8-7
Fuel Connections
CAUTION
When connecting fuel hoses, only
use soap-free lubricants such as WD40, which
runs through fuel without leaving residues that
can clog fuel jets.
A fuel return line to the supply tank must be pro-
vided.
Genset and propulsion engine fuel supply and re-
turn lines must not be interconnected.
The maximum fuel pump lift is 36 inches (914 mm).
The genset fuel pickup should be terminated higher
in the supply tank than the propulsion engine pickup
to keep from running the vehicle out of fuel.
Do not change or remove the fuel fill tube, fill limiter
vent, vapor canister, vapor lines, filler cap or any
other part of the fuel system without the express ap-
proval of the vehicle chassis manufacturer. Modifi-
cations must conform with applicable sections of the
Code of Federal Regulations, Title 49, and other
standards.
Fuel Line Materials for Model HGJAD: Replace
fuel hose clamps, hose and tubing as necessary
with the following materials. Good connections are
required to prevent fuel leakage under pump pres-
sure.
• Tubing: Use 5/16 inch O. D. (
± 0.003 inch)
welded and drawn Type 304L stainless or
AISI 1008–1010 low carbon steel tubing of
0.028 inch minimum wall thickness. The tubing
must meet requirements for 150 psi operating
pressure (Ref. ASTM A 539–99) and have cor-
rosion resistance equal to or better than hot-
dipped zinc galvanization.
• Hose Beads: Use suitable tooling to form tub-
ing ends into SAE J1231 Type 1 or Type 3
double-flare hose beads—required for all tub-
ing and fittings.
• Flexible Hose: Use 5/16 in I. D. SAE J30R9
hose.
• Hose Clamps: Use stainless steel stepless ear
clamps. Onan P/N 0503-1951-13, Oetiker
P/N 16700013 or equivalent are required.
Fuel Line Materials for Model HGJAA: Use the
same materials for the line between the pump and
genset as for Model HGJAD. Use the following ma-
terials for the supply line between the tank and
pump and for the return line between genset and
tank.
• Tubing: Use 1/4 inch O. D. (
± 0.003 inch)
welded and drawn Type 304L stainless or
AISI 1008–1010 low carbon steel tubing of
0.028 inch minimum wall thickness. The tubing
must meet requirements for 150 psi operating
pressure (Ref. ASTM A 539–99) and have cor-
rosion resistance equal to or better than hot-
dipped zinc galvanization.
• Hose Beads: Use suitable tooling to form tub-
ing ends into SAE J1231 Type 1 or Type 3
double-flare hose beads—recommended for
all tubing and fittings for fuel return.
• Flexible Hose: Use 1/4 in I. D. SAE J30R7
hose or better.
• Hose Clamps: Use stainless steel stepless ear
clamps. Onan P/N 0503-1951-08, Oetiker
P/N 16700008 or equivalent are recom-
mended.
Fuel Line Routing: If it is necessary to replace fuel
lines, route the supply and return lines side-by-side
along bulkheads and frame members such that they
are protected, and at or above the top of the fuel
tank to reduce siphoning if a line breaks or a hose
comes off. The entire length of a fuel line must be
visible for inspection and accessible for replace-
ment.
Support fuel lines to restrain movement and prevent
chaffing or contact with sharp edges, electrical wir-
ing and hot exhaust parts.
WARNING
Electric arcs can ignite gasoline
leading to severe personal injury or death. Do
not run wiring and fuel lines together.
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