ABSOLUTE GENERATORS G435 Auxiliary Fuel Pump Kit Installation Guide

ABSOLUTE GENERATORS G435 Auxiliary Fuel Pump Kit

Installation of Auxiliary Fuel Pump Kit 541-0564

The following instructions cover the installation of an auxiliary fuel pump when the genset fuel pump inlet is more than 3 feet (914 mm) above the bottom of the dip tube in the fuel tank (Figure 1 ). The auxil­iary pump has a shutoff feature that prevents drain back when it is not running. Installation of an auxilia­ry fuel shutoff solenoid is therefore not necessary with this pump.
IAWARNINGI Diesel fuel is combustible and can cause severe personal injury or death. Do not smoke or allow any flame, spark, pilot light, arc­ producing equipment, electrical switch or other ignition source around fuel or fuel components, or in areas sharing ventilation. Keep a type ABC fire extinguisher handy.

Installation

1. Securely mount the auxiliary fuel pump as close to the fuel tank as practicable and not more than 3 feet (914 mm) above the bottom of the dip tube in the fuel tank (Figure 1).

2. Using connectors in the kit and a short length of insulated 18 AWG copper wire, assemble a ground lead and secure it to the genset pump mounting screw (Figure 2).

3. Disconnect the genset pump lead from the en­gine wiring harness and cut off the connector. Using connectors in the kit and a short length of insulated 18 AWG copper wire, asssemble a lead for connecting the auxiliary pump and se­cure it and the genset pump lead together with a crimp-on quick connector in the kit (Figure 2).

4. Reconnect the pump lead to the lead from J2-2 in the engine harness.

5. Cut off the auxiliary pump lead connectors. Us­ing the insulated butt-splice connectors in the kit, connect insulated 18 AWG copper wires long enough to reach the genset with approxi­mately 1 foot (305 mm) of slack left over (Fig­ure 1). Route the pump leads away from and at least 3 inches (76 mm) above the fuel lines and support them to prevent chaffing or contact with sharp edges.
   Do not ground the black lead of the auxiliary pump at its own mounting screw. A good path to battery negative (-) from the location of the auxiliary pump cannot be assumed. Always run two wires between the auxiliary pump and gen­set.

6. Connect the fuel lines such that the two pumps flow in series (Figure 1 ). Note the end of the auxiliary pump marked “OUT.” Support the fuel lines to restrain movement and prevent chaf­fing or contact with sharp edges and hot ex­haust parts. Run fuel lines at or above the top of the fuel tank to reduce siphoning if a line breaks or a hose comes off. Read the genset Installa­tion Manual for important fuel system consider­ations and safety precautions.
   WARNING Sparks can ignite fuel and lead to severe personal injury or death. Do not run electrical wiring and fuel lines together. Separate them with conduit or tubing if run through the same opening. Do not tie them together.

7. Connect the two leads from the auxiliary fuel pump to the new connectors at the genset fuel pump such that the two pumps are electrically parallel. (Figure 2).

8. Run the genset observing all instructions and safety precautions in the Operator’s Manual and check for fuel leaks. Shut down the genset immediately if there is a leak and repair as necessary.

FIGURE 1. AUXILIARY PUMP INSTALLATION

FIGURE 2. RECOMMENDED WIRING CONNECTIONS

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