a sharp pencil, place a mark through each of the three holes in the mounting ring such that the marks can be clearly seen when the mounting ring is removed from the panel. e. With the mounting ring removed, drill accurately a 7/32-inch hole where each of the three marks appear. f. Install the mounting ring securely on the left rear side panel using three 1/4-inch self-tapping screws provided. 5. Preparing the New Tank for Service Proceed to prepare the new tank for service as follows: Page 2 December 1/95

5 a. Remove the shut-off valve from the old fuel tank for use on the new fuel tank, and remove the plastic plug from the bottom of the new tank. b. Wrap the threads of the shut-off valve with teflon tape and thread it into one of the pipe bushings (Hobart Part No. W ) provided. c. Wrap the outside threads of the bushing with teflon tape and install this assembly in the hole in the bottom of the new fuel tank. d. Wrap the threads of the elbow (Hobart Part No ) with teflon tape, and thread it into the other pipe bushing provided. e. Wrap the outside threads of the bushing with teflon tape and install this assembly in the hole in the top of the new fuel tank. f. Reconnect the supply and return hoses, securely tighten hose clamps. g. Using schematic/connection diagram , connect wires of the wiring harness (included in the installation kit), to connection points on the electric fuel gage (M408) and the engine start-run-stop switch (S404) on the front panel of the generator set, and to the electric sender (R406) on the fuel tank. 6. Installing the Canopy Top and Side Panels a. Remount the canopy top to the generator set with the 15 self-tap screws which were previously removed. b. Using the 8 hex-head bolts and washers which were previously removed, mount the 2 rear side panels. c. Reconnect negative battery cable. TO Service Information If you have any questions concerning your Hobart Ground Power Division equipment, you are invited to contact our Service Department by mail, telephone or FAX. Write: In U.S.A. Call: From Other Countries Call: FAX: Hobart Brother Company Ground Power Division Service Department 1177 Trade Square East Troy, Ohio U.S.A. (800) (Parts) (800) (Service) (513) (Parts) (513) (Service) (513) (Parts) (513) (Service) April 1/96 Page 3

6 TO-237 This page intentionally left blank. Page 4 December 1/95

Installation Instruction Manual. Low Coolant Shutdown Kit Part No Series 7004C Hobart Engine-Drive Generator Sets

TO-223 June 18/92 Installation Instruction Manual for Low Coolant Shutdown Kit Part No. 181928 for use with Series 7004C Hobart Engine-Drive Generator Sets Hobart Brothers Company Airport Systems Grroup