Bulletin TI-GCGS-E
Installation, Operation and Maintenance Manual
Technical Information
GC Gas Stations GC-4000, FID-4000
www.labgasgenerators.com
17
Remove 2 screws, using a “stubby” screw driver, holding the catalyst assembly module cover
to the base of the hydrogen purifier.
Slowly lower the module though the access opening in the base of the generator- as far as
needed to free the module from the hydrogen purifier. The rear of the generator may be
propped up to allow more clearance for module removal. Then remove module.
Replace with new assembly. Lowering module into the access opening, first, then sliding it up
into the hydrogen purifier.
Reverse above procedure – reassemble module cover onto hydrogen purifier, reconnect air
lines.
Re-attach electrical connector. Electrical connector must snap into receptacle. Connector
must be fully engaged and is designed to be installed only 1 way.
Pressurize the system and check for leaks in the air lines and fittings.
Re-assemble covers to unit and supply power.
Water Pump
Replacement
1. Switch power OFF to unit and unplug generator from power. Allow the compressed air
to continue to flow through the unit to improve heat dissipation during cooling. Purifier/
Zero Air module and cooling coil will be hot. Allow unit to cool 2 hours before opening.
2. Close the (customer installed) inlet air valve.
3. Remove left-side cover. There are 3 screws on the left side of the unit and 3 under the
hinged cover.
4. Locate water pump (see figure 7). Disconnect water pump connector.
5. Disconnect water pump tubing from the base of the water pump block and from the PEM
hydrogen cell (figure 7).
6. Remove thumb screws holding water pump block cover to water pump block.
7. Remove the 2 M3 screws that mount water pump to the water pump block cover.
8. Remove the pump and replace, using pump replacement assembly B02-0602.
9. Install 2 M3 screws into mounting holes using gaskets provided. The two gaskets are
installed on each screw on both sides of the chassis.
10. Install screws into water pump.
11. Reinstall thumbscrews to mount water pump cover.
12. Reinstall connector on water pump.
13. Reconnect tubing to water pump block and PEM hydrogen cell.
14. Briefly connect unit to power and turn unit ON to verify pump operation and no tubing
leaks. Once operation is verified reinstall covers.
15. Reinstall left-side cover and operate per the manual.
