* - Tools: * - 5.5mm A/F open end spanner * - 5.5mm A/F Socket * - Side Cutters * - Fine Flat File * - Soldering Iron * - Wiha TorqueVario Method:

Select body required for sender, select Insulating cup (200658) Grommet (200581) see pic below.

Feed Cable Grommet into hole in body side wall now locate the Insulating Cup 200658 into the larger of the two Probe Holes as shown in pic below.

One of the two 200681 probes is insulated with Plastic tube 200901. This is retained in with cable tie 201081 by gripping the end of the tube into the thread. Once assembled the tail of the Cable Tie needs to be cut off, see pic below.

Feed the Cable 200583 through the Grommet and into the sender Body see pic below.

The four wires at the end of the Cable are now carefully soldered to the PCB 10233 in the labelled positioned Black, Blue, Red, White.

The Probe with the plastic tube is now inserted into the Body through the white plastic insulating cup; the other probe is inserted into the remaining probe hole ready for attaching to the PCB assembly. The M3 nuts should have a shake proof washer fitted to them and 6mm of thread protruding prior to assembly with the PCB.

The probes are now connected to the PCB using an open end spanner to prevent the M3 Nut from turning on the underside of the board (2 places) whilst tightening the corresponding nut on the top of the Printed Circuit Board.

The PCB can now be eased into the body and screwed in position.

Using M3 x 6 pan head screw 200720 with 200508 shake proof washer, screw the Printed Circuit Board assembly securely to the Body.

The sender is now ready for programming.

Browse to the folder S:\Code\Production\3281 water Level Sender\Program AFTER Rev J\ Then select 3281bootloader.bin

Ensure the check boxes are as shown below and then select “Start Programming”

Press the re-program button

Navigate to S:\Code\Production\3271 Fuel Level Sender\Program AFTER Rev J and select 3271-v5.bin, then press “open”. Browse to the folder S:\Code\Production\3281 water Level Sender\Program AFTER Rev J\ Then select 3281bootloader.bin

Warm the compound in the water bath (this should be set to 40 degrees), this takes approximately 10 minutes for the bath to come up to temperature and 5 minutes to warm a bag of compound. Do not warm above this temperature as it will greatly reduce the pot life of the compound.

Once warm, work the black potting BEFORE removing the clip and rail – this will help remove any lumps caused by the fillers that have settled over time. Then, place back into the bath for 2 minutes. Remove the clip and rail, and mix thoroughly for approximately 2 minutes.

At this point, the cotton buds can be removed so the sender is now flat and the sender can be topped up.

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The Potting must now be left overnight to Cure and harden.

Once the Potting has set, the Serial No Label can be applied. Position symmetrically as shown in pic below. The label must show the: Part Number Serial Number Hardware and software level

You are now ready to connect the unit to the Monex system and assign the unit the serial number from the sticker and to do a final test after assembly to make sure the unit is still fully functioning and has not been damaged during the build procedure. Click SET SERIAL – input the serial number from the label Click GET PRODUCT INFO to confirm Serial Number and software level

Calibrate to Level Mode see instructions below

Calibrating the Level Sender to empty, see information below.

The Sender is now ready for packing. The user instructions are packed into Poly Bag 200332 along with 1 off Cap Assy 200310 Place sender in tube with Instructions Add Label to Packaging Tube positioned as shown Add product indicator label to cap – highlight boxes with product information. (To indicate product – Length and settings if required) Add 1x 30g tube of silicone sealant 203122 to the contents, even if we have pre cut the length.

Select product label required and place in position on tube.

— Christine Walsh 28/02/2022 11:00created