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BG 40-Gallon Dosing Step Tank

40-Gallon Dosing Step Tank

PN E101-5734

INSTALLATION  INSTRUCTIONS

Parts/Tools Needed
  • 40-Gallon Dosing Step Tank, PN E101-5734
  • Dosing Step Tank Accessory Set, PN E101-6057
  • Welder/torch
  • Grinders/cutoff tool
  • Basic hand tools (sockets, wrenches, etc.)
  • Fish tape/wire puller
  • Mini precision screwdriver set
  • Pipe tape
  • Wire strippers/crimper pliers
  • RTV sealant
  • Forklift
Reference Appendix C for a complete list of parts.

Old Tank Removal

    1. Disconnect the locomotive’s batteries to avoid electrical shock.
    2. Locate existing inverter with 75V power and ground from locomotive. Properly disconnect them from the locomotive, label, and set aside for use with new tank.
    3. Remove the old power inverter from the old tank setup.
    4. Open panel on side of the old tank and disconnect the electrical power connections.
    5. Drain old fluid from the tank by disconnecting lines and draining into suitable drain bucket.
    6. Unbolt tank if applicable. If tank is welded on, cut it off.
            1. Remove all the old brackets that are welded to the locomotive.
    7. Remove old photo eye sensors, any remaining conduit,

New Tank Installation

    1. Reference Appendix B for this section. The new tank goes at the end of the walkway on Fireman’s or left side of the locomotive, extending the step. It needs to be welded to the locomotive.
    2. Locate light/access panel on locomotive. This is where the fuel filler neck will pass through.
            1. Remove light, cut the wiring, and secure wire ends so that they do not touch.
              Note: Light will have to be relocated to the end of the tank after installation. Move light according to regulations.
            2. Remove light/access panel (indicated by the red arrow in the photo) so that the tank mates flush to install the filler neck.
    3. Loosen the rail mount (indicated by the green arrow in the photo) to swing out of the way during the tank installation.
    1. Remove the filler neck from the tank.
    2. Use a forklift with a two- or three-man team to guide the tank onto the walkway. 
    3. Once in position, mark a suitable spot on the locomotive deck where to cut a pass-through for the wiring conduit and fuel hose.
            1. Use the pass-through hole on the electrical box to locate where the hole will go through the locomotive deck.
    4. Before cutting and welding, remove the electrical box from the dosing tank by removing the four nuts from the mounting studs. Set aside the nuts for reinstallation at a later time.
    5. Slide tank back and cut hole in deck.
    1. Slide tank back into position and prepare for welding.
      IMPORTANT! Verify tank placement before welding! Make sure all access holes are cut and accessible. Check for proper alignment of pass-through and filler neck.
    2. Weld tank to locomotive.
      CAUTION! Be careful not to burn through the tank wall when welding.
      1. Weld along the entire length of the rear bottom of the tank to the locomotive walkway.
      1. Weld the entire length on the front top of the tank to the locomotive walkway.
      1. Weld three stitch welds on the side of the tank to the edge of the locomotive walkway.
      1. Weld the inner corner under electrical box to walkway.
    1. Apply Permatex 85420 Permashield Fuel Resistant Gasket Sealant or equivalent RTV that is fuel resistant to both sides of the filler neck gasket and on the threads of the filler neck bolt holes, then install filler neck to tank.
    2. Reattach the walkway rail mount securely.

Pre-electrical Installation

    1. Source 75V power and ground from locomotive.
            1. If locomotive had an existing dosing tank, use the previously pulled 75V power and ground from the old setup.
            2. 75V power and ground can be run straight to the batteries if no power wire is currently sourced.
    2. Reinstall the electrical box to the dosing tank using the four nuts removed previously during electrical box removal.
      Note: The following three sections will walk through the installation of electrical conduit, T-Junction boxes, and pulling of the wires to the electrical box at the tank.

 

75V Power and Ground

    1. Roll out supplied conduit from front compartment to filler neck for estimated length. Make sure you leave enough to get the conduit inside the front compartment. 
    2. Cut the conduit to length.
    3. Pull supplied power cable through the conduit using fish tape. Route conduit through a suitable hole into the compartment under the locomotive’s cabin, install junction box in the compartment for the 75V power and ground connections and secure conduit under locomotive with zip ties.
    1. In the compartment under the train cabin, strip back the supplied power cable insulation to expose the Power (white wire) and Ground (black wire).
    2. Connect supplied power and ground wires to 75V sourced power from the train and heat shrink the connections and then seal in supplied junction box.

Photo Eye Sensors and T-Junction Box Installation

    1. Install photo eye sensor covers. 
            1. Insert sensor into cover.
            2. Thread sensor onto adaptor.
            3. Insert snap ring to secure sensor assembly.
    1. Using the supplied fittings, apply thread tape to the fitting and install photo eye sensors in the filler neck ports on both sides of the locomotive.
    1. Install T-Junction box on the end of the conduit previously installed with power wires. Measure length of conduit from the T-Junction box routing under the locomotive to the other side’s filler neck at the photo eye sensor. Reference Appendix B.
    1. Cut conduit to length and connect to T-Junction box on dosing box side of locomotive.
    2. Add a short section of conduit to first T-Junction box and add the second T-Junction box for the photo eye on the dosing tank side.
    3. Measure and cut conduit for sensor cable on dosing box side and install to second T-Junction box.
    4. Pull sensor cables from the sensor eyes through the conduit to the T-Junction boxes.
    5. Route both sensor cables and power cables through both the T-Junction boxes.

T-Junction Box to Dosing Step Tank and Electrical Box Wiring

    1. Roll out conduit and measure length from the second T-Junction box to the dosing step tank electrical box. Cut conduit to proper length, allowing for enough to pass through the floor to the electrical box.
    1. Pull sensor cables and power cables through conduit and secure conduit under locomotive behind the air tank. Route conduit through hole in the floor and connect to the electrical box.

Fuel Line Installation

    1. Roll out fuel line and measure length from fuel tank port near the filler neck to the pump at the dosing step tank.
    2. Cut measured length of hose.
    3. Run fuel line along previously installed conduit.
    4. Install the fuel line to the fuel pump at the dosing step tank.
    5. Install the fuel line to the port on the locomotive’s fuel tank using supplied fittings.
    1. Secure fuel line under locomotive with zip ties, attaching it to the previously installed conduit.

Electrical Box Wiring Instructions

    1. Cut cables to length ensuring you have enough to reach designated spots. 
    2. Strip the power cable and sensor cables to the following lengths.
            1. Power and ground: 5/16th to 7/16th.
            2. Sensor cables: 11/16th to13/16th and fold stripped wire in half.
    3. Refer to wiring diagram above (and Appendix A) for wire positions on fuse block.
Note: All wires have their own location. Do not insert more than one wire per slot on fuse block.
            1. Install 75V power (white wire) to 75V fuse.
            2. Install 75V ground (black wire) to –75V ground on fuse block.
            3. Install Sensor 1 and Sensor 2 power (brown wires) to 12V+ locations on fuse block.
            4. Install Sensor 1 and Sensor 2 ground (blue wires) to 12V– locations on fuse block.
            5. Install Sensor 1 and Sensor 2 signal (black wires) to 106 locations on fuse block.

Timer Relay Verification

    1. Refer to photo on right for Timer Relay settings.
            1. Check/Set timer 1 = 10s
            2. Check/Set timer 2 = 7.5
            3. Check/Set timer 3 = 1m
            4. Check/Set timer 4 = 3
    1. Install electrical box cover.

Electrical Verification

    1. Reconnect locomotive batteries.
    2. Verify that the photo eye sensors light up.
    1. Test photo eyes to verify pump operation by inserting a hand into the fill neck to trigger the sensors. Pump should cycle on for a period of time and off for a period of time.
    2. Install cover on side of step tank

Final Verification

    1. Fill up dosing tank with BG DFC® With Lubricity HP for Locomotives, PN PD28.
    2. Check for leaks on tank at filler neck, sight glass, or any weld points.
    3. Activate the photo eyes and allow pump to prime the fuel line to the tank.
    4. Treat fuel in the locomotive with the proper amount of PD28 based on the current tank level.
    Treat ratio is 1 gallon of PD28 per 1,000 gallons of fuel.

Appendix A

Appendix B

Appendix C

Dosing Tank Accessory Set

PN E101-6057

PART NUMBER

E101-4509

E101-5460

E101-6059

E101-6067

E101-6064

E101-6065

E101-6066

E101-8044

E101-6058

E101-6060

E101-6061

E101-6075

E101-6069

–

–

–

–

SDDE-EN16

SDNN-EN17

QTY

  2

  2

  2

  2

  9

  2

  3

  1
  2
  1
  1
  1
  1
  2
  2
 25
  1
  1
  1

DESCRIPTION

Train Sensor Adaptor

Train Sensor Enclosure
Train Photoeye Sensor
Conduit Access Tee, ½ FNPT
Conduit Adaptor, ½
½ FNPT Coupler, Plastic
Cord Grip, ½ MNPT
.31 x .50 DIA Worm Gear Clamp, 7/32 1 5/8
Dosing Tank Sensor Cable
Dosing Tank Power Cable
Dosing Tank Conduit, ½
Dosing Tank Hose
½ MNPT x  POHB
Butt Crimp on Connector, 14-16 AWG, Heat Shrink
Side-mount Retaining Ring, 13/18, External, Steel
Zip-tie, 14.5 x 0.3, Black
Conduit Access Box, ½ FNPT
Dosing Step Tank Electrical Schematic Decal (may be installed)
Dosing Step Tank Installation Instructions

R00

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