Autopsy of Failed Fuel Level Sensor on MEP003A

[glcaines]

The fuel level sensor on my MEP003A genset failed, preventing me from using the auxilliary fuel input from my bulk diesel storage. I previously thought the problem was caused by a failed solenoid valve, but when I troubleshot the system I determined that the fuel level sensor had failed in the open position. The sensor works by having a magnetic float slide up and down a tube that contains a reed switch. The position of the magnetic float opens and closes the reed switch. Upon removing the four small screws, water poured out. The wiring and reed switch terminals were highly corroded. One wire was separated from the reed switch terminal. I sanded the terminal on the reed switch and cut off a section of wire and tried to re-solder. Unfortunately, I could not get the solder to flow on the terminal of the reed switch. I've now given up and am currently looking for a new sensor. I looked at the GEMS website, but the sensor manufacturer doesn't list this particular sensor as a current product.
MFG: GEMS
NSN: 5930-01-062-0690
P/N: LS-29385

 

[Captaincarrier]

Serious corrosion in ULSD these days.

 

[Chainbreaker]

I always wondered how the aux float switch worked. Thanks for sharing.

Newark has similar style reed switches: http://www.newark.com/switches_reed?rd=reed+switch&catalogId=15003&langId=-1&storeId=10194

You still might be able to salvage it!

 

[doghead]

I'm wondering if it was originally silver soldered.

 

[RIrvin]

Previously, conductive epoxy (two part) has worked well for me on connections where solder failed. Found it at HAM radio / electronics shop.

 

[PeterD]

I'm wondering if it was originally silver soldered.

Welded, not soldered. There is 'good' news, at least I think so... You can get reed switches at RadioShack, and any place that sells alarm systems, and they are not expensive.

 

[Keith_J]

I've got some old security system door/window magnetic switches which may work. These are soldered to a printed circuit board, through hole type soldering. So it would be easy to harvest one. Should fit in a first class envelope without additional postage.

Let me know.

Yes, you will have issues soldering the through glass leads as they are typically a special alloy to resist cracking the glass due to thermal stress. And they don't like to be soldered, they are tin plated to facilitate soldering.

 

[glcaines]

I received a quotation from WB Parts in Palm Bay, Florida for a new one at $268.00, which is too steep for me. I've gotten a lot of parts for MVs from WB in the past. They are high, but they often have parts no one else has and they have no minimum quantities. I think DH is right, it appears to have been silver-soldered. I will try that. The reed switch itself is in excellent condition. All I need to do is re-attach the wire to the terminal, and shrink wrap the assembly. It is very interesting how powerful the magnet is. I don't know what material the magnet is made of being so lightweight.

 

[Triple Jim]

GEMS has a line of level switches that may help. I haven't done the research, but here's the page from their site: http://www.gemssensors.com/Products/Level/Single-Point-Level-Switches/Float

MSC Industrial stocks some of them: http://www.mscdirect.com/browse/tn/...chterm=Gems+Sensors&navid=4294878056+12107787

 

[steelandcanvas]

Gary, did you try Delks for a replacement? Or Saturn?

 

[unclebeau]

Do you have a jeweler near you, they have way small torches and can silver solder items.
Just a thought, good luck!

 

[glcaines]

Gary, did you try Delks for a replacement? Or Saturn?

I sent an e-mail to Delks, but haven't received a response. Haven't tried Saturn yet.

 

[glcaines]

Do you have a jeweler near you, they have way small torches and can silver solder items.
Just a thought, good luck!

That's a very good idea! Thanks.

 

[Chainbreaker]

Alternatively, you could buy your own micro-torch. They are plentiful on Amazon and are under $50. Then your set to silver solder anything else that comes up in the future. I've got a roll of silver solder that I have had for decades and it does come in very handy now and then.

 

[Munchies]

Track down these guys. Their part # below. They have been sole manufacturer since early 2000's

8036-100

THE AIRFLO INSTRUMENT COMPANY, 53 ADDISON RD, GLASTONBURY, CT, 06033-1601

06102

5

07/10/2007

117

61.69

THE AIRFLO INSTRUMENT COMPANY (Duns: 001153790) 53 ADDISON RD GLASTONBURY, CT, 06033-1601 UNITED STATES Phone:8606339455 Fax:8606335222

WILLIAM LAJEWSKI AIRFLO@NTPLX.NET WILLIAM LAJEWSKI AIRFLO@NTPLX.NET

 

[bmwsyc]

Is it me, or is that completely unreadable?

 

[Munchies]

Yah didnt notice that untill after. Its because of the backround color. Highlight it with your cursor and it will be fine.

 

[glcaines]

I just received an e-mail from GEMS informing me that the sensor is still an active part manufactured by them. It isn't on their product list because no one has ever tried to buy any except the Army and Navy. They are now trying to get me a good price on one, knowing that I'm not the government with deep pockets.

 

[rustystud]

I just received an e-mail from GEMS informing me that the sensor is still an active part manufactured by them. It isn't on their product list because no one has ever tried to buy any except the Army and Navy. They are now trying to get me a good price on one, knowing that I'm not the government with deep pockets.

Let us all know what they say, since we all might be needing one in the not to distant future.

 

[PeterD]

Alternatively, you could buy your own micro-torch... .

I (strongly) suspect that the heat will damage the reed switch if you try to solder it. The wires are normally welded which transmits little heat to the part.