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-   -   Repairing Fuel low and fuel contamination sensors. (https://www.wanderlodgeownersgroup.com/forums/showthread.php?t=8004)

Bob Johannesen 10-17-2010 01:35 AM

Repairing Fuel low and fuel contamination sensors.
 
My sensors on the fuel tank had corroded enough that one of the spade connectors broke off in each sensor. I located them new from a Robertshaw distributor for $156.00 EACH! After my Chief Financial Officer regained her balance and said "We'll put them on the list, but I don't know when.....".:rolleyes:

So I figured I couldn't lose by trying to repair them. I removed them and only got one armpit full of fuel! I then took my Dremel tool and did some micro-surgery and exposed the little stub that the spade was attached to:

http://packratfxr.smugmug.com/Other/...47_D3Fm4-M.jpg

I gently soldered a wire to the stub, put an extension on the other lead, and sealed it all in silicone with heatshrink around the sides.

http://packratfxr.smugmug.com/Other/...17_dJBtS-M.jpg

Ugly but sealed:

http://packratfxr.smugmug.com/Other/...60_PVeXu-M.jpg

I installed each one within an FS electrical box epoxied around the sensor to the fuel tank so it would be protected from corrosion and damage from armadillos failing the road test! :rolleyes:

Have to use some fuel before I can test the fuel low light! :D And there is no water in the sump! :cool:

.Ya'll drive Safely!

Christian 10-17-2010 02:53 AM

Quote:

Originally Posted by Bob Johannesen (Post 77600)
My sensors on the fuel tank had corroded enough that one So I figured I couldn't lose by trying to repair them. I removed them and only got one armpit full of fuel! I then took my Dremel tool and did some micro-surgery and exposed the little stub that the spade was attached to:

http://packratfxr.smugmug.com/Other/...47_D3Fm4-M.jpg

I gently soldered a wire to the stub, put an extension on the other lead, and sealed it all in silicone with heatshrink around the sides.



Ugly but sealed:

.Ya'll drive Safely!

I noticed 3 terminals when you started and only two wires emerging from the repair pic 2nd above... was the third a ground or did I miss something... mine also is non functional

sfedeli 10-17-2010 05:08 AM

There are three wires- depending on how you want to wire the alarm. They can be "normally on" or "normally off".

Bill Pape 10-17-2010 05:41 AM

Good job Bob,
I like the old Simpson Meter,

Bob Johannesen 10-17-2010 10:37 AM

Quote:

Originally Posted by sfedeli (Post 77609)
There are three wires- depending on how you want to wire the alarm. They can be "normally on" or "normally off".


That is the TEST terminal - you can complete the circuit with a momentary buttton to light up the light on the dash.....I did think about running another wire for that test function but I talked myself out of it!:confused:

I just hope the fix works - I will give the fuel low warning light a chance before refueling the tank. It is about 3" from the bottom so it isn't too low. ;)

Old helicopter pilots do not like FUEL LOW WARNING lights! :eek:

Bill Pape 10-17-2010 11:05 AM

Bob,

Do you remember the pipe thread size to install a plug??

Christian 10-17-2010 03:57 PM

Quote:

Originally Posted by Bob Johannesen (Post 77641)

Old helicopter pilots do not like FUEL LOW WARNING lights! :eek:

I should say not!
Kind of reminds me of that movie w/the crazy judge who flys just over the 1/2 way mark an tries to make it back.. (and justice for all)

Does this sensor have a float? How does it work?:)

So the test cct would go through the closed contacts on the sensor testing only the common contact and the bulb cct...

Bob Johannesen 10-17-2010 11:20 PM

Bill,
Of course they were two different sizes. I believe the fuel contamination (water in fuel) on the bottom sump was 1/4 inch pipe and the fuel low light was 3/8 pipe. I re-confirmed that before I turned the last few threads out! I was surprised when I didn't lose very much fuel. I tied a shop rag to my wrist and didn't get too much in the armpits! Had the plug on the allen wrench "at the ready"!

Have fun!;)



Quote:

Originally Posted by Bill Pape (Post 77644)
Bob,

Do you remember the pipe thread size to install a plug??


Bill Pape 10-18-2010 05:38 AM

Quote:

Originally Posted by Bob Johannesen (Post 77729)
Bill,
Of course they were two different sizes. I believe the fuel contamination (water in fuel) on the bottom sump was 1/4 inch pipe and the fuel low light was 3/8 pipe. I re-confirmed that before I turned the last few threads out! I was surprised when I didn't lose very much fuel. I tied a shop rag to my wrist and didn't get too much in the armpits! Had the plug on the allen wrench "at the ready"!

Have fun!;)

Thanks Just curious, Good to know standard pipe thread. Usually the easy reapairs always have a hitch.
I'll put this in the notes. I have a bag of plugs.


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