tank inspection hatches installation - clean diesel

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Tank inspection hatches installation 1 INTRODUCTION Clean Diesel inspection hatches (CDIH) have been designed for periodical inspection or cleaning of diesel fuel tanks. Because of the high quality 316 grade stainless steel material used in the manufacturing process, the CDIH can also be installed on water storage tanks as well as in almost any other types of storage/holding tanks (please contact us regarding liquid compatibility). We do not recommend installation on tanks containing petrol or any other highly flammable liquids or gases. The CDIH are compatible with ALL tank materials such as stainless steel, aluminium, steel, plastic, copper alloy and fiberglass/composite. For fiberglass/composite tanks it is necessary to use the appropriate adapter rings available separately. SKILLS N’ TOOLS For best results we recommend using an authorized installer however, if you have the necessary skills to use a drill, a jigsaw and a hole saw you should complete the installation yourself in no time. You will need the following tools: - Electric drill or jigsaw with the appropriate blade for the tank material. - Hole saw 140-150 mm for 150 series CDIH, - Hole saw 90-100 mm for 100 series CDIH - Hole saw 119-121 mm for 120 series CDIH - Hole saw arbor with ¼ drill bit - Cutting oil - ¼ drill bit - 7 mm drill bit - 10mm spanner All the necessary tools are available to purchase from Clean Diesel website: www.cleandiesel.com.au SAFETY FIRST DO NOT use any electric or hand tools unless you have been trained in its safe use and operation. Potential hazards in using a drill or a jigsaw include: exposed moving parts and electrical hazard with the potential to cause harm through entanglement, impact and cutting, exposure to heat, dust, projectiles and sharp objects. Personal protective equipment (PPE) required is Eye Protection, Appropriate Footwear and Safe Work Protective Clothing. Make sure that all the installation instructions are clearly understood. When drilling: - Ensure drill bit is installed tightly into chuck and chuck key has been removed (if applicable). - Drilling holes are marked correctly. - Correct drill speed has been set. - Correct drill bit has been selected for material being drilled. - Identify ON/OFF switch and emergency stop button (if applicable). - Check that drill bit runs ‘true’ and does not wobble. - Keep hands clear of work piece and away from rotating tool. - Exercise caution when removing hot drill bit. INSTALLATION Please make sure the installation surface is clean and dry. DO NOT use any sealing compound. To complete the installation you will have to follow these 7 simple steps:

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Page 1: Tank inspection hatches installation - Clean Diesel

Tank inspection hatches installation

1

INTRODUCTION Clean Diesel inspection hatches (CDIH) have been designed for periodical inspection or cleaning of diesel fuel tanks. Because of the high quality 316 grade stainless steel material used in the manufacturing process, the CDIH can also be installed on water storage tanks as well as in almost any other types of storage/holding tanks (please contact us regarding liquid compatibility). We do not recommend installation on tanks containing petrol or any other highly flammable liquids or gases. The CDIH are compatible with ALL tank materials such as stainless steel, aluminium, steel, plastic, copper alloy and fiberglass/composite. For fiberglass/composite tanks it is necessary to use the appropriate adapter rings available separately.

SKILLS N’ TOOLS For best results we recommend using an authorized installer however, if you have the necessary skills to use a drill, a jigsaw and a hole saw you should complete the installation yourself in no time. You will need the following tools:

- Electric drill or jigsaw with the appropriate blade for the tank material. - Hole saw 140-150 mm for 150 series CDIH, - Hole saw 90-100 mm for 100 series CDIH - Hole saw 119-121 mm for 120 series CDIH - Hole saw arbor with ¼ drill bit - Cutting oil - ¼ drill bit - 7 mm drill bit - 10mm spanner

All the necessary tools are available to purchase from Clean Diesel website: www.cleandiesel.com.au

SAFETY FIRST

DO NOT use any electric or hand tools unless you have been trained in its safe use and operation. Potential hazards in using a drill or a jigsaw include: exposed moving parts and electrical hazard with the potential to cause harm through entanglement, impact and cutting, exposure to heat, dust, projectiles and sharp objects. Personal protective equipment (PPE) required is Eye Protection, Appropriate Footwear and Safe Work Protective Clothing. Make sure that all the installation instructions are clearly understood. When drilling:

- Ensure drill bit is installed tightly into chuck and chuck key has been removed (if applicable). - Drilling holes are marked correctly. - Correct drill speed has been set. - Correct drill bit has been selected for material being drilled. - Identify ON/OFF switch and emergency stop button (if applicable). - Check that drill bit runs ‘true’ and does not wobble. - Keep hands clear of work piece and away from rotating tool. - Exercise caution when removing hot drill bit.

INSTALLATION Please make sure the installation surface is clean and dry. DO NOT use any sealing compound. To complete the installation you will have to follow these 7 simple steps:

Page 2: Tank inspection hatches installation - Clean Diesel

Tank inspection hatches installation

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Step 1 Remove the M6 nuts, spring washers and flat washers securing the hatch to the flexi ring. Picture 1a

Remove the hatch from the assembly and one gasket. Place all removed fasteners in a suitable container for later use. Picture 1b

Page 3: Tank inspection hatches installation - Clean Diesel

Tank inspection hatches installation

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Step 2 Place the hatch on the desired installation area (top or side) and mark the installation holes. Make sure the installation area is not on top of a baffle. For best cleaning results the hatch should be installed as centered as possible in each baffled section. Picture 2a

Drill installation holes using a good quality 7mm drill bit suitable for the tank material (e.g. for stainless steel tanks the best drill bits are cobalt or titanium) Picture 2b

Page 4: Tank inspection hatches installation - Clean Diesel

Tank inspection hatches installation

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Step 3 Find the center of the inspection hole to be drilled in the tank by marking two intersecting lines connecting the centers of two opposite sets of installation holes. Picture 3a and 3b

Page 5: Tank inspection hatches installation - Clean Diesel

Tank inspection hatches installation

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Step 4 Drill the pilot hole using a drill bit suitable for the material of the tank. The size of the drill bit should be the same size the arbor drill bit (usually ¼ inch) Picture 4a

Drill the inspection hole using a suitable size hole saw depending on the size of the hatch. Picture 4b

Page 6: Tank inspection hatches installation - Clean Diesel

Tank inspection hatches installation

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Step 5 Fold the flexiring and install in place with the mounting studs facing outwards. Picture 5a

Secure the flexiring with the top gasket. Make sure the gasket is installed all the way down to the surface of the tank. Picture 5b

Page 7: Tank inspection hatches installation - Clean Diesel

Tank inspection hatches installation

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Step 5 Gently place the hatch in place by aligning mounting holes with the studs of the flexiring. Picture 6a

Reinstall in reverse order all the M6 fasteners removed in step one (flat washer, spring washer and nut). Never use nylock nuts or other type of fasteners as it may make installation/removal difficult or cause leaks. Picture 6B

Page 8: Tank inspection hatches installation - Clean Diesel

Tank inspection hatches installation

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Step 7 Using a 10mm spanner tighten all the nuts until hatch is firmly compressed and the gasket is squeezed slightly from the margin of the hatch. Overtightening will cause gasket damage and possible leaks. Picture 7a

If your hatch comes with SAE fuel sender hole pattern, you can install additional accessories to the hatch such as: fuel senders, fuel pick-ups, fuel returns, fuel coolers, water drains, decontamination units. Picture 7b Visit www.cleandiesel.com.au for a complete list of accessories.