2009 C300 Operators and Maintenance Manual

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OPERATION,

MAINTENANCE AND PARTS MANUAL

TRUCK, TANK, FUEL SERVICING

ISOMETRICS MODEL 505T1200

CONTRACT GS-30F-1032D

ISOMETRICS, INC.

Post Office Box 660

Reidsville, North Carolina 27320

(Rev. H, Dec 2008)

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TABLE OF CONTENTS TITLE PAGE

CHAPTER 1. INTRODUCTION 3 1-1. Scope 3 1-2. Physical Description 3 1-3. Functional Description 3 1-4. Warranty Information 5 1-5. Shipping, Handling and Storage Data 5 1-6. Preparation for Use 5 CHAPTER 2. OPERATING INSTRUCTIONS 6 2-1. Scope 6 2-2. Safety Interlocks 6 2-3. Bonding 6 2-4. Prefueling Check 6 2-5. Bottom Loading 7 2-6. Top Loading 8 2-7. Gravity Drain, Unmetered 9 2-8. Fueling Procedure 10 2-9. Tank Loading using the Truck Pump, Unmetered 11 2-10. Defueling 12 2-11. Gravity Drain, Metered 13 CHAPTER 3. MAINTENANCE AND SERVICING 15 3-1. Scope 15 3-2. Cleaning 15 3-3. Lubrication 15 3-4. Inspection 15 3-5. Troubleshooting 15 3-6. Component Repair 15 3.7. Service 15 3.8. Ready for Air Transport 16 CHAPTER 4. PARTS LIST AND COMMERCIAL LITERATURE 20 4-1. General 20 4-2. Parts List 20 CHAPTER 5. SCULLY OVERFILL PREVENTION 23

LIST OF ILLUSTRATIONS

Figure Title page 2-1 Piping Schematic 14 4-1 Pumping Compartment 21 4-2 Pump/PTO Diagram 21 4-3 Top of Tank 22 4-3 Cable Diagram 22 4-5 Electrical Schematic (Lights) 22 4-6 Scully System Schematic 23

LIST OF TABLES page

Table Title 3-1 Daily Inspection 18 3-2 Periodic Checks and Services 18 3-3 Troubleshooting 19

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CHAPTER 1

INTRODUCTION

1-1. SCOPE. This manual contains operating procedures, service and repair instructions and and replacement parts for the fuel servicing tank truck manufactured by Isometrics, Inc., Reidsville, North Carolina. This manual does not cover components of the truck chassis. Refer to the chassis manuals provided with the vehicle pertaining to operation, maintenance, and parts listings of the cab and chassis. 1-2. PHYSICAL DESCRIPTION. The fuel truck consists of a single compartment tank with baffles mounted on a commercial chassis, a bottom loading system, and a pumping system with fuel metering capability, and filtration. a. The pumping system includes a PTO driven pump with internal bypass, a strainer assembly, a flow meter with reset counter and totalizer, a suction stub, dispensing hose reel, hose, and a trigger type automatic shutoff nozzle. b. The bottom loading system includes inlet adapters, a bottom loading valve, an electronic level sensor with onboard shutoff control and fill stand connections. c. The bottom loading valve is located in the bottom of the fuel tank. The majority of all other components are mounted in a pumping compartment between the cab and tank. The pump, strainer, and associated plumbing are located underneath the fuel tank. The filtration system is located in the underslung cabinet on the driver's side of the truck. All other pumping system and bottom loading components are located in the cabinet on the curb side of the truck. d. Physical data: 1. Model No.: 505T1200 4 x 2 4 x 4 2. Tare Weight: 16,700 LBS. 17,700 LBS. 3. Dimensions: 270"L X 96"W X 96"H 270"L X 96"W X 99"H 4. Shipping Cube: 1440 Cu. Ft. 1485 Cu. Ft. 5. Environmental Conditions: -20 to 125 degrees F 1-3. FUNCTIONAL DESCRIPTION. a. General. (1) The pumping system provides for a fuel servicing capacity of 75 U.S. gallons per minute (GPM) at the discharge end of the nozzle. (2) The truck provides plumbing and controls for bottom loading, pressure off-loading, and gravity off-loading, both metered and unmetered. A suction stub is also provided to facilitate self-loading and defueling. b. Pumping System. (1) During fueling, fuel flows from the tank through the emergency valve, through the strainer to the pump. Fuel from the outlet side of the pump flows through the filter/separator, meter, hose reel, and hose and nozzle assembly. (2) The pump is driven by a power take-off (PTO) mounted on the side of the transmission.

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CAUTION

To avoid running the pump dry make sure the emergency valve is open prior to engaging the PTO. Refer to the

operating instructions for this procedure. (3) The emergency valve operator, located in the curb side pumping compartment, opens the emergency valve. This control also serves to close the valve in an emergency. Striking or pushing the handle allows an internal valve spring to close the emergency valve. Emergency controls, operable for closing the emergency valve only, are located at the right rear of the truck, at the driver's door, and on top of the tank. They are marked with red square decals with 2-inch instruction letters. (4) Two each 40 GPM filters (if so equipped) are located in the cabinet on the driver's side of the truck. They are connected in parallel from the discharge side of the pump to allow for a total flow of 80 GPM. They filter solids and separate any water in the fuel. Drains at the bottom of each filter allow for water and solids removal on a periodic basis. Each filter is equipped with a heater for cold weather applications. The heaters are activated by a toggle switch located to the left side of the steering column on the dash. (5) An air eliminator flow meter assembly is located downstream of the filters in the curb side cabinet. It is rated for 100 GPM and comes complete with reset counter and totalizer. (6) Next is the hose reel, hose, and nozzle assembly. The hose reel is of the manual rewind type with 100 feet of 1-1/2 inch commercial grade fuel hose. A 1-1/2 inch trigger type automatic shutoff nozzle rated at 75 GPM is attached to the hose. c. Bottom Loading System. (1) The bottom loading valve, located in the bottom of the tank also serves as the emergency valve. Air pressure from the emergency valve operator or the bottom loading interlock opens it. It is a balanced type valve that will remain closed, regardless of fill stand pressure, if there is no air source to open it. (2) A bottom loading manifold, located on the left side of the truck, is provided for the fill stand connection to perform the bottom loading task. Each leg of the manifold serves as a quick disconnect drybreak connection. In order to connect the fill stand coupler, a valve lever must be moved to the side. This action opens the air vent on top of the tank, sets the truck brakes, and opens the bottom loading valve unless the tank is already full. One leg of the manifold is a D-1 nozzle adapter and the other leg is a 4-inch API commercial bottom loading adapter. (3) An electronic level sensor is installed in the top of the tank. When fuel contacts this probe, an electrical signal is transmitted to a control module located on a bracket in the curb side cabinet. A socket array is also provided to interface with the appropriate fill stand connection. When fuel contacts the sensor, the fill stand controls stop the fuel flow into the tank. If fill stand controls are unavailable, the onboard system will automatically stop the flow by closing a solenoid air valve plumbed between the bottom loading valve and the brake interlock. Air will exhaust and the bottom loading valve will close.

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d. Top Loading. The tank may be loaded from the top by opening the fill cover in the manhole cover located on the top of the tank and inserting the fill hose into this opening. The hose should reach the bottom of the tank to avoid static charge buildup. e. Vent Valve. A vent valve, located in the top of the tank, vents the tank to atmosphere during loading and off loading. The vent valve opens whenever the emergency valve operator is engaged or the bottom loading interlock is activated. This valve is pneumatically controlled. The vent is equipped with an interlock feature so that pumping operations cannot be performed unless the vent is open. The vent is open to the atmosphere via vapor recovery piping that is open at the rear of the tank. A sealed flexible hood is located over the vent valve on top of the tank. The hood is connected to a header and tubing that terminates at the rear curb side of the vehicle. Three and four inch open flanged outlets are provided for connection to the vapor recovery system, if available, at the bottom loading facility. f. Gravity Unloading. Gravity unloading can be accomplished by attaching a hose to the 2-1/2 inch faucet and opening the bottom loading valve and faucet. Gravity unloading through the faucet is unmetered. g. Self-loading and Defueling. Loading the tank using the onboard pumping system or removing fuel from an item can be accomplished by attaching a suction type hose to the fuel source or item and the 2-1/2 inch faucet, opening the appropriate valves, and starting the pump. Fuel will enter the tank via the bottom loading valve. 1-4. WARRANTY INFORMATION. See the warranty page at the end of this manual. For warranty claims contact the Purchasing Department @ 336.349.2329. 1-5. SHIPPING, HANDLING, AND STORAGE DATA. a. Shipping. When shipping the vehicle on an open top trailer or rail car, the axles and landing gear should be used for securing purposes. Insure all product is removed from the tank and pumping system. A standard single drop trailer is suitable for transport. Refer to paragraph 1-1(d) for weights and dimensions. b. Handling. The only special handling procedures for this equipment is to insure that all combustible and flammable liquids are removed from the vehicle prior to shipment. Use API (American Petroleum Institute) Publication 2013, "Cleaning Mobile Tanks in Flammable or Combustible Liquid Service" as a guide for purging the tank. To obtain a copy contact: American Petroleum Institute 1220 L Street, Northwest Washington, D.C. 20005 (202) 682-8375 Attention: Publications and Distribution Section c. Storage. For long term storage, it is recommended that the vehicle be prepared as in the handling section (b) above. 1-6. PREPARATION FOR USE. The vehicle has been completely serviced and adjusted prior to shipment.

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CHAPTER 2

OPERATING INSTRUCTIONS

2-1. SCOPE. This chapter contains instructions for the operation of the controls required to perform tank loading and various fueling operations. Refer to separate truck publications for information on proper operation of truck controls, and instruments and operation of the vehicle when in motion. 2-2. SAFETY INTERLOCKS. This unit is equipped with interlocks to prevent movement when performing a fueling operation. Whenever the valve lever positioned in front of the bottom loading adapters is moved to the side or the emergency valve operator control is pulled out, the truck brakes will be applied. Either action also results in the opening of the air operated vent on top of the tank. 2-3. BONDING. After stopping the vehicle and setting the parking brake, connect a static reel cable to unit to be refueled. WARNING Always establish the static bond between the tank vehicle and the unit to be refueled. Never attempt any fueling operation until bonding is complete. NOTE Some activities require that grounding also be accomplished. The static reel is equipped with a second clamp end for connection to a suitable ground post. 2-4. PREFUELING CHECK. Prior to filling the tank or performing any fueling operation, perform the following checks: Note: Refer to Fig. 2-1 for identification and relative location of components. NOTE The butterfly valves are closed when the lever is 90 degrees to the piping and open when the lever is parallel with the fuel flow. a. Open the cabinet doors on to gain access to the fuel system components. b. Check that the bottom loading adapters (19) and (20) dust caps, the 2-1/2 inch faucet (17) dust plug, and the 2 inch faucet (14) dust cap are in place. c. Check that the lever on the interlock air valve (18) is positioned to interfere with the fill stand coupler connection. d. Verify all valves in the pumping compartment are closed.

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e. Check the manual emergency valve operating handle as follows: (1) Pull the valve operating handle (22) to its out (open) position and release. A minor amount of tension should be felt and the handle(s) should remain in the out position. Easily strike or push the valve handle toward the in (closed) position. The internal valve spring should enable the handle to move to the in position and thus close the valve. This demonstrates the correct procedure to close the valve in an emergency. During normal use the handle can simply be guided to the in position. (2) Pull the valve operating handle to the out position. Go to the right rear of the truck and pull the emergency release handle. Check to see if the valve operating handle returned to the in position. (3) Pull the valve operating handle to the out position. Go to the left front of the tank, near the driver's door, and pull the emergency release handle. Check to see if the valve operating handle returned to the in position. (4) Pull the valve operating handle to the out position. Go to the top front of the tank and pull the emergency release handle. Check to see if the valve operating handle returned to the in position. f. Make sure the hose is properly stowed on the reel and that the nozzle is properly stowed. g. Visually inspect all components and piping connections for evidence of damage, leakage, or loosening. (Periodically check nuts and bolts for proper tightness as vibration may cause them to loosen. Visual inspection will not verify tightness, physically check the fasteners to verify.) h. Reset the visual counter on the flow meter to zero by depressing the knob on the right side and rotating it clockwise as viewed into the knob. 2-5. BOTTOM LOADING. a. After the truck is stopped in the desired location, set the parking brakes from the cab. b. Shut down the engine and engage the Scully system (if unit is so equipped) by engaging the pull type switch (overfill control) on the dash. The light near the switch will light when switch is on. c. Perform the prefueling check in paragraph 2-4. d. Electrically bond the refueler to the fill stand. e. Move lever on interlock air valve (18) to side. f. Connect the fuel supply line to the bottom loading adapter (19) or (20). g. Make the necessary connections to the Scully socket, if available

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h. Start filling the tank and make sure system is working properly by pushing the precheck switch (23). It is located on the left end of the Scully control module, in the center. Hold the button in until flow stops. After flow stops, release switch to resume flow. Again, this is if unit is so equipped, not all trucks have Scully overfill prevention systems.

WARNING If the flow does not stop soon after the precheck button is depressed, stop flow from the fill stand immediately to avoid a fuel spill. The system is not operating properly and needs repair. i. Fill the tank at a rate not to exceed 600 GPM unless the fill cover in the manhole is open. WARNING Do not load at a rate exceeding 600 GPM (gallons per minute) without opening the 10-inch fill cover in the manhole assembly. Tank over-pressure- ization could result. NOTE An indication that the tank is full is a sudden flexure of the supply hose as the bottom loading valve closes. j. The flow will stop when the liquid contacts the probe located in the top of the tank if unit is Scully equipped. The onboard control system will close the bottom loading valve and the fill stand connection, if available, will shut down the flow from the fill stand. k. When the tank is full disconnect the fuel supply line from the bottom loading adapter and, if applicable, disconnect all fill stand control lines. l. Install the dust cap on the bottom loading adapter (19) or (20). m. Move the interlock valve (18) lever back in front of the bottom loading adapter. n. Remove fill stand bonding cable and disengage Scully system. 2-6. TOP LOADING. a. After the truck is stopped in the desired location, set the parking brakes from the cab. b. Shut down the engine. c. Perform the prefueling check in paragraph 2-4. d. Electrically bond the refueler to the fill stand.

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WARNING If a top loading rack is not available for fueling, two men will be required to perform filling the tank through the manhole fill cover - one to insure the fuel supply hose does not slip out of the fill opening and observe the tank level and one to manually stop the fuel flow from ground level. The man on top of the tank must signal the other when the tank is full. e. Open the manhole fill cover, insert the fuel supply hose as close to the bottom of the tank as practicable, and start the fueling operation. f. Coordinate fuel shutoff with the fuel supply operator when the tank is full. g. Remove the fuel supply hose and close the fill cover. h. Remove fill stand bonding cable. 2-7. GRAVITY DRAIN - UNMETERED. Fuel can be gravity drained from the tank by performing the following procedures: a. After the truck is stopped in the desired location, set the parking brakes from the cab. b. Shut down the engine. c. Perform the prefueling check in paragraph 2-4. d. Connect one of the static bond cables to a suitable connection. e. Connect a fuel hose to the 2-1/2 inch faucet (17) and place opposite end of hose into a suitable container. f. Open the emergency valve (5) by pulling the top emergency valve operator lever (22). g. Open faucet (17). h. When draining is complete, close faucet (17). i. Push the emergency valve operator lever (22) to the in position. j. Disconnect and stow the fueling hose and install the dust cover as required. k. Stow the static cable. CAUTION Do not allow the cable to wind freely onto the reel. When stowing the cable, hold to it and walk back to the trailer as it winds onto the reel.

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2-8. FUELING PROCEDURE. Perform the following procedures when fueling from the tank truck is to be accomplished. WARNING If at any time during the fueling operation an emergency occurs, close the emergency valve by performing one of the following procedures: 1. Push the emergency valve operator to the in position or close the cabinet doors. One of the cabinet doors will push the EV operator handle, when closed. 2. Pull the emergency release at the right rear of the tank. 3. Pull the emergency release at the left front of the tank, near the driver's door. 4. Pull the emergency release at the front top of the tank. Note: Fully open valve 16 (sectionalizing valve) prior to any pumping operation. This will reduce pump start-up pressure. Pump pressure and flow can then be regulated as required by adjusting valve 16. a. After the truck is stopped in the desired location, set the parking brakes from the cab and place the transmission in neutral. b. Perform the prefueling check in paragraph 2-4. c. Connect one of the static bond cables to a suitable connection. d. Engage the PTO control (4) located in cab. NOTE: The PTO will not engage until the EV operator handle is pulled out. e. Note: all pumping will be done at idle speed (700 rpm). f. Reset meter (13) to zero (rotate knob on register clockwise). g. Open valves (24), (15), and (11) and, if your truck is so equipped, 3 way valve (29). h. Pull the emergency valve operator (22) handle to the open (out) position. i. Unwind hose reel (9) as required and dispense fuel by opening nozzle (10) to flow. Regulate pressure and flow by adjusting valve (16) as required. j. When fueling is complete, rewind hose onto reel (9). k. Push the emergency valve operator (22) handle to the closed (in) position. l. Close valves (24), (15), and (11) and, if your truck is so equipped, valve (29). m. Disengage the PTO control (4) located in cab.

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n. Disconnect and stow the static cable. CAUTION Do not allow the cable to wind freely onto the reel. When stowing the cable, hold to it and walk back to the truck as it winds onto the reel. 2-9. TANK LOADING USING THE TRUCK PUMP, UNMETERED. Perform the following procedures when self-loading the truck tank is required. a. After the truck is stopped in the desired location, set the parking brakes from the cab. b. Engage the Scully system (if unit is so equipped) by engaging the pull type switch (overfill control) on the dash. The light near the switch will light when switch is on. c. Perform the prefueling check in paragraph 2-4. d. Connect one of the static bond cables to a suitable connection. e. Connect 2-1/2 inch suction hose(s) to faucet (17) stub. Four each suction hoses are stored in the hose tubes at the rear of the truck. Connect opposite end of hose(s) to fuel source. f. Engage the PTO control (4) located in cab. NOTE: The PTO will not engage until the brake interlock valve (18) is activated. g. Open valve (16) and faucet (17). If truck has filter/separator and canister filters, with valve (29) located upstream of filters, open this valve also. h. Open brake interlock air valve (18) by moving lever to side. This action will engage the PTO and pumping will begin. i. Start filling the tank and make sure system is working properly by pushing the precheck switch (23). It is located on the left end of the Scully control module, in the center. Hold the button in until flow stops. After flow stops, release switch to resume flow. Again, this applies only if the unit is equipped with a Scully system, not all trucks are so equipped. WARNING If the flow does not stop soon after the precheck button is depressed, stop flow by closing brake interlock valve (18) immediately to avoid a fuel spill. The system is not operating properly and needs repair. j. The flow will stop when the liquid contacts the probe located in the top of the tank. The onboard control system will close the bottom loading valve and flow will stop. NOTE: Flow into the tank will be nonmetered. k. Close brake interlock air valve (18) by moving lever to side. This action will disengage the PTO. l. Close valve (16) and faucet (17). Close valve (29) if opened (see step h above). m. Disengage the PTO control (4) located in cab.

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n. Disconnect 2-1/2 inch suction hose(s) from faucet (17) stub and fuel source. Stow hoses in the hose tubes at the rear of the truck. q. Disconnect and stow the static cable. CAUTION Do not allow the cable to wind freely onto the reel. When stowing the cable, hold to it and walk back to the truck as it winds onto the reel. 2-10. DEFUELING. A device can be defueled and the product delivered to the tank using the onboard pump by performing the following procedures. a. After the truck is stopped in the desired location, set the parking brakes from the cab. b. Engage the Scully system (if unit is so equipped) by engaging the pull type switch (overfill control) on the dash. The light near the switch will light when switch is on. c. Perform the prefueling check in paragraph 2-4. d. Connect one of the static bond cables to a suitable connection. e. Connect 2-1/2 inch suction hose(s) to faucet (17) stub. Four each hoses are stored in the hose tubes at the rear of the truck. Connect opposite end of hose(s) to the unit to be defueled. f. Engage the PTO control (4) located in cab. NOTE: The PTO will not engage until the brake interlock valve (18) is activated. g. Open valve (16) and faucet (17). If truck has filter/separator and canister filters, with valve (29) located upstream of filters, open this valve also.. h. Open brake interlock air valve (18) by moving lever to side. This action will engage the PTO and pumping will begin. i. Start filling the tank and make sure system is working properly by pushing the precheck switch (23). It is located on the left end of the Scully control module, in the center. Hold the button in until flow stops. After flow stops, release switch to resume flow. Again, this applies if unit is Scully equipped, not all trucks have Scully systems. WARNING If the flow does not stop soon after the precheck button is depressed, stop flow by closing brake interlock valve (18) immediately to avoid a fuel spill. The system is not operating properly and needs repair. j. The flow will stop when the liquid contacts the probe located in the top of the tank. The onboard control system will close the bottom loading valve and flow will stop. NOTE: Flow into the tank will be nonmetered. k. Close brake interlock air valve (18) by moving lever to side. This action will disengage the PTO. l. Close valve (16) and faucet (17). Close valve (29) if opened.

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m. Disengage the PTO control (4) located in cab. n. Disconnect 2-1/2 inch suction hose(s) from faucet (17) stub and defueled unit. Stow hoses in the hose tubes at the rear of the truck. o. Disconnect and stow the static cable. CAUTION Do not allow the cable to wind freely onto the reel. When stowing the cable, hold to it and walk back to the truck as it winds onto the reel. 2-11. GRAVITY DRAIN - METERED. Fuel can be gravity drained from the tank by performing the following procedures: a. After the truck is stopped in the desired location, set the parking brakes from the cab. b. Shut down the engine. c. Perform the prefueling check in paragraph 2-4. d. Connect one of the static bond cables to a suitable connection. e. Connect a fuel hose to the 2-inch faucet (14) and place opposite end of hose into a suitable container. f. Open the emergency valve (5) by pulling the top emergency valve operator lever (22). g. Open valves (15) and (16) and faucet (14). If truck has both canister filters and a filter/separator and valve (29) is upstream of the filters, it will not be necessary to open valve (29). h. When draining is complete, close valves (15), (16) and faucet (14). i. Push the emergency valve operator lever (22) to the in position. j. Disconnect and stow the fueling hose and install the dust cover as required. k. Stow the static cable. CAUTION Do not allow the cable to wind freely onto the reel. When stowing the cable, hold to it and walk back to the trailer as it winds onto the reel.

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Fig. 2-1 Schematic

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CHAPTER 3

MAINTENANCE AND SERVICING 3-1. SCOPE. This chapter contains instructions for inspection, lubrication, cleaning, and routine servicing procedures. 3-2. CLEANING. Should the need arise to perform welding or cutting operations on the tank, tank cleaning should be in accordance with API Publication 2013 (Cleaning Mobile Tanks in Flammable or Combustible Liquid Service). This is a safety measure to insure the tank is vapor free. If the tank is not free of flammable vapors prior to and during the performance of hot work on it, an explosion resulting in serious bodily injury or death could result. 3-3. LUBRICATION. Lubricate hose reel crank, static reel, and emergency valve operator cables weekly using MIL-C-7118 grease or equivalent. 3-4. INSPECTION. Table 3-1 lists inspections to be made daily, before, during, and after operation to insure that the fuel trailer is safe to operate and to identify any malfunction. Table 3-2 lists periodic checks and services to be made in addition to daily inspections at intervals as specified in the tabulated listing. 3-5. TROUBLESHOOTING. This section contains instructions for troubleshooting the fuel system. Table 3-3 provides a list of malfunctions that may occur. Each potential malfunction is followed by a probable cause or list of probable causes. Each probable cause is followed by a corrective action procedure. 3-6. COMPONENT REPAIR. Commercial literature for the major active components in the fueling system is provided at the end of this manual, in chapter 4. Refer to this information as necessary for maintenance, repair, servicing and adjusting, calibration, and parts listing for the affected item. 3-7. SERVICE. See tables 3-1 (Daily Inspections), 3-2 (Periodic Checks and Services) and 3-3 (Troubleshooting) for applicable servicing information.

DANGER

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3.8 Ready for Air Transport This chapter gives instructions for making vehicle air transportable. This requires lowering the height of the vehicle using following methods. a. Pull down front suspension Using ratcheting mechanism provided, pull front suspension down as shown.

Wrap chain around spring/axle and connect to ratcheting mechanism. Hook other end of tool around frame rail and pull vechicle down. After pulling down the second side, recheck the first side to make sure it is still tight. b. Release air from tires Release air from tires until pressures are: 35 psi front, 25 psi rear

Connect this end to chain wrapped

around axle/spring

This end hooks over

frame rail

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c. Dump air from air bumper under cab.

AFTER DISCONNECTING

LINKAGE, USE THIS LEVER TO RELEASE

DISCONNECT THIS

LINKAGE FROM LEVER

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Table 3-1 Daily Inspections

Before Operation

During Operation

After Operation

Item Check

X

X

Fuel System Plumbing and Components

Check plumbing and components for leaks while the unit is operating.

X

Sump Drain Valve

Place a suitable container under the sump drain valve and open the valve briefly. Check the contents of the container for water. If no water is present, the unit is ready for operation. If water is present, repeat the procedure until fuel only (no water) is drawn into the container.

X Fueling Hose and Nozzles

Check that all detachable equipment is present and properly

stored. X Fire Extinguishers Check that all fire extinguishers are

charged and inspections are up to date.

Table 3-2 Periodic Checks

Checks and Services Weekly Other Intervals 1. Clean and inspect nozzle, bottom loading adaptor and fuel strainer.

X

2. Check tank for operation of manhole fill cover latch, debris or foreign matter in tank and operation of vent(s).

x

3. Service Lube Points (see paragraph 3-3).

X

4. Check accuracy of meter and register using a graduated container.

Annually

5. Calibrate Meter When material being pumped is changed, when maintenance is performed on meter or register or when unit is obviously not measuring correctly.

6. Check tightness of bolts on valve flanges. Visual inspection will not verify tightness, physically put a wrench on these bolts.

Monthly

7. Check Torque of tie down bolts. Torque all but the spring loaded bolts to 90 ft lb. Tighten the spring loaded bolts until the spring compressed length is 3 1/2”.

Check initially upon receipt of truck, recheck after one month, followed by annual inspection.

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Table 3-3 Troubleshooting Malfunction Probable Cause Corrective Action

1. Pump operates, but system will not pump fuel

1. Tank is empty 2. Incorrect Valve Positions 3. Strainer Clogged 4. Emergency Valve Cable stretched or broken 5. Inoperative Nozzle 6. Obstruction in Piping 7. Defective Hose Valve

1. Fill the tank 2. Reset Valve settings, insure the settings are correct 3. Clean Strainer 4. Check valve travel underneath truck, adjust as needed or replace cable. 5. Repair or replace nozzle 6. Locate and remove obstruction 7. Repair or replace valve

2. Pump operates, but output is below normal

1. Partially clogged strainer 2. Engine Speed too slow 3. Emergency Valve Cable stretched

1. Clean or replace strainer 2. Increase engine speed 3. Check underneath truck for cable travel. Adjust or replace cable as needed

3. Pump operates, flow is as expected, but slows or stops after only a few minutes of operations

1. Vent valve closed or clogged

1. Pull emergency valve operator to see if vent opens 2. If vent does not open, check air lines between E/V and vent. And repair or replace as needed 3. Clean or replace vent as needed

4. Hydraulic motor rotates, but system will not pump fuel

1. Valves not positioned correctly 2. Pump to motor coupling defective 3. Defective pump

1. Reset valve settings, insure that valve settings are correct. 2. Replace defective coupling 3. Repair or replace pump.

5. Meter does not register 1. Rotor Shaft pin sheared 2. Broken Rotor

1. Replace pin 2. Replace Rotor

6. Meter registers erratically 1. Stripped gear teeth or broken teeth in the gear. 2. Worn gear plate ass’y shafts

1. Replace defective gears 2. Replace gear plate ass’y or gears

7. Pump pressure too high or too low

1. By Pass Valve out of adjustment

1. Adjust to correct pressure by turning screw on top of valve. Turn in to increase pressure, turn out to decrease pressure.

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CHAPTER 4

PARTS LIST AND COMMERCIAL LITERATURE 4-1. GENERAL. This chapter contains information that will be of assistance during repair and maintenance of vehicle components, such as identification and location of major parts. Also included is literature on various commercial components provided on this unit. 4-2. PARTS LIST. FIG. & DESCRIPTION PART NUMBER QTY INDEX NO. 4-1-1 Valve, B/F, 3-inch WD301ALV 3 -2 API Bottom Loading Adapter F5000-001 1 -3 D-1 Bottom Loading Adapter 61528BC 1 -4 Brake Interlock Valve 3418 1 -5 Valve, Check, 1/2" (inside tank) 61-103-01 1 -6 Hose Reel C1115-25-15L 1 -7 Nozzle CV90-001 1 -8 Valve, B/F, 2-inch (Victaulic) 700 1 -9 Flow Meter M7C1 1 -10 2-inch Faucet Dust Cap MS27028-11 1 -11 2-1/2 inch Faucet Dust Cap MS27028-13 1 -12 Static Reel DMI-75G40-20 1 -13 Valve, Faucet WD201ALV 1 -14 Scully Shut-Off System 09356 1 -15 Powerise Air-Springs GSS-18-21UB 4 4-2-1 Pump TXD02A 1 -2 End Yoke 10-4-123 1 -3 Driveshaft N10270-SF 1 -4 End Yoke 10-4-103 1 -5 PTO CS20-41006-H1BX 1 4-3-1 Hood, Vapor Recovery VR45962BU 1 -2 Vent AV46850ALFTS 1 -3 Manhole Cover, 20" PPVL863BXB346 1 -4 Probe, Scully Shut-off Kit 09356 1 4-4-1 Remote Trip Handle 35603SL 3 -2 Valve, Water Drain 3721X1 1 -3 Valve, Emergency / Bottom Load 64055A 1 -4 Operator, EV 41158-A 1 4-5-1 Light, Cabinet 570006 2 -2 Light, Clearance 500012 4 -3 Light, Stop, Turn, Tail 400017 2 -4 Light, Back-up 500011 2 -5 Light, I.D. 200013 1 -6 Junction Box 470041 1

21

Fig. 4-1 Pumping Compartment

Fig. 4-2 Pump/PTO Diagram

1 2

4

3

5

IN TANK

6

7

8

9 10

22

Fig. 4-3 Top of Tank

Fig. 4-4 Cable Diagram

Fig. 4-5 Electrical (Lights)

1

2

3

4

23

Chapter 56 Scully “IntellliCheck” Overfill Prevention System

5-1 Scully Operation Procedures a. The Scully system is fully self contained and should function automatically when the switch in the cab is turned on. The pilot light near the switch should illuminate. b. A good way to check the system to see if all components were properly installed and are properly functioning is to turn on the system with the switch in the cab and to place a small cup of liquid around the probe (water should work but a darker liquid such as Coke may be required, fuel will definitely work). The probe can be accessed through the manhole fill cover. When the liquid contacts the probe listen for air exhausting from the solenoid valve. This indicates that the system is functioning properly. c. Further testing should be conducted at the fill stand using the onboard pre-check system. Engaging the push button switch on the left side of the Scully Intellicheck module should cause the flow from the fill stand to stop. This check should be performed at 100 to 300 gallons into the bottom loading task.

Fig.4-6 Scully System Schematic

24

WARRANTY

Isometrics, Inc. (Company) hereby warrants its products to be free from defects in materials and workmanship for a period of one (1) year from the date of original purchase. If, upon examination by the Company, any part or parts are determined to be defective, the Company will provide, free of charge, for the repair or replacement of said items, as the Company may elect. This warranty is subject to the following exceptions and limitations:

I . The customer shall be responsible for normal maintenance and minor adjustment of the product. Notification to the Company of the need for warranty service shall be performed and any transportation charge and/or delivery of the product to and from the place where warranty service is to be performed must I-cave prior written approval from the Company. 2. This warranty does not apply to component parts or accessories applicable to the cab and chassis and tractors, which carry the warranty of the manufacturer thereof. 3. This warranty applies only to products which are placed in normal use, and does not apply to any product which has been mistreated, neglected or damaged by accident. 4. This warranty does not apply to any product repaired or altered by anyone other than a Company representative, unless such repair or alteration has been authorized by the home office.

For warranty service, contact any Company representative. For the name and location of the nearest representative, and for further warranty information, write or call:

ISOMETRICS, INC. P.O. BOX 660

1266 NORTH SCALES STREET REIDSVILLE, NORTH CAROLINA 27320

PH: 336-349-2329 FAX: 336-349-4744

Attn. David McCollum email: dmccollum@isometrics-inc.

SM64055MAINTENANCE MANUAL

FOR CARTERPART NUMBERS 64055 & 64143

4” INTERNAL/BOTTOM LOADING VALVES,

March 1, 2001, New Release

Carter Ground Fueling DivisionArgo-Tech Corporation

671 West Seventeenth StreetCosta Mesa, CA USA 92627-3605Ph: (949) 764-2200 • Fax: (949) 631-2673

Email: [email protected] • Web: www.argo-tech.com

SM64055 March 1, 2001

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SUMMARY OF REVISIONS

DATE OFCHANGE

E.O. NO. REV. PARA. ORPAGE NO.

DESCRIPTION APPROVED

3/1/2001 - NEW RELEASE

SM64055 March 1, 2001

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TABLE OF CONTENTS

1.0 INTRODUCTION................................................................................................ 4

2.0 EQUIPMENT DESCRIPTION............................................................................ 4

3.0 AVAILABLE OPTIONS ..................................................................................... 4

4.0 DISASSEMBLY .................................................................................................. 5

5.0 INSPECTION....................................................................................................... 5

6.0 REASSEMBLY ................................................................................................... 6

7.0 TEST .................................................................................................................... 6

8.0 ILLUSTRATED PARTS CATALOG.................................................................. 7

FIGURE 1A, 64055 & OPTIONS............................................................................ 10

FIGURE 1B, 64143A & OPTIONS ......................................................................... 11

FIGURE 2, 64055 PARTS BREAKDOWN ............................................................ 12


FIGURE 4, PILOT VALVE PARTS BREAKDOWN ............................................ 14

FIGURE 5 - DIAPHRAGM INSTALLATION POSITION .................................... 15

FIGURE 6 - DIAPHRAGM TORQUE SEQUENCE.............................................. 15

SM64055 March 1, 2001

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MAINTENANCE, OVERHAUL & TEST INSTRUCTIONSCARTER PART NUMBERS 64055 & 64143 INTERNAL/BOTTOM LOADING VALVES

1.0 INTRODUCTION

This manual furnishes detailed instructions covering themaintenance and overhaul of Carter Part Numbers 64055,and 64143 4” Internal/Bottom Loading Valves. Thismanual assumes that the valves will be used with a Carter64079 Level Sensor, however the 64055A, B, 64143A or

B can also be used with optic probe (s) using solenoidvalve (s) to effect the control of the pilot valve (s). If soservice manuals for these components should berequested from the manufacturer of the items used. Carterdoes not provide such items.

2.0 EQUIPMENT DESCRIPTION

The Carter 64055 family of 4” valves can be used eitheras a straight internal valve or for bottom loading control.The 64055 mounts directly into a 4” TTMA Tank SumpRing. The 64055A is used with the Carter 64079 LevelSensor for bottom loading control with a single controlpilot valve. Option “B” adds two-stage level control withtwo pilot valves. (Note: Early units contained provisionsfor only single pilot valves with the dual capabilityavailable at a later date.) Option “B” requires either theuse of 64079B, C or two 64079 Level Sensors. A CarterVent, 64078, is also available to complete the systemrequirements. A straight 64055 Internal Valve can beconverted to a bottom loading valve, 64055A, by addinga pilot valve.

The 64143 4” Bottom Loading Valve is used only forbottom loading. The difference between the 64055 andthe 64143 is the absence of an off-loading cylinder on the64143 and a different orifice system in the piston.

The units are spring loaded “overbalanced” piston valves.Fuel inlet pressure is routed to the inside of the pistonchamber through a two-staged orifice in the center of thepiston. If the piston chamber has no exit, the areas insidethe piston chamber (outer diameter of the piston) is largerthan the face seal of the piston, hence the balance of

pressure forces, plus the spring force will keep the piston(valve) closed.

If the piston chamber is vented through an open pilotvalve, options A or B, the pressure drop across the inletorifice reduces the piston chamber pressure significantly.The resultant balance of forces will cause the piston toopen, hence the valve.

When the piston chamber is once again closed [pilotvalve (s) closes], the balance of forces again causes thevalve to close.

The 64055 or 64143 A or B is normally utilized with the64079 Level Sensor. If so desired, a solenoid valve (s)can be used in the system to provide or deprive the pilotvalve of pressure (usually routed from the bottom loadingadapter) to cause the opening and closing of the valve. Inthis way the valve can be used with any optic type sensingprobe to detect the desired tank level for closure.

On the 64055, a separate air operated piston is providedto effect off-loading as desired. The direction of airpressure to this piston will cause it to pull open the mainpiston to allow for off-loading flow. When the airpressure is depleted, the spring forces will close both theair and main pistons.

3.0 AVAILABLE OPTIONS

The 64055 Basic Valve is designed for use as an internalvalve and has no other functional controls. The 64055 canbe opened for off-loading by application of air pressure tothe cylinder provided. The 64143 can only be used asoption A (64143A) since it has no off-loading capability.

The “A” option (64055A or 64143A) adds a pilot valveto the basic unit making it a bottom loading control valve.Again the 64055A can also be used for off-loading by theapplication of air pressure to the provided cylinder.

The “B” option (64055B or 64143B) adds two pilotvalves to the basic unit to close the valve in two-stages.An orifice in the secondary pilot valve will continue tovent the piston chamber after the primary pilot valve hasclosed. This orifice restricts the pressure escaping fromthe piston chamber to maintain the piston in a partiallyopen position hence flow into the tank is reducedsignificantly. This provides a more accurate final shutoffand also helps control surge pressure on final shutoff.

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4.0 DISASSEMBLY

4.1 Refer to Figures 1, 2 or 3 for exploded views of theunit.

4.2 Remove the six Screws (8) and Washers (9) fromthe Bonnet (23) or (24) and put a side for reuse.

4.3 Rotate the bonnet slightly in either direction andpull it from the Body (28). On the 64055 the Piston(12) and its attaching parts will come out of theBody (28) with the bonnet as Piston Assembly(10).. Continue on with the next paragraph if theunit being disassembled is the 64055. Ship toparagraph 4.5 if it is a 64143.

4.4 64055:

4.4.1 Find the Pin (17B) in the Shaft Assembly (17). Usethe spring pin to hold the shaft in place and removeRod (11) by unscrewing it, being careful not todrop Piston (12). Remove Piston (12) and Spring(13).

4.4.2 Remove Ring (14), Spring Pad (15) and Spring(16). Remove O-ring (22) from Bonnet (23) anddiscard it.

4.4.3 Using the pin used in paragraph 4.4.1 hold theShaft Assembly (17) while unscrewing Housing(18). Pull Housing (18) off of Bonnet (23).

4.4.4 Remove Wipe Ring (20) and Quad-Ring (21) fromBonnet (23). Discard both items. Skip to paragraph4.6.

4.5 64143:

4.5.1 Remove Bonnet (24) then remove Spring (13).Remove O-ring (22) from Bonnet (24) and discardit.

4.5.2 Reach into body (28) opening and carefully extractthe Piston Assy (25).

4.5.3 Unless replacement is needed it is recommendedthat Set Screw (27) and Nut (26) in the face of thepiston not be removed.

4.6 64055 & 64143 - Remove and discard O-ring (29)and Seal (30) from Body (28).

4.7 Unless the Screen (33) is damaged and needsreplacement, do not remove it from the Body (28).If it needs replacing then remove Screws (31) andNuts (32) to do so.

4.8 On the basic unit, remove the Plug (3) only if it hasbeen leaking. If it is removed, then discard Gasket(4).

4.9 On 64055 or 64143A - Unscrew Pilot Valve Assy(2) from Bonnet (23) or (24) and remove anddiscard Gasket (4). On “B” option to either unit,remove secondary Pilot Valve Assy (2). Orifice (5)and Gasket (6) will be found under the secondaryPilot Valve Assy (2). Remove them and discardGasket (6).

4.10 Pilot Valve Assy (2) may be replaced as acomplete unit or overhauled as follows:

4.10.1 Remove six Screws (34) and Washers (35).

4.10.2 Using a thin blade screwdriver, pry the Cover (36)from the assembly. Be careful not to scratch theflanged surface of either metal part holding thediaphragms in place.

4.10.3 Remove and discard the two Diaphragms (37).

4.10.4 Remove Pressure Pad (38) from Poppet (40) shaft.

4.10.5 Remove Ring (39), which retains Spring (42) andWasher (41) in place. This will free up theremaining parts for removal.

5.0 INSPECTION

5.1 It is recommended that all O-rings (19), (22), (29);Gaskets (4), (6); Quad Ring (21); Wipe Ring (20);Diaphragms (37) and Seal (30) be replaced at eachoverhaul.

5.2 The outer diameters of the Shaft (17A), and Piston(12) along with the inner diameter of Housing (18) shouldbe inspected for scratches that might cause leakage. Thepiston seat in the Body (28) shall also be free of pits,scratches or gouges that would cause leakage. Inspect allother metal parts for dings, gouges, abrasions, etc. On allparts except the ones listed above, use 320 grit paper tosmooth and remove sharp edges. The outer diameter of

the Shaft (17A) and the Piston (12) can be polished toremove minor scratches by using a very fine emery clothwhile the parts are rotated. Do not polish local areas ofthese diameters. Unless proper equipment is available toaccomplish this task and to polish the inner diameter ofthe Housing (18) it is recommended that the parts bereplace, If polishing is attempted, do not break throughthe hard anodized surface of the Piston (12). If scratchesare too pronounced, the parts should be replaced. Replaceany part with damage exceeding 15% of local wallthickness. Use Alodine 1200, or similar chem filmtreatment, to touch up bared aluminum.

SM64055 March 1, 2001

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The flat surfaces of the Fitting (43) and Cover (36) maybe polished to remove minor scratches by using a flatplate and very fine emery cloth. Be careful to keep the

parts flat during polishing and to not raise any burrs onthe inside diameters that bare on the diaphragms.

6.0 REASSEMBLY

6.1 Reassembly is accomplished in essentially thereverse order of disassembly noting the following:

6.1.2 Light lubrication of all O-rings and seals, usingpetroleum jelly is recommended to facilitate installation.

6.1.3 When reassembling the Pilot Valve Assy (2) usethe following procedure to assure proper diaphragmretention:

6.1.3.1 Once the Poppet (40), Spring (42), Washer (41)and Ring (39) are in place, be sure that the Pressure Pad(38) is placed onto the Poppet (40) shaft with the smallerend placed onto the shaft first. The larger flat surfaceshould be facing away from the shaft.

6.1.3.2 The two Diaphragms (37) are placed such thatthe loops in the diaphragms are facing the Pressure Pad(38).See Figure 5 for an illustration. [In operation, theloops always face in the direction in which the pressurefrom the Level Sensor or solenoid valve is applied.]Smooth out the Diaphragms (37) place onto the Fitting(43) and align the six holes in all three parts. Carefullyplace the Cover (36) onto this assembly aligning theholes.

6.1.3.3 Start the six Screws (34) with the Washers (35)in place by hand until resistance is met. Note that if noresistance is met in attempting to hand tighten the screws,it is recommended that the Screws (34) be replaced. Theyare self-locking and some resistance should be felt.

6.1.3.4 Observing the Cover (36) from the outside end(look at the threaded port in the middle), mentally numberthe holes in a clockwise direction from one to six. Refertop Figure 6. Using a properly set torque wrench, tighten

the number 1 screw to 1.6 in-lbs. (1.8 Kg-cm), followedby tightening screws number 5, 3, 6 and 4 in that order.Then repeat the tightening sequence to 3.2 in-lbs. (2.1Kg-cm) and then 5.3 in-lbs. (6.1 Kg-cm) respectively.

Let the assembly stand for a minimum of 15 hoursretighten the screws as above to the 5.3 in-lbs. (6.1 Kg-cm) setting.

6.1.4 When installing the Seal (30) onto O-ring (29) inBody (28) be sure to smooth the surface evenly with afinger. See note on Figures 2 and 3.

6.1.5 On the 64055 - Use Locktite 24221 (17C) on thethread of Shaft (17A) before screwing on Housing (18).Note the thread of both parts should be cleaned with therecommended Locktite cleaning solution prior to using24221. Read the instructions on 24221 before using.

6.1.6 Once the Piston/Bonnet Assy (10) has beeninserted into the Body (28) the Rod (11) must be adjustedto provide a gap of 0.012±0.005 (.305±.127 mm)between the under side of the hex head of the rod and themating flat surface of the Piston (12). A feeler gageshould be used for this purpose. This will assure that theproper surge control during shutoff will be effective. Onthe 64143 if the Set Screw (27) and Nut (26) wereremoved it will be necessary to adjust the face of the SetScrew (27) to .409 ± .005 inches (10.388 ± .127 mm)from the face of the Nut (26).

6.1.7 If the Screen (33) was removed and replaced, thereplacement will be provided in a flat condition and itwill be necessary to carefully shape it to fit the Body (28).

7.0 TEST

7.1 The following test procedures will beaccomplished after overhaul:

7.2 Test conditions

7.2.1 Test media shall be odorless kerosene, Jet A orequivalent at 75° + 15°F.

7.3 Functional Test - If testing prior to reinstalling theunit in the refueler is desired conduct the following tests:

7.3.1 Connect the inlet of the unit to a test mediapressure source with a minimum of 150-psig available.

Tee off the inlet pressure line to the primary pilot valveand to the secondary pilot valve on “B” option units.Install a small ball valve between the inlet pressure sourceand each pilot valves. Install a bleed valve between thepilot valve (s) and the ball valve. Gauges should beinstalled in the pressure line to the main valve’s inlet andin the line to the pilot valve (s).

7.3.2 On the 64055 connect the air port to a 100-psig airpressure source with a gauge in the line.

SM64055 March 1, 2001

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7.3.3 Bleed all air from the valve by applying 10-psigtest media pressure to the inlet and opening the bleedvalve (s) in the lines to the pilot (s). Once the air is bled,close the valve in the line to the pilot (s) and bleed allliquid trapped in the line (s).

7.3.4 Increase the pressure to the valve to approximately25-psig for one minute and then increase it to 150-psigfor one minute. Observe for external leakage during thetest period. No leakage except from the main piston shallbe allowed. This leakage should be limited to 100cc/minute.

7.3.5 On the 64055, following the above test with thevalve still full of liquid apply air pressure to the unitstarting at 35-psig and slowly increasing slowly until thevalve opens. The valve should open at an air pressure of50-psig maximum. If testing the 64143 skip thisparagraph and go on to 7.3.6. Shutoff the air pressure andbleed it to atmosphere. The valve should return to theclosed position.

7.3.6 Apply liquid pressure slowly to the valve inlet andsimultaneously to the pilot (s). Observe when the mainpiston opens. The valve shall open with an inlet pressureof 15-psig or less.

8.0 ILLUSTRATED PARTS CATALOG

Table 1.0 tabulates the parts and sub-assembliescomprising the various versions of both the 64055 and64143 Valves with all options. The item numbers of the

table are keyed to the exploded views of the unitdiagrammed in Figures 1, 2 or 3.

TABLE 1.064055 & 64143 Bottom Loading Valves & Options

Refer to Figures 1A and 1B

Figure Item Part Number Description Units PerAssembly

Option Spares/10Units/Yr.

1A 1 64055 Internal Valve, Bottom Loading andOff-loading (Figure 1A).................... 1 - -

1A 3 GF814-10D Plug................................................... 2 Basic -4 MS29512-10 Gasket ............................................... 2 Basic 202 47097 Pilot Valve, Primary (FIGURE 4) .... 1 A -3 GF814-10D Plug................................................... 1 A -4 MS29512-10 Gasket ............................................... 2 A 202 47097 Pilot Valve, Secondary (FIGURE 4) 2 B -4 MS29512-10 Gasket ............................................... 2 B 205 221087 Orifice............................................... 1 B -6 MS29512-08 Gasket ............................................... 1 B 10

1B 1 64143 Internal Valve, Bottom Loading Only(Figure 1B) ....................................... 1 - -

3 GF814-10D Plug................................................... 1 A -4 MS29512-10 Gasket ............................................... 2 A, B 202 47097 Pilot Valve, Primary (FIGURE 4) .... 1 A -2 47097 Pilot Valve, Secondary (FIGURE 4) 2 B -5 221087 Orifice............................................... 1 B -6 MS29512-08 Gasket ............................................... 1 B 10

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TABLE 2.0Parts Breakdown, 64055 & 64143 Basic Valves



2, 3 8 GF35275-265 Screws............................................... 8 All -9 GF35338-138 Washers ............................................ 8 All -

2 10 No number Piston/Bonnet Assy........................... 1 64055 -11 220447 Rod........................................... 1 64055 -12 47096 Piston ....................................... 1 64055 113 220436 Spring....................................... 1 64055 -14 GF16633-4050 Ring.......................................... 1 64055 -15 220438 Spring Pad................................ 1 64055 -16 220437 Spring....................................... 1 64055 -17 47095 Shaft Assembly ........................ 1 64055 -

17A 220448 Shaft .................................. 1 64055 -17B GF16562-238 Pin..................................... 1 64055 -17C 24221 Locktite .................................... 1 6405518 220450 Housing .................................... 1 64055 -19 MS29513-112 O-ring....................................... 1 64055 1020 220453 Wipe Ring ................................ 1 64055 1021 Q4325-366Y Quad Ring ................................ 1 64055 1022 MS29513-157 O-ring....................................... 1 64055 1023 47099 Bonnet ...................................... 1 64055 -

3 22 MS29513-157 O-ring ............................................... 1 64143 1024 221108 Bonnet .............................................. 1 64143 -25 47284 Piston Assy ....................................... 1 64143 112 47096 Piston ....................................... 1 64143 126 GF51971-3 Nut ........................................... 1 64143 -27 221109 Set Screw, Orifice .................... 1 64143 -13 220436 Spring ............................................... 1 64143 -

2, 3 28 220458 Body ................................................. 1 All -29 MS29513-248 O-ring ............................................... 1 All 1030 220456 Seal ................................................... 1 All 1031 GF515C4-5 Screw................................................ 2 All -32 GF20365D440 Nut .................................................... 2 All -33 220431 Screen ............................................... 1 All -

SM64055 March 1, 2001

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TABLE 3.0Pilot Valve Parts Breakdown



1A, 1B 2 47097 Pilot Valve Assy, Primary................. 1 A & B -4 34 LP35275-230 Screw........................................ 6 A & B -

35 GF620C6 Washer ..................................... 6 A & B -36 220441 Cover........................................ 1 A & B -37 220445 Diaphragm................................ 2 A & B 2038 220443 Pressure Pad............................. 1 A & B -39 GF16633-4018 Ring.......................................... 1 A & B -40 220434 Poppet ...................................... 1 A & B -41 220442 Washer ..................................... 1 A & B -42 220444 Spring....................................... 1 A & B -43 220433 Fitting....................................... 1 A & B -

1 5 47097 Pilot Valve Assy, Secondary............. 1 B -4 34 LP35275-230 Screw........................................ 6 B -

35 GF620C6 Washer ..................................... 6 B -36 220441 Cover........................................ 1 B -37 220445 Diaphragm................................ 2 B 2038 220443 Pressure Pad............................. 1 B -39 GF16633-4018 Ring.......................................... 1 B -40 220434 Poppet ...................................... 1 B -41 220442 Washer ..................................... 1 B -42 220444 Spring....................................... 1 B -43 220433 Fitting....................................... 1 B -

There are several kits of parts designed to provide the necessary items to overhaul the units as described below.

KIT NUMBER DESCRIPTIONKD64055-1 Kit, seal replacement for 64055A Valve. Contains items 4, 19, 20, 21, 22,

29, 30 & 37.KD64055-2 Kit, seal replacement for 64055 Basic Valve. Contains items 4, 19, 20, 21,

22, 29 & 30.KD64055-3 Kit; seal replacement for 64055B Valve. Contains items 4, 6, 19, 20, 21, 22,

29, 30 & 37.KD64129-3 Kit; Overhaul for 47097 Pilot Valve Assy. Contains items 4 & 37.KD64143-1 Kit; seal replacement for 64143A Valve. Contains items 4, 22, 29, 30 & 37.KD64143-2 Kit; seal replacement for 64143B Valve. Contains items 4, 6, 22, 29, 30 &

37.Notes: 1. All part numbers beginning with "GF" Are interchangeable with those beginning with either "AN" or "MS".

If three numbers follow the “GF” it is interchangeable with an "AN" part, otherwise it is interchangeablewith an "MS" part of the same number.

2. The recommended spare parts shown Above Are the number required to support 10 units for one year oreach overhaul whichever is sooner. These quantities do not include replacement spares for intermediatereplacement of parts required by Abuse or misuse of the equipment. The recommended quantities are basedon the ratio of spare parts sold for each unit during A one-year period of time. The actual quantity requiredwill vary from location to location.

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FIGURE 1A64055 & OPTIONS

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FIGURE 1B - 64143A & OPTIONS

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FIGURE 264055 PARTS BREAKDOWN

SM64055 March 1, 2001

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SM64055 March 1, 2001

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FIGURE 4PILOT VALVE PARTS BREAKDOWN

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FIGURE 5DIAPHRAGE INSTLLATION POSITION

FIGURE 6DIAPHRAGM TORQUE SEQUENCE

4” BOTTOM LOADING COMPONENTSMODELS 64055, 64079, 64143

The Carter 4” family of Bottom Loading Valvesand accompanying Level Sensor are designed foruse in refuelers where bottom loading/off-loadingrates of up to 800 gpm are desired. There are twointernal valves in the family, one for use inloading and off-loading while the other is strictlyused for loading. Off-loading requires the use ofair pressure to open the internal valve. Both areused with the Carter 64079 Level Sensor or as analternative they can be used with an optic probecontrol. Bottom loading control is accomplishedautomatically, as in all Carter units when the tankliquid level reaches the pre-set level sensor. Seeaccompanying brochure 64055 for detailinformation on the operation of all Carter bottomloading units.

Both of the available internal valves can bepurchased to use with either a single or dual levelsensor as explained below.

64055A 4”Internal Valve

64079ALevel Sensor

FEATURES:❏ Pilot valve is identical on all Carter Bottom Loading components for lower maintenance costs. There is no

through hole in the diaphragm in the pilot to cause leakage and ultimate failure.

❏ Either single level or dual level control available. Dual level control, when used with 64079B Level Sensorprovides better shutoff level accuracy and lower surge pressures resulting from closing at very high rates offlow.

❏ 50-psi min. air pressure and standard air controlling valves (not furnished by Carter) required for off-loading- 64055. No off-loading control provided on the 64143.

❏ Internal Valve mates standard TTMA sump flange.❏ Can be used with optic sensing system.❏ Low pressure loss:

Bottom Loading – 4.5 psi at 600 gpmOff-loading - 1.5 psi at 600 gpm

Bulletin 64143 9/2000

671 W. 17th St., Costa Mesa, CA 92627 • Ph (949) 764-2200 • Fax (949) 631-2673 • E-mail [email protected] • ISO 9001 Certified


ORDERING INFORMATION:

64055 (basic configuration) - 4” INTERNAL OFF-LOADING VALVE - provides off-loading by use of air pressure.

64143A (no basic configuration available) - 4” BOTTOM LOADING VALVE - For use for loading the refueler only, no off-loading capability.

One or more of the following options may be added to change the function or configuration of the units above:

OPTION DESCRIPTION

A Adds pilot valve to basic unit (64055 only, 64143A only unit available) to provide bottom loading control whenused with Carter 64079 Jet Level Sensor or optic sensing probe system.

B Adds dual pilot valves to either unit for use with either two 64079 or one 64079B Level Sensors to improveaccuracy of the tank shutoff level or to reduce surge at closure.

64079 LEVEL SENSOR

There are no moving parts or seals in the Carter Level Sensor which, when used with 64055A or 64143ABottom Loading Valve will provide high level bottom loading control. There are no wearing parts in theunit hence it lasts indefinitely. Truck vibration will have no affect on the unit, unlike float valves, whichare subject to vibration damage. It is available with an optional mounting stud for adjustable level control.The stud is located outside of the collector/drain can for better level control. A collector/drain can andprecheck feature are provided as standard equipment.

One of the following options may be added to the basic 64079 part number to achieve the degree ofcustomization desired when used with either the 64055A or 64143A:

OPTION DESCRIPTION .

A Adds stud to basic unit to provide mounting and level adjustment., ½-13 UNC-2B thread

B Adds second Level Sensor with accompanying single mounting stud for use with 64055B or 64143B, ½-13 UNC-2B thread.

EQUIVALENT PART NUMBERS – WHITTAKER TO CARTER

The following table presents the equivalent part numbers for Carter units to replace Whittaker units:

ITEM DESCRIPTION WHITTAKERPART NO.

CARTERPART NO.

COMMENTS – APPLICABLE TOCARTER UNITS

4” Internal Valve for Off-loadingonly

F614 64055 Air pressure required for off-loading.

4” Internal Valve for BottomLoading and Off-loading

F614A or B 64055A or B Either single or dual pilots available.Air required for off-loading

4” Internal Valve for BottomLoading only.

None 64143A No off-loading capability, a separateinternal valve has to be used.

Level Sensor, no options F613 64079 Precheck and collector drain cansstandard on Carter unit.

Level Sensor with mounting stud F613A 64079A Mounting stud located outside ofprecheck and drain cans for bettercontrol.

Dual Level Sensor with mountingstud

F613B 64079B Same comment as above.

AVERY HARDOLL EQUIVALENT UNITS - The Carter 4” 64143 bottom loading valve and 64079A LevelSensor can be used in lieu of the 4” Avery Hardoll Jet Able Bottom Loading Valve. Bot systems function basicallythe same.

ALTERNATIVE BOTTOM LOADING UNITS

Carter also provides bottom loading equipment for 3” and 6” installations. See Brochure 64055 for completeinformation on this type of equipment.

INSTALLATION TIPS

❐ Install the internal valve from the outside of the tank with sufficient flexible line between the pilot (s) and thelevel sensor for easier removal and maintenance.

❐ Inlet line to 64079 Level Sensor from pressure source (adapter) must be at least 3/8” diameter tubing. It shouldbe routed from a port on the bottom loading adapter, such as Carter’s 6958, or 61528 that have ports designed forthis application. (See brochure 60373 for adapter choices). Routing the inlet pressure source closer to the internalvalve may not allow sufficient pressure for the system to function correctly. If the optional mounting stud (optionA) is used sufficient length of flexible tubing should be used to allow for adequate adjustment.

❐ Line between the pilot on the 64129A and the 64079 should be 1/4” diameter for best operation. Pressure surgingmay occur if larger tubing is used.

❐ If desired a separate precheck system may also be routed from the adapter to the precheck port on the 64079although the same affect can be achieved by installing a 3/8” spring loaded normally open ball valve in the inletpressure line. It will be necessary to adjust the precheck gate in the bottom of the 64079 to make the precheckeffective in either case. This is a trial and error adjustment. Note that there are no “tuning” plugs on the Carter64079 as on the Whittaker F613. A simple “gate” type valve in the bottom of the precheck can provides adjustingof the precheck flow.

❐ It is essential for safety reasons to install a plastic tube to the drain fitting on the bottom of the 64079 LevelSensor. Draining fuel from the Level Sensor if not collected and drained properly could generate a staticdischarge, which could lead to a fire.

❐ The optional mounting stud is located outside of the precheck and drain cans on the Carter unit. Unlike theWhittaker F613 there is not holes to plug with loose o-rings if the stud is used. If not used the can on the Carterunit is already sealed and there are no plugs to install. If installed correctly the level in the tank can be adjustedover a wide range simply by screwing the stud up or down to the desired level.

❐ If the Carter Internal Valve is to be used with an optic probe system a three-way solenoid valve must be installedin the pressure line from the adapter. When the tank level is below the probe the inlet pressure should be routed tothe pilot on the internal valve to cause it to open. When the optic probe is sensing fuel (level below the probe) thepilot on the internal valve must be vented to tank and the inlet pressure shutoff. This will cause the internal valveto close and stop the bottom loading process.

ENVELOPE DIMENSIONS

64055 INTERNAL VALVE

64079 LEVEL SENSOR


FOR CARTERPART NUMBERS 6958, 61272, 61409, 61528, 61529 & 64040

BOTTOM LOADING & RECIRCULATION ADAPTERS

Revised December 1, 1994

Supercedes manual issued July 1, 1992




SM6958 December 1, 1994

TABLE OF CONTENTS

PAGE

1.0 INTRODUCTION ........................................................................3

2.0 EQUIPMENT DESCRIPTION.....................................................3

3.0 TABLE OF OPTIONS ..................................................................3

4.0 DISASSEMBLY ...........................................................................4

5.0 INSPECTION................................................................................4

6.0 REASSEMBLY ............................................................................4

7.0 TEST .............................................................................................4

8.0 ILLUSTRATED PARTS LIST .....................................................5

FIGURE 1.....................................................................................................6


MAINTENANCE, OVERHAUL & TEST INSTRUCTIONSCARTER PART NUMBERS 6958, 61272, 61409, 61528, 64040 & 61529


1.0 INTRODUCTION

This manual furnishes detailed instructions coveringthe maintenance and overhaul of Carter Part Number6958, 61272, 61409, 61528, 64040 & 61529 Bottom

Loading and Recirculation Adapters. These units allutilize the MS24484 type refueling modular adapter.


These Carter units are all of similar design in thatthey all utilize the 2½ inch MS24484 type refuelingmodular adapter. This type of adapter is only suitedfor bottom loading and recirculation or otherrelatively low pressure type applications. ForHydrant System applications one should use Carter60195 or 60373 for 2½ inch installations or 60505or 61526 Adapters for the 4 inch API typeapplications. These adapters consist of a castaluminum housing in which is mounted either thecommercial version, MS24484-2, or the current QPLversion, MS24484-5, refueling modular adapter.Both of these MS24484 units are dimensionallyidentical. The only differences lie in two areas, bothrelated to high temperature applications normallyseen in fighter aircraft applications:

• Poppet seal on the MS24484-5 is of a hightemperature elastomer for use in temperatures up

to 350°F. The seal on the MS24484-2 is suitablefor temperatures up 160°F.

• The bayonet flange to which the nozzle connectson the MS24484-5, has a greater tensile strengthrequirement required by the 350°F requirement.Again, the MS24484-2 was designed for serviceat temperatures up to 160°F.

The MS24484-5 is only manufactured by specificallyqualified suppliers, among which is our parentcompany, J. C. Carter. The MS24484-2, a previouslylisted qualified product is made by Carter GroundFueling Co.

All of the models discussed herein, except for thebasic module, 61529, are similar, varying mainly inthe outlet mounting configuration.

3.0 TABLE OF OPTIONS

Each of the basic units may be obtained in various configurations by adding one or more of the options listed inthe table below.

Option Letter Description Comments

A Adds Pressure Dust Cap (61531) In lieu of Option B on all models.

B Adds Plastic Dust Cap (41607) In lieu of Option A on all models.

C Adds Commercial MS24484-2 Adapter In lieu of Option D on all models except 61529.(Either C or D must be specified to obtain acomplete unit).

D Adds Military MS24484-5 Adapter In lieu of Option C on all models except 61529.(Either C or D must be specified to obtain acomplete unit).

G Adds 2-1/2" - 8 NPT Female Outlet In lieu of Option H on 6958 only. (Either G or Hmust be specified to obtain a complete unit).

H Adds 2-1/2" - BSPP Female Outlet In lieu of Option G on 6958 only (Either G or Hmust be specified to obtain a complete unit).


-4-

4.0 DISASSEMBLY

Refer to Figure 1 for an exploded view of the Unit.

4.1 Remove six Screws (1). Pull Adapter Module (2 or2A) from Housing (3) and remove and discard O-ring (4). Remove Cap (11 or 11A) from AdapterModule (2 or 2A). If present (available only onsome units), do not remove the two pipe Plugs (5)from the Housing (3) unless replacement isrequired.

4.2 Spare parts for the Cap (11 or 11A) are notavailable. If it is faulty replace as a complete unit.

4.3 Noting the warning below, carefully remove the sixScrews (6) from the Adapter Module (2 or 2A).

WARNINGThe Spider (7 or 7A) is spring loaded and care should

be exercised in removing the attaching Screws (6).

5.0 INSPECTION

5.1 Special Tools - Use Adapter Wear Gauge, 61657-2to check the Flange (9 or 9A) of Adapter Module(2 or 2A) for suitability for continued use. Refer toService Manual SM61657 for instructions on itsuse. This gauge will indicate whether the slots andlugs of the Flange (9 or 9A) of Adapter Module (2or 2A) are worn beyond safe use.

5.2 Check the seal on Cap (11A) for deterioration, cutsor nicks. Replace the Cap (11A) if such aberrationsare apparent.

5.3 Check Cap (11) for aging cracks or other damage.Replace as needed.

5.4 Inspect Poppet (8 or 8A) for damage to the seal.The seal is bonded into the metal poppet and is notremovable. Replace Poppet (8 or 8A) as needed.

6.0 REASSEMBLY


6.2 Light lubrication of all O-rings and seals, usingpetroleum jelly is recommended to facilitateinstallation.

6.3 Reassemble Adapter Module (2 or 2A).

6.4 Place the O-ring (4) in the groove in AdapterModule (2 or 2A) before installing in the Housing(3). Torque Screws (1) to 20 ± 2 in-lbs (.23 m-kg).

6.5 Reattach Cap (11 or 11A) to tab on AdapterModule (2 or 2A) if utilized.

7.0 TEST


7.2 Test conditions

7.2.1 Test media shall be Stoddard Solvent (FederalSpecification P-D-680), JP-4 per MIL-J-5624Dat 75° + 15°F, Jet A or equivalent.

7.3 Functional Test

7.3.1 Attach adapter to a 120 psi fluid pressure sourcethrough the outlet (flanged or threaded end).Attach a Carter 60427 or 61428 type nozzle tothe inlet Adapter Module (2 or 2A). The nozzleshall be plugged at the inlet end with a plug and asmall petcock or hand valve. With the nozzle andpetcock open, slowly increase the pressure intothe adapter outlet to fully bleed the air from thetest unit. Close the petcock and increase the test


-5-

pressure to 120 psi. Check for external leakagefrom the joint between the nozzle and adapterand from the adapter housing and joints.

7.3.2 Bleed the pressure from the test unit and removethe nozzle.

7.3.3 Slowly increase the system pressure again to 120psi and check for leakage from the AdapterModule (2 or 2A) Poppet (10 or 10A).


Table 1.0 tabulates the parts and sub-assemblies comprising the various adapters covered by this manual. Theitem numbers of the table are keyed to the exploded views of the Units diagrammed in Figure 1.

TABLE 1.0

Item Part Number DescriptionNumberRequired

Spares/10Units/Yr. Used on

1 GF24693C73 Screw ........................................ 6 6 All except 615292 61529 Adapter Module (MS24484-2) . 1 - All except Option D6 LP500-6-5 Screw ................................. 6 6 All7 20876 Spider................................. 1 - All8 2753 Spring ................................ 1 - All9 20748-2 Flange ................................ 1 1 All except Option D

10 20780 Poppet................................ 1 2 All except Option D2A 61247 Adapter Module (MS24484-5) . 1 - Option D only6 LP500-6-5 Screw ................................. 6 6 All7 20876 Spider................................. 1 - All8 2753 Spring ................................ 1 - All

9A 20748-1 Flange ................................ 1 1 Option D only10A 208197 Poppet................................ 1 2 Option D only3A 24176 Body, 2½" NPT ........................ 1 - 6958 Option G only3B 204563 Body, 2½" BSPP...................... 1 - 6958 Option H only3C 210201 Body, 4" TTMA........................ 1 - 61272 only3D 210136 Body, 4" ANSI.......................... 1 - 61409 only3E 210216 Body, 3" TTMA........................ 1 - 61528 only4 MS29513-153 O-ring........................................ 1 10 All (not furnished with

61529)3F 220288 Body, 3" ANSI 1 - 64040 only5 210462 Plug........................................... 2 - Some 6958, 61272 and

61528 only11 41607 Cap, Plastic ............................... 1 3 Option B only

11A 61531 Cap, Metal Sealing.................... 1 1 Option A only

Notes: 1. All part numbers beginning with "GF" are interchangeable with those beginning with either "AN" or"MS". If the "GF" is followed by three numbers it is interchangeable with and "AN" part, otherwise itis interchangeable with an "MS" part of the same number.

2. The recommended spare parts shown above are the number required to support 10 Units for one year.The recommended quantities are based on the ratio of spare parts sold for each unit during a one yearperiod of time. The actual quantity required will vary from location to location.

DESCRIPTION

Remote control of emergency valves through flexible cable. Maxi-mum 3/16" cable. Replaceable fuse adaptor releases at 210°F.Threaded take-up for cable slack adjusts conveniently in place.Choice of 15/8 " or 23/8 " cable travel positions. Dual trip levers provideshutoff of emergency valves from two locations.

SPECIFICATION OPTIONS:

CHART KEY:A—Compartment: 1, 2, 3, 4, 5B—Air Operated: Y for Yes, N for NoC—Material/Coating: P for PowderCoated.D—LengthE—WidthF—HeightWeight—Shipping Weight

Figure 507AO

Figure 507

Fig. 507 Emergency Valve OperatorMorrison Bros. Co.

Specification Sheet

www.morbros.com

P.O. Box 238 • Dubuque, Iowa 52004-0238563.583.5701 (tel) • 800.553.4840 • 563.583.5028 (fax)

w w w . m o r b r o s . c o m

I.D. NUMBER A B C D E F WT.507---0100 AO 1 N P 16 3/4 4 13/16 12 1/8 6507---0200 AO 2 N P 16 3/4 4 13/16 12 1/8 8507---0300 AO 3 N P 16 3/4 8 3/8 12 1/8 11.5507---0400 AO 4 N P 16 3/4 8 3/8 12 1/8 13.25507---0500 AO 5 N P 16 3/4 8 3/8 12 1/8 15507AO-0100 AO 1 Y P 20 1/2 6 3/16 12 1/8 7507AO-0200 AO 2 Y P 20 1/2 6 3/16 12 1/8 10507AO-0300 AO 3 Y P 20 1/2 9 3/4 12 1/8 13507AO-0400 AO 4 Y P 20 1/2 9 3/4 12 1/8 15507AO-0500 AO 5 Y P 20 1/2 9 3/4 12 1/8 17

FILTERS

FROM PUMP

TO PIPING

JUNCTION BOX

HEATER

SENSOR

AIR ELIMINATOR

WARREN, PA.INDUSTRIES, INC.

TM

Sept 1999

Section 86 Page 19A

R

Note: Manhole assemblies, as listed above, have Buna-N gaskets (suffix “B”). For variation in gasketing change last letter of assembly number as follows. Suffix “V” indicates Viton collar gasket & Viton 10” fill gasket Suffix “W” indicates White Hypalon collar gasket & White Hypalon 10” fill gasket Suffix “T” indicates Teflon envelope collar gasket & Tef-Sil 10” fill o-ring Manhole collars are available in aluminum, steel, and stainless steel. Please see parts page for correct numbers. When welding collars to tank, care should be exercised to insure collar remains flat and round.

With Integral Relief Valve/10” Fill

PAF manholes with integral latch style surge suppression relief valves are designed for use on DOT406 and replacement on MC306 specification cargo tanks. Manholes are certified and marked in accordance with 49CFR178.345-5 with a test pressure of 36 psig. Manhole covers are 7 gage steel or stainless and are secured to the tank weld collar with a clamp ring and bolt which can be easily removed to provide access into the tank. The integral 10” relief valve provides emergency pressure relief and meets the 1 liter surge leakage limit imposed by 49CFR178.345-10(b)(3)(ii). The relief valve also serves as a 10” latch style fill which can be easily opened to provide access for filling the tank or for inspection. Relief valves contain an adjustment feature to allow for fine-tuning of set pressure in the field. Other standard features include a heavy duty clamp ring, secondary safety latch and model 6496ALB pressure-vacuum vent mounted in the 10” relief valve cover. Manholes are available with a self-latching feature that allows the 10” relief valve/fill cover to drop and securely latch upon movement of the tank if the cover is inadvertently left open. For self-latching model substitute L863 for L820 in assembly number.

TE

ST

PR

ES

SU

RE

36 PS

IGM

EE

TS

DO

T 178.345-5

ISS

UE

D A

ND

PE

ND

ING

CO

VE

RE

D B

Y P

ATE

NTS

WA

RR

EN

, PA

. U.S

.A.

BE

TT

S IN

DU

ST

RIE

S, IN

C.

CT-0040

INTEGRAL RELIEF VALVE/10” FILL

LESS THAN 1 LITER LEAKAGE

SET PRESSURE ADJUSTMENT

INCREASED FLOW RATE

SECONDARY SAFETY LATCH Note: 31/2” Vent and Liquid Level Switch not included in assembly.

Cover Plate

Relief Valve

Clamping Ring, Bolt, Washer,

Strongback, & Latch

Clamping Ring Nut Normal Vent Wt.

(lb.) Assembly No.

Steel Zinc Plt. Alum. Steel Zinc Plt. Brass Alum. 29.7 PPVL820BXB Stnls 304 Alum. Stnls 304 Stnls 304 Alum. 30.2 PPVL820CXB Stnls 316 Alum. Stnls 304 Stnls 304 Alum. 30.2 PPVL820DXB

20” PAF 406-98 OFFSET MANHOLE

Pressure Relief Valve setting 3.63 psig Rated Pressure Actuated Emergency Venting: 494,084 cu. ft. free air per hour @ 6.25 psig Rated Liquid Flow Capacity 1335 gpm @ 5.0 psig


TM

Sept 1999

Section 86 Page 19B

Replace oil cylinder using Automatic Transmission Fluid Dexron III/Mercon, SAE 5W-20 with viscosity of 177 SUS at 100°F and a pour point of no greater than –45°F. MAINTENANCE: Manhole assemblies should be inspected with sufficient frequency to insure 10” Integral Relief Valve functions properly. Any worn, damaged or missing parts must be replaced. Gaskets should be replaced if their effectiveness to insure a liquid tight seal is impaired in any way. Replacement gaskets must be compatible with products carried.

No. Description Material Part No. No. Description Material Part No. 1 Fill Cover Alum/E-Coated 8297ALEY 9 Vent Assembly Aluminum 6496ALB 1a Fill Cover (O-Ring Grvd.) Alum/E-Coated 8297ALEY389 10 Gasket Buna-N 3716BN

Buna-N 3119BN 11 Cylinder Assembly Aluminum 6657AL Viton 3119VT 12 Piston Aluminum 6654AL 2 Gasket -

Integral Relief Valve Wh. Hypalon 3119WH 13 Stem Stnls 304 6688SL

2a O-Ring Tef-Sil 3902TS 14 Spring Steel 4122MS Steel Zinc Plt. 3029ZC 15 1/2” NPT Plug Zinc Plt. Steel Zinc Plt. 9V4907 3 Bolt-Clamp Ring Stnls 304 3029SL 17 Stem O-Ring -112 Buna-N 4118BN Brass 3030BR 18 Cylinder O-Ring –137 Buna-N 4015BN 4 Nut-Clamp Ring Stnls 304 9Q5809 19 Piston O-Ring –137 Tef-Sil 4015TS Steel Zinc Plt. 3031ZC 20 O-Ring Retainer Alum/E-Coated 4117ALEY 5 Washer-Clamp Ring Stnls 304 3031SL 21 Retainer Ring Stnls 304 9Q4961 Steel 3036MS 22 Bellows EPDM 4020EPDM Steel Zinc Plt. 3036ZC 23 Lockwasher Ext. Tooth 7/16” Stnls 304 9Q5961 6 Clamping Ring Stnls 304 3036SL 24 Nut Hex 7/16x20 Stnls 304 9Q5960 Buna-N 3560BN 25 Plastic Plug Polyethylene 9Z6163 Viton 3560VT 26 3/8-16 Hex Nut w/ Insert Steel Zinc Plt. 9Q5896 Wh. Hypalon 3560WH 7 Manhole Gasket

Channel Type Teflon Env. w/ Wh. Hypalon 3033TF

Steel 3176MS Aluminum 3176AE Stnls 304 3176SL

8 Manhole Collar Channel Type

Stnls 316 3176SS

PLAN VIEW DIMENSIONS A 41/4” Dia. (107.95mm) B 8 Holes-.390 Dia. (9.90mm) on 47/8” (123.83mm) B.C. C 23/8” Dia. (60.325mm) Hole D 1/4” N.P.T. Coupling E 7” Rad. (177.8mm) F 63/8” (161.93mm) G 43/4” (120.65mm) H 31/4” (82.55mm)

PARTS LIST

20” PAF 406-98 MANHOLE Self-Latching Model Illustrated

WARNING Consult PAF406-98 maintenance manual prior to disassembly of this relief valve. Use only genuine Betts Industries Inc. replacement parts. Use of substitute parts can impair the proper functioning of this product.

Gasket Maximum Temperature Buna-N (Nitrile) 250°F Viton 400°F White Hypalon 250°F Teflon-Silicone 400°F Teflon Envelope w/ White Hypalon Insert 250°F

Betts Industries, Inc. Warren, PA 16365 Phone: 814-723-1250

MAINTENANCE MANUAL

FOR

PAF 406-96 & 406-98 SURGE

RELIEF VALVE

Section 1: Identification of Adjustable PAF 406-96 & 98 Section 2: Maintenance and Testing for PAF 406-96 & 98 Section 3: Set Pressure Adjustment of PAF 406-96 & 98 Section 4: Removal of PAF 406-96 & 98 from Closure Assembly Section 5: Disassembly of PAF 406-96 & 98 Section 6: Assembly of PAF 406-96 & 98

9/16/99


SECTION 1:

IDENTIFICATION OF ADJUSTABLE PAF SURGE RELIEF VALVE (PAF 406-96 & 98)

Betts PAF Surge Relief Valves (PAF 406-96 and PAF 406-98) meet or exceed all U.S. DOT requirements for primary pressure relief valves on DOT406 cargo tanks as contained in 49CFR178.345-10 and 49CFR178.346-3 of the Code of Federal Regulations. The Betts PAF Surge Relief Valve is able to withstand a brief pressure surge and contain lading (liquid cargo) leakage to less than one liter (per TTMA RP NO 81). Betts PAF Surge Relief Valve (PAF 406-96 & 406-98) protects the cargo tank from rupture due to over-pressurization caused by overfilling or fire and is, therefore, crucial to the safe operation of the tank. In order to maintain your Betts PAF Surge Relief Valve in proper working condition, the following procedures must be followed.

All PAF 406-96’s are cast with “MODEL PAF 406-96”

And PAF 406-98’s are cast with

“MODEL PAF 406-98”

The adjustable PAF 406-96 & 98 have an internal hex at the top of the stem under the plastic yellow cap, as well as, a Black E-coated cover.

BLACK E-COATED COVER

PLASTIC CAP

HEX

DETAIL


SECTION 2:

MAINTENANCE AND TESTING FOR PAF SURGE RELIEF VALVE 406-96 & 98

A. U.S. DOT Requirements: This portion of the manual refers to the DOT regulations and is intended to

serve as an interface to relate the manual to the code. This manual does not take the place of the Code of Federal Regulations. A current copy of the Code of Federal Regulations should be reviewed and followed to insure the requirements are met for each individual case.

There are three basic tests/inspections mandated by 49CFR Part 180 for MC306 and DOT406 cargo tanks.

Test/Inspection Interval Period Code Paragraph External Visual Inspection 1 year 49CFR180.407(d) Leakage Test 1 year 49CFR180.407(h) Pressure Retest 5 year 49CFR180.407(g)

1. External Visual Inspection: As part of the annual external visual inspection, 49CFR180.407(d)(3)

requires that all pressure relief valves, be visually inspected for any corrosion or damage which might prevent the valve from functioning. If the cargo tank is used to haul product that is corrosive to the relief valve, the valve must be removed from the cargo tank for inspection and bench testing.

Note: Betts recommends that the external visual inspection of vents be performed monthly.

1.1. Visually inspect all external surfaces of the manhole and PAF, which includes opening the

Latch (1) and Strongback (5). NOTE: If any corrosion or damage to the PAF or manhole is observed, it must be repaired and successfully bench tested prior to returning to service. Refer to 3.5 for PAF bench test procedure.

1.1.1. Clean and inspect the bottom side of the PAF for signs of damage, corrosion, or product gumming that could effect the operation of the Relief Valve.

1.1.2. Closely inspect the Cylinder (10) for any damage or dents. Also, insure Cylinder (10) is threaded tightly to the Cover (9). See figure 1.

1.1.3. Inspect and clean the Normal Vent (8). 1.1.4. Inspect the 10” Seat (25) for damage or corrosion. Build-up or grim on the seat should be

removed. Nicks on the 10” seat may cause the gasket not to seal. 1.1.5. Inspect the 10” Fill Gasket (24) for signs of wear or degradation. Replace gasket if required. 1.1.6. Inspect the Clamp Ring Gasket (26) for evidence of product seepage. Replace any gaskets

where seepage is detected.

Inspect CYLINDER (10)

Inspect & clean NORMAL VENT (8)

Inspect GASKET (26) for leakage

Inspect SEAT (25)

Inspect & clean GASKET (24)

COVER (9)

STRONGBACK (5)

Figure 1


2. Leakage Test: 49CFR180.407(h) requires tanks to be tested annually at 80 % of the tank design

pressure or MAWP, whichever is marked on the tank certification or specification plate. All tank components must remain in place during this test, except any re-closing pressure relief valve with a set pressure less than the leakage test pressure must be removed or rendered inoperative during the test. Betts Normal Vents, therefore, must be removed during the leakage test.

2.1. Remove Normal Vent from manhole cover and plug opening with Betts Plug No. 3013. 2.2. Apply test pressure in accordance with 49CFR180.407(h) 2.3. Inspect all gasket joints on PAF and manhole for leaks. If PAF leaks, adjust in accordance with

Set Pressure Adjustment instructions (Section 3 of this manual) and retest the unit. Replace damaged or worn gaskets as required.

3. Pressure Retest: As part of the pressure retest, 49CFR180.407(g)(ii)(A) requires that all re-closing

pressure relief valves be removed from the tank for inspection and bench tested to verify that the relief valve is functioning properly. The pressure retest and the relief valve bench test must be performed at least every five years.

Note: Betts recommends that the PAF 406-96 and PAF 406-98 be bench tested annually.

3.1. Pressure Retest Procedures: 3.1.1. 49CFR180.407(g)(1)(vii) requires that all closures except pressure relief devices must be in

place during the test. 3.1.2. Manholes must remain in place during pressure test. 3.1.3. Open 10” PAF Relief Valve. 3.1.4. Install Betts Retest Fixture (part no. 6556LCB) to seal the 10” opening. See figure 2.

3.2. Betts Push and Air Operated Vapor Recovery Valves remain in place during the test. NOTE: If vapor recovery valves from other manufactures are installed, refer to the manufacturers’ instructions to see if they should be removed.

3.3. After preparing the rest of the tank, perform the pressure test in accordance with the regulations. Inspect all parts of manhole assembly for leakage. Repair or replace parts as required.

3.4. Remove all clamps or plugs from relief valve immediately after test is completed.

Clamp Channel Inside of 10” Fill

Retest Fixture (Part No. 6556LCB)

Inspect for Leakage Here

Figure 2


Air in fromregulator

BubblesIndicateLeakage

Water Jar

Tubing

Reducer Bushing

Seal

Air out tomanometeror gage.

Test Tank6687AL

Pressure Release Pressure Release



PRESSURE TEST VACUUM TEST

3.5. Bench Test Procedure for PAF Surge 406-96 & 98 3.5.1. Remove manhole assembly from tank by removing the clamp ring bolt and clamp ring. 3.5.2. Remove Normal Vent (8) and plug port with Betts Plug (No. 3013) 3.5.3. Attach manhole assembly to appropriate Betts PAF 406-96 Test Fixture (No. 6685SL.) 3.5.4. Apply a soap solution around the perimeter of the DoveTail 10” Gasket. 3.5.5. Gradually apply pressure to the tank and observe the pressure at which bubbles first appear. 3.5.6. Per 49CFR178.346-3(c) the set pressure must not be less than 3.63 psig and not more than

4.55 psig for a tank with a MAWP of 3.3 psig. 3.5.7. Slowly release the pressure from the test fixture and verify the PAF reseals not less than the

MAWP of the tank. 3.5.8. Replace or adjust any relief valve that fails the set pressure test requirements. Refer to

instructions for Set Pressure Adjustment (Section 3 of this manual) to adjust the set pressure, and retest the unit.

4. Model 6496AL (Normal vent for DOT 406) Test Procedure:

A Normal Vent Test Tank (Part No. 6687AL) must be used to test the Normal Vents. Note: A regulator must be used to slowly apply pressure to the tank.

4.1. Pressure Test: 49CFR 178.346-3(b)(2) states that the normal vent for a DOT 406 must be set to open at not less than 1 psig.

4.1.1. Screw the Normal Vent into the lid of the test tank as shown in figure 3 A. In order to detect leakage, attach the reducer bushing, compression fitting, and tubing. Place the end of the tubing in a water jar. The water jar is not included with the test tank.

4.1.2. Slowly apply pressure to the tank. Bubbles will indicate the opening pressure of the vent. 4.1.3. A properly functioning 6496AL Normal Vent should open between 1.0 to 1.5 psig, but in no

case open less than 1 psig. 4.2. Vacuum Test: 178.346-3(c)(2) states that the normal vent for a DOT 406 must be set to open at

no more than 6 ounces vacuum (.375 psig). 4.2.1. Screw the Normal Vent into the lid of the test tank as shown in figure 3 B. 4.2.2. Slowly apply pressure to the tank and inspect the top opening for pressure release. Apply

soapy water to the top of the vent in order to detect the point at which the vent opens. 4.2.3. A properly functioning 6496AL Normal Vent should vacuum relieve between 0.25 to 0.375

psig, but in no case more than 0.375 psig. 4.3. Repair or replace any Normal Vent that does not meet the specifications.

Figure 3A Figure 3B


Loosen Nut

Increase Set Pressure

SECTION 3:

SET PRESSURE ADJUSTMENT OF PAF SURGE RELIEF VALVE

NOTE: THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL 306-98, 406-98 AND PAF

406-96 W/ BLACK E-COATED COVER AND STEM WITH INTERNAL HEX AT THE TOP. 1. Relieve vapor pressure or vacuum from cargo tank.

Failure to relieve tank pressure may result in sudden, unexpected loss of pressure. Severe personal injury or death may result.

2. Open Latch (1) to expose yellow Plastic Plug (2) as shown in figure 4. 3. Remove yellow Plastic Plug (2). 4. Place an 11/16 box end wrench over Hex Nut (3). 5. Place a 7/32 allen wrench into the hex socket of the Stem (4). 6. Hold the allen wrench stationary and rotate the box end wrench counterclockwise to

loosen the Hex Nut (3) two full turns. 7. At this point, the PAF can be adjusted by rotating the Stem (4) with the allen wrench. 8. To increase the set pressure, turn the Stem (4) clockwise.

Note: The Stem (4) must fully engage threads of Hex Nut (3) when nut is tightened.

Betts Industries, Inc. Warren, PA 16365 Phone: 814-723-1250 9. To decrease the set pressure, turn the Stem (4) counter-clockwise.

Note: The amount of adjustment in the counter-clockwise direction is limited by a shoulder stop on the Stem (4).

10. The adjustment feature is sensitive, so that, one turn of the stem may increase the set pressure significantly. Adjust stem ¼ turn at a time, until the desired setting is achieved.

Never adjust the relief valve so that a person must stand on the Strongback (5) to operate the Latch (1). This could cause a person to loose their balance and fall, if there is any residual pressure in the tank when the relief valve is opened.

11. After adjusting the PAF surge relief valve, use the box wrench to tighten the Hex Nut

(3), while using the allen wrench to hold the stem stationary. 12. Replace the Plastic Plug (2). 13. After adjustment, test the set pressure to verify that it falls within the required range.

13.1. Per 49CFR178.346-3(c) the set pressure for models PAF406-96 & 406-98 must not be less than 3.63 psig and not more than 4.55 psig for a tank with a MAWP of 3.3 psig.

13.2. Per 49CFR178.341(d)(2) the set pressure of model PAF306-98 must not be less than 3.0 psi for a MC306 tank

14. If the adjustment does not achieve the desired pressure setting, check the following: 14.1. Inspect the 10” metal seat. Remove any build up and repair any nicks. 14.2. Replace the 10” gasket. 14.3. Insure strongback is not bent or damaged. 14.4. Insure the collar that is welded to the tank is not excessively warped. 14.5. Insure closure assembly was mounted correctly to manhole collar.

14.5.1. Unbolt clamp-ring and loosen closure assembly from collar seat. 14.5.2. Release latch to relieve force on 10” fill cover. 14.5.3. While the 10” fill is opened, tighten clamp-ring bolt while

tapping circumference of clamp-ring with a hammer. 14.5.4. Close 10” fill and latch.


DISASSEMBLE

DISASSEMBLE

SUPPORT HERE

SECTION 4:

REMOVAL OF PAF SURGE RELIEF VALVE FROM CLOSURE ASSEMBLY

NOTE: THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL PAF 406-96 & 98 WITH

BLACK E-COATED COVER AND STEM WITH INTERNAL HEX AT THE TOP. 1. Relieve vapor pressure or vacuum from cargo tank.


2. Open latch to expose Yellow Plug (2) as shown in figure 5. 3. Remove yellow Plastic Plug (2). 4. Use an 11/16 socket or box end wrench to remove Hex Nut (3). 5. Remove Star Washer (6). 6. Open fill assembly as shown in figure 6. 7. Place a 7/32 allen wrench in the hex socket of the Stem (4). 8. By rotating the stem clockwise, the PAF assembly can be unscrewed from the closure

assembly. NOTE: During removal, care should be taken not to damage the last threads on the stem, by supporting the PAF with a hand under the cylinder.

9. Remove the Bellow (7). 10. At this point, further disassembly should be conducted at a workbench. Follow the

procedure “Disassembly of PAF Surge Relief Valve” if disassembly of the cylinder is required.


SECTION 5:

DISASSEMBLY OF PAF SURGE RELIEF VALVE

NOTES: Ø THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL PAF 406-96 & PAF

406-98 WITH BLACK E-COATED COVER AND STEM WITH INTERNAL HEX AT THE TOP.

Ø UNDER NORMAL CIRCUMSTANCES, THE DISASSEMBLY OF THE SPRING CYLINDER IS

NOT REQUIRED NOR RECOMMENDED, UNLESS ALL OTHER ATTEMPTS TO REPAIR THE RELIEF VALVE HAVE FAILED. IT IS RECOMMENDED THAT THE VALVE BE RETURNED TO BETTS INDUSTRIES FOR REPAIR.

Ø A PAF SURGE DISASSEMBLY TOOL (PART # 6684MS) IS REQUIRED TO DISASSEMBLE THE SPRING CYLINDER.

1. Remove the PAF surge relief valve assembly from the closure assembly by following

the steps outlined in the procedure “Removal of PAF Surge Relief Valve from Closure Assembly”.

2. Remove Normal Vent (8) by griping with slip joint pliers and unscrewing from Cover (9). See figure 7.

The cylinder contains a compressed spring, which could cause injury, if the cylinder is removed improperly. Review the following section carefully before attempting to remove cylinder.

3. The Cylinder (10) contains Hydraulic Oil (11) that must be drained. 4. Use a 3/8 allen wrench to remove the ½ in. NPT Plug (12) while holding the Cylinder

(10) stationary by gripping with slip joint pliers within one inch from the bottom. It is very important that the cylinder does not unscrew from the cover at this time.

5. If the unit has a 1/8 in. NPT Plug (13) remove it at this time. 6. Drain the oil that is on the top and bottom of the Piston (14).

Insure CYLINDER Does NOT Unscrew

Grip Here to Remove

Grip With Slip-Joint Pliers Here.

Betts Industries, Inc. Warren, PA 16365 Phone: 814-723-1250 7. Insert the 3/8 female thread end of the Disassembly Tool (15) (part # 6684MS) into the

½ in. NPT opening as shown in figure 8. 8. Thread the Disassembly Tool (15) onto the 3/8 male thread of the Stem (4) that extends

from the Lock Nut (16). See figure 8. The tool should engage at least four threads. Note: Use a 7/32 allen wrench on the bottom of the tool and one at the top of the stem to tighten tool completely down.

9. At this point, a 7/32 allen wrench must be used to hold the shaft of the tool stationary

with respect to the cylinder, while an 11/16 wrench is used to turn the Tool Nut (17) clockwise. Once the nut has made contact with the cylinder, turn the nut two complete turns to compress the Spring (18). See figure 9.

Hold Shaft Stationary

Tool Must Thread Completely to Nut

Two Turns Clockwise To Compress Spring

Screw Tool to End of STEM (4)

3/8 Female Thread of Tool

NOTE: Tool is Shown Shorter Than Actual Length

Betts Industries, Inc. Warren, PA 16365 Phone: 814-723-1250 10. The Cover (9) can now be unscrewed from the Cylinder (10). Do NOT unscrew the

stem from the tool. If slip joint pliers are required to grip the cylinder, only grip within one inch from the end. See figure 10.

After the cover is removed, the spring is still under load in the cylinder. Do NOT point the open end of the tube toward yourself or a bystander.

11. To release the spring, hold the allen wrench stationary with respect to the

cylinder, and turn the Tool Nut (17) counter-clockwise. It is imperative that the shaft of the tool does not unscrew from the Stem (4) during disassembly process. Continue to back off the Tool Nut (17) until the piston is extended beyond the length of the spring. See figure 11.

12. At this point insure the spring tension is released, and the Tool (15) can be unscrewed from the Stem (4).

Grip Cylinder On This End



Unscrew Nut


Apply petroleum jelly here during re-assembly.

13. Disassemble the stem/piston assembly by inserting a 7/32

allen wrench into the top of the Stem (4) and unscrew the LockNut (16) using a 9/16 socket. See Figure 12. Note: The piston may appear different than shown depending on the model you may have.

14. If the Piston O-ring (19) requires removal, cut the o-ring with

a razor blade, being careful not to damage the piston groove. 15. The Stem O-ring (22) and O-ring Retainer (21) are removed

by using a snap ring tool to remove Snap Ring (20). See figure 13.

16. If the Cylinder O-ring (23) requires removal, cut the o-ring

with a razor blade being careful not to damage the o-ring groove.

17. If the 10” Fill Gasket (24) requires removal, cut a small slot

in the center of the gasket and use a screwdriver to pry gasket out of dovetail groove, being careful not to damage groove. See figure 13.

For maintenance or assembly instructions consult appropriate procedures.

Slice Gasket as Shown & Pry Out with Screwdriver.


SECTION 6:

ASSEMBLY OF PAF SURGE RELIEF VALVE

NOTE: THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL PAF 406-96 & PAF

406-98 W/ BLACK E-COATED COVER AND STEM WITH INTERNAL HEX AT THE TOP. 1. Preparation of O-Rings and Components:

1.1. All parts should be cleaned and degreased to insure the removal of all product build up. 1.2. All components should be inspected for damage or wear. 1.3. To insure integrity of the seals, all o-rings and gaskets should be replaced using Betts’

replacement parts. 1.4. Inspect all o-ring grooves for damage (nicks, scratches, or burrs).

2. Cover sub-assembly: Refer to figure 14.

2.1. Insert Stem O-ring (22) into Cover (9). 2.2. Insert O-ring Retainer (21) and use a snap ring tool to insert the Snap Ring (20) into

groove. 2.3. Place black Buna Cylinder O-ring (23) into o-ring groove on Cover (9). 2.4. Use Betts’ Dove Tail Gasket Tool (26) (part # 6504AL) to place 10” Fill Gasket (24)

into Cover (9). See figure 14. 2.4.1. Lubricate the gasket and dovetail groove with a soap solution. 2.4.2. Using fingers, pinch the back side of the gasket together and insert a small section

of the gasket into the groove. 2.4.3. Use short strokes with the Dove Tail Gasket Tool (26) to insert the gasket. 2.4.4. The last portion of the gasket will need to be pushed in with fingers.

Note: The gasket can also be installed by hand. A 10” o-ring (4100BN) is also available for use as a replacement for the dovetail gasket and can be installed in the groove.

Apply never-seize here.

Apply petroleum jelly here.


3. Piston/Stem sub-assembly: Refer to figure 12 of section 5.

3.1. Inspect Stem (4) for signs of wear or corrosion. Replace as required. 3.2. Insert 3/8 end of Stem (4) into counter sunk hole of Piston (14). Note: The piston may

appear different depending on which model you have. 3.3. Insert a 7/32 allen wrench into the top of the Stem (4) and tighten the Lock Nut (16)

completely down using a 9/16 socket. Note: The Stem (4) MUST turn freely in the Piston (14) after the nut is tightened.

3.4. Pre-heat the orange Tef-Sil Piston O-ring (19) in warm water and immediately slide the o-ring over the Piston (14) and position it into groove.

3.5. Smear a thin layer of petroleum jelly around the Piston O-ring (19) to facilitate ease of installing the piston into the cylinder.

4. Loading the Spring: Refer to figure 11 of section 5.

4.1. Inspect the inside of the Cylinder (10) for damage (dents, scratches, or corrosion). If the cylinder is damaged it must be replaced.

4.2. Insert the 3/8 female thread end of the Disassembly Tool (15) (part # 6684MS) into the ½ “ NPT opening of the Cylinder (10).

4.3. Place the Spring (18) into the Cylinder (10). 4.4. Thread the 3/8 stub that extends from the Piston/Stem assembly into the Disassembly

Tool (15) and tighten with two allen wrenches. NOTE: Ensure the end of tool is tight against the Lock Nut (16) as shown in figure 11 of section 5.

4.5. Compress the Spring (18) by using a 7/32 allen wrench to hold the shaft of the tool stationary with respect to the cylinder, while an 11/16 wrench is used to turn the Tool Nut (17) clockwise. (See figure 11 of section 5.) Insure the threads are not damaged on the cylinder when the piston is pulled into the top of the cylinder.

After the spring is compressed in the cylinder, do NOT point the open end of the tube toward yourself or a bystander.

4.6. Continue to turn the Tool Nut (17) until the top of the piston is at least 7/8“ below the

top of the Cylinder (10). See figure 10 of section 5. 5. Installing the Cover (9):

5.1. Smear a thin amount of never-seize compound on the threads of the Cover (9) as shown in figure 14.

5.2. Smear petroleum jelly around Cylinder O-ring (23) as shown in figure 14 and the top of the Stem (4) as shown in figure 12 of section 5.

5.3. Position the Cover (9) over the Stem (4) as shown in figure 12 of section 5. 5.4. Slowly screw the Cover (9) onto the Cylinder (10). Care should be taken not to damage

the threads of the cylinder or cover. Beware of cross threading. Ensure that the cover is screwed completely down to the cylinder so there is NO gap. See figure 15.

The Cylinder must be threaded completely on the Cover prior to the Disassembly Tool being removed.

5.5. The Spring (18) can now be released by holding the allen wrench stationary with respect to the Cylinder (10) and turning the Tool Nut (17) counter-clockwise.

5.6. Once the Tool Nut (17) has released the spring pressure, the tool can be unscrewed and removed from the Cylinder (10).


6. Re-filling the hydraulic oil: Refer to figure 15.

Note: Replace the oil in the cylinder with Automatic Transmission Fluid DexronIII/Mercon SAE 5W-20 with a viscosity of 177 SUS at 100°F and a pour point of no greater than –45°F.

6.1. If this unit has a 1/8” NPT, place thread sealant on the 1/8” NPT Plug (13) and insert it in the Cover (9).

6.2. Turn the PAF upside down and pour ATF fluid through the ½” NPT opening at the bottom of the Cylinder (10).

6.3. It is very important that this lower chamber is completely full of oil, with NO air pockets.

6.4. Place thread sealant on the ½” NPT Plug (12) and insert it into the bottom of the Cylinder (10). Tighten the plug using a 3/8 allen wrench.

7. Smear a small amount of never-seize compound on the threads of the Normal Vent (8) and screw it into the opening of the Cover (9).

8. To attach the PAF Relief Valve to the closure assembly, refer to figure 6 of section 4. 8.1. Place the Bellow (7) over the Stem (4). 8.2. Thread Stem (4) into Wobble Support (27) on Strongback (5). NOTE: Use an 7/32 allen

wrench inserted from the top of the Wobble Support (27) and turn counterclockwise to screw in the stem.

8.3. Insure the first thread is not damaged as the stem is started into the wobble support. 8.4. As the stem is threaded in, insure the Locating Ears (28) are aligned at the hinge side of

the Strongback (5) and straddle the strongback as shown in figure 4 of section 3. Tighten the stem all the way in.

8.5. Insert Lock Washer (6) and thread Hex Nut (3) onto Stem (4) as shown in figure 6 of section 4.

8.6. To adjust the set pressure and tighten down the stem, refer to Section 3 of this manual.

Fill the Bottom Chamber Completely

Ensure NO Gap

NO Oil in this Chamber

1

OPERATION,

MAINTENANCE AND PARTS MANUAL

TRUCK, TANK, FUEL SERVICING

ISOMETRICS MODEL 505T1200

CONTRACT GS-30F-1032D

ISOMETRICS, INC.

Post Office Box 660

Reidsville, North Carolina 27320

(Rev. G, Oct 2008)

2

TABLE OF CONTENTS TITLE PAGE

CHAPTER 1. INTRODUCTION 3 1-1. Scope 3 1-2. Physical Description 3 1-3. Functional Description 3 1-4. Warranty Information 5 1-5. Shipping, Handling and Storage Data 5 1-6. Preparation for Use 5 CHAPTER 2. OPERATING INSTRUCTIONS 6 2-1. Scope 6 2-2. Safety Interlocks 6 2-3. Bonding 6 2-4. Prefueling Check 6 2-5. Bottom Loading 7 2-6. Top Loading 8 2-7. Gravity Drain, Unmetered 9 2-8. Fueling Procedure 10 2-9. Tank Loading using the Truck Pump, Unmetered 11 2-10. Defueling 12 2-11. Gravity Drain, Metered 14 3-1. Procedure 16 CHAPTER 3. MAINTENANCE AND SERVICING 17 3-1. Scope 17 3-2. Cleaning 17 3-3. Lubrication 17 3-4. Inspection 17 3-5. Troubleshooting 17 3-6. Component Repair 17 3.7. Service 17 3.8. Ready for Air Transport 18 CHAPTER 4. PARTS LIST AND COMMERCIAL LITERATURE 23 4-1. General 22 4-2. Parts List 22 CHAPTER 5. SCULLY OVERFILL PREVENTION 25

LIST OF ILLUSTRATIONS

Figure Title page 2-1 A Piping Schematic (for Trucks with Filters) 15 2-1 B Piping Schematic (for Trucks without Filters) 15 4-1 Pumping Compartment 23 4-2 Pump/PTO Diagram 23 4-3 Cable Diagram 24 4-5 Electrical Schematic (Lights) 24 4-6 Scully System Schematic 25

LIST OF TABLES page

Table Title 3-1 Daily Inspection 20 3-2 Periodic Checks and Services 20 3-3 Troubleshooting 21

3

CHAPTER 1

INTRODUCTION 1-1. SCOPE. This manual contains operating procedures, service and repair instructions and and replacement parts for the fuel servicing tank truck manufactured by Isometrics, Inc., Reidsville, North Carolina. This manual does not cover components of the truck chassis. Refer to the chassis manuals provided with the vehicle pertaining to operation, maintenance, and parts listings of the cab and chassis. 1-2. PHYSICAL DESCRIPTION. The fuel truck consists of a single compartment tank with baffles mounted on a commercial chassis, a bottom loading system, and a pumping system with fuel metering capability, and filtration. a. The pumping system includes a PTO driven pump with internal bypass, a strainer assembly, a flow meter with reset counter and totalizer, a suction stub, dispensing hose reel, hose, and a trigger type automatic shutoff nozzle. b. The bottom loading system includes inlet adapters, a bottom loading valve, an electronic level sensor with onboard shutoff control and fill stand connections. c. The bottom loading valve is located in the bottom of the fuel tank. The majority of all other components are mounted in a pumping compartment between the cab and tank. The pump, strainer, and associated plumbing are located underneath the fuel tank. The filtration system is located in the underslung cabinet on the driver's side of the truck. All other pumping system and bottom loading components are located in the cabinet on the curb side of the truck. d. Physical data: 1. Model No.: 505T1200 4 x 2 4 x 4 2. Tare Weight: 16,700 LBS. 17,700 LBS. 3. Dimensions: 270"L X 96"W X 96"H 270"L X 96"W X 99"H 4. Shipping Cube: 1440 Cu. Ft. 1485 Cu. Ft. 5. Environmental Conditions: -20 to 125 degrees F 1-3. FUNCTIONAL DESCRIPTION. a. General. (1) The pumping system provides for a fuel servicing capacity of 75 U.S. gallons per minute (GPM) at the discharge end of the nozzle. (2) The truck provides plumbing and controls for bottom loading, pressure off-loading, and gravity off-loading, both metered and unmetered. A suction stub is also provided to facilitate self-loading and defueling. b. Pumping System. (1) During fueling, fuel flows from the tank through the emergency valve, through the strainer to the pump. Fuel from the outlet side of the pump flows through the filter/separator, meter, hose reel, and hose and nozzle assembly. (2) The pump is driven by a power take-off (PTO) mounted on the side of the transmission.

4

CAUTION

To avoid running the pump dry make sure the emergency valve is open prior to engaging the PTO. Refer to the

operating instructions for this procedure. (3) The emergency valve operator, located in the curb side pumping compartment, opens the emergency valve. This control also serves to close the valve in an emergency. Striking or pushing the handle allows an internal valve spring to close the emergency valve. Emergency controls, operable for closing the emergency valve only, are located at the right rear of the truck, at the driver's door, and on top of the tank. They are marked with red square decals with 2-inch instruction letters. (4) Two each 40 GPM filters (if so equipped) are located in the cabinet on the driver's side of the truck. They are connected in parallel from the discharge side of the pump to allow for a total flow of 80 GPM. They filter solids and separate any water in the fuel. Drains at the bottom of each filter allow for water and solids removal on a periodic basis. Each filter is equipped with a heater for cold weather applications. The heaters are activated by a toggle switch located to the left side of the steering column on the dash. (5) An air eliminator flow meter assembly is located downstream of the filters in the curb side cabinet. It is rated for 100 GPM and comes complete with reset counter and totalizer. (6) Next is the hose reel, hose, and nozzle assembly. The hose reel is of the manual rewind type with 100 feet of 1-1/2 inch commercial grade fuel hose. A 1-1/2 inch trigger type automatic shutoff nozzle rated at 75 GPM is attached to the hose. c. Bottom Loading System. (1) The bottom loading valve, located in the bottom of the tank also serves as the emergency valve. Air pressure from the emergency valve operator or the bottom loading interlock opens it. It is a balanced type valve that will remain closed, regardless of fill stand pressure, if there is no air source to open it. (2) A bottom loading manifold, located on the left side of the truck, is provided for the fill stand connection to perform the bottom loading task. Each leg of the manifold serves as a quick disconnect drybreak connection. In order to connect the fill stand coupler, a valve lever must be moved to the side. This action opens the air vent on top of the tank, sets the truck brakes, and opens the bottom loading valve unless the tank is already full. One leg of the manifold is a D-1 nozzle adapter and the other leg is a 4-inch API commercial bottom loading adapter. (3) An electronic level sensor is installed in the top of the tank. When fuel contacts this probe, an electrical signal is transmitted to a control module located on a bracket in the curb side cabinet. A socket array is also provided to interface with the appropriate fill stand connection. When fuel contacts the sensor, the fill stand controls stop the fuel flow into the tank. If fill stand controls are unavailable, the onboard system will automatically stop the flow by closing a solenoid air valve plumbed between the bottom loading valve and the brake interlock. Air will exhaust and the bottom loading valve will close.

5

d. Top Loading. The tank may be loaded from the top by opening the fill cover in the manhole cover located on the top of the tank and inserting the fill hose into this opening. The hose should reach the bottom of the tank to avoid static charge buildup. e. Vent Valve. A vent valve, located in the top of the tank, vents the tank to atmosphere during loading and off loading. The vent valve opens whenever the emergency valve operator is engaged or the bottom loading interlock is activated. This valve is pneumatically controlled. The vent is equipped with an interlock feature so that pumping operations cannot be performed unless the vent is open. The vent is open to the atmosphere via vapor recovery piping that is open at the rear of the tank. A sealed flexible hood is located over the vent valve on top of the tank. The hood is connected to a header and tubing that terminates at the rear curb side of the vehicle. Three and four inch open flanged outlets are provided for connection to the vapor recovery system, if available, at the bottom loading facility. f. Gravity Unloading. Gravity unloading can be accomplished by attaching a hose to the 2-1/2 inch faucet and opening the bottom loading valve and faucet. Gravity unloading through the faucet is unmetered. g. Self-loading and Defueling. Loading the tank using the onboard pumping system or removing fuel from an item can be accomplished by attaching a suction type hose to the fuel source or item and the 2-1/2 inch faucet, opening the appropriate valves, and starting the pump. Fuel will enter the tank via the bottom loading valve. 1-4. WARRANTY INFORMATION. See the warranty page at the end of this manual. For warranty claims contact the Purchasing Department @ 336.349.2329. 1-5. SHIPPING, HANDLING, AND STORAGE DATA. a. Shipping. When shipping the vehicle on an open top trailer or rail car, the axles and landing gear should be used for securing purposes. Insure all product is removed from the tank and pumping system. A standard single drop trailer is suitable for transport. Refer to paragraph 1-1(d) for weights and dimensions. b. Handling. The only special handling procedures for this equipment is to insure that all combustible and flammable liquids are removed from the vehicle prior to shipment. Use API (American Petroleum Institute) Publication 2013, "Cleaning Mobile Tanks in Flammable or Combustible Liquid Service" as a guide for purging the tank. To obtain a copy contact: American Petroleum Institute 1220 L Street, Northwest Washington, D.C. 20005 (202) 682-8375 Attention: Publications and Distribution Section c. Storage. For long term storage, it is recommended that the vehicle be prepared as in the handling section (b) above. 1-6. PREPARATION FOR USE. The vehicle has been completely serviced and adjusted prior to shipment.

6

CHAPTER 2

OPERATING INSTRUCTIONS 2-1. SCOPE. This chapter contains instructions for the operation of the controls required to perform tank loading and various fueling operations. Refer to separate truck publications for information on proper operation of truck controls, and instruments and operation of the vehicle when in motion. 2-2. SAFETY INTERLOCKS. This unit is equipped with interlocks to prevent movement when performing a fueling operation. Whenever the valve lever positioned in front of the bottom loading adapters is moved to the side or the emergency valve operator control is pulled out, the truck brakes will be applied. Either action also results in the opening of the air operated vent on top of the tank. 2-3. BONDING. After stopping the vehicle and setting the parking brake, connect a static reel cable to unit to be refueled. WARNING Always establish the static bond between the tank vehicle and the unit to be refueled. Never attempt any fueling operation until bonding is complete. NOTE Some activities require that grounding also be accomplished. The static reel is equipped with a second clamp end for connection to a suitable ground post. 2-4. PREFUELING CHECK. Prior to filling the tank or performing any fueling operation, perform the following checks: Note: Refer to Fig. 2-1 for identification and relative location of components. NOTE The butterfly valves are closed when the lever is 90 degrees to the piping and open when the lever is parallel with the fuel flow. a. Open the cabinet doors on to gain access to the fuel system components. b. Check that the bottom loading adapters (19) and (20) dust caps, the 2-1/2 inch faucet (17) dust plug, and the 2 inch faucet (14) dust cap are in place. c. Check that the lever on the interlock air valve (18) is positioned to interfere with the fill stand coupler connection. d. Verify all valves in the pumping compartment are closed.

7

e. Check the manual emergency valve operating handle as follows: (1) Pull the valve operating handle (22) to its out (open) position and release. A minor amount of tension should be felt and the handle(s) should remain in the out position. Easily strike or push the valve handle toward the in (closed) position. The internal valve spring should enable the handle to move to the in position and thus close the valve. This demonstrates the correct procedure to close the valve in an emergency. During normal use the handle can simply be guided to the in position. (2) Pull the valve operating handle to the out position. Go to the right rear of the truck and pull the emergency release handle. Check to see if the valve operating handle returned to the in position. (3) Pull the valve operating handle to the out position. Go to the left front of the tank, near the driver's door, and pull the emergency release handle. Check to see if the valve operating handle returned to the in position. (4) Pull the valve operating handle to the out position. Go to the top front of the tank and pull the emergency release handle. Check to see if the valve operating handle returned to the in position. f. Make sure the hose is properly stowed on the reel and that the nozzle is properly stowed. g. Visually inspect all components and piping connections for evidence of damage, leakage, or loosening. (Periodically check nuts and bolts for proper tightness as vibration may cause them to loosen. Visual inspection will not verify tightness, put a wrench on the fastener to verify.) h. Reset the visual counter on the flow meter to zero by depressing the knob on the right side and rotating it clockwise as viewed into the knob. 2-5. BOTTOM LOADING. a. After the truck is stopped in the desired location, set the parking brakes from the cab. b. Shut down the engine and engage the Scully system (if unit is so equipped) by engaging the pull type switch (overfill control) on the dash. The light near the switch will light when switch is on. c. Perform the prefueling check in paragraph 2-4. d. Electrically bond the refueler to the fill stand. e. Move lever on interlock air valve (18) to side. f. Connect the fuel supply line to the bottom loading adapter (19) or (20). g. Make the necessary connections to the Scully socket, if available.

8

h. Start filling the tank and make sure system is working properly by pushing the precheck switch (23). It is located on the left end of the Scully control module, in the center. Hold the button in until flow stops. After flow stops, release switch to resume flow. Again, this is if unit is so equipped, not all trucks have Scully overfill prevention systems.

WARNING If the flow does not stop soon after the precheck button is depressed, stop flow from the fill stand immediately to avoid a fuel spill. The system is not operating properly and needs repair. i. Fill the tank at a rate not to exceed 600 GPM unless the fill cover in the manhole is open. WARNING Do not load at a rate exceeding 600 GPM (gallons per minute) without opening the 10-inch fill cover in the manhole assembly. Tank over-pressure- ization could result. NOTE An indication that the tank is full is a sudden flexure of the supply hose as the bottom loading valve closes. j. The flow will stop when the liquid contacts the probe located in the top of the tank if unit is Scully equipped. The onboard control system will close the bottom loading valve and the fill stand connection, if available, will shut down the flow from the fill stand. k. When the tank is full disconnect the fuel supply line from the bottom loading adapter and, if applicable, disconnect all fill stand control lines. l. Install the dust cap on the bottom loading adapter (19) or (20). m. Move the interlock valve (18) lever back in front of the bottom loading adapter. n. Remove fill stand bonding cable and disengage Scully system. 2-6. TOP LOADING. a. After the truck is stopped in the desired location, set the parking brakes from the cab. b. Shut down the engine. c. Perform the prefueling check in paragraph 2-4. d. Electrically bond the refueler to the fill stand.

9

WARNING If a top loading rack is not available for fueling, two men will be required to perform filling the tank through the manhole fill cover - one to insure the fuel supply hose does not slip out of the fill opening and observe the tank level and one to manually stop the fuel flow from ground level. The man on top of the tank must signal the other when the tank is full. e. Open the manhole fill cover, insert the fuel supply hose as close to the bottom of the tank as practicable, and start the fueling operation. f. Coordinate fuel shutoff with the fuel supply operator when the tank is full. g. Remove the fuel supply hose and close the fill cover. h. Remove fill stand bonding cable. 2-7. GRAVITY DRAIN - UNMETERED. Fuel can be gravity drained from the tank by performing the following procedures: a. After the truck is stopped in the desired location, set the parking brakes from the cab. b. Shut down the engine. c. Perform the prefueling check in paragraph 2-4. d. Connect one of the static bond cables to a suitable connection. e. Connect a fuel hose to the 2-1/2 inch faucet (17) and place opposite end of hose into a suitable container. f. Open the emergency valve (5) by pulling the top emergency valve operator lever (22). g. Open faucet (17). h. When draining is complete, close faucet (17). i. Push the emergency valve operator lever (22) to the in position. j. Disconnect and stow the fueling hose and install the dust cover as required. k. Stow the static cable. CAUTION Do not allow the cable to wind freely onto the reel. When stowing the cable, hold to it and walk back to the trailer as it winds onto the reel.

10

2-8. FUELING PROCEDURE. Perform the following procedures when fueling from the tank truck is to be accomplished. WARNING If at any time during the fueling operation an emergency occurs, close the emergency valve by performing one of the following procedures: 1. Push the emergency valve operator to the in position or close the cabinet doors. One of the cabinet doors will push the EV operator handle, when closed. 2. Pull the emergency release at the right rear of the tank. 3. Pull the emergency release at the left front of the tank, near the driver's door. 4. Pull the emergency release at the front top of the tank. Note: Open valve 16 (sectionalizing valve) approximately 1/2 turn prior to any pumping operation. This will reduce pump start-up pressure. Pump pressure can then be regulated as required by adjusting valve 16. a. After the truck is stopped in the desired location, set the parking brakes from the cab and place the transmission in neutral. b. Perform the prefueling check in paragraph 2-4. c. Connect one of the static bond cables to a suitable connection. d. Engage the PTO control (4) located in cab. NOTE: The PTO will not engage until the EV operator handle is pulled out. e. Set the throttle for the desired pumping rate (1000 rpm maximum). NOTE: 1000 rpm will result in around 75-80 gpm flow. To increase throttle, turn the cruise control rocker switch to the left of the steering column ON. Engine speed is increased by holding the RESUME / SET rocker switch in the RESUME / ACCELERATE position and releasing when the desired speed is obtained. Holding the switch in the SET / COAST position will reduce speed. To bring the engine to idle, turn the cruise control switch OFF. f. Reset meter (13) to zero (rotate knob on register clockwise). g. Open valves (24), (15), and (11). h. Pull the emergency valve operator (22) handle to the open (out) position. i. Unwind hose reel (9) as required and dispense fuel by opening nozzle (10) to flow. Regulate pressure by adjusting valve (16) as required. j. When fueling is complete, rewind hose onto reel (9).

11

k. Push the emergency valve operator (22) handle to the closed (in) position. l. Close valves (24), (15), and (11). m. Set throttle to idle. NOTE: Turn OFF cruise control. n. Disengage the PTO control (4) located in cab. o. Disconnect and stow the static cable. CAUTION Do not allow the cable to wind freely onto the reel. When stowing the cable, hold to it and walk back to the truck as it winds onto the reel. 2-9. TANK LOADING USING THE TRUCK PUMP, UNMETERED. Perform the following procedures when self-loading the truck tank is required. a. After the truck is stopped in the desired location, set the parking brakes from the cab. b. Engage the Scully system (if unit is so equipped) by engaging the pull type switch (overfill control) on the dash. The light near the switch will light when switch is on. c. Perform the prefueling check in paragraph 2-4. d. Connect one of the static bond cables to a suitable connection. e. Connect 2-1/2 inch suction hose(s) to faucet (17) stub. Four each suction hoses are stored in the hose tubes at the rear of the truck. Connect opposite end of hose(s) to fuel source. f. Engage the PTO control (4) located in cab. NOTE: The PTO will not engage until the brake interlock valve (18) is activated. g. Set the throttle for the desired pumping rate (1000 rpm maximum). NOTE: 1000 rpm will result in around 100 gpm flow. To increase throttle, turn the cruise control rocker switch to the left of the steering column ON. Engine speed is increased by holding the RESUME / SET rocker switch in the RESUME / ACCELERATE position and releasing when the desired speed is obtained. Holding the switch in the SET / COAST position will reduce speed. To bring the engine to idle, turn the cruise control switch OFF. h. Open valve (16) and faucet (17). If truck has filter/separator and canister filters, with valve (15) located upstream of filters, open this valve also. i. Open brake interlock air valve (18) by moving lever to side. This action will engage the PTO and pumping will begin. j. Start filling the tank and make sure system is working properly by pushing the precheck switch (23). It is located on the left end of the Scully control module, in the center. Hold the button in until flow stops. After flow stops, release switch to resume flow. Again, this applies only if the unit is equipped with a Scully system, not all trucks are so equipped.

12

WARNING If the flow does not stop soon after the precheck button is depressed, stop flow by closing brake interlock valve (18) immediately to avoid a fuel spill. The system is not operating properly and needs repair. k. The flow will stop when the liquid contacts the probe located in the top of the tank. The onboard control system will close the bottom loading valve and flow will stop. NOTE: Flow into the tank will be nonmetered. l. Close brake interlock air valve (18) by moving lever to side. This action will disengage the PTO. m. Close valve (16) and faucet (17). Close valve (15) if opened (see step h above). n. Set throttle to idle. NOTE: Turn OFF cruise control. o. Disengage the PTO control (4) located in cab. p. Disconnect 2-1/2 inch suction hose(s) from faucet (17) stub and fuel source. Stow hoses in the hose tubes at the rear of the truck. q. Disconnect and stow the static cable. CAUTION Do not allow the cable to wind freely onto the reel. When stowing the cable, hold to it and walk back to the truck as it winds onto the reel. 2-10. DEFUELING. A device can be defueled and the product delivered to the tank using the onboard pump by performing the following procedures. a. After the truck is stopped in the desired location, set the parking brakes from the cab. b. Engage the Scully system (if unit is so equipped) by engaging the pull type switch (overfill control) on the dash. The light near the switch will light when switch is on. c. Perform the prefueling check in paragraph 2-4. d. Connect one of the static bond cables to a suitable connection. e. Connect 2-1/2 inch suction hose(s) to faucet (17) stub. Four each hoses are stored in the hose tubes at the rear of the truck. Connect opposite end of hose(s) to the unit to be defueled. f. Engage the PTO control (4) located in cab. NOTE: The PTO will not engage until the brake interlock valve (18) is activated.

13

g. Set the throttle for the desired pumping rate (1000 rpm maximum). NOTE: 1000 rpm will result in around 100 gpm flow. To increase throttle, turn the cruise control rocker switch to the left of the steering column ON. Engine speed is increased by holding the RESUME / SET rocker switch in the RESUME / ACCELERATE position and releasing when the desired speed is obtained. Holding the switch in the SET / COAST position will reduce speed. To bring the engine to idle, turn the cruise control switch OFF. h. Open valve (16) and faucet (17). If truck has filter/separator and canister filters, with valve (15) located upstream of filters, open this valve also.. i. Open brake interlock air valve (18) by moving lever to side. This action will engage the PTO and pumping will begin. j. Start filling the tank and make sure system is working properly by pushing the precheck switch (23). It is located on the left end of the Scully control module, in the center. Hold the button in until flow stops. After flow stops, release switch to resume flow. Again, if unit is Scully equipped, not all trucks have Scully systems. WARNING If the flow does not stop soon after the precheck button is depressed, stop flow by closing brake interlock valve (18) immediately to avoid a fuel spill. The system is not operating properly and needs repair. k. The flow will stop when the liquid contacts the probe located in the top of the tank. The onboard control system will close the bottom loading valve and flow will stop. NOTE: Flow into the tank will be nonmetered. l. Close brake interlock air valve (18) by moving lever to side. This action will disengage the PTO. m. Close valve (16) and faucet (17). Close valve (15) if opened. n. Set throttle to idle. NOTE: Turn OFF cruise control. o. Disengage the PTO control (4) located in cab. p. Disconnect 2-1/2 inch suction hose(s) from faucet (17) stub and defueled unit. Stow hoses in the hose tubes at the rear of the truck. q. Disconnect and stow the static cable. CAUTION Do not allow the cable to wind freely onto the reel. When stowing the cable, hold to it and walk back to the truck as it winds onto the reel.

14

2-11. GRAVITY DRAIN - METERED. Fuel can be gravity drained from the tank by performing the following procedures: a. After the truck is stopped in the desired location, set the parking brakes from the cab. b. Shut down the engine. c. Perform the prefueling check in paragraph 2-4. d. Connect one of the static bond cables to a suitable connection. e. Connect a fuel hose to the 2-inch faucet (14) and place opposite end of hose into a suitable container. f. Open the emergency valve (5) by pulling the top emergency valve operator lever (22). g. Open valves (15) and (16) and faucet (14). If truck has both canister filters and a filter/separator and valve (15) is upstream of the filters, it will not be necessary to open valve (15). h. When draining is complete, close valves (15), if used, (16) and faucet (14). i. Push the emergency valve operator lever (22) to the in position. j. Disconnect and stow the fueling hose and install the dust cover as required. k. Stow the static cable. CAUTION Do not allow the cable to wind freely onto the reel. When stowing the cable, hold to it and walk back to the trailer as it winds onto the reel.

15

Fig. 2-1A Schematic (for trucks with filters)

16

Fig. 2-1B Schematic (for trucks without filters)

17

CHAPTER 3

MAINTENANCE AND SERVICING 3-1. SCOPE. This chapter contains instructions for inspection, lubrication, cleaning, and routine servicing procedures. 3-2. CLEANING. Should the need arise to perform welding or cutting operations on the tank, tank cleaning should be in accordance with API Publication 2013 (Cleaning Mobile Tanks in Flammable or Combustible Liquid Service). This is a safety measure to insure the tank is vapor free. If the tank is not free of flammable vapors prior to and during the performance of hot work on it, an explosion resulting in serious bodily injury or death could result. 3-3. LUBRICATION. Lubricate hose reel crank, static reel, and emergency valve operator cables weekly using MIL-C-7118 grease or equivalent. 3-4. INSPECTION. Table 3-1 lists inspections to be made daily, before, during, and after operation to insure that the fuel trailer is safe to operate and to identify any malfunction. Table 3-2 lists periodic checks and services to be made in addition to daily inspections at intervals as specified in the tabulated listing. 3-5. TROUBLESHOOTING. This section contains instructions for troubleshooting the fuel system. Table 3-3 provides a list of malfunctions that may occur. Each potential malfunction is followed by a probable cause or list of probable causes. Each probable cause is followed by a corrective action procedure. 3-6. COMPONENT REPAIR. Commercial literature for the major active components in the fueling system is provided at the end of this manual, in chapter 4. Refer to this information as necessary for maintenance, repair, servicing and adjusting, calibration, and parts listing for the affected item. 3-7. SERVICE. See tables 3-1 (Daily Inspections), 3-2 (Periodic Checks and Services) and 3-3 (Troubleshooting) for applicable servicing information.

DANGER

18

3.8 Ready for Air Transport This chapter gives instructions for making vehicle air transportable. This requires lowering the height of the vehicle using following methods. a. Pull down front suspension Using ratcheting mechanism provided, pull front suspension down as shown.

Wrap chain around spring/axle and connect to ratcheting mechanism. Hook other end of tool around frame rail and pull vechicle down. After pulling down the second side, recheck the first side to make sure it is still tight. b. Release air from tires Release air from tires until pressures are: 35 psi front, 25 psi rear

Connect this end to chain wrapped

around axle/spring

This end hooks over

frame rail

19

c. Dump air from air bumper under cab.

AFTER DISCONNECTING

LINKAGE, USE THIS LEVER TO RELEASE

DISCONNECT THIS

LINKAGE FROM LEVER

20

Table 3-1 Daily Inspections

Before Operation

During Operation

After Operation

Item Check

X

X

Fuel System Plumbing and Components

Check plumbing and components for leaks while the unit is operating.

X

Sump Drain Valve

Place a suitable container under the sump drain valve and open the valve briefly. Check the contents of the container for water. If no water is present, the unit is ready for operation. If water is present, repeat the procedure until fuel only (no water) is drawn into the container.

X Fueling Hose and Nozzles

Check that all detachable equipment is present and properly

stored. X Fire Extinguishers Check that all fire extinguishers are

charged and inspections are up to date.

Table 3-2 Periodic Checks

Checks and Services Weekly Other Intervals 1. Clean and inspect nozzle, bottom loading adaptor and fuel strainer.

X

2. Check tank for operation of manhole fill cover latch, debris or foreign matter in tank and operation of vent(s).

x

3. Service Lube Points (see paragraph 3-3).

X

4. Check accuracy of meter and register using a graduated container.

Annually

5. Calibrate Meter When material being pumped is changed, when maintenance is performed on meter or register or when unit is obviously not measuring correctly.

6. Check tightness of bolts on valve flanges. Visual inspection will not verify tightness, physically put a wrench on these bolts.

Monthly

7. Check Torque of tie down bolts. Torque all but the spring loaded bolts to 90 ft lb. Tighten the spring loaded bolts until the spring compressed length is 3 1/2”.

Check initially upon receipt of truck, recheck after one month, followed by annual inspection.

21

Table 3-3 Troubleshooting Malfunction Probable Cause Corrective Action

1. Pump operates, but system will not pump fuel

1. Tank is empty 2. Incorrect Valve Positions 3. Strainer Clogged 4. Emergency Valve Cable stretched or broken 5. Inoperative Nozzle 6. Obstruction in Piping 7. Defective Hose Valve

1. Fill the tank 2. Reset Valve settings, insure the settings are correct 3. Clean Strainer 4. Check valve travel underneath truck, adjust as needed or replace cable. 5. Repair or replace nozzle 6. Locate and remove obstruction 7. Repair or replace valve

2. Pump operates, but output is below normal

1. Partially clogged strainer 2. Engine Speed too slow 3. Emergency Valve Cable stretched

1. Clean or replace strainer 2. Increase engine speed 3. Check underneath truck for cable travel. Adjust or replace cable as needed

3. Pump operates, flow is as expected, but slows or stops after only a few minutes of operations

1. Vent valve closed or clogged

1. Pull emergency valve operator to see if vent opens 2. If vent does not open, check air lines between E/V and vent. And repair or replace as needed 3. Clean or replace vent as needed

4. Hydraulic motor rotates, but system will not pump fuel

1. Valves not positioned correctly 2. Pump to motor coupling defective 3. Defective pump

1. Reset valve settings, insure that valve settings are correct. 2. Replace defective coupling 3. Repair or replace pump.

5. Meter does not register 1. Rotor Shaft pin sheared 2. Broken Rotor

1. Replace pin 2. Replace Rotor

6. Meter registers erratically 1. Stripped gear teeth or broken teeth in the gear. 2. Worn gear plate ass’y shafts

1. Replace defective gears 2. Replace gear plate ass’y or gears

7. Pump pressure too high or too low

1. By Pass Valve out of adjustment

1. Adjust to correct pressure by turning screw on top of valve. Turn in to increase pressure, turn out to decrease pressure.

22

CHAPTER 4

PARTS LIST AND COMMERCIAL LITERATURE

4-1. GENERAL. This chapter contains information that will be of assistance during repair and maintenance of vehicle components, such as identification and location of major parts. Also included is literature on various commercial components provided on this unit. 4-2. PARTS LIST. FIG. & DESCRIPTION PART NUMBER QTY INDEX NO. 4-1-1 Valve, B/F, 3-inch WD301ALV 3 -2 API Bottom Loading Adapter F5000-001 1 -3 D-1 Bottom Loading Adapter 61528BC 1 -4 Brake Interlock Valve 3418 1 -5 Valve, Check, 1/2" (inside tank) 61-103-01 1 -6 Hose Reel C1115-25-15L 1 -7 Nozzle CV90-001 1 -8 Valve, B/F, 2-inch (Victaulic) 700 1 -9 Flow Meter M7C1 1 -10 2-inch Faucet Dust Cap MS27028-11 1 -11 2-1/2 inch Faucet Dust Cap MS27028-13 1 -12 Static Reel DMI-75G40-20 1 -13 Valve, Faucet WD201ALV 1 -14 Scully Shut-Off System 09356 1 -15 Powerise Air-Springs GSS-18-21UB 4 4-2-1 Pump TXD02A 1 -2 End Yoke 10-4-123 1 -3 Driveshaft N10270-SF 1 -4 End Yoke 10-4-103 1 -5 PTO CS20-41006-H1BX 1 4-3-1 Hood, Vapor Recovery VR45962BU 1 -2 Vent AV46850ALFTS 1 -3 Manhole Cover, 20" PPVL863BXB346 1 -4 Probe, Scully Shut-off Kit 09356 1 4-4-1 Remote Trip Handle 35603SL 3 -2 Valve, Water Drain 3721X1 1 -3 Valve, Emergency / Bottom Load 64055A 1 -4 Operator, EV 41158-A 1 4-5-1 Light, Cabinet 570006 2 -2 Light, Clearance 500012 4 -3 Light, Stop, Turn, Tail 400017 2 -4 Light, Back-up 500011 2 -5 Light, I.D. 200013 1 -6 Junction Box 470041 1

23

Fig. 4-1 Pumping Compartment

Fig. 4-2 Pump/PTO Diagra

1 2

4

3

5

IN TANK

6

7

8

9 10

24

Fig. 4-3 Top of Tank

Fig. 4-4 Cable Diagram

Fig. 4-5 Electrical (Lights)

1

2

3

4

25

Chapter 56 Scully “IntellliCheck” Overfill Prevention System

5-1 Scully Operation Procedures a. The Scully system is fully self contained and should function automatically when the switch in the cab is turned on. The pilot light near the switch should illuminate. b. A good way to check the system to see if all components were properly installed and are properly functioning is to turn on the system with the switch in the cab and to place a small cup of liquid around the probe (water should work but a darker liquid such as Coke may be required, fuel will definitely work). The probe can be accessed through the manhole fill cover. When the liquid contacts the probe listen for air exhausting from the solenoid valve. This indicates that the system is functioning properly. c. Further testing should be conducted at the fill stand using the onboard pre-check system. Engaging the push button switch on the left side of the Scully Intellicheck module should cause the flow from the fill stand to stop. This check should be performed at 100 to 300 gallons into the bottom loading task.

Fig.4-6 Scully System Schematic

26

WARRANTY

Isometrics, Inc. (Company) hereby warrants its products to be free from defects in materials and workmanship for a period of one (1) year from the date of original purchase. If, upon examination by the Company, any part or parts are determined to be defective, the Company will provide, free of charge, for the repair or replacement of said items, as the Company may elect. This warranty is subject to the following exceptions and limitations:

I . The customer shall be responsible for normal maintenance and minor adjustment of the product. Notification to the Company of the need for warranty service shall be performed and any transportation charge and/or delivery of the product to and from the place where warranty service is to be performed must I-cave prior written approval from the Company. 2. This warranty does not apply to component parts or accessories applicable to the cab and chassis and tractors, which carry the warranty of the manufacturer thereof. 3. This warranty applies only to products which are placed in normal use, and does not apply to any product which has been mistreated, neglected or damaged by accident. 4. This warranty does not apply to any product repaired or altered by anyone other than a Company representative, unless such repair or alteration has been authorized by the home office.

For warranty service, contact any Company representative. For the name and location of the nearest representative, and for further warranty information, write or call:

ISOMETRICS, INC. P.O. BOX 660

1266 NORTH SCALES STREET REIDSVILLE, NORTH CAROLINA 27320

PH: 336-349-2329 FAX: 336-349-4744

Attn. David McCollum email: dmccollum@isometrics-inc.


FOR CARTERPART NUMBERS 64055 & 64143

4” INTERNAL/BOTTOM LOADING VALVES,

March 1, 2001, New Release




SM64055 March 1, 2001

- 2 -

SUMMARY OF REVISIONS

DATE OFCHANGE

E.O. NO. REV. PARA. ORPAGE NO.

DESCRIPTION APPROVED

3/1/2001 - NEW RELEASE

SM64055 March 1, 2001

- 3 -

TABLE OF CONTENTS

1.0 INTRODUCTION................................................................................................ 4

2.0 EQUIPMENT DESCRIPTION............................................................................ 4

3.0 AVAILABLE OPTIONS ..................................................................................... 4

4.0 DISASSEMBLY .................................................................................................. 5

5.0 INSPECTION....................................................................................................... 5

6.0 REASSEMBLY ................................................................................................... 6

7.0 TEST .................................................................................................................... 6

8.0 ILLUSTRATED PARTS CATALOG.................................................................. 7

FIGURE 1A, 64055 & OPTIONS............................................................................ 10

FIGURE 1B, 64143A & OPTIONS ......................................................................... 11



FIGURE 4, PILOT VALVE PARTS BREAKDOWN ............................................ 14

FIGURE 5 - DIAPHRAGM INSTALLATION POSITION .................................... 15

FIGURE 6 - DIAPHRAGM TORQUE SEQUENCE.............................................. 15

SM64055 March 1, 2001

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MAINTENANCE, OVERHAUL & TEST INSTRUCTIONSCARTER PART NUMBERS 64055 & 64143 INTERNAL/BOTTOM LOADING VALVES

1.0 INTRODUCTION

This manual furnishes detailed instructions covering themaintenance and overhaul of Carter Part Numbers 64055,and 64143 4” Internal/Bottom Loading Valves. Thismanual assumes that the valves will be used with a Carter64079 Level Sensor, however the 64055A, B, 64143A or

B can also be used with optic probe (s) using solenoidvalve (s) to effect the control of the pilot valve (s). If soservice manuals for these components should berequested from the manufacturer of the items used. Carterdoes not provide such items.


The Carter 64055 family of 4” valves can be used eitheras a straight internal valve or for bottom loading control.The 64055 mounts directly into a 4” TTMA Tank SumpRing. The 64055A is used with the Carter 64079 LevelSensor for bottom loading control with a single controlpilot valve. Option “B” adds two-stage level control withtwo pilot valves. (Note: Early units contained provisionsfor only single pilot valves with the dual capabilityavailable at a later date.) Option “B” requires either theuse of 64079B, C or two 64079 Level Sensors. A CarterVent, 64078, is also available to complete the systemrequirements. A straight 64055 Internal Valve can beconverted to a bottom loading valve, 64055A, by addinga pilot valve.

The 64143 4” Bottom Loading Valve is used only forbottom loading. The difference between the 64055 andthe 64143 is the absence of an off-loading cylinder on the64143 and a different orifice system in the piston.

The units are spring loaded “overbalanced” piston valves.Fuel inlet pressure is routed to the inside of the pistonchamber through a two-staged orifice in the center of thepiston. If the piston chamber has no exit, the areas insidethe piston chamber (outer diameter of the piston) is largerthan the face seal of the piston, hence the balance of

pressure forces, plus the spring force will keep the piston(valve) closed.

If the piston chamber is vented through an open pilotvalve, options A or B, the pressure drop across the inletorifice reduces the piston chamber pressure significantly.The resultant balance of forces will cause the piston toopen, hence the valve.

When the piston chamber is once again closed [pilotvalve (s) closes], the balance of forces again causes thevalve to close.

The 64055 or 64143 A or B is normally utilized with the64079 Level Sensor. If so desired, a solenoid valve (s)can be used in the system to provide or deprive the pilotvalve of pressure (usually routed from the bottom loadingadapter) to cause the opening and closing of the valve. Inthis way the valve can be used with any optic type sensingprobe to detect the desired tank level for closure.

On the 64055, a separate air operated piston is providedto effect off-loading as desired. The direction of airpressure to this piston will cause it to pull open the mainpiston to allow for off-loading flow. When the airpressure is depleted, the spring forces will close both theair and main pistons.

3.0 AVAILABLE OPTIONS

The 64055 Basic Valve is designed for use as an internalvalve and has no other functional controls. The 64055 canbe opened for off-loading by application of air pressure tothe cylinder provided. The 64143 can only be used asoption A (64143A) since it has no off-loading capability.

The “A” option (64055A or 64143A) adds a pilot valveto the basic unit making it a bottom loading control valve.Again the 64055A can also be used for off-loading by theapplication of air pressure to the provided cylinder.

The “B” option (64055B or 64143B) adds two pilotvalves to the basic unit to close the valve in two-stages.An orifice in the secondary pilot valve will continue tovent the piston chamber after the primary pilot valve hasclosed. This orifice restricts the pressure escaping fromthe piston chamber to maintain the piston in a partiallyopen position hence flow into the tank is reducedsignificantly. This provides a more accurate final shutoffand also helps control surge pressure on final shutoff.

SM64055 March 1, 2001

- 5 -

4.0 DISASSEMBLY

4.1 Refer to Figures 1, 2 or 3 for exploded views of theunit.

4.2 Remove the six Screws (8) and Washers (9) fromthe Bonnet (23) or (24) and put a side for reuse.

4.3 Rotate the bonnet slightly in either direction andpull it from the Body (28). On the 64055 the Piston(12) and its attaching parts will come out of theBody (28) with the bonnet as Piston Assembly(10).. Continue on with the next paragraph if theunit being disassembled is the 64055. Ship toparagraph 4.5 if it is a 64143.

4.4 64055:

4.4.1 Find the Pin (17B) in the Shaft Assembly (17). Usethe spring pin to hold the shaft in place and removeRod (11) by unscrewing it, being careful not todrop Piston (12). Remove Piston (12) and Spring(13).

4.4.2 Remove Ring (14), Spring Pad (15) and Spring(16). Remove O-ring (22) from Bonnet (23) anddiscard it.

4.4.3 Using the pin used in paragraph 4.4.1 hold theShaft Assembly (17) while unscrewing Housing(18). Pull Housing (18) off of Bonnet (23).

4.4.4 Remove Wipe Ring (20) and Quad-Ring (21) fromBonnet (23). Discard both items. Skip to paragraph4.6.

4.5 64143:

4.5.1 Remove Bonnet (24) then remove Spring (13).Remove O-ring (22) from Bonnet (24) and discardit.

4.5.2 Reach into body (28) opening and carefully extractthe Piston Assy (25).

4.5.3 Unless replacement is needed it is recommendedthat Set Screw (27) and Nut (26) in the face of thepiston not be removed.

4.6 64055 & 64143 - Remove and discard O-ring (29)and Seal (30) from Body (28).

4.7 Unless the Screen (33) is damaged and needsreplacement, do not remove it from the Body (28).If it needs replacing then remove Screws (31) andNuts (32) to do so.

4.8 On the basic unit, remove the Plug (3) only if it hasbeen leaking. If it is removed, then discard Gasket(4).

4.9 On 64055 or 64143A - Unscrew Pilot Valve Assy(2) from Bonnet (23) or (24) and remove anddiscard Gasket (4). On “B” option to either unit,remove secondary Pilot Valve Assy (2). Orifice (5)and Gasket (6) will be found under the secondaryPilot Valve Assy (2). Remove them and discardGasket (6).

4.10 Pilot Valve Assy (2) may be replaced as acomplete unit or overhauled as follows:

4.10.1 Remove six Screws (34) and Washers (35).

4.10.2 Using a thin blade screwdriver, pry the Cover (36)from the assembly. Be careful not to scratch theflanged surface of either metal part holding thediaphragms in place.

4.10.3 Remove and discard the two Diaphragms (37).

4.10.4 Remove Pressure Pad (38) from Poppet (40) shaft.

4.10.5 Remove Ring (39), which retains Spring (42) andWasher (41) in place. This will free up theremaining parts for removal.

5.0 INSPECTION

5.1 It is recommended that all O-rings (19), (22), (29);Gaskets (4), (6); Quad Ring (21); Wipe Ring (20);Diaphragms (37) and Seal (30) be replaced at eachoverhaul.

5.2 The outer diameters of the Shaft (17A), and Piston(12) along with the inner diameter of Housing (18) shouldbe inspected for scratches that might cause leakage. Thepiston seat in the Body (28) shall also be free of pits,scratches or gouges that would cause leakage. Inspect allother metal parts for dings, gouges, abrasions, etc. On allparts except the ones listed above, use 320 grit paper tosmooth and remove sharp edges. The outer diameter of

the Shaft (17A) and the Piston (12) can be polished toremove minor scratches by using a very fine emery clothwhile the parts are rotated. Do not polish local areas ofthese diameters. Unless proper equipment is available toaccomplish this task and to polish the inner diameter ofthe Housing (18) it is recommended that the parts bereplace, If polishing is attempted, do not break throughthe hard anodized surface of the Piston (12). If scratchesare too pronounced, the parts should be replaced. Replaceany part with damage exceeding 15% of local wallthickness. Use Alodine 1200, or similar chem filmtreatment, to touch up bared aluminum.

SM64055 March 1, 2001

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The flat surfaces of the Fitting (43) and Cover (36) maybe polished to remove minor scratches by using a flatplate and very fine emery cloth. Be careful to keep the

parts flat during polishing and to not raise any burrs onthe inside diameters that bare on the diaphragms.

6.0 REASSEMBLY


6.1.2 Light lubrication of all O-rings and seals, usingpetroleum jelly is recommended to facilitate installation.

6.1.3 When reassembling the Pilot Valve Assy (2) usethe following procedure to assure proper diaphragmretention:

6.1.3.1 Once the Poppet (40), Spring (42), Washer (41)and Ring (39) are in place, be sure that the Pressure Pad(38) is placed onto the Poppet (40) shaft with the smallerend placed onto the shaft first. The larger flat surfaceshould be facing away from the shaft.

6.1.3.2 The two Diaphragms (37) are placed such thatthe loops in the diaphragms are facing the Pressure Pad(38).See Figure 5 for an illustration. [In operation, theloops always face in the direction in which the pressurefrom the Level Sensor or solenoid valve is applied.]Smooth out the Diaphragms (37) place onto the Fitting(43) and align the six holes in all three parts. Carefullyplace the Cover (36) onto this assembly aligning theholes.

6.1.3.3 Start the six Screws (34) with the Washers (35)in place by hand until resistance is met. Note that if noresistance is met in attempting to hand tighten the screws,it is recommended that the Screws (34) be replaced. Theyare self-locking and some resistance should be felt.

6.1.3.4 Observing the Cover (36) from the outside end(look at the threaded port in the middle), mentally numberthe holes in a clockwise direction from one to six. Refertop Figure 6. Using a properly set torque wrench, tighten

the number 1 screw to 1.6 in-lbs. (1.8 Kg-cm), followedby tightening screws number 5, 3, 6 and 4 in that order.Then repeat the tightening sequence to 3.2 in-lbs. (2.1Kg-cm) and then 5.3 in-lbs. (6.1 Kg-cm) respectively.

Let the assembly stand for a minimum of 15 hoursretighten the screws as above to the 5.3 in-lbs. (6.1 Kg-cm) setting.

6.1.4 When installing the Seal (30) onto O-ring (29) inBody (28) be sure to smooth the surface evenly with afinger. See note on Figures 2 and 3.

6.1.5 On the 64055 - Use Locktite 24221 (17C) on thethread of Shaft (17A) before screwing on Housing (18).Note the thread of both parts should be cleaned with therecommended Locktite cleaning solution prior to using24221. Read the instructions on 24221 before using.

6.1.6 Once the Piston/Bonnet Assy (10) has beeninserted into the Body (28) the Rod (11) must be adjustedto provide a gap of 0.012±0.005 (.305±.127 mm)between the under side of the hex head of the rod and themating flat surface of the Piston (12). A feeler gageshould be used for this purpose. This will assure that theproper surge control during shutoff will be effective. Onthe 64143 if the Set Screw (27) and Nut (26) wereremoved it will be necessary to adjust the face of the SetScrew (27) to .409 ± .005 inches (10.388 ± .127 mm)from the face of the Nut (26).

6.1.7 If the Screen (33) was removed and replaced, thereplacement will be provided in a flat condition and itwill be necessary to carefully shape it to fit the Body (28).

7.0 TEST


7.2 Test conditions

7.2.1 Test media shall be odorless kerosene, Jet A orequivalent at 75° + 15°F.

7.3 Functional Test - If testing prior to reinstalling theunit in the refueler is desired conduct the following tests:

7.3.1 Connect the inlet of the unit to a test mediapressure source with a minimum of 150-psig available.

Tee off the inlet pressure line to the primary pilot valveand to the secondary pilot valve on “B” option units.Install a small ball valve between the inlet pressure sourceand each pilot valves. Install a bleed valve between thepilot valve (s) and the ball valve. Gauges should beinstalled in the pressure line to the main valve’s inlet andin the line to the pilot valve (s).

7.3.2 On the 64055 connect the air port to a 100-psig airpressure source with a gauge in the line.

SM64055 March 1, 2001

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7.3.3 Bleed all air from the valve by applying 10-psigtest media pressure to the inlet and opening the bleedvalve (s) in the lines to the pilot (s). Once the air is bled,close the valve in the line to the pilot (s) and bleed allliquid trapped in the line (s).

7.3.4 Increase the pressure to the valve to approximately25-psig for one minute and then increase it to 150-psigfor one minute. Observe for external leakage during thetest period. No leakage except from the main piston shallbe allowed. This leakage should be limited to 100cc/minute.

7.3.5 On the 64055, following the above test with thevalve still full of liquid apply air pressure to the unitstarting at 35-psig and slowly increasing slowly until thevalve opens. The valve should open at an air pressure of50-psig maximum. If testing the 64143 skip thisparagraph and go on to 7.3.6. Shutoff the air pressure andbleed it to atmosphere. The valve should return to theclosed position.

7.3.6 Apply liquid pressure slowly to the valve inlet andsimultaneously to the pilot (s). Observe when the mainpiston opens. The valve shall open with an inlet pressureof 15-psig or less.


Table 1.0 tabulates the parts and sub-assembliescomprising the various versions of both the 64055 and64143 Valves with all options. The item numbers of the

table are keyed to the exploded views of the unitdiagrammed in Figures 1, 2 or 3.

TABLE 1.064055 & 64143 Bottom Loading Valves & Options

Refer to Figures 1A and 1B



1A 1 64055 Internal Valve, Bottom Loading andOff-loading (Figure 1A).................... 1 - -

1A 3 GF814-10D Plug................................................... 2 Basic -4 MS29512-10 Gasket ............................................... 2 Basic 202 47097 Pilot Valve, Primary (FIGURE 4) .... 1 A -3 GF814-10D Plug................................................... 1 A -4 MS29512-10 Gasket ............................................... 2 A 202 47097 Pilot Valve, Secondary (FIGURE 4) 2 B -4 MS29512-10 Gasket ............................................... 2 B 205 221087 Orifice............................................... 1 B -6 MS29512-08 Gasket ............................................... 1 B 10

1B 1 64143 Internal Valve, Bottom Loading Only(Figure 1B) ....................................... 1 - -

3 GF814-10D Plug................................................... 1 A -4 MS29512-10 Gasket ............................................... 2 A, B 202 47097 Pilot Valve, Primary (FIGURE 4) .... 1 A -2 47097 Pilot Valve, Secondary (FIGURE 4) 2 B -5 221087 Orifice............................................... 1 B -6 MS29512-08 Gasket ............................................... 1 B 10

SM64055 March 1, 2001

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TABLE 2.0Parts Breakdown, 64055 & 64143 Basic Valves



2, 3 8 GF35275-265 Screws............................................... 8 All -9 GF35338-138 Washers ............................................ 8 All -

2 10 No number Piston/Bonnet Assy........................... 1 64055 -11 220447 Rod........................................... 1 64055 -12 47096 Piston ....................................... 1 64055 113 220436 Spring....................................... 1 64055 -14 GF16633-4050 Ring.......................................... 1 64055 -15 220438 Spring Pad................................ 1 64055 -16 220437 Spring....................................... 1 64055 -17 47095 Shaft Assembly ........................ 1 64055 -

17A 220448 Shaft .................................. 1 64055 -17B GF16562-238 Pin..................................... 1 64055 -17C 24221 Locktite .................................... 1 6405518 220450 Housing .................................... 1 64055 -19 MS29513-112 O-ring....................................... 1 64055 1020 220453 Wipe Ring ................................ 1 64055 1021 Q4325-366Y Quad Ring ................................ 1 64055 1022 MS29513-157 O-ring....................................... 1 64055 1023 47099 Bonnet ...................................... 1 64055 -

3 22 MS29513-157 O-ring ............................................... 1 64143 1024 221108 Bonnet .............................................. 1 64143 -25 47284 Piston Assy ....................................... 1 64143 112 47096 Piston ....................................... 1 64143 126 GF51971-3 Nut ........................................... 1 64143 -27 221109 Set Screw, Orifice .................... 1 64143 -13 220436 Spring ............................................... 1 64143 -

2, 3 28 220458 Body ................................................. 1 All -29 MS29513-248 O-ring ............................................... 1 All 1030 220456 Seal ................................................... 1 All 1031 GF515C4-5 Screw................................................ 2 All -32 GF20365D440 Nut .................................................... 2 All -33 220431 Screen ............................................... 1 All -

SM64055 March 1, 2001

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TABLE 3.0Pilot Valve Parts Breakdown



1A, 1B 2 47097 Pilot Valve Assy, Primary................. 1 A & B -4 34 LP35275-230 Screw........................................ 6 A & B -

35 GF620C6 Washer ..................................... 6 A & B -36 220441 Cover........................................ 1 A & B -37 220445 Diaphragm................................ 2 A & B 2038 220443 Pressure Pad............................. 1 A & B -39 GF16633-4018 Ring.......................................... 1 A & B -40 220434 Poppet ...................................... 1 A & B -41 220442 Washer ..................................... 1 A & B -42 220444 Spring....................................... 1 A & B -43 220433 Fitting....................................... 1 A & B -

1 5 47097 Pilot Valve Assy, Secondary............. 1 B -4 34 LP35275-230 Screw........................................ 6 B -

35 GF620C6 Washer ..................................... 6 B -36 220441 Cover........................................ 1 B -37 220445 Diaphragm................................ 2 B 2038 220443 Pressure Pad............................. 1 B -39 GF16633-4018 Ring.......................................... 1 B -40 220434 Poppet ...................................... 1 B -41 220442 Washer ..................................... 1 B -42 220444 Spring....................................... 1 B -43 220433 Fitting....................................... 1 B -

There are several kits of parts designed to provide the necessary items to overhaul the units as described below.

KIT NUMBER DESCRIPTIONKD64055-1 Kit, seal replacement for 64055A Valve. Contains items 4, 19, 20, 21, 22,

29, 30 & 37.KD64055-2 Kit, seal replacement for 64055 Basic Valve. Contains items 4, 19, 20, 21,

22, 29 & 30.KD64055-3 Kit; seal replacement for 64055B Valve. Contains items 4, 6, 19, 20, 21, 22,

29, 30 & 37.KD64129-3 Kit; Overhaul for 47097 Pilot Valve Assy. Contains items 4 & 37.KD64143-1 Kit; seal replacement for 64143A Valve. Contains items 4, 22, 29, 30 & 37.KD64143-2 Kit; seal replacement for 64143B Valve. Contains items 4, 6, 22, 29, 30 &

37.Notes: 1. All part numbers beginning with "GF" Are interchangeable with those beginning with either "AN" or "MS".

If three numbers follow the “GF” it is interchangeable with an "AN" part, otherwise it is interchangeablewith an "MS" part of the same number.

2. The recommended spare parts shown Above Are the number required to support 10 units for one year oreach overhaul whichever is sooner. These quantities do not include replacement spares for intermediatereplacement of parts required by Abuse or misuse of the equipment. The recommended quantities are basedon the ratio of spare parts sold for each unit during A one-year period of time. The actual quantity requiredwill vary from location to location.

SM64055 March 1, 2001

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FIGURE 1A64055 & OPTIONS

SM64055 March 1, 2001

- 11 -

FIGURE 1B - 64143A & OPTIONS

SM64055 March 1, 2001

- 12 -


SM64055 March 1, 2001

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SM64055 March 1, 2001

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FIGURE 4PILOT VALVE PARTS BREAKDOWN

SM64055 March 1, 2001

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FIGURE 5DIAPHRAGE INSTLLATION POSITION

FIGURE 6DIAPHRAGM TORQUE SEQUENCE

4” BOTTOM LOADING COMPONENTSMODELS 64055, 64079, 64143

The Carter 4” family of Bottom Loading Valvesand accompanying Level Sensor are designed foruse in refuelers where bottom loading/off-loadingrates of up to 800 gpm are desired. There are twointernal valves in the family, one for use inloading and off-loading while the other is strictlyused for loading. Off-loading requires the use ofair pressure to open the internal valve. Both areused with the Carter 64079 Level Sensor or as analternative they can be used with an optic probecontrol. Bottom loading control is accomplishedautomatically, as in all Carter units when the tankliquid level reaches the pre-set level sensor. Seeaccompanying brochure 64055 for detailinformation on the operation of all Carter bottomloading units.

Both of the available internal valves can bepurchased to use with either a single or dual levelsensor as explained below.

64055A 4”Internal Valve

64079ALevel Sensor

FEATURES:❏ Pilot valve is identical on all Carter Bottom Loading components for lower maintenance costs. There is no

through hole in the diaphragm in the pilot to cause leakage and ultimate failure.

❏ Either single level or dual level control available. Dual level control, when used with 64079B Level Sensorprovides better shutoff level accuracy and lower surge pressures resulting from closing at very high rates offlow.

❏ 50-psi min. air pressure and standard air controlling valves (not furnished by Carter) required for off-loading- 64055. No off-loading control provided on the 64143.

❏ Internal Valve mates standard TTMA sump flange.❏ Can be used with optic sensing system.❏ Low pressure loss:

Bottom Loading – 4.5 psi at 600 gpmOff-loading - 1.5 psi at 600 gpm

Bulletin 64143 9/2000

671 W. 17th St., Costa Mesa, CA 92627 • Ph (949) 764-2200 • Fax (949) 631-2673 • E-mail [email protected] • ISO 9001 Certified


ORDERING INFORMATION:

64055 (basic configuration) - 4” INTERNAL OFF-LOADING VALVE - provides off-loading by use of air pressure.

64143A (no basic configuration available) - 4” BOTTOM LOADING VALVE - For use for loading the refueler only, no off-loading capability.

One or more of the following options may be added to change the function or configuration of the units above:

OPTION DESCRIPTION

A Adds pilot valve to basic unit (64055 only, 64143A only unit available) to provide bottom loading control whenused with Carter 64079 Jet Level Sensor or optic sensing probe system.

B Adds dual pilot valves to either unit for use with either two 64079 or one 64079B Level Sensors to improveaccuracy of the tank shutoff level or to reduce surge at closure.

64079 LEVEL SENSOR

There are no moving parts or seals in the Carter Level Sensor which, when used with 64055A or 64143ABottom Loading Valve will provide high level bottom loading control. There are no wearing parts in theunit hence it lasts indefinitely. Truck vibration will have no affect on the unit, unlike float valves, whichare subject to vibration damage. It is available with an optional mounting stud for adjustable level control.The stud is located outside of the collector/drain can for better level control. A collector/drain can andprecheck feature are provided as standard equipment.

One of the following options may be added to the basic 64079 part number to achieve the degree ofcustomization desired when used with either the 64055A or 64143A:

OPTION DESCRIPTION .

A Adds stud to basic unit to provide mounting and level adjustment., ½-13 UNC-2B thread

B Adds second Level Sensor with accompanying single mounting stud for use with 64055B or 64143B, ½-13 UNC-2B thread.

EQUIVALENT PART NUMBERS – WHITTAKER TO CARTER

The following table presents the equivalent part numbers for Carter units to replace Whittaker units:

ITEM DESCRIPTION WHITTAKERPART NO.

CARTERPART NO.

COMMENTS – APPLICABLE TOCARTER UNITS

4” Internal Valve for Off-loadingonly

F614 64055 Air pressure required for off-loading.

4” Internal Valve for BottomLoading and Off-loading

F614A or B 64055A or B Either single or dual pilots available.Air required for off-loading

4” Internal Valve for BottomLoading only.

None 64143A No off-loading capability, a separateinternal valve has to be used.

Level Sensor, no options F613 64079 Precheck and collector drain cansstandard on Carter unit.

Level Sensor with mounting stud F613A 64079A Mounting stud located outside ofprecheck and drain cans for bettercontrol.

Dual Level Sensor with mountingstud

F613B 64079B Same comment as above.

AVERY HARDOLL EQUIVALENT UNITS - The Carter 4” 64143 bottom loading valve and 64079A LevelSensor can be used in lieu of the 4” Avery Hardoll Jet Able Bottom Loading Valve. Bot systems function basicallythe same.

ALTERNATIVE BOTTOM LOADING UNITS

Carter also provides bottom loading equipment for 3” and 6” installations. See Brochure 64055 for completeinformation on this type of equipment.

INSTALLATION TIPS

❐ Install the internal valve from the outside of the tank with sufficient flexible line between the pilot (s) and thelevel sensor for easier removal and maintenance.

❐ Inlet line to 64079 Level Sensor from pressure source (adapter) must be at least 3/8” diameter tubing. It shouldbe routed from a port on the bottom loading adapter, such as Carter’s 6958, or 61528 that have ports designed forthis application. (See brochure 60373 for adapter choices). Routing the inlet pressure source closer to the internalvalve may not allow sufficient pressure for the system to function correctly. If the optional mounting stud (optionA) is used sufficient length of flexible tubing should be used to allow for adequate adjustment.

❐ Line between the pilot on the 64129A and the 64079 should be 1/4” diameter for best operation. Pressure surgingmay occur if larger tubing is used.

❐ If desired a separate precheck system may also be routed from the adapter to the precheck port on the 64079although the same affect can be achieved by installing a 3/8” spring loaded normally open ball valve in the inletpressure line. It will be necessary to adjust the precheck gate in the bottom of the 64079 to make the precheckeffective in either case. This is a trial and error adjustment. Note that there are no “tuning” plugs on the Carter64079 as on the Whittaker F613. A simple “gate” type valve in the bottom of the precheck can provides adjustingof the precheck flow.

❐ It is essential for safety reasons to install a plastic tube to the drain fitting on the bottom of the 64079 LevelSensor. Draining fuel from the Level Sensor if not collected and drained properly could generate a staticdischarge, which could lead to a fire.

❐ The optional mounting stud is located outside of the precheck and drain cans on the Carter unit. Unlike theWhittaker F613 there is not holes to plug with loose o-rings if the stud is used. If not used the can on the Carterunit is already sealed and there are no plugs to install. If installed correctly the level in the tank can be adjustedover a wide range simply by screwing the stud up or down to the desired level.

❐ If the Carter Internal Valve is to be used with an optic probe system a three-way solenoid valve must be installedin the pressure line from the adapter. When the tank level is below the probe the inlet pressure should be routed tothe pilot on the internal valve to cause it to open. When the optic probe is sensing fuel (level below the probe) thepilot on the internal valve must be vented to tank and the inlet pressure shutoff. This will cause the internal valveto close and stop the bottom loading process.

ENVELOPE DIMENSIONS

64055 INTERNAL VALVE

64079 LEVEL SENSOR


FOR CARTERPART NUMBERS 6958, 61272, 61409, 61528, 61529 & 64040


Revised December 1, 1994

Supercedes manual issued July 1, 1992





TABLE OF CONTENTS

PAGE

1.0 INTRODUCTION ........................................................................3

2.0 EQUIPMENT DESCRIPTION.....................................................3

3.0 TABLE OF OPTIONS ..................................................................3

4.0 DISASSEMBLY ...........................................................................4

5.0 INSPECTION................................................................................4

6.0 REASSEMBLY ............................................................................4

7.0 TEST .............................................................................................4

8.0 ILLUSTRATED PARTS LIST .....................................................5

FIGURE 1.....................................................................................................6


MAINTENANCE, OVERHAUL & TEST INSTRUCTIONSCARTER PART NUMBERS 6958, 61272, 61409, 61528, 64040 & 61529


1.0 INTRODUCTION

This manual furnishes detailed instructions coveringthe maintenance and overhaul of Carter Part Number6958, 61272, 61409, 61528, 64040 & 61529 Bottom

Loading and Recirculation Adapters. These units allutilize the MS24484 type refueling modular adapter.


These Carter units are all of similar design in thatthey all utilize the 2½ inch MS24484 type refuelingmodular adapter. This type of adapter is only suitedfor bottom loading and recirculation or otherrelatively low pressure type applications. ForHydrant System applications one should use Carter60195 or 60373 for 2½ inch installations or 60505or 61526 Adapters for the 4 inch API typeapplications. These adapters consist of a castaluminum housing in which is mounted either thecommercial version, MS24484-2, or the current QPLversion, MS24484-5, refueling modular adapter.Both of these MS24484 units are dimensionallyidentical. The only differences lie in two areas, bothrelated to high temperature applications normallyseen in fighter aircraft applications:

• Poppet seal on the MS24484-5 is of a hightemperature elastomer for use in temperatures up

to 350°F. The seal on the MS24484-2 is suitablefor temperatures up 160°F.

• The bayonet flange to which the nozzle connectson the MS24484-5, has a greater tensile strengthrequirement required by the 350°F requirement.Again, the MS24484-2 was designed for serviceat temperatures up to 160°F.

The MS24484-5 is only manufactured by specificallyqualified suppliers, among which is our parentcompany, J. C. Carter. The MS24484-2, a previouslylisted qualified product is made by Carter GroundFueling Co.

All of the models discussed herein, except for thebasic module, 61529, are similar, varying mainly inthe outlet mounting configuration.

3.0 TABLE OF OPTIONS

Each of the basic units may be obtained in various configurations by adding one or more of the options listed inthe table below.

Option Letter Description Comments

A Adds Pressure Dust Cap (61531) In lieu of Option B on all models.

B Adds Plastic Dust Cap (41607) In lieu of Option A on all models.

C Adds Commercial MS24484-2 Adapter In lieu of Option D on all models except 61529.(Either C or D must be specified to obtain acomplete unit).

D Adds Military MS24484-5 Adapter In lieu of Option C on all models except 61529.(Either C or D must be specified to obtain acomplete unit).

G Adds 2-1/2" - 8 NPT Female Outlet In lieu of Option H on 6958 only. (Either G or Hmust be specified to obtain a complete unit).

H Adds 2-1/2" - BSPP Female Outlet In lieu of Option G on 6958 only (Either G or Hmust be specified to obtain a complete unit).


-4-

4.0 DISASSEMBLY

Refer to Figure 1 for an exploded view of the Unit.

4.1 Remove six Screws (1). Pull Adapter Module (2 or2A) from Housing (3) and remove and discard O-ring (4). Remove Cap (11 or 11A) from AdapterModule (2 or 2A). If present (available only onsome units), do not remove the two pipe Plugs (5)from the Housing (3) unless replacement isrequired.

4.2 Spare parts for the Cap (11 or 11A) are notavailable. If it is faulty replace as a complete unit.

4.3 Noting the warning below, carefully remove the sixScrews (6) from the Adapter Module (2 or 2A).

WARNINGThe Spider (7 or 7A) is spring loaded and care should

be exercised in removing the attaching Screws (6).

5.0 INSPECTION

5.1 Special Tools - Use Adapter Wear Gauge, 61657-2to check the Flange (9 or 9A) of Adapter Module(2 or 2A) for suitability for continued use. Refer toService Manual SM61657 for instructions on itsuse. This gauge will indicate whether the slots andlugs of the Flange (9 or 9A) of Adapter Module (2or 2A) are worn beyond safe use.

5.2 Check the seal on Cap (11A) for deterioration, cutsor nicks. Replace the Cap (11A) if such aberrationsare apparent.

5.3 Check Cap (11) for aging cracks or other damage.Replace as needed.

5.4 Inspect Poppet (8 or 8A) for damage to the seal.The seal is bonded into the metal poppet and is notremovable. Replace Poppet (8 or 8A) as needed.

6.0 REASSEMBLY


6.2 Light lubrication of all O-rings and seals, usingpetroleum jelly is recommended to facilitateinstallation.

6.3 Reassemble Adapter Module (2 or 2A).

6.4 Place the O-ring (4) in the groove in AdapterModule (2 or 2A) before installing in the Housing(3). Torque Screws (1) to 20 ± 2 in-lbs (.23 m-kg).

6.5 Reattach Cap (11 or 11A) to tab on AdapterModule (2 or 2A) if utilized.

7.0 TEST


7.2 Test conditions

7.2.1 Test media shall be Stoddard Solvent (FederalSpecification P-D-680), JP-4 per MIL-J-5624Dat 75° + 15°F, Jet A or equivalent.

7.3 Functional Test

7.3.1 Attach adapter to a 120 psi fluid pressure sourcethrough the outlet (flanged or threaded end).Attach a Carter 60427 or 61428 type nozzle tothe inlet Adapter Module (2 or 2A). The nozzleshall be plugged at the inlet end with a plug and asmall petcock or hand valve. With the nozzle andpetcock open, slowly increase the pressure intothe adapter outlet to fully bleed the air from thetest unit. Close the petcock and increase the test


-5-

pressure to 120 psi. Check for external leakagefrom the joint between the nozzle and adapterand from the adapter housing and joints.

7.3.2 Bleed the pressure from the test unit and removethe nozzle.

7.3.3 Slowly increase the system pressure again to 120psi and check for leakage from the AdapterModule (2 or 2A) Poppet (10 or 10A).


Table 1.0 tabulates the parts and sub-assemblies comprising the various adapters covered by this manual. Theitem numbers of the table are keyed to the exploded views of the Units diagrammed in Figure 1.

TABLE 1.0

Item Part Number DescriptionNumberRequired

Spares/10Units/Yr. Used on

1 GF24693C73 Screw ........................................ 6 6 All except 615292 61529 Adapter Module (MS24484-2) . 1 - All except Option D6 LP500-6-5 Screw ................................. 6 6 All7 20876 Spider................................. 1 - All8 2753 Spring ................................ 1 - All9 20748-2 Flange ................................ 1 1 All except Option D

10 20780 Poppet................................ 1 2 All except Option D2A 61247 Adapter Module (MS24484-5) . 1 - Option D only6 LP500-6-5 Screw ................................. 6 6 All7 20876 Spider................................. 1 - All8 2753 Spring ................................ 1 - All

9A 20748-1 Flange ................................ 1 1 Option D only10A 208197 Poppet................................ 1 2 Option D only3A 24176 Body, 2½" NPT ........................ 1 - 6958 Option G only3B 204563 Body, 2½" BSPP...................... 1 - 6958 Option H only3C 210201 Body, 4" TTMA........................ 1 - 61272 only3D 210136 Body, 4" ANSI.......................... 1 - 61409 only3E 210216 Body, 3" TTMA........................ 1 - 61528 only4 MS29513-153 O-ring........................................ 1 10 All (not furnished with

61529)3F 220288 Body, 3" ANSI 1 - 64040 only5 210462 Plug........................................... 2 - Some 6958, 61272 and

61528 only11 41607 Cap, Plastic ............................... 1 3 Option B only

11A 61531 Cap, Metal Sealing.................... 1 1 Option A only

Notes: 1. All part numbers beginning with "GF" are interchangeable with those beginning with either "AN" or"MS". If the "GF" is followed by three numbers it is interchangeable with and "AN" part, otherwise itis interchangeable with an "MS" part of the same number.

2. The recommended spare parts shown above are the number required to support 10 Units for one year.The recommended quantities are based on the ratio of spare parts sold for each unit during a one yearperiod of time. The actual quantity required will vary from location to location.

DESCRIPTION

Remote control of emergency valves through flexible cable. Maxi-mum 3/16" cable. Replaceable fuse adaptor releases at 210°F.Threaded take-up for cable slack adjusts conveniently in place.Choice of 15/8 " or 23/8 " cable travel positions. Dual trip levers provideshutoff of emergency valves from two locations.

SPECIFICATION OPTIONS:

CHART KEY:A—Compartment: 1, 2, 3, 4, 5B—Air Operated: Y for Yes, N for NoC—Material/Coating: P for PowderCoated.D—LengthE—WidthF—HeightWeight—Shipping Weight

Figure 507AO

Figure 507

Fig. 507 Emergency Valve OperatorMorrison Bros. Co.

Specification Sheet

www.morbros.com

P.O. Box 238 • Dubuque, Iowa 52004-0238563.583.5701 (tel) • 800.553.4840 • 563.583.5028 (fax)

w w w . m o r b r o s . c o m

I.D. NUMBER A B C D E F WT.507---0100 AO 1 N P 16 3/4 4 13/16 12 1/8 6507---0200 AO 2 N P 16 3/4 4 13/16 12 1/8 8507---0300 AO 3 N P 16 3/4 8 3/8 12 1/8 11.5507---0400 AO 4 N P 16 3/4 8 3/8 12 1/8 13.25507---0500 AO 5 N P 16 3/4 8 3/8 12 1/8 15507AO-0100 AO 1 Y P 20 1/2 6 3/16 12 1/8 7507AO-0200 AO 2 Y P 20 1/2 6 3/16 12 1/8 10507AO-0300 AO 3 Y P 20 1/2 9 3/4 12 1/8 13507AO-0400 AO 4 Y P 20 1/2 9 3/4 12 1/8 15507AO-0500 AO 5 Y P 20 1/2 9 3/4 12 1/8 17

FILTERS

FROM PUMP

TO PIPING

JUNCTION BOX

HEATER

SENSOR

AIR ELIMINATOR


TM

Sept 1999

Section 86 Page 19A

R

Note: Manhole assemblies, as listed above, have Buna-N gaskets (suffix “B”). For variation in gasketing change last letter of assembly number as follows. Suffix “V” indicates Viton collar gasket & Viton 10” fill gasket Suffix “W” indicates White Hypalon collar gasket & White Hypalon 10” fill gasket Suffix “T” indicates Teflon envelope collar gasket & Tef-Sil 10” fill o-ring Manhole collars are available in aluminum, steel, and stainless steel. Please see parts page for correct numbers. When welding collars to tank, care should be exercised to insure collar remains flat and round.

With Integral Relief Valve/10” Fill

PAF manholes with integral latch style surge suppression relief valves are designed for use on DOT406 and replacement on MC306 specification cargo tanks. Manholes are certified and marked in accordance with 49CFR178.345-5 with a test pressure of 36 psig. Manhole covers are 7 gage steel or stainless and are secured to the tank weld collar with a clamp ring and bolt which can be easily removed to provide access into the tank. The integral 10” relief valve provides emergency pressure relief and meets the 1 liter surge leakage limit imposed by 49CFR178.345-10(b)(3)(ii). The relief valve also serves as a 10” latch style fill which can be easily opened to provide access for filling the tank or for inspection. Relief valves contain an adjustment feature to allow for fine-tuning of set pressure in the field. Other standard features include a heavy duty clamp ring, secondary safety latch and model 6496ALB pressure-vacuum vent mounted in the 10” relief valve cover. Manholes are available with a self-latching feature that allows the 10” relief valve/fill cover to drop and securely latch upon movement of the tank if the cover is inadvertently left open. For self-latching model substitute L863 for L820 in assembly number.

TE

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36 PS

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CT-0040

INTEGRAL RELIEF VALVE/10” FILL

LESS THAN 1 LITER LEAKAGE

SET PRESSURE ADJUSTMENT

INCREASED FLOW RATE

SECONDARY SAFETY LATCH Note: 31/2” Vent and Liquid Level Switch not included in assembly.

Cover Plate

Relief Valve

Clamping Ring, Bolt, Washer,

Strongback, & Latch

Clamping Ring Nut Normal Vent Wt.

(lb.) Assembly No.

Steel Zinc Plt. Alum. Steel Zinc Plt. Brass Alum. 29.7 PPVL820BXB Stnls 304 Alum. Stnls 304 Stnls 304 Alum. 30.2 PPVL820CXB Stnls 316 Alum. Stnls 304 Stnls 304 Alum. 30.2 PPVL820DXB

20” PAF 406-98 OFFSET MANHOLE

Pressure Relief Valve setting 3.63 psig Rated Pressure Actuated Emergency Venting: 494,084 cu. ft. free air per hour @ 6.25 psig Rated Liquid Flow Capacity 1335 gpm @ 5.0 psig


TM

Sept 1999

Section 86 Page 19B

Replace oil cylinder using Automatic Transmission Fluid Dexron III/Mercon, SAE 5W-20 with viscosity of 177 SUS at 100°F and a pour point of no greater than –45°F. MAINTENANCE: Manhole assemblies should be inspected with sufficient frequency to insure 10” Integral Relief Valve functions properly. Any worn, damaged or missing parts must be replaced. Gaskets should be replaced if their effectiveness to insure a liquid tight seal is impaired in any way. Replacement gaskets must be compatible with products carried.

No. Description Material Part No. No. Description Material Part No. 1 Fill Cover Alum/E-Coated 8297ALEY 9 Vent Assembly Aluminum 6496ALB 1a Fill Cover (O-Ring Grvd.) Alum/E-Coated 8297ALEY389 10 Gasket Buna-N 3716BN

Buna-N 3119BN 11 Cylinder Assembly Aluminum 6657AL Viton 3119VT 12 Piston Aluminum 6654AL 2 Gasket -

Integral Relief Valve Wh. Hypalon 3119WH 13 Stem Stnls 304 6688SL

2a O-Ring Tef-Sil 3902TS 14 Spring Steel 4122MS Steel Zinc Plt. 3029ZC 15 1/2” NPT Plug Zinc Plt. Steel Zinc Plt. 9V4907 3 Bolt-Clamp Ring Stnls 304 3029SL 17 Stem O-Ring -112 Buna-N 4118BN Brass 3030BR 18 Cylinder O-Ring –137 Buna-N 4015BN 4 Nut-Clamp Ring Stnls 304 9Q5809 19 Piston O-Ring –137 Tef-Sil 4015TS Steel Zinc Plt. 3031ZC 20 O-Ring Retainer Alum/E-Coated 4117ALEY 5 Washer-Clamp Ring Stnls 304 3031SL 21 Retainer Ring Stnls 304 9Q4961 Steel 3036MS 22 Bellows EPDM 4020EPDM Steel Zinc Plt. 3036ZC 23 Lockwasher Ext. Tooth 7/16” Stnls 304 9Q5961 6 Clamping Ring Stnls 304 3036SL 24 Nut Hex 7/16x20 Stnls 304 9Q5960 Buna-N 3560BN 25 Plastic Plug Polyethylene 9Z6163 Viton 3560VT 26 3/8-16 Hex Nut w/ Insert Steel Zinc Plt. 9Q5896 Wh. Hypalon 3560WH 7 Manhole Gasket

Channel Type Teflon Env. w/ Wh. Hypalon 3033TF

Steel 3176MS Aluminum 3176AE Stnls 304 3176SL

8 Manhole Collar Channel Type

Stnls 316 3176SS

PLAN VIEW DIMENSIONS A 41/4” Dia. (107.95mm) B 8 Holes-.390 Dia. (9.90mm) on 47/8” (123.83mm) B.C. C 23/8” Dia. (60.325mm) Hole D 1/4” N.P.T. Coupling E 7” Rad. (177.8mm) F 63/8” (161.93mm) G 43/4” (120.65mm) H 31/4” (82.55mm)

PARTS LIST

20” PAF 406-98 MANHOLE Self-Latching Model Illustrated

WARNING Consult PAF406-98 maintenance manual prior to disassembly of this relief valve. Use only genuine Betts Industries Inc. replacement parts. Use of substitute parts can impair the proper functioning of this product.

Gasket Maximum Temperature Buna-N (Nitrile) 250°F Viton 400°F White Hypalon 250°F Teflon-Silicone 400°F Teflon Envelope w/ White Hypalon Insert 250°F


MAINTENANCE MANUAL

FOR

PAF 406-96 & 406-98 SURGE

RELIEF VALVE

Section 1: Identification of Adjustable PAF 406-96 & 98 Section 2: Maintenance and Testing for PAF 406-96 & 98 Section 3: Set Pressure Adjustment of PAF 406-96 & 98 Section 4: Removal of PAF 406-96 & 98 from Closure Assembly Section 5: Disassembly of PAF 406-96 & 98 Section 6: Assembly of PAF 406-96 & 98

9/16/99


SECTION 1:

IDENTIFICATION OF ADJUSTABLE PAF SURGE RELIEF VALVE (PAF 406-96 & 98)

Betts PAF Surge Relief Valves (PAF 406-96 and PAF 406-98) meet or exceed all U.S. DOT requirements for primary pressure relief valves on DOT406 cargo tanks as contained in 49CFR178.345-10 and 49CFR178.346-3 of the Code of Federal Regulations. The Betts PAF Surge Relief Valve is able to withstand a brief pressure surge and contain lading (liquid cargo) leakage to less than one liter (per TTMA RP NO 81). Betts PAF Surge Relief Valve (PAF 406-96 & 406-98) protects the cargo tank from rupture due to over-pressurization caused by overfilling or fire and is, therefore, crucial to the safe operation of the tank. In order to maintain your Betts PAF Surge Relief Valve in proper working condition, the following procedures must be followed.

All PAF 406-96’s are cast with “MODEL PAF 406-96”

And PAF 406-98’s are cast with

“MODEL PAF 406-98”

The adjustable PAF 406-96 & 98 have an internal hex at the top of the stem under the plastic yellow cap, as well as, a Black E-coated cover.

BLACK E-COATED COVER

PLASTIC CAP

HEX

DETAIL


SECTION 2:

MAINTENANCE AND TESTING FOR PAF SURGE RELIEF VALVE 406-96 & 98

A. U.S. DOT Requirements: This portion of the manual refers to the DOT regulations and is intended to

serve as an interface to relate the manual to the code. This manual does not take the place of the Code of Federal Regulations. A current copy of the Code of Federal Regulations should be reviewed and followed to insure the requirements are met for each individual case.

There are three basic tests/inspections mandated by 49CFR Part 180 for MC306 and DOT406 cargo tanks.

Test/Inspection Interval Period Code Paragraph External Visual Inspection 1 year 49CFR180.407(d) Leakage Test 1 year 49CFR180.407(h) Pressure Retest 5 year 49CFR180.407(g)

1. External Visual Inspection: As part of the annual external visual inspection, 49CFR180.407(d)(3)

requires that all pressure relief valves, be visually inspected for any corrosion or damage which might prevent the valve from functioning. If the cargo tank is used to haul product that is corrosive to the relief valve, the valve must be removed from the cargo tank for inspection and bench testing.

Note: Betts recommends that the external visual inspection of vents be performed monthly.

1.1. Visually inspect all external surfaces of the manhole and PAF, which includes opening the

Latch (1) and Strongback (5). NOTE: If any corrosion or damage to the PAF or manhole is observed, it must be repaired and successfully bench tested prior to returning to service. Refer to 3.5 for PAF bench test procedure.

1.1.1. Clean and inspect the bottom side of the PAF for signs of damage, corrosion, or product gumming that could effect the operation of the Relief Valve.

1.1.2. Closely inspect the Cylinder (10) for any damage or dents. Also, insure Cylinder (10) is threaded tightly to the Cover (9). See figure 1.

1.1.3. Inspect and clean the Normal Vent (8). 1.1.4. Inspect the 10” Seat (25) for damage or corrosion. Build-up or grim on the seat should be

removed. Nicks on the 10” seat may cause the gasket not to seal. 1.1.5. Inspect the 10” Fill Gasket (24) for signs of wear or degradation. Replace gasket if required. 1.1.6. Inspect the Clamp Ring Gasket (26) for evidence of product seepage. Replace any gaskets

where seepage is detected.

Inspect CYLINDER (10)

Inspect & clean NORMAL VENT (8)

Inspect GASKET (26) for leakage

Inspect SEAT (25)

Inspect & clean GASKET (24)

COVER (9)

STRONGBACK (5)

Figure 1


2. Leakage Test: 49CFR180.407(h) requires tanks to be tested annually at 80 % of the tank design

pressure or MAWP, whichever is marked on the tank certification or specification plate. All tank components must remain in place during this test, except any re-closing pressure relief valve with a set pressure less than the leakage test pressure must be removed or rendered inoperative during the test. Betts Normal Vents, therefore, must be removed during the leakage test.

2.1. Remove Normal Vent from manhole cover and plug opening with Betts Plug No. 3013. 2.2. Apply test pressure in accordance with 49CFR180.407(h) 2.3. Inspect all gasket joints on PAF and manhole for leaks. If PAF leaks, adjust in accordance with

Set Pressure Adjustment instructions (Section 3 of this manual) and retest the unit. Replace damaged or worn gaskets as required.

3. Pressure Retest: As part of the pressure retest, 49CFR180.407(g)(ii)(A) requires that all re-closing

pressure relief valves be removed from the tank for inspection and bench tested to verify that the relief valve is functioning properly. The pressure retest and the relief valve bench test must be performed at least every five years.

Note: Betts recommends that the PAF 406-96 and PAF 406-98 be bench tested annually.

3.1. Pressure Retest Procedures: 3.1.1. 49CFR180.407(g)(1)(vii) requires that all closures except pressure relief devices must be in

place during the test. 3.1.2. Manholes must remain in place during pressure test. 3.1.3. Open 10” PAF Relief Valve. 3.1.4. Install Betts Retest Fixture (part no. 6556LCB) to seal the 10” opening. See figure 2.

3.2. Betts Push and Air Operated Vapor Recovery Valves remain in place during the test. NOTE: If vapor recovery valves from other manufactures are installed, refer to the manufacturers’ instructions to see if they should be removed.

3.3. After preparing the rest of the tank, perform the pressure test in accordance with the regulations. Inspect all parts of manhole assembly for leakage. Repair or replace parts as required.

3.4. Remove all clamps or plugs from relief valve immediately after test is completed.

Clamp Channel Inside of 10” Fill

Retest Fixture (Part No. 6556LCB)

Inspect for Leakage Here

Figure 2



BubblesIndicateLeakage

Water Jar

Tubing

Reducer Bushing

Seal


Test Tank6687AL

Pressure Release Pressure Release



PRESSURE TEST VACUUM TEST

3.5. Bench Test Procedure for PAF Surge 406-96 & 98 3.5.1. Remove manhole assembly from tank by removing the clamp ring bolt and clamp ring. 3.5.2. Remove Normal Vent (8) and plug port with Betts Plug (No. 3013) 3.5.3. Attach manhole assembly to appropriate Betts PAF 406-96 Test Fixture (No. 6685SL.) 3.5.4. Apply a soap solution around the perimeter of the DoveTail 10” Gasket. 3.5.5. Gradually apply pressure to the tank and observe the pressure at which bubbles first appear. 3.5.6. Per 49CFR178.346-3(c) the set pressure must not be less than 3.63 psig and not more than

4.55 psig for a tank with a MAWP of 3.3 psig. 3.5.7. Slowly release the pressure from the test fixture and verify the PAF reseals not less than the

MAWP of the tank. 3.5.8. Replace or adjust any relief valve that fails the set pressure test requirements. Refer to

instructions for Set Pressure Adjustment (Section 3 of this manual) to adjust the set pressure, and retest the unit.

4. Model 6496AL (Normal vent for DOT 406) Test Procedure:

A Normal Vent Test Tank (Part No. 6687AL) must be used to test the Normal Vents. Note: A regulator must be used to slowly apply pressure to the tank.

4.1. Pressure Test: 49CFR 178.346-3(b)(2) states that the normal vent for a DOT 406 must be set to open at not less than 1 psig.

4.1.1. Screw the Normal Vent into the lid of the test tank as shown in figure 3 A. In order to detect leakage, attach the reducer bushing, compression fitting, and tubing. Place the end of the tubing in a water jar. The water jar is not included with the test tank.

4.1.2. Slowly apply pressure to the tank. Bubbles will indicate the opening pressure of the vent. 4.1.3. A properly functioning 6496AL Normal Vent should open between 1.0 to 1.5 psig, but in no

case open less than 1 psig. 4.2. Vacuum Test: 178.346-3(c)(2) states that the normal vent for a DOT 406 must be set to open at

no more than 6 ounces vacuum (.375 psig). 4.2.1. Screw the Normal Vent into the lid of the test tank as shown in figure 3 B. 4.2.2. Slowly apply pressure to the tank and inspect the top opening for pressure release. Apply

soapy water to the top of the vent in order to detect the point at which the vent opens. 4.2.3. A properly functioning 6496AL Normal Vent should vacuum relieve between 0.25 to 0.375

psig, but in no case more than 0.375 psig. 4.3. Repair or replace any Normal Vent that does not meet the specifications.

Figure 3A Figure 3B


Loosen Nut

Increase Set Pressure

SECTION 3:

SET PRESSURE ADJUSTMENT OF PAF SURGE RELIEF VALVE

NOTE: THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL 306-98, 406-98 AND PAF

406-96 W/ BLACK E-COATED COVER AND STEM WITH INTERNAL HEX AT THE TOP. 1. Relieve vapor pressure or vacuum from cargo tank.


2. Open Latch (1) to expose yellow Plastic Plug (2) as shown in figure 4. 3. Remove yellow Plastic Plug (2). 4. Place an 11/16 box end wrench over Hex Nut (3). 5. Place a 7/32 allen wrench into the hex socket of the Stem (4). 6. Hold the allen wrench stationary and rotate the box end wrench counterclockwise to

loosen the Hex Nut (3) two full turns. 7. At this point, the PAF can be adjusted by rotating the Stem (4) with the allen wrench. 8. To increase the set pressure, turn the Stem (4) clockwise.

Note: The Stem (4) must fully engage threads of Hex Nut (3) when nut is tightened.

Betts Industries, Inc. Warren, PA 16365 Phone: 814-723-1250 9. To decrease the set pressure, turn the Stem (4) counter-clockwise.

Note: The amount of adjustment in the counter-clockwise direction is limited by a shoulder stop on the Stem (4).

10. The adjustment feature is sensitive, so that, one turn of the stem may increase the set pressure significantly. Adjust stem ¼ turn at a time, until the desired setting is achieved.

Never adjust the relief valve so that a person must stand on the Strongback (5) to operate the Latch (1). This could cause a person to loose their balance and fall, if there is any residual pressure in the tank when the relief valve is opened.

11. After adjusting the PAF surge relief valve, use the box wrench to tighten the Hex Nut

(3), while using the allen wrench to hold the stem stationary. 12. Replace the Plastic Plug (2). 13. After adjustment, test the set pressure to verify that it falls within the required range.

13.1. Per 49CFR178.346-3(c) the set pressure for models PAF406-96 & 406-98 must not be less than 3.63 psig and not more than 4.55 psig for a tank with a MAWP of 3.3 psig.

13.2. Per 49CFR178.341(d)(2) the set pressure of model PAF306-98 must not be less than 3.0 psi for a MC306 tank

14. If the adjustment does not achieve the desired pressure setting, check the following: 14.1. Inspect the 10” metal seat. Remove any build up and repair any nicks. 14.2. Replace the 10” gasket. 14.3. Insure strongback is not bent or damaged. 14.4. Insure the collar that is welded to the tank is not excessively warped. 14.5. Insure closure assembly was mounted correctly to manhole collar.

14.5.1. Unbolt clamp-ring and loosen closure assembly from collar seat. 14.5.2. Release latch to relieve force on 10” fill cover. 14.5.3. While the 10” fill is opened, tighten clamp-ring bolt while

tapping circumference of clamp-ring with a hammer. 14.5.4. Close 10” fill and latch.


DISASSEMBLE

DISASSEMBLE

SUPPORT HERE

SECTION 4:

REMOVAL OF PAF SURGE RELIEF VALVE FROM CLOSURE ASSEMBLY

NOTE: THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL PAF 406-96 & 98 WITH

BLACK E-COATED COVER AND STEM WITH INTERNAL HEX AT THE TOP. 1. Relieve vapor pressure or vacuum from cargo tank.


2. Open latch to expose Yellow Plug (2) as shown in figure 5. 3. Remove yellow Plastic Plug (2). 4. Use an 11/16 socket or box end wrench to remove Hex Nut (3). 5. Remove Star Washer (6). 6. Open fill assembly as shown in figure 6. 7. Place a 7/32 allen wrench in the hex socket of the Stem (4). 8. By rotating the stem clockwise, the PAF assembly can be unscrewed from the closure

assembly. NOTE: During removal, care should be taken not to damage the last threads on the stem, by supporting the PAF with a hand under the cylinder.

9. Remove the Bellow (7). 10. At this point, further disassembly should be conducted at a workbench. Follow the

procedure “Disassembly of PAF Surge Relief Valve” if disassembly of the cylinder is required.


SECTION 5:

DISASSEMBLY OF PAF SURGE RELIEF VALVE

NOTES: Ø THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL PAF 406-96 & PAF

406-98 WITH BLACK E-COATED COVER AND STEM WITH INTERNAL HEX AT THE TOP.

Ø UNDER NORMAL CIRCUMSTANCES, THE DISASSEMBLY OF THE SPRING CYLINDER IS

NOT REQUIRED NOR RECOMMENDED, UNLESS ALL OTHER ATTEMPTS TO REPAIR THE RELIEF VALVE HAVE FAILED. IT IS RECOMMENDED THAT THE VALVE BE RETURNED TO BETTS INDUSTRIES FOR REPAIR.

Ø A PAF SURGE DISASSEMBLY TOOL (PART # 6684MS) IS REQUIRED TO DISASSEMBLE THE SPRING CYLINDER.

1. Remove the PAF surge relief valve assembly from the closure assembly by following

the steps outlined in the procedure “Removal of PAF Surge Relief Valve from Closure Assembly”.

2. Remove Normal Vent (8) by griping with slip joint pliers and unscrewing from Cover (9). See figure 7.

The cylinder contains a compressed spring, which could cause injury, if the cylinder is removed improperly. Review the following section carefully before attempting to remove cylinder.

3. The Cylinder (10) contains Hydraulic Oil (11) that must be drained. 4. Use a 3/8 allen wrench to remove the ½ in. NPT Plug (12) while holding the Cylinder

(10) stationary by gripping with slip joint pliers within one inch from the bottom. It is very important that the cylinder does not unscrew from the cover at this time.

5. If the unit has a 1/8 in. NPT Plug (13) remove it at this time. 6. Drain the oil that is on the top and bottom of the Piston (14).

Insure CYLINDER Does NOT Unscrew

Grip Here to Remove

Grip With Slip-Joint Pliers Here.

Betts Industries, Inc. Warren, PA 16365 Phone: 814-723-1250 7. Insert the 3/8 female thread end of the Disassembly Tool (15) (part # 6684MS) into the

½ in. NPT opening as shown in figure 8. 8. Thread the Disassembly Tool (15) onto the 3/8 male thread of the Stem (4) that extends

from the Lock Nut (16). See figure 8. The tool should engage at least four threads. Note: Use a 7/32 allen wrench on the bottom of the tool and one at the top of the stem to tighten tool completely down.

9. At this point, a 7/32 allen wrench must be used to hold the shaft of the tool stationary

with respect to the cylinder, while an 11/16 wrench is used to turn the Tool Nut (17) clockwise. Once the nut has made contact with the cylinder, turn the nut two complete turns to compress the Spring (18). See figure 9.


Tool Must Thread Completely to Nut

Two Turns Clockwise To Compress Spring

Screw Tool to End of STEM (4)

3/8 Female Thread of Tool


Betts Industries, Inc. Warren, PA 16365 Phone: 814-723-1250 10. The Cover (9) can now be unscrewed from the Cylinder (10). Do NOT unscrew the

stem from the tool. If slip joint pliers are required to grip the cylinder, only grip within one inch from the end. See figure 10.

After the cover is removed, the spring is still under load in the cylinder. Do NOT point the open end of the tube toward yourself or a bystander.

11. To release the spring, hold the allen wrench stationary with respect to the

cylinder, and turn the Tool Nut (17) counter-clockwise. It is imperative that the shaft of the tool does not unscrew from the Stem (4) during disassembly process. Continue to back off the Tool Nut (17) until the piston is extended beyond the length of the spring. See figure 11.

12. At this point insure the spring tension is released, and the Tool (15) can be unscrewed from the Stem (4).

Grip Cylinder On This End



Unscrew Nut


Apply petroleum jelly here during re-assembly.

13. Disassemble the stem/piston assembly by inserting a 7/32

allen wrench into the top of the Stem (4) and unscrew the LockNut (16) using a 9/16 socket. See Figure 12. Note: The piston may appear different than shown depending on the model you may have.

14. If the Piston O-ring (19) requires removal, cut the o-ring with

a razor blade, being careful not to damage the piston groove. 15. The Stem O-ring (22) and O-ring Retainer (21) are removed

by using a snap ring tool to remove Snap Ring (20). See figure 13.

16. If the Cylinder O-ring (23) requires removal, cut the o-ring

with a razor blade being careful not to damage the o-ring groove.

17. If the 10” Fill Gasket (24) requires removal, cut a small slot

in the center of the gasket and use a screwdriver to pry gasket out of dovetail groove, being careful not to damage groove. See figure 13.

For maintenance or assembly instructions consult appropriate procedures.

Slice Gasket as Shown & Pry Out with Screwdriver.


SECTION 6:

ASSEMBLY OF PAF SURGE RELIEF VALVE

NOTE: THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL PAF 406-96 & PAF

406-98 W/ BLACK E-COATED COVER AND STEM WITH INTERNAL HEX AT THE TOP. 1. Preparation of O-Rings and Components:

1.1. All parts should be cleaned and degreased to insure the removal of all product build up. 1.2. All components should be inspected for damage or wear. 1.3. To insure integrity of the seals, all o-rings and gaskets should be replaced using Betts’

replacement parts. 1.4. Inspect all o-ring grooves for damage (nicks, scratches, or burrs).

2. Cover sub-assembly: Refer to figure 14.

2.1. Insert Stem O-ring (22) into Cover (9). 2.2. Insert O-ring Retainer (21) and use a snap ring tool to insert the Snap Ring (20) into

groove. 2.3. Place black Buna Cylinder O-ring (23) into o-ring groove on Cover (9). 2.4. Use Betts’ Dove Tail Gasket Tool (26) (part # 6504AL) to place 10” Fill Gasket (24)

into Cover (9). See figure 14. 2.4.1. Lubricate the gasket and dovetail groove with a soap solution. 2.4.2. Using fingers, pinch the back side of the gasket together and insert a small section

of the gasket into the groove. 2.4.3. Use short strokes with the Dove Tail Gasket Tool (26) to insert the gasket. 2.4.4. The last portion of the gasket will need to be pushed in with fingers.

Note: The gasket can also be installed by hand. A 10” o-ring (4100BN) is also available for use as a replacement for the dovetail gasket and can be installed in the groove.

Apply never-seize here.

Apply petroleum jelly here.


3. Piston/Stem sub-assembly: Refer to figure 12 of section 5.

3.1. Inspect Stem (4) for signs of wear or corrosion. Replace as required. 3.2. Insert 3/8 end of Stem (4) into counter sunk hole of Piston (14). Note: The piston may

appear different depending on which model you have. 3.3. Insert a 7/32 allen wrench into the top of the Stem (4) and tighten the Lock Nut (16)

completely down using a 9/16 socket. Note: The Stem (4) MUST turn freely in the Piston (14) after the nut is tightened.

3.4. Pre-heat the orange Tef-Sil Piston O-ring (19) in warm water and immediately slide the o-ring over the Piston (14) and position it into groove.

3.5. Smear a thin layer of petroleum jelly around the Piston O-ring (19) to facilitate ease of installing the piston into the cylinder.

4. Loading the Spring: Refer to figure 11 of section 5.

4.1. Inspect the inside of the Cylinder (10) for damage (dents, scratches, or corrosion). If the cylinder is damaged it must be replaced.

4.2. Insert the 3/8 female thread end of the Disassembly Tool (15) (part # 6684MS) into the ½ “ NPT opening of the Cylinder (10).

4.3. Place the Spring (18) into the Cylinder (10). 4.4. Thread the 3/8 stub that extends from the Piston/Stem assembly into the Disassembly

Tool (15) and tighten with two allen wrenches. NOTE: Ensure the end of tool is tight against the Lock Nut (16) as shown in figure 11 of section 5.

4.5. Compress the Spring (18) by using a 7/32 allen wrench to hold the shaft of the tool stationary with respect to the cylinder, while an 11/16 wrench is used to turn the Tool Nut (17) clockwise. (See figure 11 of section 5.) Insure the threads are not damaged on the cylinder when the piston is pulled into the top of the cylinder.

After the spring is compressed in the cylinder, do NOT point the open end of the tube toward yourself or a bystander.

4.6. Continue to turn the Tool Nut (17) until the top of the piston is at least 7/8“ below the

top of the Cylinder (10). See figure 10 of section 5. 5. Installing the Cover (9):

5.1. Smear a thin amount of never-seize compound on the threads of the Cover (9) as shown in figure 14.

5.2. Smear petroleum jelly around Cylinder O-ring (23) as shown in figure 14 and the top of the Stem (4) as shown in figure 12 of section 5.

5.3. Position the Cover (9) over the Stem (4) as shown in figure 12 of section 5. 5.4. Slowly screw the Cover (9) onto the Cylinder (10). Care should be taken not to damage

the threads of the cylinder or cover. Beware of cross threading. Ensure that the cover is screwed completely down to the cylinder so there is NO gap. See figure 15.

The Cylinder must be threaded completely on the Cover prior to the Disassembly Tool being removed.

5.5. The Spring (18) can now be released by holding the allen wrench stationary with respect to the Cylinder (10) and turning the Tool Nut (17) counter-clockwise.

5.6. Once the Tool Nut (17) has released the spring pressure, the tool can be unscrewed and removed from the Cylinder (10).


6. Re-filling the hydraulic oil: Refer to figure 15.

Note: Replace the oil in the cylinder with Automatic Transmission Fluid DexronIII/Mercon SAE 5W-20 with a viscosity of 177 SUS at 100°F and a pour point of no greater than –45°F.

6.1. If this unit has a 1/8” NPT, place thread sealant on the 1/8” NPT Plug (13) and insert it in the Cover (9).

6.2. Turn the PAF upside down and pour ATF fluid through the ½” NPT opening at the bottom of the Cylinder (10).

6.3. It is very important that this lower chamber is completely full of oil, with NO air pockets.

6.4. Place thread sealant on the ½” NPT Plug (12) and insert it into the bottom of the Cylinder (10). Tighten the plug using a 3/8 allen wrench.

7. Smear a small amount of never-seize compound on the threads of the Normal Vent (8) and screw it into the opening of the Cover (9).

8. To attach the PAF Relief Valve to the closure assembly, refer to figure 6 of section 4. 8.1. Place the Bellow (7) over the Stem (4). 8.2. Thread Stem (4) into Wobble Support (27) on Strongback (5). NOTE: Use an 7/32 allen

wrench inserted from the top of the Wobble Support (27) and turn counterclockwise to screw in the stem.

8.3. Insure the first thread is not damaged as the stem is started into the wobble support. 8.4. As the stem is threaded in, insure the Locating Ears (28) are aligned at the hinge side of

the Strongback (5) and straddle the strongback as shown in figure 4 of section 3. Tighten the stem all the way in.

8.5. Insert Lock Washer (6) and thread Hex Nut (3) onto Stem (4) as shown in figure 6 of section 4.

8.6. To adjust the set pressure and tighten down the stem, refer to Section 3 of this manual.

Fill the Bottom Chamber Completely

Ensure NO Gap

NO Oil in this Chamber

InstInstInstInstInstallation & Partallation & Partallation & Partallation & Partallation & Parts Manuals Manuals Manuals Manuals ManualM/MA MetersM/MA MetersM/MA MetersM/MA MetersM/MA Meters

Installation: M100-10Installation: M100-10Installation: M100-10Installation: M100-10Installation: M100-10

22222

TTTTTable of Contentable of Contentable of Contentable of Contentable of Contents and Safety Proceduress and Safety Proceduress and Safety Proceduress and Safety Proceduress and Safety Procedures

DescriptionDescriptionDescriptionDescriptionDescription Page NumberPage NumberPage NumberPage NumberPage NumberHow LC Meters Work ........................................... 3Owner�s Information Packet ................................. 4Installation Requirements ..................................... 6Operation Requirements ....................................... 7Meter Start Up and Operation .............................. 8Reversing the Meter Registration ......................... 9Setting the Standard Adjuster .............................. 10Meter Maintenance ............................................... 10Relieving Internal Pressure ................................... 11Servicing the Drive Components ........................... 12Removing the Dust Cover ..................................... 12Removing the Adjuster andAdjuster Drive Assembly ...................................... 12Buna/Viton/Teflon Packing Gland ......................... 15The Retaining Plate .............................................. 15Disassembling the Meter ...................................... 16Removing the Non-CorrodedRotor Gears .......................................................... 18Removing Corroded Rotor Gears .......................... 18Reassembling the Meter ...................................... 20Timing the Rotor Gears ........................................ 21Torque Chart ......................................................... 22Wrench and Socket Size Chart ........................... 23Troubleshooting .................................................... 24How to Order Replacement Parts ........................ 26Illustrated Parts Breakdown ................................. 27-30Quality Statement ................................................ 31

Please have the following information available when youmake inquires, order replacement parts, or scheduleservice. If a specific meter accessory is involved, pleaseprovide the model and serial number of the accessory inquestion (see page 4).

Your Meter�s Serial Number: ________________________

Your Full-Service Distributor: _______________________

Your Full-Service Distributor�sTelephone Number: _______________________________

Be PrepBe PrepBe PrepBe PrepBe PreparedaredaredaredaredMake sure that all necessary safety precautions have beentaken. Provide for proper ventilation, temperature control,fire prevention, evacuation and fire management.

Provide easy access to the appropriate fire extinguishersfor your product. Consult with your local fire departmentand state and local codes to make sure that you areadequately prepared.

Read this manual as well as all the literature provided inyour owner�s packet.

In the Event of a Gas LeakIn the Event of a Gas LeakIn the Event of a Gas LeakIn the Event of a Gas LeakIn the Event of a Gas LeakIn the event of a large gas leak: In the event of a large gas leak: In the event of a large gas leak: In the event of a large gas leak: In the event of a large gas leak: Evacuate the area andnotify the fire department.

In the event of a small, contained gas leak:In the event of a small, contained gas leak:In the event of a small, contained gas leak:In the event of a small, contained gas leak:In the event of a small, contained gas leak:1. Stop the leak and prevent accidental ignition.

2. Prevent the entrance of gas into other portions of thebuildings. Some gases, such as LPG, seek lowerlevels, while other gases seek higher levels.

3. Evacuate all people from the danger zone.

4. See that the gas is dispersed before resuming businessand operating motors. If in doubt, notify your local firedepartment.

In the Event of a Gas FireIn the Event of a Gas FireIn the Event of a Gas FireIn the Event of a Gas FireIn the Event of a Gas FireIn the event of large fires or fires that are spreading:In the event of large fires or fires that are spreading:In the event of large fires or fires that are spreading:In the event of large fires or fires that are spreading:In the event of large fires or fires that are spreading:Evacuate the building and notify your local fire department.Stop the leakage only if you can safely reach the equipment.

In the event of small, contained fires that you canIn the event of small, contained fires that you canIn the event of small, contained fires that you canIn the event of small, contained fires that you canIn the event of small, contained fires that you cansafely control: safely control: safely control: safely control: safely control: Stop the leakage if you can safely reachthe equipment. Then use the appropriate extinguisher:Class B fire extinguisher, water, fog, etc., depending onthe materials. If in doubt, call your local fire department.

NOTICENOTICENOTICENOTICENOTICE

This manual provides warnings and procedures that areintended to inform the owner and/or operator of thehazards present when using the Liquid Controls Meteron LP-Gas and other products. The reading of thesewarnings and the avoidance of such hazards is strictlyin the hands of the owner-operators of the equipment.Neglect of that responsibility is not within the control ofthe manufacturer of the meter.

Safety ProceduresSafety ProceduresSafety ProceduresSafety ProceduresSafety Procedures!!!!! W W W W WARNINGARNINGARNINGARNINGARNING

All internal pressures must be relieved beforedisassembly or inspection of the strainer, air eliminator,any valves in the system, the packing gland, and thefront or rear covers. See �Relieving Internal Pressure�(page 11).

33333

How LC Meters WorkHow LC Meters WorkHow LC Meters WorkHow LC Meters WorkHow LC Meters Work

Liquid Controls meters are positive displacement meters.They are designed for liquid measurement in both custodytransfer and process control applications. They can beinstalled in pump or gravity flow systems. Because oftheir simple design, they are easy to maintain, and easyto adapt to a variety of systems.

The meter housing (1) is designed with three cylindricalbores (2). Three rotors, the blocking rotor (3) and twodisplacement rotors (4, 5), turn in synchronizedrelationship within the bores. The three rotors aresupported by bearing plates (6, 7). The ends of the rotorsprotrude through the bearing plates. Blocking rotor gear(8) is placed on the end of the blocking rotor. Displacementrotor gears (9, 10) are placed on the ends of thedisplacement rotors. These gears create the synchronizedtimed relationship between the three rotors.

As fluid moves through the meter housing, the rotorassembly turns. The liquid is broken into uniform sectionsby the turning rotors. Fluid displacement happenssimultaneously. As fluid enters, another portion of thefluid is being partitioned and measured. At the same time,the fluid ahead of it is being displaced out of the meter andinto the discharge line. Since the volume of the bores isknown, and the same amount of fluid passes through themeter during each revolution of the blocking rotor, the exactvolume of liquid that has passed through the meter can beaccurately determined.

This true rotary motion is transmitted through the packinggland, the face gear, the adjuster drive shaft, and theadjuster to the register stack and counter. True rotarymotion output means consistent accuracy since theregister indication is in precise agreement with the actualvolume throughput at any given instant.

At any position in the cycle, the meter body, the blockingrotor, and at least one of the displacement rotors form acontinuous capillary seal between the un-metered upstreamproduct and the metered downstream product.

Capillary seals mean no metal-to-metal contact withinthe metering element. This means no wear. No wearmeans no increase in slippage, and no increase in slippagemeans no deterioration in accuracy.

Throughout the metering element, the mating surfaces areeither flat surfaces or cylindrical faces and sections thatare accurately machined. These relatively simplemachining operations, plus the fact that there is nooscillating or reciprocating motion within the device,permits extremely close and consistent tolerances withinthe LC meter.

The product flowing through the meter exerts a dynamicforce that is at right angles to the faces of the displacementrotors. The meter is designed so that the rotor shafts arealways in a horizontal plane. These two facts result in noaxial thrust. Therefore, with no need for thrust washers orthrust bearings, the rotors automatically seek the centerof the stream between the two bearing plates eliminatingwear between the ends of the rotors and the bearing plates.Once again, no wear results in no metal fatigue and nofriction.

The Liquid Controls meters are made of a variety of materialsto suit a variety of products. Because of our no-weardesign, capillary seals, and unique rotary metering, LCmeters provide unequalled accuracy, long operating life,and unusual dependability.

Meter Element Exploded Line Drawing

44444

OwnerOwnerOwnerOwnerOwner��s Information Packets Information Packets Information Packets Information Packets Information Packet

1.1.1.1.1. Is all your documentation included with yourIs all your documentation included with yourIs all your documentation included with yourIs all your documentation included with yourIs all your documentation included with yourmeter? meter? meter? meter? meter? LC meters come in many variations. Theinformation sent to you depends on the accessoriesyou have ordered with your meter. Make an inventoryof your owner�s information packet. First, find yourLC packing slip with the computer printout. Locatethe serial number and the meter model number onthis printout. Cross reference the packing slip numberwith the actual meter numbers. The illustration onthis page will help you locate the Specification andSerial Number Plates on the meter and its accessories.

2.2.2.2.2. Record your meter serial number Record your meter serial number Record your meter serial number Record your meter serial number Record your meter serial number in the spaceprovided on the inside cover of this manual. The insidecover also provides a space for your full-servicedistributor�s name and telephone number. Fill in thisinformation and keep it handy. You will always needyour meter serial number and model number whencalling for service or parts! See �How to OrderReplacement Parts� in this manual.

55555

3.3.3.3.3. Identify your meterIdentify your meterIdentify your meterIdentify your meterIdentify your meter��s model-accessory letters model-accessory letters model-accessory letters model-accessory letters model-accessory letter. . . . . Usethe charts shown above to familiarize yourself withmeter accessories. Find the meter and letter on thechart which represents your meter, then check withthe chart below to see that your red owner�s informationpacket is complete. Not all accessory levels areavailable for every model of LC meter.

4.4.4.4.4. Check your owner�s information packet Check your owner�s information packet Check your owner�s information packet Check your owner�s information packet Check your owner�s information packet with thechart shown above to make sure that all thedocumentation needed for your meter and accessoriesis in your red information packet. If documentation ismissing, call your full-service distributor or LiquidControls for replacement materials.


66666

InstInstInstInstInstallation Requirementallation Requirementallation Requirementallation Requirementallation Requirementsssss

Make sure that all necessary safety precautions have beentaken. Provide for proper ventilation, temperature control,fire prevention, evacuation and fire management.


Read this manual as well as all the literature provided inyour owner�s manual. If you have any questions, consultwith your full-service distributor or call the ServiceDepartment at Liquid Controls.

Install the meter and accessories in conformance withapplicable state and federal construction, electrical andsafety codes.

NOTE: NOTE: NOTE: NOTE: NOTE: Class 10 LPG meters must be installed inaccordance with the requirements of ANSI-NFPA 58 inaddition to all other state and local codes.

WWWWWARNING: ARNING: ARNING: ARNING: ARNING: Under normal operation, do not expose anyportion of the LP-Gas system to pressures in excess ofrated working pressures without an automatic safety valveto vent the over pressure discharge to a place of safetyaway from the operator and other people. Failure to providesuch a safety relief may result in leakage or rupture of oneor more of the components in the system. This can resultin injury of death from the gas, a fire, or pieces of flyingdebris from the rupture.

Before shipment, protective thread caps were placed in allmeter and accessory openings. They should remain inplace until you are ready to attach piping.

Prior to meter installation, the entire piping system shouldbe thoroughly flushed of all debris, with a liquid that iscompatible with the construction of the meter.

Keep external surfaces of the meter clean.

The meter must always be securely bolted to a platform orsupporting member, regardless of the mounting positionof the meter. Never �hang� a meter on the connecting piping.

Install meter only on the discharge side (downstream) ofthe system pump.

Apply pipe compound to male threads only.

Position the meter with service in mind. Provide amplework space. Removing covers can be difficult when workspace is not available. Always supply a platform or supportfor the meter mounting.

A meter is metallurgically designed to be physicallycompatible with a given type of liquid, as originally specifiedby the customer, and as indicated on the Serial NumberPlate. A meter should not be used with a liquid differentfrom the liquid originally specified, unless the physicalcharacteristics and pH rating are similar and the applicationhas been checked with LC Sales and Engineering throughyour full-service distributor.

Install a strainer on the meter inlet to avoid damage fromforeign matter, such as weld slag, from entering the system.The strainer must always be located on the inlet side.

All meters are tagged identifying their direction of flow.Meters are set with a flow direction of left to right asstandard. However, when a meter is ordered, the customercan specify that the flow be set from either direction. If themeter register counts in reverse, the meter is reading thedirection of flow in reverse. If this occurs, the meterregistration must be reset. See �Reversing the MeterRegistration� in this manual for mechanical output meters.Refer to your accessory manual for electrical output meters(such as meters equipped with a pulser).

NOTENOTENOTENOTENOTE

Always request up-to-date, engineering approved,dimensional drawings before starting any construction.Do not rely on catalog pictures or drawings which arefor reference only. After receiving prints, check to seethat all equipment ordered is shown and that any extrapressure taps, plugs, etc. are noted and their sizespecified.

77777

Operation RequirementOperation RequirementOperation RequirementOperation RequirementOperation Requirementsssss

The meter must remain full of product at all times.The meter must remain full of product at all times.The meter must remain full of product at all times.The meter must remain full of product at all times.The meter must remain full of product at all times.An easy way to accomplish this is to put the meterassembly in the line below the piping center-line (a sumpposition). This requires adding elbows and flanges prior toinstalling the meter. The meter should be installed in abypass loop, below the pipe center-line, with block valvesupstream and downstream. A block valve should be locatedin the mainstream, labeled as the bypass valve.

Caution: Caution: Caution: Caution: Caution: Any portion of pipe system that might isolate orblock flow should be provided with a pressure relief toprevent damage from thermal expansion. There areexcellent benefits to this type of installation. First, themeter is kept full. Second, this type of installation allowsthe meter to be isolated for servicing and calibration whilecontinuing flow through the bypass valve.

Upstream lines must be maintained fullUpstream lines must be maintained fullUpstream lines must be maintained fullUpstream lines must be maintained fullUpstream lines must be maintained full to prevent airfrom entering the meter. If upstream or inlet lines areconstructed in a manner which allows reverse flow, footvalves or back checks must be installed.

Underground tanks Underground tanks Underground tanks Underground tanks Underground tanks that are furnished with a submersiblepump will eliminate many problems that occur with positivedisplacement pumps (suction pumps) when suction pipingis incorrectly sized or when the lift is too great.

Every meter should be calibrated Every meter should be calibrated Every meter should be calibrated Every meter should be calibrated Every meter should be calibrated under actual serviceand installation conditions per the API Manual of PetroleumMeasurement Standards:

Chapter 4 - Proving SystemsChapter 5 - MeteringChapter 6 - Metering AssembliesChapter 11 Section 2.3 -Water Calibration of Volumetric ProversChapter 12 Section 2 -Calculation of Petroleum Quantities

These chapters of the API Manual of PetroleumMeasurement Standards supersedes the API standard1101.

Provide a means Provide a means Provide a means Provide a means Provide a means of conveniently diverting liquid forcalibration purposes.

Give careful attention to your system�s pumpingGive careful attention to your system�s pumpingGive careful attention to your system�s pumpingGive careful attention to your system�s pumpingGive careful attention to your system�s pumpingequipment and piping equipment and piping equipment and piping equipment and piping equipment and piping because of their influence on liquidbeing measured as it enters the metering assembly.Systems should be made free of conditions that cause orintroduce entrained air or vapor.

Follow the manufacturer�s recommendation fullyFollow the manufacturer�s recommendation fullyFollow the manufacturer�s recommendation fullyFollow the manufacturer�s recommendation fullyFollow the manufacturer�s recommendation fullywhen installing pumps. when installing pumps. when installing pumps. when installing pumps. when installing pumps. Give particular attention tofactors like: use of foot valves, pipe size to the inlet andconformance to net positive suction head (NPSH)conditions when suction pumping is required. Followingthe manufacturer�s recommendations will minimize air andvapor elimination problems.

For liquids such as light hydrocarbons For liquids such as light hydrocarbons For liquids such as light hydrocarbons For liquids such as light hydrocarbons For liquids such as light hydrocarbons that tend toflash or vaporize easily at higher ambient temperatures, itis desirable to use flooded suctions and piping sized largerthan the nominal pump size.

On systems such as vehicle tank installations, On systems such as vehicle tank installations, On systems such as vehicle tank installations, On systems such as vehicle tank installations, On systems such as vehicle tank installations, pipinglayout is important in preventing problems with splitcompartment test conformance. Piping should slope awayfrom a P.D. pump to prevent resurgent re-priming of thepump due to drain back.

Hydraulic shock is harmful to all componentsHydraulic shock is harmful to all componentsHydraulic shock is harmful to all componentsHydraulic shock is harmful to all componentsHydraulic shock is harmful to all components of anoperating system including valves, meter and the pump.In particular, meters must be afforded protection from shockbecause of their need to measure with high precision.Generally the best protection is prevention, which can bereadily accomplished by adjusting valve closing rates insuch a manner that shock does not occur.

Thermal expansion like hydraulic shock is aThermal expansion like hydraulic shock is aThermal expansion like hydraulic shock is aThermal expansion like hydraulic shock is aThermal expansion like hydraulic shock is aphenomenon that can easily damage meters phenomenon that can easily damage meters phenomenon that can easily damage meters phenomenon that can easily damage meters phenomenon that can easily damage meters andsystems in general. Care should be taken in designingthe system to include pressure relief valves in any portionor branch of the system that might be closed off by closureof operating valves or block valves.

88888

Meter SMeter SMeter SMeter SMeter Stttttart Up and Operationart Up and Operationart Up and Operationart Up and Operationart Up and Operation

Prior to meter start upPrior to meter start upPrior to meter start upPrior to meter start upPrior to meter start up, use extreme caution. Makesure that:

1. The meter is properly secured2. All connections are tight3. All valves are in the closed position

Placing your meter in operation: Placing your meter in operation: Placing your meter in operation: Placing your meter in operation: Placing your meter in operation: When placing yourmeter in operation, the meter and system must be filledslowly with liquid and be free of air prior to start-up. Extremecare must be taken to avoid damaging the meter duringthis time. The system may be filled by gravity (preferred)or by use of the pump (if required) when filling the systemwith liquid for the first time.

Gravity filling - Gravity filling - Gravity filling - Gravity filling - Gravity filling - systems with positive head pressurefrom product storage above the inlet port of the meter.

1. Make sure all valves (up stream and down stream ofthe meter) in the system are closed.

2. Crack open the valve located at the storage tank. Themeter�s register/counter will start to move and thenstop, provided there is not a valve between the tankand the meter inlet. If there is another valve betweenthe tank and meter, repeat this process with each valveuntil the meter is exposed to the liquid.

3. Once you are assured that the meter has registeredsome volume and stopped, continue to fully open thetank valve.

4. With the valve(s) open between the tank and the meter,now go to the valve located down stream of the meter.Open the down stream valve slowly until the meter�sregister/counter starts to move. Do not run the meterany faster than 25% of its rated flow during start-up.Once the product is flowing out the end of your system,the outlet valve can be opened all the way providedthat the system is designed not to exceed the flowrate marked on the meter.

NOTENOTENOTENOTENOTE: If the valves are not manual, consult the valvemanufacturer for slow flow start-up.


Make sure that your pump can operate against aMake sure that your pump can operate against aMake sure that your pump can operate against aMake sure that your pump can operate against aMake sure that your pump can operate against adead head pressure. If NOTdead head pressure. If NOTdead head pressure. If NOTdead head pressure. If NOTdead head pressure. If NOT, consult the factory, consult the factory, consult the factory, consult the factory, consult the factoryfor assistance.for assistance.for assistance.for assistance.for assistance.

!!!!! W W W W WARNINGARNINGARNINGARNINGARNING


Filling the system with a pump - Filling the system with a pump - Filling the system with a pump - Filling the system with a pump - Filling the system with a pump - Consult the pumpmanufacturer for proper pump priming. Once the pump isprimed with product, proceed as follows:

� Follow steps one through four above for proper meterstart-up.

Never operate the meter or system when partiallyNever operate the meter or system when partiallyNever operate the meter or system when partiallyNever operate the meter or system when partiallyNever operate the meter or system when partiallyfilled with liquid, or with pockets of compressed airfilled with liquid, or with pockets of compressed airfilled with liquid, or with pockets of compressed airfilled with liquid, or with pockets of compressed airfilled with liquid, or with pockets of compressed airor vapor present. If these conditions cannot beor vapor present. If these conditions cannot beor vapor present. If these conditions cannot beor vapor present. If these conditions cannot beor vapor present. If these conditions cannot beavoided, air and vapor elimination systems may beavoided, air and vapor elimination systems may beavoided, air and vapor elimination systems may beavoided, air and vapor elimination systems may beavoided, air and vapor elimination systems may berequired. If you cannot fill the meter slowly byrequired. If you cannot fill the meter slowly byrequired. If you cannot fill the meter slowly byrequired. If you cannot fill the meter slowly byrequired. If you cannot fill the meter slowly bygravity or by using a valve to throttle back the flow,gravity or by using a valve to throttle back the flow,gravity or by using a valve to throttle back the flow,gravity or by using a valve to throttle back the flow,gravity or by using a valve to throttle back the flow,consult the factoryconsult the factoryconsult the factoryconsult the factoryconsult the factory.....

Do not operate the meter at a pressure exceeding thatmarked on the Serial Number Plate. Under any and allpressure producing circumstances, for instance, thermalexpansion and hydraulic shock, the working pressuremust not exceed the indicated maximum.

If the meter is operated at a rate greater than themaximum recommended GPM, excessive wear andpremature failure may occur.

The meter can be calibrated for flows below minimumratings if the flow remains constant and varies withinnarrow limits or if the product is viscous. A meter shouldnever be run beyond the maximum flow rate determinedfor that class meter and/or liquid measured.

99999

Reversing the Meter RegistrationReversing the Meter RegistrationReversing the Meter RegistrationReversing the Meter RegistrationReversing the Meter Registration

The direction of flow is specified by the customer whenthe meter is ordered. The standard direction of flow isfrom left to right when facing the front of the meter. A redpressure sensitive label indicating inlet is affixed to themeter at time of shipment.

If the meter is equipped with a strainer and/or valve, thestrainer (and/or valve) MUSTMUSTMUSTMUSTMUST be moved when reversing thedirection of flow through the meter. The strainer shouldThe strainer shouldThe strainer shouldThe strainer shouldThe strainer shouldalways be located on the inlet side of the meteralways be located on the inlet side of the meteralways be located on the inlet side of the meteralways be located on the inlet side of the meteralways be located on the inlet side of the meter..... Whenthe meter is equipped with a valve, it is moved to the outletside of the meter. Some repositioning of the valvecomponents may be required. See the Valve Manual inthe Owner�s Information Packet.

When the meter is first installed, check the register. If theregister counts DOWN,DOWN,DOWN,DOWN,DOWN, meaning that the register numbersdecrease rather than increase, you must reverse thedirection of registration by reversing the position of theadjuster drive gear.

Reversing the drive to the register is accomplished byreversing the position of the adjuster drive gear relative tothe pinion gear of the packing gland, as shown to the left.See below for step-by-step instructions.

1. Refer to �Servicing the Drive Components�, Step 1 toremove the dust cover (page 12).

2. Remove the retaining ring (4) with a screwdriver orpliers.

3. Remove the two retaining spring screws (1) with astandard screwdriver. Note: For M-15, M-25, M-30,Note: For M-15, M-25, M-30,Note: For M-15, M-25, M-30,Note: For M-15, M-25, M-30,Note: For M-15, M-25, M-30,and M-40 modelsand M-40 modelsand M-40 modelsand M-40 modelsand M-40 models loosen the single set screw.

4. Remove the retaining spring (2).

5. Remove the drive shaft (3) mounted with the adjusterdrive gear assembly including (4) Retaining Ring and(5) Adjuster Drive Gear.

6. Remove the adjuster drive gear (5) and turn it 180° sothat it is upside down from the original installationposition. The bushing (7) supports the adjuster drivegear in the lower position. The retaining ring (4)supports the adjuster drive gear in the upper position.

Adjuster drive gearengaged from the top.

Adjuster drive gearengaged from thebottom.

7. Reassemble the parts in reverse order. Make surethat the adjuster drive gear meshes with the packinggland�s pinion gear (6) without being too tight. Makesure there is a little play in the gear teeth. The retainingring (4) should be placed in the groove provided on thedrive shaft (3), regardless of the adjuster drive gearposition. The packing gland pinion gear to adjusterdrive gear ratio is either 1:1 or 2:1. In the 2:1 ratio, thepinion of the packing gland is smaller in diameter.

Packing Gland

1010101010

Setting the SSetting the SSetting the SSetting the SSetting the Stttttandard andard andard andard andard AdjusterAdjusterAdjusterAdjusterAdjuster

NOTE:NOTE:NOTE:NOTE:NOTE: These instructions apply to meters equipped withmechanical output accessories only. If your meter isequipped with an electrical output (i.e., electronic pulser)refer to your accessory manual, such as the Pulser Manualsupplied in your owner�s information packet.


2. Check meter registration by delivering product to areliable, accurate prover. Perform multiple delivery teststo verify the meter repeatability.

3. Record the setting indicated on the adjuster:

4. Note the difference between the volume of the proverand the volume indicated on the meter counter.Calculate the % correction required, as follows:

5. Loosen the adjuster clamp screw.

6. When the prover volume is less than the meter countervolume, add the percentage to the original adjustersetting by turning the thimble towards the arrow markedlarger (volume). Correct the original setting byapproaching the number desired from the next largernumber. For example, if the desired adjuster settingis 2.4, turn the adjuster thimble to the left to number5, then to the right to obtain the 2.4 setting. Adjusteris currently set at 2.3 in the illustration to the right.

7. When the prover volume is moremoremoremoremore than the metercounter volume, subtract the percentage from theoriginal adjuster setting by turning the thimble in thedirection of the arrow marked smaller volume percent.

8. Retighten the adjuster clamp screw. Run productthrough the meter to allow the adjuster to take a set.Then make several prover runs to check for accuracy

Meter Maintenance andMeter Maintenance andMeter Maintenance andMeter Maintenance andMeter Maintenance andrepeatrepeatrepeatrepeatrepeatabilityabilityabilityabilityability.....Prevent pipe strain or stress Prevent pipe strain or stress Prevent pipe strain or stress Prevent pipe strain or stress Prevent pipe strain or stress from occurring when makingmeter or accessory repairs. Pipe strain and stress occurswhen the pipes are not supported or are not alignedcorrectly to the meter. The weight of the pipes must alwaysbe supported independent of the meter. This means thatthe meter and accessories can be easily removed withoutaffecting the pipes or the pipe alignment. Never leave anyof the pipes hanging.

Seasonal meter storageSeasonal meter storageSeasonal meter storageSeasonal meter storageSeasonal meter storage If the meter is used for seasonalwork, at the end of each season the meter should beremoved from the system and thoroughly flushed with acompatible liquid. This includes removing the drain on thefront and rear covers. Then flush the product from the frontand rear covers. If flushing with water is preferred, extracare should be taken to drain the meter completely anddry all internal parts. Immediate refilling with a compatibleliquid (or oil misting) is essential to prevent corrosion aswell as ice damage to parts from moisture that wasoverlooked after flushing and drying.

VVVVVolume in prover - volume on meter counterolume in prover - volume on meter counterolume in prover - volume on meter counterolume in prover - volume on meter counterolume in prover - volume on meter counter % correction = X 100 % correction = X 100 % correction = X 100 % correction = X 100 % correction = X 100

volume in provervolume in provervolume in provervolume in provervolume in prover

1111111111

Meter MaintenanceMeter MaintenanceMeter MaintenanceMeter MaintenanceMeter Maintenance

Do not mar or scratch Do not mar or scratch Do not mar or scratch Do not mar or scratch Do not mar or scratch any of the precision machinedsurfaces by prying or sanding parts.

TTTTTorque orque orque orque orque all fasteners such as screws and bolts inaccordance with specifications listed in the �Torque Chart�in this manual (page 22).

Stone the machined surfaces Stone the machined surfaces Stone the machined surfaces Stone the machined surfaces Stone the machined surfaces when reassembling themeter to assure that the machined surfaces are free ofburrs and mars.

Repair pulled threads Repair pulled threads Repair pulled threads Repair pulled threads Repair pulled threads with threaded insert fasteners.These can be used in many instances. Contact your full-service distributor for advice if this occurs.

Coat threads Coat threads Coat threads Coat threads Coat threads with anti-seize when removing and replacingbolts and castings in a meter.

Removing flange gaskets Removing flange gaskets Removing flange gaskets Removing flange gaskets Removing flange gaskets When removing the flangeassembly, always carefully scrape off the flange gaskets.Make sure that the flange surface has been scraped clean.Discard the old flange gasket and install a new flangegasket. Never reuse old flange gaskets.

Examine all fasteners Examine all fasteners Examine all fasteners Examine all fasteners Examine all fasteners to make sure they are not bent,rusted, or have pulled threads. The threads should all

appear evenly placed. If the bolts are bent, check thehousing and cover for flatness. Use a straight edge todetermine flatness.

Look for gapLook for gapLook for gapLook for gapLook for gaps s s s s when disassembling a meter. Use a feelergauge to check for gaps between the bearing plate andhousing. If you do find gaps, check the bearing plates forflatness with a straight edge. Gaps can be caused byshock problems that must be resolved. Contact your full-service distributor for assistance if this occurs.

Check the O-rings Check the O-rings Check the O-rings Check the O-rings Check the O-rings for damage. Cracked, rough, or wornO-rings should be replaced. However, a more seriousproblem of shock may be indicated if the O-rings looknibbled. Shock problems must be verified and resolved.Contact your full-service distributor for assistance if thisoccurs.

Check the bearing plates Check the bearing plates Check the bearing plates Check the bearing plates Check the bearing plates for flatness. Use a straightedge. Warped bearing plates can be caused by shockproblems that must be resolved. Contact your full-servicedistributor for assistance if this occurs.

Check with regulatory agencyCheck with regulatory agencyCheck with regulatory agencyCheck with regulatory agencyCheck with regulatory agency that governs Weights &Measures in your area. Removing the dust cover sealwire or other maintenance procedures may require Weights& Measures recalibration.

WARNING

Relieving Internal PressureRelieving Internal PressureRelieving Internal PressureRelieving Internal PressureRelieving Internal PressureAll internal pressure must be relieved to zero pressureAll internal pressure must be relieved to zero pressureAll internal pressure must be relieved to zero pressureAll internal pressure must be relieved to zero pressureAll internal pressure must be relieved to zero pressure

before disassembly or inspection of the strainer, air eliminator any valves in the system,the packing gland, and the front or rear covers.

Serious injury or death from fire or explosion could result from maintenance of anSerious injury or death from fire or explosion could result from maintenance of anSerious injury or death from fire or explosion could result from maintenance of anSerious injury or death from fire or explosion could result from maintenance of anSerious injury or death from fire or explosion could result from maintenance of animproperly depressurized and evacuated system.improperly depressurized and evacuated system.improperly depressurized and evacuated system.improperly depressurized and evacuated system.improperly depressurized and evacuated system.


4. Slowly open the valve/nozzle at the end of the supplyline.

5. After product has bled off, close the valve/nozzle atthe end of the supply line.

6. Slowly crack the fitting on top of the differential valveto relieve product pressure in the system. Productwill drain from the meter system.

7. As product is bleeding from the differential valve, slowlyreopen and close the valve/nozzle on the dischargeline. Repeat this step until the product stops drainingfrom the differential valve and discharge line valve/nozzle.

8. Leave the discharge line valve/nozzle open whileworking on the system.

Procedure for Non-LPG Meters1. Turn off pump pressure to the system.2. Close valves before and after the meter.3. Remove pressure by removing the drain plugs and

draining the meter.

Procedure for LPG Meters1. Close the belly valve of the supply tank.2. Close the valve on the vapor return line.3. Close the manual valve in the supply line on the inlet

side of the meter. If no manual valve exists on theinlet side, consult the truck manufacturer forprocedures to depressurize the system.

1212121212

Servicing the Drive ComponentServicing the Drive ComponentServicing the Drive ComponentServicing the Drive ComponentServicing the Drive Componentsssss

Removing the Dust CoverRemoving the Dust CoverRemoving the Dust CoverRemoving the Dust CoverRemoving the Dust Cover1. Cut the dust cover seal wire with a side cutters.

Remove the dust cover screws with a 5/16� wrench orslotted screwdriver and then remove the dust cover.See �Relieving Internal Pressure� �Relieving Internal Pressure� �Relieving Internal Pressure� �Relieving Internal Pressure� �Relieving Internal Pressure� and �Regulatory �Regulatory �Regulatory �Regulatory �RegulatoryAgency� Agency� Agency� Agency� Agency� in the �Meter Maintenance� section (page11) of this manual.

Removing the Removing the Removing the Removing the Removing the Adjuster and Adjuster and Adjuster and Adjuster and Adjuster and Adjuster Drive Adjuster Drive Adjuster Drive Adjuster Drive Adjuster Drive AssemblyAssemblyAssemblyAssemblyAssembly

1. Record the adjuster micrometer setting.

2. Carefully note the adjuster drive gear position. Thegear engages the packing gland pinion from below orabove. This gear must be reinstalled in its originalposition or the meter counter will run backwards.

1313131313


3. Use a standard screwdriver to loosen (or remove) thetwo retaining spring screws.

4. Swing the retaining spring off the adjuster drive bushing.

5. Loosen the adjuster mounting clamp screw with aphillips head screwdriver.

Removing the adjuster from the top of the meter when topaccess is easiest. Front access instructions are on thenext page.

6. Remove screws that secure adjuster mounting plateto counter adapter.

7. Lift adjuster mounting bracket with adjuster out of thecounter adapter.

8. Remove the adjuster drive assembly from the housing.

1414141414


Removing the adjuster from the front of the meter whenfront access is easiest. Top access instructions are onthe previous page.


10. Remove the slotted head screw that secures theadjuster to the mounting plate.

11. Bring the adjuster out through the front of the meterby rotating it from left to right to clear the adjustermounting plate and then pull down to remove from themeter.

Servicing the Packing GlandServicing the Packing GlandServicing the Packing GlandServicing the Packing GlandServicing the Packing GlandThe packing gland is affected by the liquid being metered,the operating temperature, and other system conditions.After prolonged use, the gland may show leakage fromthe metering chamber. This is a sign of wear. The glandshould be replaced or repaired if this occurs. It can beserviced in the field.

1. Remove the two packing gland retaining plate screwswith a 5/16� socket and ratchet drive extension or5/16� nut driver.

2. Pull out the packing gland.

3. Take apart the packing gland by gently prying off theretaining ring with a standard screwdriver.

4. Pull the driver out from the assembly.



1515151515

Buna/VBuna/VBuna/VBuna/VBuna/Viton/Titon/Titon/Titon/Titon/Teflon Packing Glandeflon Packing Glandeflon Packing Glandeflon Packing Glandeflon Packing Gland

1. Driver2. Shaft3. Stainless steel thrust washer4. Rulon thrust washer5. Buna/Viton/Teflon �U� Cup 6. Aluminum/stainless housing 7. Washer - Nylon 8. Output gear 2:1 9. Retaining ring10. Bushing11. Retaining plate12. Buna/Viton/Teflon O-ring13. Two retaining plate screws14. Output gear 1:115. Carbon Guide Bearing16. Washer - Stainless Steel

Packing Gland RetPacking Gland RetPacking Gland RetPacking Gland RetPacking Gland Retaining Plateaining Plateaining Plateaining Plateaining PlateThe retaining plate has four holes: two that are drilled 1-1/2� on center and two that are drilled 1-5/8� on center. Ifyour meter has a counter adapter dust cover (Item #0366)shaped like the illustration shown below, use the holesdrilled 1- 5/8� on center to mount the packing gland retainingplate.

If your meter does notnotnotnotnot have the counter adapter dust covershaped like the illustration shown on the right, use the twoholes drilled 1-1/2� on center to mount the packing glandretaining plate.

Packing Gland ComponentPacking Gland ComponentPacking Gland ComponentPacking Gland ComponentPacking Gland Componentsssss

Adapter Dust Cover for holesdrilled 1-5/8� on center

Standard Packing Gland

LPG Packing Gland

Item 11 (above)

1616161616

Disassembling the MeterDisassembling the MeterDisassembling the MeterDisassembling the MeterDisassembling the Meter

Mechanical Output Meters*Mechanical Output Meters*Mechanical Output Meters*Mechanical Output Meters*Mechanical Output Meters*

* For electrical output meters refer to the Pulser Manualsupplied in your owner�s information packet.

1. Remove the counter bracket screws with a box wrenchor socket driver. The counter bracket can be removedwith or without removing the adjuster assembly.

NOTE: For Aluminum M-30 and M-40 modelsNOTE: For Aluminum M-30 and M-40 modelsNOTE: For Aluminum M-30 and M-40 modelsNOTE: For Aluminum M-30 and M-40 modelsNOTE: For Aluminum M-30 and M-40 models the counterbracket and front cover are one piece. Go to step 2.

2. Turn the meter on either the inlet or outlet side. Let itstand to allow the product to drain from the meterchamber.

3. Locate the drain plugs on the front and rear covers.Remove the drain plugs using an allen wrench. Let themeter stand to allow product to drain from the frontand rear covers.



1717171717

4. Use a socket wrench or box end wrench to removethe screws securing the front cover. Remove thescrews that hold the rear cover. The number of screwswill vary depending on meter size.

5. Remove the front and rear covers. MA-4, M-5, andMA-4, M-5, andMA-4, M-5, andMA-4, M-5, andMA-4, M-5, andMA-5 old style models, M-60 and M-80 currentMA-5 old style models, M-60 and M-80 currentMA-5 old style models, M-60 and M-80 currentMA-5 old style models, M-60 and M-80 currentMA-5 old style models, M-60 and M-80 currentmodelsmodelsmodelsmodelsmodels have a driven reduction gear attached with ashoulder bolt to the center of the front bearing plate.

6. Carefully remove the O-rings / flat gaskets from frontand rear of the housing. Undamaged Buna or Viton O-rings may be reused. Flat gaskets and Teflon O-ringsshould always be replaced and never reused.

7. Hold a spare displacement rotor gear between the rightdisplacement rotor gear and the blocking rotor gear tokeep them from turning (if unavailable, use a shop ragbetween gear teeth). Use the rotor gear wrench orsocket to remove the right displacement rotor gearscrew and washer.

MA-4, M-5, and MA-5 old style models, M-60 and M-80MA-4, M-5, and MA-5 old style models, M-60 and M-80MA-4, M-5, and MA-5 old style models, M-60 and M-80MA-4, M-5, and MA-5 old style models, M-60 and M-80MA-4, M-5, and MA-5 old style models, M-60 and M-80current models:current models:current models:current models:current models:Rotor gears are on the meter back.

All other models:All other models:All other models:All other models:All other models:Rotor gears are on the front.

8. Hold the spare gear between the left displacementrotor gear and blocking rotor gear. Use the rotor gearwrench or socket to remove the screw and the packinggland driver held by the screw.

9. Hold the spare gear between the right displacementrotor gear and the blocking rotor gear. Use the rotorgear wrench or socket to remove the left displacementrotor gear screw and washer.


1818181818


1. Insert two standard screwdrivers behind the blockingrotor gear: Gently pry the gear off its rotor taperedend. If the gears show signs of corrosion, or do notpry off easily, use the alternative method described insteps 5-8.

2. Use the same method to remove the left rotor gearand the right rotor gear. Remember, if the gear doesnot pry off easily, or feels stuck, use the alternativemethod described in steps 5-8.

3. As each gear comes off the rotor remove the key (1)from the rotor keyway (2). Save the key to use whenreassembling the meter.

4. Use the bearing plate wrench to remove the screwsthat hold the front bearing plate to the meter housing.On the back of the meter housing, remove the screwsthat hold the rear bearing plate to the housing. Go tostep 1, Removing the Bearing Plates.

Removing Corroded Rotor GearsRemoving Corroded Rotor GearsRemoving Corroded Rotor GearsRemoving Corroded Rotor GearsRemoving Corroded Rotor Gears5. Replace all three rotor gear screws, without washers,

halfway onto each of the rotor ends.

6. On the back of the meter housing, remove the screwsthat hold the rear bearing plate to the housing usingthe bearing plate wrench or socket. The number ofscrews varies with the size of meter.

Removing Non-Corroded Rotor GearsRemoving Non-Corroded Rotor GearsRemoving Non-Corroded Rotor GearsRemoving Non-Corroded Rotor GearsRemoving Non-Corroded Rotor Gears

1919191919


7. With a plastic or non-metallic mallet, tap on the headsof the screws lightly and equally. As you tap on thescrew heads, the gears are driven off the rotors. Asthe rotors are driven in, the rear bearing plate and therotor assembly are pushed away from the housing.

NOTENOTENOTENOTENOTE: For carbon insert bearing plates, remove therear plate first and then each rotor as it is handsupported.

8. Use the bearing plate wrench or socket to remove thescrews that hold the front bearing plate to the meterhousing. The number of screws varies between differentmeter sizes.

Removing the Bearing PlatesRemoving the Bearing PlatesRemoving the Bearing PlatesRemoving the Bearing PlatesRemoving the Bearing Platesand Rotorsand Rotorsand Rotorsand Rotorsand Rotors1. Insert a screwdriver into each of the two notches near

the dowel pins. Be careful not to mar any of thesurfaces. Gently pry the front bearing plate off the dowelpins.

2. Remove the front bearing plate and rotor assembly bypulling a rotor straight out from the housing. Be carefulnot to mar any of the surfaces. MA-4, M-5, and MA-5MA-4, M-5, and MA-5MA-4, M-5, and MA-5MA-4, M-5, and MA-5MA-4, M-5, and MA-5old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:Pull the rotor from the rear bearing plate. This will alsoremove the drive reduction gear which is attached tothe blocking rotor.

3. Remove the remaining bearing plate from the otherside by inserting a screwdriver into each of the twonotches near the dowel pins. Be careful not to marany surfaces. Gently pry the front bearing plate off thedowel pins. NOTE: MA-4, M-5, and MA-5 old styleNOTE: MA-4, M-5, and MA-5 old styleNOTE: MA-4, M-5, and MA-5 old styleNOTE: MA-4, M-5, and MA-5 old styleNOTE: MA-4, M-5, and MA-5 old stylemodels, M-60 and M-80 current models models, M-60 and M-80 current models models, M-60 and M-80 current models models, M-60 and M-80 current models models, M-60 and M-80 current models have adriven reduction gear in attached with a shoulder boltto the center of the front bearing plate.

4. Inspect and clean all critical surfaces like gear teeth,rotors and internal housing faces. Remove anycrystalline formations using fine emery cloth or a finewire brush. Be careful not to mar or alter the shape ofany of the parts. Changing the shape of the parts mayinterfere with their operation. Remove nicks and burrson metal parts with a stone. Remove all grit and otherforeign particles. These may also damage parts andinterfere with proper operation. Replace all parts thatappear worn or damaged.

2020202020

Reassembling the MeterReassembling the MeterReassembling the MeterReassembling the MeterReassembling the Meter

1. MA-4, M-5, and MA-5 old style models, M-60 andMA-4, M-5, and MA-5 old style models, M-60 andMA-4, M-5, and MA-5 old style models, M-60 andMA-4, M-5, and MA-5 old style models, M-60 andMA-4, M-5, and MA-5 old style models, M-60 andM-80 current models:M-80 current models:M-80 current models:M-80 current models:M-80 current models: Rotor gears are on the rearbearing plate. All other models: Rotor gears are onthe front bearing plate. Install the non-rotor gear bearingplate using the bearing plate screws and wrench.

2. Insert the non-tapered ends on the three rotors intothe housing. Place each rotor into its respective borein the installed bearing plate. MA-4, M-5, and MA-5MA-4, M-5, and MA-5MA-4, M-5, and MA-5MA-4, M-5, and MA-5MA-4, M-5, and MA-5old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:Make sure that the teeth of the driving reduction gearmesh with the teeth of the driven reduction gear.

3. Place the remaining bearing plate over the three taperedrotor ends and fasten it with the bearing plate screws.Use the bearing plate wrench. The number of screwsvaries with meter size.

4. The rotors should have a small amount of end-playand be easy to turn. Test each rotor, one at a time.Turn the rotors to make sure that they revolve freely.Jog the rotors from end to end to check for end-play.If they do not move easily in both tests, remove therotors and check for burrs and corrosion deposits.Clean them thoroughly.

Repeat Steps 2, 3 and 4.

5. The rotor key is a small wedge of metal. Each rotorhas a notch, or �keyway�, to hold a key. Position akey into each one of the three rotors. Press the keysinto the rotor keyways with your thumb and forefinger.

6. Slide the blocking rotor gear on its tapered rotor end.Slide the right displacement rotor gear on its taperedrotor end so that the timing marks line up between thetwo gears. See �Timing the Rotor Gears� on the nextpage. Hint: Before you place the right displacementrotor gear on its tapered end, hold the right rotor gearin position. Turn the blocking rotor gear. Try to line upthe timing marks before you place the rightdisplacement rotor gear on its tapered rotor end.

7. Position the left displacement rotor gear on its taperedrotor end so that its timing mark lines up with theblocking rotor gear. See �Timing the Rotor Gears�.

2121212121


Timing the Rotor GearsTiming the Rotor GearsTiming the Rotor GearsTiming the Rotor GearsTiming the Rotor GearsRotor gears are timed by lining up the timing marks. Theblocking rotor gear has a tooth directly in frontdirectly in frontdirectly in frontdirectly in frontdirectly in front of itstiming mark. On the displacement rotor gears, the timingmark falls in front of the space betweenin front of the space betweenin front of the space betweenin front of the space betweenin front of the space between two gearteeth. Make sure that the tooth in front of the timing markon the blocking rotor gear connects with the space infront of the timing mark on the displacement rotor gear.You may need to remove the gears and reposition themseveral times on their rotor ends in order to get the timingmarks to line up correctly. For more information, See�Troubleshooting�.

1. Position the spare displacement rotor gear betweenthe left displacement rotor gear and the blocking rotorgear to prevent the gears from moving. Attach the rightdisplacement gear washer and screw using the rotorgear wrench. Tighten the screw to the torquespecification listed in the Torque Chart (page 22).

2. Keep the spare displacement rotor gear positioned bythe left displacement rotor gear. Attach the leftdisplacement gear washer and screw using the rotorgear wrench. Tighten the screw to the torquespecification listed in the Torque Chart.

3. Position the spare displacement rotor gear betweenthe right displacement rotor gear and the blocking rotorgear. Attach the blocking rotor gear with the packinggland driver and screw using the rotor gear wrench.Tighten the screw to the torque specification listed inthe Torque Chart.

4. Rotate the gears to make sure that the rotors turnfreely. Burrs, foreign material, or marred surfaces canrestrict the rotor movements. It may be necessary toremove the gears and rotors and deburr and clean thesurfaces again.

5. Install an O-ring (1) into the groove (2) on the front ofthe meter housing. The M-60 and M-80 modelsM-60 and M-80 modelsM-60 and M-80 modelsM-60 and M-80 modelsM-60 and M-80 models use aflat gasket.

6. Fasten the front cover (3) with the cover screws (4)using the cover socket or open end/box end wrench.NOTE: 6A.NOTE: 6A.NOTE: 6A.NOTE: 6A.NOTE: 6A. LC recommends tightening the front coverscrews in a criss-cross or �star� pattern with a minimumof two passes. First pass should be at half-torque,with final pass(es) at full torque. This will ensureuniform seal compression on cover O-ring or gasket.See M-7 pattern on page 22 for reference.

Meter Assembly Exploded View

7. Install the front drain plug (6) in the front drain plughole (7) using the drain plug allen wrench.

8. Install an O-ring (8) into the groove (9) on the rear ofthe meter housing. The M-60 and M-80 modelsM-60 and M-80 modelsM-60 and M-80 modelsM-60 and M-80 modelsM-60 and M-80 models usea flat gasket.

9. Fasten the rear cover (10) with the cover screws (11)using the cover socket or open end/box end wrench.NOTE: 9ANOTE: 9ANOTE: 9ANOTE: 9ANOTE: 9A. LC recommends tightening the rear coverscrews in a criss-cross or �star� pattern with a minimumof two passes. First pass should be at half torque,with final pass(es) at full torque. This will ensureuniform seal compression on cover O-ring or gasket.See M-7 pattern on page 22 reference.

10. Install the rear drain plug (12) in the rear drain plughole (13) using the drain plug allen wrench.

11. If your meter is equipped with an electrical outputaccessory, such as a digital pulser, reinstall it accordingto the instructions outlined under �Reinstalling...� inyour accessory manual, such as the PulserInstallation, Operation and Maintenance Manualsupplied in your owner�s information packet. Installthe front drain plug (6) in the front drain plug hole (7)using the drain plug allen wrench.

2222222222

TTTTTorque Chartorque Chartorque Chartorque Chartorque Chart


TTTTTORQUE PORQUE PORQUE PORQUE PORQUE PAAAAATTERN M-7 COVERSTTERN M-7 COVERSTTERN M-7 COVERSTTERN M-7 COVERSTTERN M-7 COVERS

*Torque Tolerance is ± 10%

2323232323

Wrench and Socket Size ChartWrench and Socket Size ChartWrench and Socket Size ChartWrench and Socket Size ChartWrench and Socket Size Chart

NOTE: FOR ROTOR GEAR SCREWSNOTE: FOR ROTOR GEAR SCREWSNOTE: FOR ROTOR GEAR SCREWSNOTE: FOR ROTOR GEAR SCREWSNOTE: FOR ROTOR GEAR SCREWS

Please apply these techniques when repairing meters in the field.

1. Prior to installation, apply a small amount of Locquic Primer N764 to each screw.2. Apply a light coat of Loctite 242 in three even strokes to each screw. The Loctite and Locquic primer are notto be applied to the female connection in the rotor.

2424242424

TTTTTroubleshootingroubleshootingroubleshootingroubleshootingroubleshooting

PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:Leakage past packing gland drive shaft housing from internal metering chamber.

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:Internal seal of packing gland assembly is worn. Replace packing gland and O-ring seal.

OPERAOPERAOPERAOPERAOPERATING NOTE:TING NOTE:TING NOTE:TING NOTE:TING NOTE:Two common causes of packing gland leakage are thermal expansion and hydraulic shock. If two valves in apiping system (on either side of the meter) are closed at one time, and if the temperature rises as little as 1°F inthe system, it could result in a rise in pressure within the system that would exceed the working pressure ratingof the meter. To avoid this hazard caused by thermal expansion, a pressure-relief valve of some kind must beinstalled in the system. Hydraulic shock occurs when a large volume (mass) of liquid is moving through a pipe lineat some flow rate and a valve is suddenly closed. When the flow is stopped, the entire mass of the liquid in thepiping system acts as a battering ram causing a shock effect within the meter. The greater the mass length of lineand/or velocity, the greater the hydraulic shock. Since the valve is usually located at the meter outlet, the meterhousing, packing gland and the meter internal members receive the full impact of such hydraulic shock. To preventthis hazard a slow closing two-stage valve should be used with the meter. On those systems where mass lengthof line, etc. are of such magnitude as to preclude the elimination of hydraulic shock with the use of a two-stageslow closing valve, an impact-absorbing air cushioning device should be used.

PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:Leakage from the cover gasket.

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:Gasket has been damaged due to shock pressure or cover bolts have not been tightened sufficiently.

PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:Product flows through meter but the register does not operate.

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:A.A.A.A.A. Check packing gland, and gear train.

B.B.B.B.B. If all meter parts are moving then problem is in register. Faulty register should be checked and repaired bytrained mechanic.

C.C.C.C.C. Remove register from meter. If all meter parts are moving but output shaft of adjuster assembly is not, adjusteris worn and must be replaced.

D.D.D.D.D. If totalizer numerals (small numbers) on register are recording, but the big numerals are not moving, registerneeds repair.

E.E.E.E.E. Packing gland gear not turning. For M-60 and M-80 meters, the drive blade may be sheared. Replace thepacking gland. This may be caused by starting the flow too rapidly.


All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in thesystem, the packing gland, and the front or rear covers. See �Relieving Internal Pressure� (page 11).

2525252525


PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:Breaking teeth on timing gears.

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:A.A.A.A.A. Starting or stopping flow in meter too rapidly.B.B.B.B.B. Pump bypass not adjusted properly.

PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:Product flows through meter but register does not record correctly.

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:A.A.A.A.A. Adjuster not properly calibrated.B.B.B.B.B. Incorrect gear plate or gear ratio has been installed.C. Air is in the system.

PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:No flow through meter.

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:A.A.A.A.A. Faulty non-functioning pump.B.B.B.B.B. Valve not open or not functioning.C.C.C.C.C. Meter �frozen� due to build-up of chemical �salts� or foreign material inside metering chamber. To correct,

clean the meter and inspect for damage.

PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:Meter runs too slowly.

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:A.A.A.A.A. Valve internal mechanism faulty. Valve does not open fully.B.B.B.B.B. Meter gears or rotors partially �salted� enough to slow up rotation of parts. To correct, clean the meter.C. Downstream restriction.D. Clogged strainer basket.

PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:The meter counts down in reverse (the meter numbers decrease).

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:It is necessary to reverse the direction of flow by reversing the adjuster drive gear. See �M-7/MA-7 Meter Start Upand Operation: Reversing the Meter Registration� in this manual.

2626262626

How to Order Replacement PartHow to Order Replacement PartHow to Order Replacement PartHow to Order Replacement PartHow to Order Replacement Partsssss

1. Refer to the exploded view drawings on Pages 27-31.Find the four digit item number for the part you want toorder. The item numbers are listed on the explodeddrawings.

2. Find the computer printout titled Parts List that hasbeen inserted in the Owner�s Information Packet whichwas shipped with your order. Look up the item numberon the Parts List. The Parts List shows each itemnumber with a corresponding part number. Find thecorresponding five digit part number for the item youwant to order. The part number represents an individualpiece, a kit, or a complete assembly.

3. Inform your distributor of the part number that you need.The part number is the only number that allows thedistributor to find the correct component for your meter.

The Bills of Material for most meter classes are onThe Bills of Material for most meter classes are onThe Bills of Material for most meter classes are onThe Bills of Material for most meter classes are onThe Bills of Material for most meter classes are onthe LC public website. the LC public website. the LC public website. the LC public website. the LC public website. Always check the website forAlways check the website forAlways check the website forAlways check the website forAlways check the website forthe most current BOM.the most current BOM.the most current BOM.the most current BOM.the most current BOM.

2727272727

Illustrated PartIllustrated PartIllustrated PartIllustrated PartIllustrated Parts Breakdowns Breakdowns Breakdowns Breakdowns Breakdown

M5 through M25 Meters (including MA Meters)M5 through M25 Meters (including MA Meters)M5 through M25 Meters (including MA Meters)M5 through M25 Meters (including MA Meters)M5 through M25 Meters (including MA Meters)

NOTENOTENOTENOTENOTE: Numbers shown are ITEM ITEM ITEM ITEM ITEM numbers, not Part Numbers. Refer to the Bill of Materials supplied in the red Owner�sInformation Packet to locate the PPPPPARARARARARTTTTT NUMBER NUMBER NUMBER NUMBER NUMBER associated with these ITEM NUMBERSITEM NUMBERSITEM NUMBERSITEM NUMBERSITEM NUMBERS.

NOTENOTENOTENOTENOTE: Meter components may appear different between models.

2828282828


M30, M40 MetersM30, M40 MetersM30, M40 MetersM30, M40 MetersM30, M40 Meters



2929292929


M60, M80 Meter CoverM60, M80 Meter CoverM60, M80 Meter CoverM60, M80 Meter CoverM60, M80 Meter Cover



3030303030


M60, M80 Meter ElementM60, M80 Meter ElementM60, M80 Meter ElementM60, M80 Meter ElementM60, M80 Meter Element



3131313131

Quality SQuality SQuality SQuality SQuality Stttttatementatementatementatementatement

At Liquid Controls, we are dedicated to being the world leader in the field of liquid measurement.

Everyone associated with the enterprise must be committed to our quality effort and pursuing perfection.

To gain satisfaction in the eyes of our customers, we must accurately define and fulfill the customers� present andcontinuing needs.

We will strive to minimize the users� cost by providing products of high reliability, maintainability, serviceability, and no ofno planned obsolescence, which combine to give the customer superior value.

Our people are our greatest resource. We will create a positive, team-oriented environment which every person has trustand respect for one another, is recognized for achievement, and motivated toward excellence.

Absolute accountability for our efforts is determined by significant measures: our customers� level of satisfaction, thedevelopment of our people, and our contribution to the community.

Our goal is to be Simply the BestSimply the BestSimply the BestSimply the BestSimply the Best.

© 2004 Liquid Controls© 2004 Liquid Controls© 2004 Liquid Controls© 2004 Liquid Controls© 2004 Liquid ControlsPub. No. 48683Pub. No. 48683Pub. No. 48683Pub. No. 48683Pub. No. 48683

(05/04)(05/04)(05/04)(05/04)(05/04)

A Unit of IDEX Corporation105 Albrecht DriveLake Bluff, IL 60044-22421.800.458.5262 • 847.295.1050Fax: 847.295.1057www.lcmeter.com

LIQUIDCONTROLSA Unit of IDEX Corporation

P A R T S M A N U A L

M-7 ®, MA-7 ®

, M-10 ®Meters

Exploded View: M-7/MA-7/M-10 Meter Covers

0566 Plug,pipe-hex socket (2, one for each cover)

0627 Hex washer head screw(20, for both covers)

0125 Cover, rear

0126 Bracket, counter adapter

0202 Adjuster assembly

0364 Plate, adjuster mounting

0673 Screw (4)

0705 Washer, flat (4)

01

2

12 3 4

560

CAUTION

ALIGNCOUNTERDRIVESHAFTWITHSLOT

0603 Screw (2)

0382 Shaft, adjuster

0574 Ring,retaining

0165 Gear,packing gland

0366 Plate, dust cover

0630 Screw (2)

0780 Seal wire

0336 Gear

0250 PackingGland Assy.

0609 Screw, mounting plate (2)

0613 Screw, adjuster

LIQUID CONTROLS CORP. LAKE BLUFF, IL, USAMODEL NO.SERIAL NO.

MAX PRESSURE

VOL/REV

TEMP ERATURE

PRODUCT

FLOW RATE

®

ACCURACY

UK811783

Driveshaft bushing (2)

How to OrderReplacement Parts1. Find the item number listed on the exploded

drawing. The 4 digit item numbers are listed with a word description.

2. Find the computer printout titled Parts List that has been inserted in this manual. Look up the itemnumber on the Parts List. The Parts List shows eachitem number with a corresponding part number.Find the corresponding 5 digit part number for theitem you want to order. The part number representsan individual piece, a kit or a complete assembly.

3. Inform your distributor of the part number that youneed. The part number is the only number thatallows the distributor to find the correct componentfor your meter.

Exploded View: M-7/MA-7/M-10 Meter Housing

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© 2001 Liquid Controls

SOLD AND SERVICED BY A NETWORK OF HIGHLY TRAINEDFULL SERVICE DISTRIBUTORS

Backed By Our Worldwide Reputation ForQuality, Accuracy and Advanced Design.

LIQUID CONTROLSA Unit of IDEX Corporation105 Albrecht DriveLake Bluff, IL 60044-2242(847) 295-1050FAX: (847) 295-1057Website: www.lcmeter.com

Bulletin #48496B $1Printed in U.S.A.(03/01)

Backed By Our Worldwide Reputation For Quality, Accuracy and Advanced Design.

Distributed By:

Printed with vegetable inks on recycled paper. Please Recycle!

WARRANTY:Liquid Controls (“Seller”) products are warranted againstdefects in material or workmanship for a period of one (1)year from date of installation, provided that the warranty shall not extend beyond twenty-four (24) monthsfrom the date of original shipment from Seller. Seller’s obligations, set forth below, shall apply only to failure(s) tomeet the foregoing obligations provided that Seller is givenwritten notice within thirty (30) days of any occurrencefrom which a claim of defect arises. If a warranty disputeoccurs, the Purchaser shall be required to provide Sellerwith proof of date of sale. The minimum requirement toestablish date of sale shall be a copy of the Seller’s invoice.In the event that a factory inspection by Seller or itsdesignee(s) supports the validity of a claim, at the discretion of Seller, repair, replacement or refund shall bethe sole remedy for defect and shall be made, free of

charge, ex-works factory. In no event shall Seller be liablefor any special, consequential, incidental, indirect or exemplary damages arising out of warranty, contract, tort(including negligence) or otherwise, including but not lim-ited to, loss of profit or revenue, loss of use of the product orany associated products and/orequipment, cost of substitutegoods or services, downtime costs or claims of or byPurchaser’s clients or customers. In any event, the total liability of Seller for any and all claims arising out of orresulting from the performance, non-performance or use ofthe product shall not exceed the purchase price of the indi-vidual product giving rise to the claim. All other guaranties,warranties, conditions and representations, either express orimplied, whether arising under any statute, common law,commercial usage or otherwise are excluded. ElectronicProducts require installation, start-up and servicing bylocal factory-trained service representatives. In the absence

of installation, start-up and servicing of Electronic Productsby Seller trained service representatives, this warranty isnull and void. Seller’s obligations as set forth above shallnot apply to any product, or, or any component or partthereof, which is not properly installed, used, maintained or repaired, or which is modified other than pursuant toSeller’s instructions or approval. NOTE: The above warranty applies only to products manufactured by LiquidControls, Lake Bluff, Illinois. Private label, OEM, and/orproducts manufactured by Liquid Controls licensee(s) arespecifically excluded from the above warranty. Consult factory for all non-Liquid Controls manufacturers’ warranties. NO IMPLIED OR STATUTORY WARRANTIESOF MERCHANTABILITY OR FITNESS FOR A PARTICULARPURPOSE SHALL APPLY.

VALUE 90 11/2"AUTOMATIC BULK FUELING NOZZLE

Catlow’s Value 90 Nozzle is an extra heavy duty, high flow, bulk fueling nozzle for marine, truck and bus or home fueloil delivery.The Value 90 has been designed for durability and yet economically priced. This rebuildable nozzle comes completewith automatic venturi shut-off and a dual position, hold-open mechanism.

Features:

Ordering Specifications:

CATLOW Inc. Sales Desk (800) 222-8569Sales Fax (937) 898-8631 Phone (937) 898-32362750 US RT 40, Tipp City, OH 45371©2006 CATLOW Inc. All Rights Reserved CV900306

• Curved lever design for easier gripping• Dual Poppet Assembly makes nozzle easier to open against high inlet pressure• Dash Pot minimizes line shock• Dual position hold-open mechanism for user friendly operation• BSPP and BSPT threads available upon request

• Strong body casting resists cracking• Venturi type automatic shut-off prevents accidental spillage • Spout assembly easily replaced• Nozzle design allows easy access to awkward fueling

positions• Lighter in weight

• CV90-001 11/2" Bulk Fueling Nozzle, New• CV90-002 11/2" Bulk Fueling Nozzle, New (ULC)• RV90 11/2" Bulk Fueling Nozzle, Rebuilt

Benefits:

Materials:• Body.......Aluminum• Weight....5.3 lbs.• Inlet........11/2" NPT• Spout.....Aluminum 1 3/8" OD• Seals......Viton and Buna

Accessories:• V90S Replacement spout assembly• V90SW 1 1/2" x 1 1/2" Swivel

BLACKMER TRUCK PUMPSINSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS

MODELS: TX, TXS, TXD, TXSD 1.5, 2A, 2.5A, 3E, 4ATXV 2.5B, 3B

and Discontinued TX(S) 2, 21/2, 3; TXV 2(A)(B), 21/2(A), 3(A) Models

960280INSTRUCTIONS NO. 201-A00Page 1 of 12Section 200Effective March 2003Replaces June 2001

TABLE OF CONTENTS Page

SAFETY DATA.................................................................1-2

PUMP DATA .........................................................................2Technical Data.......................................................2Initial Start Up Information .....................................2

INSTALLATION ...............................................................2-3Pre-Installation Cleaning .......................................2Location and Piping...............................................2Truck Mounting......................................................3Pump Drive............................................................3Pump Rotation.......................................................3To Change Pump Rotation ....................................3

OPERATION .....................................................................4-5Pre-Start Up Check List.........................................4Start Up Procedures ..............................................4Pump Speed..........................................................4Reverse Rotation...................................................4Flushing the Pump ................................................4Relief Valve ...........................................................4Relief Valve Setting and Adjustment .....................5

MAINTENANCE ...............................................................5-8Lubrication.............................................................5Vane Replacement ................................................5Pump Disassembly................................................6Pump Assembly ....................................................6

GENERAL PUMP TROUBLESHOOTING .................9-10

NOTICE:Blackmer truck pumps MUST only be installed insystems which have been designed by qualifiedengineering personnel. The system MUST conform toall applicable local and national regulations and safetystandards.

This manual is intended to assist in the installationand operation of the Blackmer truck pumps, andMUST be kept with the pump.

Blackmer truck pump service shall be performed byqualified technicians ONLY. Service shall conform toall applicable local and national regulations and safetystandards.

Thoroughly review this manual, all instructions andhazard warnings, BEFORE performing any work onthe Blackmer truck pumps.

Maintain ALL system and Blackmer truck pumpoperation and hazard warning decals.

SAFETY DATA

NOTE: Numbers in parentheses following individualparts indicate reference numbers on thecorresponding Blackmer Parts Lists.

This is a SAFETY ALERT SYMBOL.When you see this symbol on the product, or in the manual, look for

one of the following signal words and be alert to the potential forpersonal injury, death or major proper ty damage.

Warns of hazards that WILL cause serious personal injury, death or major proper ty damage.

Warns of hazards that CAN cause serious personal injury, death or major property damage.

Warns of hazards that CAN cause personal injuryor property damage.

NOTICE:Indicates special instructions which are very

impor tant and must be followed.

PRE-INSTALLATION CLEANINGForeign matter entering the pump WILL cause extensivedamage. The supply tank and intake piping MUST be cleanedand flushed prior to pump installation and operation.

LOCATION AND PIPINGAn improperly designed piping system or unit installation WILLsignificantly reduce pump performance and life. Blackmerrecommends the following piping system layout and unitinstallation.

1. To minimize intake losses, locate the pump as close aspossible to the source of supply.

2. Piping MUST be properly supported to prevent any pipingloads from being placed on the pump.

3. Intake piping and fittings MUST be at least as large indiameter as the pump intake connection.

SAFETY DATAFAILURE TO SET THE VEHICLE

EMERGENCY BRAKE AND CHOCK

WHEELS BEFORE PERFORMING

SERVICE CAN CAUSE SEVERE

PERSONAL INJURY OR PROPERTY

DAMAGE.

Hazardous machinerycan cause severepersonal injury or

property damage.

FAILURE TO RELIEVE SYSTEM

PRESSURE PRIOR TO PERFORMING

PUMP SERVICE OR MAINTENANCE

CAN CAUSE PERSONAL INJURY OR

PROPERTY DAMAGE.Hazardous pressurecan cause personal injury orproperty damage.

DISCONNECTING FLUID OR

PRESSURE CONTAINMENT

COMPONENTS DURING PUMP

OPERATION CAN CAUSE SERIOUS

PERSONAL INJURY, DEATH OR MAJOR


Hazardous or toxicfluids can causeserious injury.

IF PUMPING HAZARDOUS FLUIDS

SYSTEM MUST BE FLUSHED PRIOR

TO PERFORMING SERVICE.

PUMP DATA

* Optional materials of construction may be required to meet the operating limits listed above. Refer to Blackmer Material Specs 201/91-92 for TX(S)(D) models or 202/91-92 for TXV models.

1 780 RPM maximum pump speed for TX(S)(D)1.5, 2 and 2.5 models.500 RPM maximum pump speed for TX4A pump models.

TX(S)(D) TXV Models Models

Maximum Temperature* 300oF (149oC) 375oF (190oC)

Maximum Pump Speed 640 RPM1

Maximum Viscosity* 50,000 SSU (10,800 cSt)

Maximum Differential Pressure 125 psi (8.6 bar)

Maximum Working Pressure 175 psi (12.1 bar)(Inlet Pressure + Differential Pressure)

TECHNICAL DATA INITIAL START UP INFORMATION

Model No.

Serial No.

Date of Installation:

Pressure Gauge Reading:

Vacuum Gauge Reading:

Flow Rate:

INSTALLATION

NOTICE:BLACKMER TRUCK PUMPS MUST ONLY BEINSTALLED IN SYSTEMS DESIGNED BY QUALIFIEDENGINEERING PERSONNEL. SYSTEM DESIGN MUSTCONFORM WITH ALL APPLICABLE REGULATIONSAND CODES AND PROVIDE WARNING OF ALLSYSTEM HAZARDS.

FAILURE TO SET THE VEHICLE





DAMAGE.

Hazardous machinerycan cause severepersonal injury orproperty damage.

2

3

Figure 1 - Pump Drive

4. Minimize the number of intake line fittings (valves, elbows,etc.) and piping turns or bends.

5. Temporarily install vacuum and pressure gauges in the 1/4"NPT intake and discharge ports located on the pumpcylinder to check pump performance at start-up.

6. Install a strainer in the inlet line to protect the pump fromforeign matter. Placement of intake strainers shouldfacilitate frequent cleaning.

7. Intake and discharge piping MUST be free of all leaks.

TRUCK MOUNTINGThe pump will operate satisfactorily in any position. ConsultBlackmer factory for vertical shaft mounts. The pump can bebolted to the truck frame or on a saddle hung below the frame,and MUST be adequately supported. Mounting the pump withthe cylinder feet down, or with the intake port up, isrecommended for thorough draining of the pump.

PUMP DRIVE The pump may be driven by a power take-off through universaljoints. When using universal joints, a splined slip joint,properly lubricated, must be used on the connecting jack shaftto prevent end thrust on the pump shaft.

It is very important to install a proper drive line to avoidexcessive wear, vibration and noise (see Fig. 1 and Table 1).

General guidelines to follow for proper pump drive:

1. Do not use square slip joints.

2. Use the least number of jack shafts as is practical.

3. Use an even number of universal joints.

4. The pump shaft and power take-off shaft should be parallelin all respects. Use an angular level measuring device toensure the PTO and pump shaft are parallel to each other.If necessary, the pump can be shimmed to correct anymisalignment. The PTO shaft coming off at thetransmission does not need to be perfectly horizontal as

Table 1

Angle of Drive Shaft

1o through 5o 6o through 10o 11o through 15o

Very Good Good Fair

INSTALLATIONlong as the pump is shimmed to have its shaft parallel in allrespects to the PTO shaft.

5. The yokes of the universals at both ends of the jack shaftmust be parallel and in phase.

6. The maximum recommended angle between the jack shaftand the pump shaft is 15 degrees. Refer to Table 1.

Failure to follow any of these guidelines may result in a gallopor uneven turning of the pump rotor, which will in turn cause asurging vibration to the liquid stream and piping system.Contact the supplier of the drive line components for specificdesign assistance.

Hydraulic DriveThe pump may also be driven hydraulically. Hydraulic motorsmust be well supported with their shafts parallel to the pumpshaft in all respects. Blackmer provides an optional close-coupled hydraulic motor adapter. The adapter provides forstraight alignment of a hydraulic motor drive through a solidcoupling connected to a straight key pump shaft. Thiscoupling connection requires grease lubrication every threemonths at minimum. Refer to the "Lubrication" section of thismanual.

PUMP ROTATIONNOTICE:

CONFIRM CORRECT PUMP ROTATION BY CHECKINGTHE PUMP ROTATION ARROWS RESPECTIVE TO PUMPDRIVER ROTATION.

TO CHANGE PUMP ROTATION

TX(S)D and TXV ModelsThe TX(S)D and TXV pump models are equipped with adouble ended rotor and shaft, enabling them to be driven fromeither shaft end. To change rotation, rotate the pump 180degrees so that the opposite shaft becomes the driven shaft.On TX(S)D pump models, the shaft protector (186) MUST bemounted over the non-driven shaft end. On TXV pumpmodels, the outboard bearing cover (27) MUST be mountedover the non-driven shaft end.

OPERATION WITHOUT SHAFT

PROTECTOR CAN CAUSE SERIOUS

PERSONAL INJURY, MAJOR

PROPERTY DAMAGE, OR DEATH.

Do not operatewithout guardin place.

TX1.5, TX4 Models and Discontinued TX(S) ModelsTo reverse the pump rotation, remove the bearing covers,locknuts/lockwashers or lock collars (if equipped), from bothinboard and outboard heads. Remove the inboard headassembly and reverse the rotor and shaft, so that the drivenend of the shaft protrudes from the outboard head. Removeand replace the vanes so that the relief grooves face in thedirection of pump rotation. Refer to the "Maintenance" Sectionof this manual for pump disassembly and assembly.

(Yokes must be in phase)

OPERATION

PRE-START UP CHECK LIST1. Check the alignment of the pipes to the pump. Pipes must

be supported so that they do not spring away or drop downwhen the pump flanges or union joints are disconnected.

2. Temporarily install vacuum and pressure gauges in the 1/4"NPT ports located on the pump cylinder. These can beused to check the actual suction and discharge conditionsafter pump start-up.

3. Inspect complete piping system to ensure that no pipingloads are being placed on the pump.

4. Secure appropriate hose connections.

START UP PROCEDURES

4

NOTICE:CONSULT THE "GENERAL PUMP TROUBLESHOOTING"SECTION OF THIS MANUAL IF DIFFICULTIES DURINGSTART UP ARE EXPERIENCED.

1. Start the pump. Priming should occur within one minute.

2. Check the vacuum and pressure gauges to ensure thesystem is operating within expected parameters. Recordthe gauge readings in the "Initial Start Up Information"section of this manual for future reference.

3. Inspect piping, fittings, and associated system equipmentfor leaks, noise, vibration and overheating.

4. Check the flow rate to ensure the pump is operating withinthe expected parameters.

5. Check the pressure sett ing of the relief valve bymomentarily closing a valve in the discharge line andreading the pressure gauge. This pressure should be 15 -20 psi (1.0 - 1.4 bar) higher than the maximum systemoperating pressure, or the external bypass valve setting (ifequipped). DO NOT operate the pump against a closeddischarge valve for more than 15 seconds. Ifadjustments need to be made, refer to the "Relief ValveSetting and Adjustment" section of this manual.

PUMP SPEEDPTO and hydraulically driven units MUST contain speedcontrol devices to prevent pump speeds above the maximumRPM specifications, regardless of the truck engine unloadingspeeds. Should fluid delivery be appreciably less thanexpected, see the "General Pump Troubleshooting" section.

PUMP OPERATING AGAINST A

CLOSED VALVE CAN CAUSE

SYSTEM COMPONENT FAILURE,

PERSONAL INJURY AND PROPERTY

DAMAGE.Hazardous pressurecan cause personal injury orproperty damage.

REVERSE ROTATION

NOTICE:PUMPS OPERATED IN REVERSE MUST HAVE ASEPARATE PRESSURE RELIEF VALVE INSTALLED TOPROTECT THE PUMP FROM EXCESSIVE PRESSURE.

It may be desirable to run the pump in reverse rotation forsystem maintenance. The pump will operate satisfactorily inreverse rotation to strip lines, at a reduced performance level.When operating the pump in reverse, a separate bypass valveMUST be installed to protect the pump from excessivepressure.

FLUSHING THE PUMP

NOTICE:IF FLUSHING FLUID IS TO BE LEFT IN THE PUMP FORAN EXTENDED TIME, IT MUST BE A LUBRICATING,NON-CORROSIVE FLUID. IF A CORROSIVE, NON-LUBRICATING FLUID IS USED, IT MUST BE FLUSHEDFROM THE PUMP IMMEDIATELY.

To flush the pump, use the following procedure:

1. Allow the pump to evacuate as much fluid as possible.

2. Run cleaning fluid through the pump intake. The cleaningfluid must be compatible with the pump O-rings and vanematerial. When handling "sticky" fluids that solidify withinthe pump (i.e., waxes, adhesives, resins, asphalts, etc.),use a fluid that will prevent solidification of the fluid beingtransferred and facilitate flushing.

3. Operate the pump against a closed discharge for 15seconds to allow the cleaning fluid to recirculate throughthe internal relief valve.

RELIEF VALVE

NOTICE:THE PUMP INTERNAL RELIEF VALVE IS DESIGNED TOPROTECT THE PUMP FROM EXCESSIVE PRESSUREAND MUST NOT BE USED AS A SYSTEM PRESSURECONTROL VALVE.

Pumping volati le l iquids under suction l i ft may causecavitation. Partial closing of the discharge valve WILL result ininternal relief valve chatter and must not be done. For theseapplications, install an external bypass valve, and anynecessary piping, back to the storage tank. This bypasssystem must be used when operating for extended periods(more than 1 minute) against a closed discharge valve.

RELIEF VALVE SETTING AND ADJUSTMENTThe relief valve pressure setting is marked on a metal tagattached to the valve cover. Generally, the relief valve shouldbe set at least 15 - 20 psi (1.0 - 1.4 bar) higher than theoperating pressure, or the external bypass valve setting (ifequipped).

OPERATION

5

Relief Valve Adjustment Procedure:

1. To INCREASE the pressure setting , remove the reliefvalve cap, loosen the locknut, and turn the adjusting screwinward, or clockwise. Replace the valve cap.

2. To DECREASE the pressure setting, remove the reliefvalve cap, loosen the locknut, and turn the adjusting screwoutward, or counterclockwise. Replace the valve cap.

Refer to the individual Blackmer pump parts lists for variousspring pressure ranges. The pumps are supplied from thefactory with the relief valve adjusted to the mid-point of thespring range. If the pump is equipped with a Blackmer airvalve, refer to setting and adjustment procedures covered inBlackmer Air Valve Instructions and Parts List No. 201-F00,286/F or 201-B00.

INCORRECT SETTINGS OF THE

PRESSURE RELIEF VALVE CAN

CAUSE SYSTEM COMPONENT

FAILURE, PERSONAL INJURY AND


MAINTENANCE






DAMAGE.


property damage.










NOTICE:MAINTENANCE SHALL BE PERFORMED BY QUALIFIED

TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE

PROCEDURES AND WARNINGS AS PRESENTED IN

THIS MANUAL.







LUBRICATIONBall bearings and hydraulic motor couplings (if equipped) mustbe lubricated every three months at a minimum. More frequentlubrication may be required, depending on the application andthe operating conditions. TXV pump model bearings MUSTbe replaced after each 1000 hours of service if f luidtemperature is greater than 250oF (120oC).

Recommended Grease:

TX(S)(D) Models - Exxon (Esso) - Ronex MP or Mobile -

Mobilith AW-2, or equivalent Lithium grease.

TXV Models - Exxon (Esso) - Polyres or Mobile - Mobile Poly372, or equivalent Polyurea grease.

Greasing Procedure:

1. Remove the grease relief fittings (76A) from the bearing covers (27 and 27A) or hydraulic motor adapter (135).

2. SLOWLY apply grease with a hand gun until grease beginsto escape from the grease relief fitting port. Discard excess grease in accordance with the proper codes and regulations.

3. Replace the grease relief fittings (76A).

DO NOT overgrease pump bearings. While it is normal forsome grease to escape from the grease tell-tale hole afterlubrication, excessive grease on pumps equipped withmechanical seals can cause seal failure.

VANE REPLACEMENTNOTICE:

MAINTENANCE SHALL BE PERFORMED BY QUALIFIEDTECHNICIANS ONLY, FOLLOWING THE APPROPRIATEPROCEDURES AND WARNINGS AS PRESENTED INTHIS MANUAL.

1. Remove the head assembly from the outboard (non-driven) side of the pump according to steps 2 - 6 in the"Pump Disassembly" section of this manual.

2. Turn the shaft by hand until a vane comes to the top (12o'clock) position of the rotor. Remove the vane.

3. Install a new vane, ensuring that the rounded edge is UP,

NOTICE:WHERE REGULATIONS REQUIRE, HOLES IN R/V CAP (1) ANDCAPSCREW W / HOLE (5C) ARE USED BY THE WEIGHTS ANDMEASURES OFFICIAL (S) TO APPLY A SECURITY SEAL OR TAG.

PUMP DISASSEMBLY

NOTICE:FOLLOW ALL HAZARD WARNINGS ANDINSTRUCTIONS PROVIDED IN THE "MAINTENANCE"SECTION OF THIS MANUAL.

1. Starting on the inboard (driven) end of the pump, clean thepump shaft thoroughly, making sure the shaft is free ofnicks and burrs. This wil l prevent damage to themechanical seal or lip seal when the inboard headassembly is removed.

2. Remove the inboard bearing cover capscrews (28) andslide the inboard bearing cover (27A) and gasket (26) offthe shaft. Discard the bearing cover gasket. On the 1.5, 2,2.5, and 3-inch pump models, the dirt shield (123A) willcome off with the bearing cover.

3. Remove the outboard bearing cover capscrews (28) andslide the outboard bearing cover (27) and gasket (26) offthe shaft. Discard the bearing cover gasket.

4. If equipped with locknuts and lockwashers (24A and 24B):

Figure 3 - Vane Installation - TXV Models**NOTE: 2-inch pump models have four (4) vanes.

Figure 2 - Vane Installation - TX(S)(D) Models**NOTE: 1.5 and 2-inch pump models have four (4) vanes.

MAINTENANCE

6

and the relief grooves are facing towards the direction ofrotation. See Figures 2 and 3.

4. Repeat steps 2 and 3 until all vanes have been replaced.

5. Reassemble the pump according to steps 2 - 7 and 12 - 17of the "Pump Assembly." section of this manual.

a. Bend up the engaged lockwasher tang and rotate thelocknut counterclockwise to remove it from the shaft

b. Slide the lockwasher off the shaft. Inspect thelockwasher for damage and replace as required.

c. Repeat steps a and b on the opposite shaft end.

5. The TX(S)4-inch pump model is equipped with bearing lockcollars (24A). To remove:

a. Remove the jam nuts (24C) and loosen the two setscrews (24B).

b. Slide the lock collar off the shaft.


6. Remove the head capscrews (21) and carefully pry thehead (20) away from the cylinder (12).

7. Slide the head off the shaft. The head O-ring (72), bearing(24), and mechanical seal (153) or lip seal (152) will comeoff with the head assembly. Remove and discard the headO-ring.

a. Pull the bearing (24) from the housing in the head (20).

b.To remove the mechanical seal (153), use two screwdrivers to gently push the backside of the seal jacket topush the seal from the head (see Figure 4). Use carewhen placing the screw drivers to prevent damage tothe seal faces. Remove and discard mechanical sealO-rings.

Figure 4 - Mechanical Seal Removal

c. To remove the lip seal assembly (152), use a thin prybar against the lip seal retaining ring to gently push thehousing (152B) out of the head (20). Use care not todamage the lip seal (152A). To remove the lip seal(152A), remove the retaining ring (152D) from thehousing, and gently pry the lip seal from the housing.Remove and discard the housing O-ring(s) (152C and152E).

8. Pull the rotor and shaft (13) from the cylinder (12). Whileone hand is pulling the shaft, the other hand should becupped underneath the rotor to prevent the vanes (14) andpush rods (77) from falling out. Carefully set the rotor andshaft aside for future vane replacement and reassembly.

9. Remove the remaining components from the outboard sideof the pump, as instructed in steps 6 and 7 above.

PUMP ASSEMBLYBefore reassembling the pump, inspect all componentparts for wear or damage, and replace as required. Washout the bearing/seal recess of the head and remove anyburrs or nicks from the rotor and shaft.

MAINTENANCE

7

1. Reassemble the OUTBOARD side of the pump first:

a. For a CLOCKWISE rotation pump, position the pumpcylinder with the INTAKE port to the left.

b. For a COUNTERCLOCKWISE rotation pump, positionthe pump cylinder with the INTAKE port to the right.

2. Install a new head O-ring (72) in the groove on the insideface of the head (20). Lay the O-ring flat and start in onone side of the groove, stretching ahead with the fingers,as shown in Figure 5.

Figure 5 - Head O-ring Installation

3. Install the head (20) on the outboard side of the cylinder(12). Install and uniformly tighten four head capscrews(21) 90o apart, torquing to 25 lbs ft (34 Nm).

4. MECHANICAL SEAL (If equipped)Apply a small amount of motor oil in the head recess. Pushthe mechanical seal assembly (153) into the recess of thehead with seal jacket drive tangs inward. The pin in thestationary seat must be between the lugs in the back of thehead recess.

5. LIP SEAL ASSEMBLY (if equipped)

The lip seal assembly (152) consists of a metal housingwith elastomer(s) around its outer diameter(s), and a teflonlip seal in its inner diameter. TXV “A” model pumps areequipped with spacer washers. Refer to Figures 6 and 7.

a. Apply a small amount of light motor oil on the innerdiameter of the lip seal housing (152B) to facilitate lipseal (152A) installation.Note: When installing the lip seal, be careful not to damage the lip seal O-ring.

b. On TXV “B” model pumps, push the lip seal (152A)squarely into the housing (152B) with the pin in the lipseal aligned with the hole in the back of the housing.The lip seal should seat flush or slightly recessed in thehousing, around its entire diameter.

c. On TXV “A” model pumps, insert the spacer washers(152F) into the housing, then push the lip seal (152A)squarely into the housing (152B) with flat side of the lipseal against the spacer washers. The lip seal shouldseat flush or slightly recessed in the housing, around itsentire diameter. Note: If necessary, the spacerwashers can also be located after the lip seal, as shownin Figure 7, to re-position the lip seal on the pump shaft.

d. Insert the retaining ring (152D) into the groove in thehousing.

e. Install new housing O-ring(s) (152C and 152E) in thegroove(s) of the housing. Lightly grease the housing O-ring(s) and push the lip seal and housing assembly intothe head recess with the lip seal inward. The lips of thelip seal will face the rotor when the housing is installed.Make sure the housing is bottomed out in the back ofthe head (20).

Figure 6 - Lip Seal - TXV “B” Models

Figure 7 - Lip Seal - Discontinued TXV “A” Models

6. Hand pack the ball bearing (24) with grease. Refer to the"Lubrication" section for the recommended grease.

7. Install the bearing (24) into the head recess. The bearingballs must face outward, with the grease shield inward.Ensure the bearing is fully and squarely seated against thelip seal housing (152B) or mechanical seal (153). On TXVpump models, install two 3/8" (10 mm) washers and twobearing cover capscrews (28) to clamp the bearing andcompress the lip seal housing inner O-ring (152E) forproper bearing locknut adjustment (see Figure 8). Thewashers and capscrews will be removed after the locknutsare adjusted.

Figure 8 - Clamping the Bearing

MAINTENANCE

8

c. Loosen both locknuts (24A) one complete turn.

d. Tighten one locknut (24A) until a slight rotor drag is feltwhen turning the shaft by hand.

e. Back off the nut the width of one lockwasher tang "B".Secure the nut by bending the closest al ignedlockwasher tang into the slot in the locknut. The pumpshould turn freely when rotated by hand.

f. Tighten the opposite locknut (24A) by hand until it issnug against the bearing (24). Then, using a spannerwrench, tighten the nut the width of one lockwashertang. Tighten just past the desired tang, then back offthe nut to align the tang with the locknut slot. Securethe nut by bending the aligned lockwasher tang into theslot in the locknut. The pump should continue to turnfreely when rotated by hand.

g. To check adjustment, grasp the nut and washer withfingers and rotate back and forth. If this cannot bedone, one or both locknuts (24A) are too tight andshould be alternately loosened one stop at a time(.001") (25 microns). Begin by loosening the locknutadjusted last.

h. On TXV pumps, after adjustment is complete, removethe bearing cover capscrews (28) and 3/8" washers fromboth ends of the pump.

13. LOCK COLLAR INSTALLATION - TX(S)4 Pump Modelsa. Slide the lock collar (24A) over the shaft and against the

bearing (24), with the counterbored side towards thebearing.

b. Push the collar (24A) forcibly against the bearing (24)by hand, while tightening the two setscrews (24B).Install and tighten the two jam nuts (24C) against thecollar.

c. Repeat this procedure on the opposite pump end. Afterinstalling both lock collars, verify the shaft turns freelywhen rotated by hand.

14. Inspect the grease seal (104) for wear or damage andreplace as required. Grease the outside diameter of thegrease seal and push it into the bearing cover (27 or 27A)with the lip of the seal inward. The lip will face outwardwhen the bearing cover is installed on the head.

15.Attach a new bearing cover gasket (26) and the bearingcover (27 or 27A) to the head (20). Install and torque thebearing cover capscrews (28) to 15 lbs ft (20 Nm).

16.Follow steps 14 and 15 to install the grease seal (104) andbearing cover (27 or 27A ) on the opposite side of thepump. On TXV pump models, the outboard bearing cover(27) is also a shaft protector and must be installed on thenon-driven shaft end.

17.On 1.5, 2 and 2.5-inch pump models, push the dirt shield(123A) over the inboard shaft and firmly against thebearing cover (27).

18.On TX(S)D pump models, attach the shaft protector (186)on the non-driven shaft end.

8. Turn the pump cylinder (12) around and begin assembly onthe opposite, inboard end.

9. Remove the vanes (14) and push rods (77) from the rotorand shaft assembly (13). Inspect for wear and damage,and replace as follows:

a. Partially install the non-driven end of the rotor and shaft(13) into the open side of the pump cylinder (12).

b. Leave part of the rotor outside of the cylinder so that thebottom vanes (14) can be installed and held in place asthe push rods (77) are installed in the push rod holes ofthe rotor. Insert the new vanes into the rotor slots withthe rounded edges outward, and the vane reliefgrooves facing TOWARDS the direction of rotation.Refer to Figures 2 and 3.

c. After the bottom vanes (14) and push rods (77) areinstalled, insert the rotor and shaft (13) fully into thecylinder (12).

d. Install the remaining vanes (14) into the top positions ofthe rotor. If equipped with a mechanical seal (153),rotate the shaft by hand to engage the drive tangsof the seal jacket in the rotor slots.

10. Install the inboard head (20), mechanical seal (153) or lipseal (152), and bearing (24) as instructed in steps 2through 7. Apply a thin coating of motor oil on the inboardshaft to aid installation.

11. Rotate the shaft by hand to engage the mechanical sealdrive tangs (if equipped), and to test for binding or tightspots. If the rotor does not turn freely, lightly tap the rims ofthe heads (20) with a soft faced mallet until the correctposition is found. Install all of the remaining headcapscrews (21) for each head (20) and uniformly torque to25 lbs ft (34 Nm).

12.LOCKNUT INSTALLATION (if equipped)

It is important that the bearing locknuts (24A) andlockwashers (24B) be installed and adjusted properly.Overtightening locknuts can cause bearing (24) failure or abroken lockwasher tang. Loose locknuts will allow the rotor(13) to shift against the heads, causing wear. See Figure 9.

a. On both ends of the pump shaft, Install a lockwasher(24B) with the tangs facing outward, followed by alocknut (24A) with the tapered end inward. Ensure theinner tang "A" of the lockwasher is located in the slot inthe shaft threads, bending it slightly, if necessary.

b. Tighten both locknuts (24A) to ensure that the bearings(24) are bottomed in the head recess. DO NOTovertighten and bend or shear the lockwasher innertang.

Figure 9 - Locknut Adjustment






9

GENERAL PUMP TROUBLESHOOTING

NOTICE:MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANSONLY, FOLLOWING THE APPROPRIATE PROCEDURES ANDWARNINGS AS PRESENTED IN THIS MANUAL.

SYMPTOM PROBABLE CAUSE

Pump Not Priming 1. Pump not wetted.2. Worn vanes.3. Suction valve closed.4. Leaks in the suction line.5. Strainer clogged.6. Suction line or valves clogged or too restrictive.7. Broken drive train.8. Pump vapor-locked.9. Pump speed too low for priming.

10. Relief valve partially open, worn or not seating properly.

Reduced Capacity 1. Pump speed too low.2. Suction valves not fully open.3. Leaks in the suction line.4. Excessive restriction in the suction line (i.e.: undersized piping, too many elbows

& fittings, clogged strainer, etc.).5. Damaged or worn parts.6. Excessive restriction in discharge line causing partial flow through the relief valve.7. Relief Valve worn, set too low, or not seating properly.8. Vanes installed incorrectly (see "Vane Replacement").

Noise 1. Excessive vacuum on the pump due to:

a. Undersized or restricted fittings in the suction line.b. Pump speed too fast for the viscosity or volatility of the liquid.c. Pump too far from fluid source.

2. Running the pump with a closed discharge line.3. Pump not securely mounted.4. Improper drive line (see "Pump Drive").5. Bearings worn or damaged.6. Vibration from improperly anchored piping.7. Bent shaft, or drive coupling misaligned.8. Excessively worn rotor.9. Malfunctioning valve in the system.

10. Relief valve setting too low.11. Damaged vanes (see following category).

Damaged Vanes 1. Foreign objects entering the pump.2. Running the pump dry.3. Cavitation.4. Viscosity too high for the vanes and/or the pump speed.5. Incompatibility with the liquids pumped.6. Excessive heat.7. Worn or bent push rods, or worn push rod holes.8. Settled or solidified material in the pump at start-up.9. Hydraulic hammer - pressure spikes.

10. Vanes installed incorrectly (see"Vane Replacement").

Troubleshooting continued on page 10.


Broken Shaft 1. Foreign objects entering the pump.2. Viscosity too high for the pump speed.3. Relief valve not opening.4. Hydraulic hammer - pressure spikes.5. Pump/driver misalignment.6. Excessively worn vanes or vane slots.7. Settled or solidified material in the pump at start-up.

Lip Seal / Mechanical Seal Leakage 1. O-rings not compatible with the liquids pumped.2. O-rings nicked, cut or twisted.3. Shaft at seal area damaged, worn or dirty.4. Ball bearings overgreased.5. Excessive cavitation.6. Lip seal not seated properly.7. Corrosion on lip seal housing.8. Mechanical seal faces cracked, scratched, pitted or dirty.


10

NOTES

11

1809 Century Avenue, Grand Rapids, Michigan 49509-1595, U.S.A.Telephone: (616) 241-1611 • Fax: (616) 241-3752

E-mail: [email protected] • Internet Address: www.blackmer.com Litho in U.S.A • © Copyright 2003

INSTALLATION INSTRUCTIONS

The RCI Technologies water sensor and indicator have been designed to operate when the RCI Technologies Fuel Purifier is in need of purging. A buzzer followed by a red indicator light will come on when the water level in the purifier reaches the sensor level. The buzzer will last 10 seconds. The light will stay on until the unit is purged.

466 W. Arrow Hwy, Ste D

San Dimas, CA 91773 Tel: 800-868-2088 Fax: 909-305-1245

Email: [email protected] International Email: [email protected]

NOTE: First determine power supply – 12 volt or 24 volt. Installation:

Remove heater from package. Apply Teflon tape (or other approved thread sealant) to the threads of the heater. Insert heater into the heater coupling and tighten into the body of the purifier.

Wiring 12 VDC Heater

1. Connect the two black leads together and attach to the negative side of a switch controlled fused circuit (using appropriate wire connectors).

2. Connect the common lead (white with black tracer) to the positive

side of the switch controlled fused circuit (again using the appropriate wire connectors).


1. Remove excess wire from the common lead (white with black tracer) leaving 1 to 2 inches of wire. Cap common lead with appropriate wire cap and crimp.

2. Connect the two black leads to the 24-volt switched fused power

supply (using the appropriate connectors).

For Assistance or Technical support call: (800) 868-2088

12 Volt – 6 amps 24 Volt – 3 amps

INSTALLATION AND WIRING INSTRUCTIONS


TM

May 1999 Section 29 Page 1A

Ø.56 HOLE

7.26

1.071.64

(5) Ø.28 HOLES

1.97.75

1.00

1.91

2.75

.75

Operator Accessories

Description Part No. Material Weight (lb) Remote Control Assy. 35603SL 1.10

Cable Clamp only 9Q1660 Stainless

.10 New design provides greater stroke (2-1/8”) and leverage. Stainless steel to resist corrosion. Remote attaches to trip lever on operator using cable. Pulling remote lever rotates operator trip lever and bar assembly, causing all open emergency valves to close. Per 49CFR178.345-11, remote must be located at least 10 feet away from loading/unloading outlet (where vehicle length allows) or on the end of the cargo tank farthest from the loading/unloading outlet. Test cable remote controls and operators at least once a day to insure proper functioning.

Part No. Material Weight (lb) 21050A Steel .17

Heavy duty fusible cable links are designed to attach the cable to the emergency valve cable lever arm and to provide thermal activation at the emergency valve. Fusible element melts at not more than 250°F, releasing the cable tension and allowing the emergency valve to close. Uses same non-slip, adjustable cable attachment as on Betts operators.

Fusible Link 3.86

Ø.31 x .75CLEVIS PIN

1.71

.47 COTTER PIN

.40

.60

716-20 UNFHEX NUT

.28

VEEDER-ROOT INSTALLATION, OPERATION AND SERVICE INSTRUCTIONS

SERIES 7886SERIES 7886 HIGHHIGH--CAPCAPACITYACITY & SERIES 7887& SERIES 7887

METER REGISTERSMETER REGISTERS Manual No. 251325 (REV. B)

VEEDER-ROOT Petroleum Products

Installation, Operation and Service Manual Series 7886 High-Capacity & 7887 Meter Registers TABLE OF CONTENTS SECTION 1. INTRODUCTION A. General ..................................... I SECTION 2. SERIES 7887 DESCRIPTION A. General ..................................... I B. Specifications ................................ 2 SECTION 3. SERIES 7886 DESCRIPTION A. General ..................................... 3 B. Specifications ................................ 3 SECTION 4. PERIODIC INSPECTION A. General ..................................... 5 B. Disassembly Prior to Cleaning ............... 5 C. Cleaning .................................... 5 D. Inspection ................................... 5 E. Lubrication .................................. 5 F. Troubleshooting .............................. 7 SECTION 5. DISASSEMBLY AND ASSEMBLY A. General ..................................... 8 B. Removal of Major Groups ...................... 8 C. Individual Parts Replacement .................. 10 D. Installation of Major Groups .................... 10 E. Final Checks and Adjustments ............. 15 F. Operational Check ............................ 16 SECTION 6. DAMAGE CLAIMS AND WARRANTY A. Damage Claims ............................... 16 B. Return Shipping .............................. 16 C. Warranty and Conditions ...................... 16

SECTION 1. INTRODUCTION A. GENERAL. These instructions are for servicing the Series 7886 High-Capacity and Series 7887 Meter Registers designed and manufactured by the Veeder-Root Company, 6th Avenue at Burns Crossing. P.O@ Box 1673, Altoona, PA 16603. Phone: (814) 695-4476. When a vertical bar I appears adjacent to text orILlu strations, information has been added or changed at the last issue date. Note- Consult Veeder-Root on any unusual application, installation or possible modification of this basic design. Every Meter Register is thoroughly tested at the Veeder-Root factory and by the meter manufacturer when installed on the meter. However, like any precision mechanism, it requires periodic care to ensure maximum service. This manual is for use in areas where factory rebuilding facilities and adequate exchange stocks are not readily accessible.

Where manufacturer's replacement stocks are available, it is important that no attempt be made to repair any meter register defective within the terms of the warranty as by doing so, the warranty is void and the user is deprived of the protection provided by the warranty. It is recommended that, when possible, meter registers be replaced and the defective unit returned to the meter manufacturer. Note: See Section 6 for complete Damage Claims and Warranty.

IMPORTANT! The instructions, photographs and drawings in Sec tions 4 and 5 are based on the Series 7887 Meter Register. With the exception of an additional counting wheel, the Series 7886 High-Capacity Meter Register is physically similar and the same procedures should be followed.

SECTION 2. SERIES 7887 DESCRIPTION A. GENERAL. 1. Physical. The Series 7887 Meter Register, Figure 1, displays a running account, final total and accumulated total of the quantity of liquid product delivery. Contained in a 4'x I O'diecast enclosure, individual delivery data is displayed on five 3/4' high flgures while totalizer information is recorded on eight 1/8' high figures. Reset of the Meter Register is accomplished through a reset knob on the right-hand side of the unit. 2. Operational. The Meter Register is operated by a drive shaft connected to a group of gears on the gear plate which converts the drive revolutions to the appropriate ratio. The output bevel gear of the group drives a bevel gear, Figure 5, which is connected to the drive shaft and clutch assembly. In rotating, this shaft drives a gear on the

clutch assembly which in turn drives a gear on the right (unit)wheel assembly. Revolutions are then accumulated on the wheels. In addition, this rotating shaft drives the bracket group connected to the accumulative totalizer shaft, thus both displays are driven from the same source, assuring accurate recording of information. During the reset operation, the clutch is disconnected from the drive shaft, a shutter moves into place covering the display wheels and reset fingers engage heart-shaped cams on the individual wheels to move them back to a zero position. In addition, a set of anti-topping fingers engages the wheels to preventjamming. At the completion of reset, the display wheels will read all zeros, and the shutter will rise to the normal operating position. The clutch will engage the drive shaft to transfer the information from the next delivery. The totalizer wheels will be unaffected by this reset operation, thus displaying an accurate measure of the accumulated totals of many deliveries.

B. SPECIFICATIONS. Specifications listed are standard unless otherwise noted. Optional features are available at additional cost. Speed: 250 rpm. Torque: Average running torque at room temperature with 1: I input: 4 oz-in. During display wheel transfer from all 9's to all O's, the instantaneous peak torque may reach 40 oz-in. Operating Temperature Range: -40' to +710C (-400 to + I 60'F). Number of Figures: Meter Register: 5. Accumulative Totalizer: 8 Size of Figures: Meter Register: 0.750' high x 0.400' wide (I 9.05 x 10. 16 mm). Totalizer: 0. 1 25' high x 0.078' wide (3.175 x 1.98 mm). Color of Figures: White on black, except right-hand totalizer wheel which is black on white when recording tenths of units, and white on black when recording whole units.

Style of Figures: Veeder-Root/Cornell for optimum read- ability. Character Configuration: 0 to 9 (options available). Reset: Single handle on register. Designed for one-handed operation. Mounting: Eight 1/4 x 28 tapped holes with steel inserts on a 6.625' (168.28 mm) diameter. Special adaptors are available for nearly all meters. Construction: Cover: cast aluminum. Case and sub frame: cast Zamak. Wheels, pinions, and clutch: acetal resin. Gearing: 1:1 is standard. 1:1 through 42:1 are available. Lubrication: Periodic. OPTIONS Nonreset Pulser: Meter Register with Series 1871 or 7671 Pulse Transmitter.

SECTION 3. SERIES 7886 DESCRIPTION A. GENERAL. 1. Physical. The Series 7886 High-Capacity Meter Register, Figure 3, displays a running account, final total and accumulated total of the quantity of liquid product delivery. Contained in a 4' x 10' die cast enclosure, individual delivery data is displayed on six 5/8' high figures while totalizer information is recorded on eight 1/8' high figures. Reset of the Meter Register is accomplished through a reset knob on the right-hand side of the unit. 2. Operational. The Meter Register is operated by a drive shaft connected to a group of gears on the gear plate which converts the drive revolutions to the appropriate ratio. The output bevel gear of the group drives a bevel gear, Figure 5, which is connected to the drive shaft and clutch assembly. In rotating, this shaft drives a gear on the clutch assembly which in turn drives a gear on the right (unit) wheel assembly. Revolutions are then accumulated on the wheels. In addition, this rotating shaft also drives the bracket group connected to the accumulative totalizer shaft, thus both displays are driven from the same source, assuring accurate recording of information. During the reset operation, the clutch is disconnected from the drive shaft, a shutter moves into place covering the display wheels and reset fingers engage heart-shaped cams on the individual wheels to move them back to a zero position. In addition, a set of anti-topping fingers engages the wheels to prevent jamming. At the completion of reset, the display wheels will read all zeros, and the shutter will rise to the normal operating position. The clutch will engage the drive shaft to transfer the information from the next delivery. The totalizer wheels will be unaffected by this reset operation, thus displaying an accurate measure of the accumulated totals of many deliveries.

B. SPECIFICATIONS. Specifications listed are standard unless otherwise noted. Optional features are available at additional cost. Speed: 250 rpm. Torque: Average running torque at room temperature with 1:1 input: 4oz-in. During displaywheeltransfer from all 9s to all O's, the instantaneous peak torque may reach 40 oz-in. Operating Temperature Range: -40' to +71'C (-40' to + 160'F). Number of Figures: Meter Register: 6. Accumulative Totalizer: 8 Size of Figures: Meter Register: 0.625' high x 0.300' wide (15.87 x 7.62 mm). Totalizer: 0.125' high x 0.078' wide (3.175 x 1.98 mm). Colorof Figures: White on black, except right-hand totalizer wheel which is black on white when recording tenths of units, and white on black when recording whole units. Style of Figures: Veeder-Hoot/Cornell for optimum read- ability. Character Configuration: 0 to 9 (options available). Reset: Single handle on register. Designed for one-handed operation. Mounting: Eight 1/4 x 28 tapped holes with steel inserts on a 6.625' (168.28 mm) diameter. Special adaptors are available for nearly all meters. Construction: Cover: cast aluminum. Case and sub frame: cast Zarnak. Wheels, pinions, and clutch: acetal resin. Gearing: 1:1 is standard. 1:1 through 42:1 are available. Lubrication: Periodic. OPTIONS Nonreset Pulser: Meter Register with Series 1871 or 7671 Pulse Transmitter.

SECTION 4. PERIODIC INSPECTION (For Series 7886 High-Capacity and Series 7887 Meter Registers) A. GENERAL The Meter Register is fully lubricated and property adjusted at manufacture. However, periodic cleaning and lubrication are required. Judgment of the intervals at which the meter register requires such service must necessarily be left to the individual user due to varying conditions of service. Under normal conditions, this will be at least once a year, or after each 2-1/2 million units of measure delivered, whichever comes first. B. DISASSEMBLY PRIOR TO CLEANING. Remove the meter register from its housing as follows: I .Remove the bolts securing the cover (if present) to the top of the housing. These bolts are hex head and are located at the four corners of the bottom of the housing. Remove the cover. 2. Remove the three button-head bolts securing the meter register to the housing. Remove the meter register. 3. Remove the screws securing the gear plate to the bottom of the housing. Remove the gear plate. C. CLEANING. CAUTION: DO NOT USE A WIRE BRUSH. 1. Wipe bezel crystal with a clean lint-free rag. 2. If the wheel faces are dirty, gently clean with a clean lint-free rag dipped in mild soapy water. 3. Clean the gears on the base plate by flushing or with a brush dipped in solvent. Blow dry with compressed air. 4. Clean housing by dipping, flushing or brushing with solvent. Blow dry with compressed air. D. INSPECTION. A periodic inspection of the entire meter register, housing and gear plate is required to make sure that they function property, parts are in place, and no binding or excessive side-to-side motion of shafts occurs. A checklist on such procedures follows: 1. Check the following shafts for perceptible side-to-side motion. Note: Remove the meter register from the housing before checking shaft freedom. a. Wheel Shaft b. Anti-Topping Finger Group Shaft c. Reset Finger Group Shaft d. Clutch Group Shaft e. Pinion Shaft 2. Temporarily install the base plate and meter register in the housing and check for proper engagement and freedom of movement of: a. All gears on gear plate. b. Output bevel gear on gear plate with the bevel drive gear on drive shaft.

c. 57 tooth gear on clutch assembly with gear on right wheel assembly. d. Gear drive shaft with gear train that operates the totalizer, and gear connecting the drive train to the totalizer. 3. Rotate drive shaft by hand to see that unit operates freely and then reset, checking for proper reset and shutter action. Adjust pointer after reset as required. 4. Check all screws, retaining rings and groove pins to see that they are tight and seated properly. E. LUBRICATION. 1. Recommended Lubricants Note: Chelae and Vischem products are manufactured by Ultrachem Inc., 1400 N. Walnut St., P.O. Box 2053 Wilmington, DE 19899 Oil: Chemlube 201 or equivalent with a temperature range of -65F to + 275F (-54'C to + 135'C). Grease: Vischem 352 or equivalent with a temperature range of -65'F to +300'F (-54'C to + 149'C). Note: All lubricants used in the register must be of a type

which remains fluid over the full temperature range to which the register will be subjected. Also, they should not oxidize or dry out leaving a gummy or perceptible residue.

If the Chemlube 201 oil lubricant is not available, a substitute with equivalent properties may be used. To assist field personnel in obtaining suitable lubricants for the meter register and ticket printers, the following list showing equivalent lubricants has been prepared:

OIL AEROSHELL FLUID NO. 3 REGENT SPINTEX OIL 60 GARGOYLE ARCTIC OIL LIGHT CASTROL HYSPIN 40 ANDEROL 401D

GREASE AEROSHELL 14 ESSO BEACON 325 ANDEROL 795 2. Points to Lubricate Oil: All points indicated as "Oil" on Figure 6 should be lubricated with oil as described above. This includes all shafts, studs, and bosses on which a moving part bears. Grease: Grease should be applied to all points indicated as "Grease' on Figure 6. This includes gears and the no-back ratchet and pinion. Note: The oil and grease should be applied with a small

brush to make certain that all areas will he properly lubricated. In this manner, the amount of lubrican t being used will be more easily controlled.

TROUBLE POSSIBLE CAUSE CORRECTION 1. Drive shaft hard to turn. Pointer or brake rubbing on first wheel

Dirt or pieces of foreign material in teeth of drive gears, gear plate, totalizer or bevel gear train driving totalizer.

Check pointer and break positioning. Adjust as required. Remove case. Check all gears, clean and lubricate as necessary. See Sect 4.

2. Binding occurs during reset cycle Missing washers on outside of clutch shaft. Pinion jam, anti-topping finger(s) broken or spring(s) missing

Check end play and washer as required. Check end play of wheel shaft. Replace broken anti-topping finger(s) or missing spring(s)

3. Reset knob turns hard Reset knob flange on the case binds on reset shaft. Wheel shaft group is bent. Reset fingers rubbing on wheel or retaining rings.

Remove reset knob. Loosen flange screws, center the flange on the shaft and tighten the screws. Replace wheel shaft. Check for missing retaining rings on reset finger and wheel shafts. Replace as required.

4. Any one wheel will not reset to zero Broken reset finger. Locking disc pin out of wheel groove.

Replace reset fingers as required. Disassemble wheel group and insert locking disc pin into groove in wheel.

5. Incomplete reset cycle. Knob turns but reset does not occur.

Key in large multiple cam broken. Reset actuating lever not engaged in cam or reset arm broken.

Replace cam with new cam and key. Remove cam, inspect and replace parts as required, and assemble properly.

6. Shutter partially obscured wheels at completion of reset cycle or completely covers wheels at reset cycle.

Shutter disconnected from reset lever. Connect shutter to reset lever.

7. Shutter will not drop into place or loss of detent action during reset.

Detent lever spring missing or broken. Install new spring.

8. Pointer not aligned with unit wheel. Improper adjustment of brake or pointer. Adjust brake to proper clearance. Adjust pointer to center mark.

9. Unit wheel can be turned in reverse by hand.

Dirty drive shaft clutch assembly. Clean clutch group and lubricate. See Section 4.

10. Cannot drive meter register. Pinion jam, reset fingers are engaged, heart cams hit on detent lever shutter stud, clutch not engaged.

Check washers on pinion shaft. Check and play of shafts. Clean and lubricate clutch.

F. TROUBLESHOOTING. Tabel 1 is used to assist in locating problems and making repairs and corrections. In some problems, similar defects can be produced by several causes of an entirely different nature. Cause of trouble must be determined and the correction made.

Table 1. Troubleshooting

SECTION 5. DISASSEMBLY AND ASSEMBLY (For Series 7886 High-Capacity and Series 7887 Meter Registers) A. GENERAL. When disassembling the meter register, be extremely careful not to lose or intermix any of the washers found on the shafts. By doing so, potential problems with end-play and backlash adjustments will be greatly lessened. When removing retaining rings or other parts from shafts, do not hold the shaft with any tool that might gouge or create burrs on the shaft. B. REMOVAL OF MAJOR GROUPS. Instructions for removal of all shaft groups are provided.

1. If present, remove the retaining ring securing the reset idler gear to the reset idler gear shaft. 2. Remove retaining rings and washers securing the pinion, reset, anti-topping and clutch shafts to the right-hand side plate (Figure 7). Remove screws and lockwasher securing the totalizer group and rear mounting bar from right-hand side plate. 3. Remove side plate. CAUTION: DO NOT LOSE OR INTERMIX WASHERS FROM EACH SHAFT. Note: Remove only those shaft groups necessary to gain access to parts being replaced.

4. Clutch Shaft Group Removal. a. Remove retaining ring and washers securing the clutch shaft group to the left-hand side plate. See Figure 8. b. Move clutch lever group so clutch is free. See Figure 9. Remove clutch shaft group. See Paragraph C, 1 for parts replacement. 5. Reset Finger Group Removal. a. Remove retaining ring and washer securing the reset group to the left-hand side plate. See Figure 8. b. Disengage the reset fingers and no-back pawl from th wheels. SeeFigure 10. Rernovethegroup. See Paragraph C, 2 for parts replacement. 6. Stop Shaft Removal. a. Remove the springs from between the anti-topping fingers and the stop shaft. b. Remove the spring from between the detent lever group and the stop shaft. c. Remove the stop shaft. 7. Anti-Topping Finger Group Removal. a. Remove the retaining ring and washers securing the anti- topping finger group shaft to the left-hand side plate. See Figure 8. b. Disengage the anti-topping fingers and the clutch lever group from the wheels. See Figure I 1. c. Remove the group from the side plate. See Paragraph C, 3 for parts replacement. 8. Totalizer Group Removal. a. Remove the screws securing the totalizer group to the left-hand and right-hand side plates. See Figures 7 and 8. b. Remove the totalizer group. c. No additional disassembly of the totalizer is possible. If the totalizer is inoperable, replace the group.

Note: If the inoperable totalizer has a small bevel gear (approx. 11/32 inch dia.) on the drive shaft, replace the bracket group on the left side frame as well as the totalizer group (see Figure 31 and Paragraph D, 7 and E, 5). Remove the screw holding the pointer onto the old totalizer and save for installation on new totalizer. 9. Pinion Removal. a. Remove retaining ring securing pinion shaft to the left- hand side plate. See Figure 8. b. Rotate the detent lever group so it will clear the reset cam. Remove shaft. c. Remove pinions, detent lever group washers and retaining rings from shaft. 10. Wheel Group Removal. a. Mark relationship of reset gear to wheel group shaft to assure proper positioning during assembly. b. Remove pin securing reset gear to the wheel group shaft. c. Remove gear, retaining ring and washer. Remove shaft. See Paragraph C, 4 for parts replacement.

C. INDIVIDUAL PARTS REPIACEMENT 1. Clutch Shaft Parts Replacement. See Figure 12. a. Totalizer and Drive Bevel Gears.

(1) Drift out pin securing gear to shaft. (2) Remove gear. (3) Remove retaining rings and washers that position drive gear. Do not change the order of the rings and washers. (4) Drift out pin holding drive gear and remove gear.

(5) Install new gear, pin, retaining rings and washers. Use new pin if required. (6) Install totalizer bevel gear and secure with pin.

CAUTION: CHECK SHAFT FOR STRAIGHTNESS AFFER PINNING. A BENT SHAFT WILL CAUSE BINDING DURING DRIVING OF METER REGISTER. CLUTCH MUST NOT BE DISASSEMBLED OR REPLACED AS AN INDIVIDUAL GROUP. IF CLUTCH IS BROKEN OR MALFUNCTIONS, REPLACE COMPLETE SHAFT AND CLUTCH AS AN ASSEMBLY. 2. Reset Finger Group Parts Replacement. See Figure 13. Individual reset fingers, reset arm, no-back pawl and pawl spring may be replaced as required. a. Remove retaining rings and appropriate washer to reach particular part. b. Replace defective items with new part. Assemble remaining parts on shaft. Install retaining rings and washers. Check end play per Figure 28. 3. Anti-ToppingFingerGroupPartsReplacement.SeeFigure 14. Individual anti-topping fingers, reset lever and clutch lever may be replaced as required. a. Remove retaining rings, washers and parts as required to get to part that is to be replaced. b. Install parts, retaining rings and washers in the sequence shown in Figure 14. Be sure to install parts so they are in the proper direction. Check end play per Figure 28. 4. Wheel Group Parts Replacement. See Figures 15, 16, 17 and 18. The reset cam, individual wheels, locking discs and eccentrics may be replaced as required. a. Remove retaining rings, washers and key as required to remove reset cam, wheels, locking discs and eccentrics. b. Install parts, retaining rings, washers and key in the sequence shown in Figure 17. When installing wheels, be sure the pin on the locking disc engages the groove in the wheel as shown in Figure 18. Check end play per Figure 28. D. INSTALLATION OF MAJOR GROUPS Prior to installing each shaft, lubricate per Paragraph E in Section 4. During assembly, do not intermix washers from one shaft to another. 1. Wheel Group Installation. a. lfnotpresent,installaO.030inchthickwasheroverthe end of the wheel group shaft opposite the cam. b. Install the shaft into the proper hole in the left-hand side plate. See Figure S. 2. Anti-Topping Finger Group Installation. See Figure 19. a. Hold wheel and side plate assembly upside down. b. Install anti-topping finger group in proper hole in left- hand side plate (see Figure 8). Be sure all fingers and clutch lever are free of wheels and the pin on the reset ievel, engages the track on the cam.

c. Seat the shaft, install washers and retaining ring to secure shaft to left-hand side plate. d. See that all fingers are free to engage wheels. 3. Stop Shaft Installation. a. Install retaining rings on ends of shaft. b. Insert stop shaft into proper hole in left-hand side plate. See Figure 8. 4. Reset Finger Shaft Group Installation. a. Rotate no-back pawl so that spring puts pawl under tension. Slip an elastic band over the reset fingers and pawl to hold pawl in position. See Figure 20. b. Install shaft into left-hand side plate and secure with retaining ring and washers. See Figure 8. c. Engage pin on reset lever group with slot in reset arm. See Figure 22. 5. Clutch Shaft Group Installation. a. Install shaft in proper hole in left-hand side plate. Add washers and secure with retaining ring. See Figure 8. b. Make sure that bevel gears that drive the totalizer are free to turn.

6. Right-Hand Side Plate Installation a. Hold meter register assembly as shown in Figure 22 and place a rubber band around the assembly to hold it together. Be sure the pin in the reset lever group remains engaged in the slot in the reset arm. b. Install side plate over wheel shaft first, then engage the other shafts. c. Temporarilysecure the side plate to the rear mounting bar with screws. 7. Bracket Group (if required) and Totalizer Installation. a. If required, install new bracket group to inside of left side frame and secure with two screws and lockwashers. See Figure 31. b. Install pointer with screw (saved from old totalizer) onto new totalizer group but do not tighten screw securely. Pointer position must be adjusted after totalizer group is installed. See Paragraph F, 2. c. Install the totalizer group so that the bevel gear is in mesh with the top bevel gear on the bracket group and secure with retaining screws. For adjustment of bevel gear drive, see Paragraph E, 5.

8. Spring Installation. a. See Figure 23 for identification of springs. b. Install the five anti-topping finger springs between the anti-topping fingers and the stop shaft. See Figure 24. c. Install the reset spring between the reset lever and the pinion shaft. d. Install the detent spring between the detent lever group and the stop shaft. e. Install the clutch spring between the clutch lever group and the pinion shaft. 9. Pinion Shaft Assembly Installation a. If not previously accomplished, remove all parts from pinion shaft. b. Rotate wheel shaft so reset fingers are fully engaged in the heart-shaped cams on each wheel. c. Place pinions, with short finger up, in between each wheel as shown in Figure 25. d. Install the end of the shaft closest to the two retaining ring slots into the left-hand side plate and through each pinion.

e. Install washers and detent lever group onto shaft and engage shutter with tab on detent lever. f. Push shaft through the right-hand side plate and secure with washer and retaining ring. g. Secure detent lever group into position with retaining rings. h. After assembly, rotate wheel shaft to make sure all pinions have been positioned properly. If binding occurs, reposition pinions per step c. 10. Reset Gear Installation. a. Install reset gear on wheel shaft, aligning orientation mark made at disassembly. b. Secure gear to shaft with pin. II. Reset Idler Gear Installation. a. If present, install reset idler gear on the reset idler gear shaft. See Figure 8. b. Secure with retaining ring. Note: This gear will be tirned when the meter duplicator and meter register are assembled together.

E. FINAL CHECKS AND ADJUSTMENTS. 1. End Play Check: Check end play (back and forth motion) of shafts and parts as follows: a. For proper measurement, the meter register must be installed in the TD-42383 mounting fixture, Figure 26, to constrain the frame into the same position that it is when installed in the housing. b. Secure the meter register to the fixture with two 1/4-28 button- head bolts. See Figure 27. c. Take end play measurements of each shaft. Add or subtract washers as necessary to obtain correct end play. 2. Input Drive Bevel Gear Engagement Adjustment. a. Install the gear plate onto the fixture using the appropriate hardware. b. Remove the retaining ring behind the bevel gear and add or subtract washers as required for proper rnesh between the bevel gear on the gear plate and the drive bevel gear on the clutch shaft. The shaft end play must be maintained as specified in Figure 28. c. Replace the retaining ring after adjustment. 3. Clutch Lever Positioning Adjustment. a. Rotate the reset gear until the clutch is fully disengaged. b. Measure the clearances as shown in Figure 29. c. If the dimensions cannot be obtained, add or remove washers as required, or replace the clutch and shaft. d. The amount of face engagement between the spur gear on the input clutch and the first wheel should be 75% + 20%. 4. Wheel Brake Adjustment. a. Rotate reset gear to position earn as shown in Figure 30. b. Measure clearance between brake and first wheel. If clearance is not within the dimensions given, adjust brake by loosening screw and moving brake into position. c. Remove the meter register from the fixture by removing the two button-head screws. Remove the gear plate from the fixture. 5. Gearing Adjustment for Totalizer. See Figure 31. Loosen set screw on bottom bevel gear. Mesh the top bevel gear tightly with the totalizer bevel gear. Press the register clutch shaft toward the left side frame. Adjust the bottom bevel gear such that it has 0.012 - 0.015 end play when meshing with the clutch shaft bevel gear. Tighten set screw and secure with a sealant (Loctite 222 or equivalent) to prevent loosening. 6. ApplyAnderoIL-795orequivalentgreaseonteethofbevel gears. 7. Backlash Compensating Mechanism Adjustment for EEC UNITS ONLY. While unit is running at 100-200 RPM, adjust screw so that pawl is approximately in the middle of clip as shown in Figure 32 (on Page 16). Oscillation of pawl is permissible. To check for proper operation, use a 1: I gear plate and operate register at 100-200 RPM. Stop counting, hold input shaft of gear plate and reset register. Wheel should reset so that some part of graduation at zero always aligns with pointer.

F. OPERATIONAL CHECK. Before returning the meter register to normal service, check that it operates properly as follows: 1. Rotate the input bevel gear and see that the totalizer and individual delivery wheels are driven and that they record the same amount. There should be no binding or drag. 2. Rotate the reset gear and see that the shutter drops into place, the wheels all reset and that there is no binding or drag. At the completion of reset, the zeros should align with the pointer. 3. See Troubleshooting, Table 1. Page 5, if there are any problems. SECTION 6. DAMAGE CLAIMS AND WARRANTY A. DAMAGE CLAIMS 1. Thoroughly examine the enclosure as soon as it is received. If damaged, write on the face of the freight bill a complete and detailed description of the damage. Have the carrier's agent sign the description. Note: Insist that the carrier's agent verify the inspection and sign the description. 2. Immediately notify the delivering carrier of damage or loss. This notification may be given either in person or by telephone. Written confirmation must be mailed within 48 hours. Railroads and motor carriers are understandably reluctant to make adjustments for damaged merchandise unless inspected and reported promptly. 3. Riskoflossofordamagetomerchandiseremainswiththe liuyer. It is the liuyer's responsibility to file a claim with,,the carrier involved. 4. Imniediately advise your Veeder-Root representative, distributor, oi, the factory so that we may assist you.

B. RETURN SHIPPING. All shipments of Veeder-Root products must be prepaid. Equipment must be packed in a strong exterior container and surrounded by shock absorbing material. Veeder-Root will accept no liability foi- damage caused by improper packing. It is suggested that the original shipping containei- be used if it is available. Address shipment to Veeder-Root Co., 6t]i Avenue at Burns Crossing, 11.0. liox 1673, Altoona, I'A 16603. C. WARRANTY AND CONDITIONS 1. WARRANTY. We warrant that our products shall he free from defects in material and workmanship for a period of one year from the date of shipment thereof or the product's total rated life, whichever first occurs. Within the warranty period we shall repair or replace such products which are returned to us with shipping charges prepaid and which are deter- inined by us to be defective. This warranty will not apply to any product which has been subjected to misuse, negligence, or accident; or misapplied; or used in violation of product manuals, instructions, or warnings; or modified or repaired by unauthorized persons; or improperly installed. 2. INSPECTION. You shall inspect the produ(-t promptly after i-eceipt and shall notify us at oui- Altoona office, in wi-iting,ofanyclaims,includingclaii-nsofbreactiofwarraiity, within thirty days aftei- you discover or should have dis- (-ovei-edtliefactsuponwliielitlieclaimishased.Yourfailtire to give written notice of a (-Iaiin within the time period shall be deeiiie(i to be a waivei- of sii(-Ii claim. 3. LIMITATION OF REMEDY AND WARRANTY. The provisions of Paragraph I are our sole obligation and exclude all other remedies or warranties, express or implied, including warranties of MERCHANTA-BILITY and FITNESS FOR A PARTICULAR PURPOSE, whether or not purposes or specifications are described herein. We further disclaim any responsibility whatsoever to you or to any other person for injury to person or damage to or loss of property or value caused by any product which has been subjected to misuse, negligence, or accident; or misapplied; or used in violation of product manuals, instructions, or warnings; or modified or repaired by unauthorized persons; or improperly installed. 4. LIMITATION OF DAMAGES. Under no circumstances shall we be liable for any incidental, consequential or special damages, losses or expenses arising from this contract or its performance or in connection with the use of, or inability to use, our product for any purpose whatsoever. 5. LIMITATION OF ACTIONS. No action regardless of form arising out of this contract may be commenced more than one year after- the cause of action has accrued, except an action for nonpayment. 6. COLLATERAL PROMISES. There are no representations, warranties, or conditions express or implied, statutory or otherwise except those herein contained, and no agreements or waivers collateral hereto shall be binding on either party unless in writing and signed by you and accepted by us at our Altoona office. 7. INTERPRETATION. Rights and liabilities arising out of any contract with us shall be determined under the Uniform Commercial Code as enacted in Connecticut.

VEEDERVEEDER--ROOTROOT Petroleum Products

6th Avenue at Burns Crossing

P.O. Box 1673 Altoona, PA 16603-1673 Phone (800) 873-3313

Fax (800) 234-5350 or

Phone (814) 695-4476 Fax (814) 695-7605

Copied from

Veeder-Root Technical Manual 8-014

Issued:12/95 Supersedes: 5/93

Compiled by:

Michael Leffew, Isometrics, Inc. Reidsville, NC


TM

Feb 1995

Section 20 Page 1A

INSTALLATION: The Wet-R-Dri Valve may be mounted in any position with handle located for easy operation. Valve, as assembled, opens by turning handle 1/4 turn counter clockwise (right hand operation). If clockwise rotation is desired (left hand operation) please specify. Care should be taken when mounting valve to be sure the I.D. of adjoining flanges or pipe is large enough to allow disc of valve to open freely. We suggest using our accompanying flanges and adapters shown in Section 20, Page 5A.

NOTE: Standard drilling fits TTMA recommended standards. Valves are available with the following options: Stainless steel liners and shafts, grease fittings installed in the drive and bearing shafts, and “E” Coating of aluminum valves (recommended for aluminum valves used in water service). For repair kit, see Section 20, Page 5B.

O.D.

I.D.

A

B

Wet-R-Dri Valve LIGHTWEIGHT

COMPACT

VERSATILE

Standard Model Detent Model Standard Material Size Assembly No.

Wt. Assembly No.

Wt. Body Disc

Max. Working Pressure

Temperature Range

WD200 AL B 2.4 WD201 AL B 2.4 Aluminum 2” WD200 GI B 4.6 WD201 GI B 4.6 Grey Iron

Buna-N 75 PSI


Buna-N 75 PSI

WD400 AL V 4.5 WD401 AL V 4.5 Aluminum 4” WD400 GI V 8.3 WD401 GI V 8.3 Grey Iron

Viton 75 PSI

5” WD500 AL V 7.9 WD501 AL V 7.9 Aluminum Viton 50 PSI 6” WD600 AL U 11.8 WD601 AL U 11.8 Aluminum Urethane 50 PSI 8” WD800 AL U 17.3 WD801 AL U 17.3 Aluminum Urethane 50 PSI

See

Cha

rt B

elow

Dimensions Suffix for Disc Material

Buna-N Urethane Size A B C I.D. O.D. B.C. Holes Black White

Viton Black White

EPDM

2” 63/4 41/4 11/8 21/4 33/4 33/4 6-7/16 B WB V U WU E 3” 63/4 45/8 11/8 33/8 55/8 47/8 8-7/16 -40°F -40°F -0°F -40°F -40°F -50°F 4” 63/4 51/8 11/8 43/8 65/8 57/8 8-7/16 +200°F +200°F +400°F +200°F +200°F +300°F 5” 63/4 63/8 21/8 57/16 75/8 7 12-7/16 6” 12 7 21/8 61/8 85/8 81/8 12-7/16 8” 12 8 21/2 8 107/8 101/8 16-7/16

NOTE: Temperature ranges based on published information and may vary due to actual operating conditions.

TTMA STYLE


TM

Jan 1993

Section 20 Page 1B

WARNING Use only genuine Betts Industries Inc. replacement parts. Use of substitute parts can impair the proper functioning of the Wet-R-Dri Valve.

STANDARD MODEL

7

9

4

WD101-3

92

BU

8

1

6

2

DETENT MODEL

WD101-3

7

9

5

92

BU

8

1

6

101211

2

Wet-R-Dri VALVE

2” Size 3” Size 4” Size 5” Size 6” Size 8” Size No. Description Material Part No. Part No. Part No. Part No. Part No. Part No.

Buna-N WD101-2 BN WD101-3 BN WD101-4 BN WD101-5 BN WD101-6 BN WD101-8 BN Viton WD101-2 VT WD101-3 VT WD101-4 VT WD101-5 VT WD101-6 VT WD101-8 VT Urethane WD101-2 PY WD101-3 PY WD101-4 PY WD101-5 PY WD101-6 PY WD101-8 PY

1 Disc

EPDM WD101-2 EP WD101-3 EP WD101-4 EP WD101-5 EP WD101-6 EP WD101-8 EP Handle Mall. “E” Coated 25884EY 25884EY 25884EY 25884EY 25933AL 25933AL Cap Screw Steel Zinc Plt. 9Q5813 9Q5813 9Q5813 9Q5813 9Q5898 9Q5898 2 Hex. Nut Steel Zinc Plt. 9Q5808 9Q5808 9Q5808 9Q5808 9Q5808 9Q5808

4 Drive Shaft Steel 27053MS 27050MS 27050MS 27051MS 16229MS 16229MS002 5 Drive Shaft Steel 27053MS001 27050MS001 27050MS001 27051MS001 16229MS 16229MS002 6 O-Ring To Match Disc Mat’l. 17889** 17889** 17889** 17889** 18831** 18831** 7 Bearing Shaft Steel 16006MS 15913MS 15913MS 15913MS 16230MS 16230MS002 8 O-Ring To Match Disc Mat’l. 17781** 18141** 18141** 18141** 18831** 18831** 9 Driv-Lok-Pin Steel Zinc Plt. 9Q4893 9Q4893 9Q4893 9Q4925 9Q4926 9Q4938 10 Detent Ball 440 Stnls 9Z4856 9Z4856 9Z4856 9Z4856 9Z4856 9Z4856 11 Detent Spring 304 Stnls 15229SL 15229SL 15229SL 15229SL 15229SL 15229SL 12 Ret. Screw 304 Stnls 9Q5838 9Q5838 9Q5838 9Q5838 9Q5838 9Q5838

PARTS LIST

** O-Ring material suffix to match Disc suffix (i.e.-17889VT)

InstInstInstInstInstallation & Partallation & Partallation & Partallation & Partallation & Parts Manuals Manuals Manuals Manuals ManualM/MA MetersM/MA MetersM/MA MetersM/MA MetersM/MA Meters

Installation: M100-10Installation: M100-10Installation: M100-10Installation: M100-10Installation: M100-10

22222

TTTTTable of Contentable of Contentable of Contentable of Contentable of Contents and Safety Proceduress and Safety Proceduress and Safety Proceduress and Safety Proceduress and Safety Procedures

DescriptionDescriptionDescriptionDescriptionDescription Page NumberPage NumberPage NumberPage NumberPage NumberHow LC Meters Work ........................................... 3Owner�s Information Packet ................................. 4Installation Requirements ..................................... 6Operation Requirements ....................................... 7Meter Start Up and Operation .............................. 8Reversing the Meter Registration ......................... 9Setting the Standard Adjuster .............................. 10Meter Maintenance ............................................... 10Relieving Internal Pressure ................................... 11Servicing the Drive Components ........................... 12Removing the Dust Cover ..................................... 12Removing the Adjuster andAdjuster Drive Assembly ...................................... 12Buna/Viton/Teflon Packing Gland ......................... 15The Retaining Plate .............................................. 15Disassembling the Meter ...................................... 16Removing the Non-CorrodedRotor Gears .......................................................... 18Removing Corroded Rotor Gears .......................... 18Reassembling the Meter ...................................... 20Timing the Rotor Gears ........................................ 21Torque Chart ......................................................... 22Wrench and Socket Size Chart ........................... 23Troubleshooting .................................................... 24How to Order Replacement Parts ........................ 26Illustrated Parts Breakdown ................................. 27-30Quality Statement ................................................ 31

Please have the following information available when youmake inquires, order replacement parts, or scheduleservice. If a specific meter accessory is involved, pleaseprovide the model and serial number of the accessory inquestion (see page 4).

Your Meter�s Serial Number: ________________________

Your Full-Service Distributor: _______________________

Your Full-Service Distributor�sTelephone Number: _______________________________

Be PrepBe PrepBe PrepBe PrepBe PreparedaredaredaredaredMake sure that all necessary safety precautions have beentaken. Provide for proper ventilation, temperature control,fire prevention, evacuation and fire management.


Read this manual as well as all the literature provided inyour owner�s packet.

In the Event of a Gas LeakIn the Event of a Gas LeakIn the Event of a Gas LeakIn the Event of a Gas LeakIn the Event of a Gas LeakIn the event of a large gas leak: In the event of a large gas leak: In the event of a large gas leak: In the event of a large gas leak: In the event of a large gas leak: Evacuate the area andnotify the fire department.

In the event of a small, contained gas leak:In the event of a small, contained gas leak:In the event of a small, contained gas leak:In the event of a small, contained gas leak:In the event of a small, contained gas leak:1. Stop the leak and prevent accidental ignition.

2. Prevent the entrance of gas into other portions of thebuildings. Some gases, such as LPG, seek lowerlevels, while other gases seek higher levels.

3. Evacuate all people from the danger zone.

4. See that the gas is dispersed before resuming businessand operating motors. If in doubt, notify your local firedepartment.

In the Event of a Gas FireIn the Event of a Gas FireIn the Event of a Gas FireIn the Event of a Gas FireIn the Event of a Gas FireIn the event of large fires or fires that are spreading:In the event of large fires or fires that are spreading:In the event of large fires or fires that are spreading:In the event of large fires or fires that are spreading:In the event of large fires or fires that are spreading:Evacuate the building and notify your local fire department.Stop the leakage only if you can safely reach the equipment.

In the event of small, contained fires that you canIn the event of small, contained fires that you canIn the event of small, contained fires that you canIn the event of small, contained fires that you canIn the event of small, contained fires that you cansafely control: safely control: safely control: safely control: safely control: Stop the leakage if you can safely reachthe equipment. Then use the appropriate extinguisher:Class B fire extinguisher, water, fog, etc., depending onthe materials. If in doubt, call your local fire department.

NOTICENOTICENOTICENOTICENOTICE

This manual provides warnings and procedures that areintended to inform the owner and/or operator of thehazards present when using the Liquid Controls Meteron LP-Gas and other products. The reading of thesewarnings and the avoidance of such hazards is strictlyin the hands of the owner-operators of the equipment.Neglect of that responsibility is not within the control ofthe manufacturer of the meter.

Safety ProceduresSafety ProceduresSafety ProceduresSafety ProceduresSafety Procedures!!!!! W W W W WARNINGARNINGARNINGARNINGARNING


33333

How LC Meters WorkHow LC Meters WorkHow LC Meters WorkHow LC Meters WorkHow LC Meters Work

Liquid Controls meters are positive displacement meters.They are designed for liquid measurement in both custodytransfer and process control applications. They can beinstalled in pump or gravity flow systems. Because oftheir simple design, they are easy to maintain, and easyto adapt to a variety of systems.

The meter housing (1) is designed with three cylindricalbores (2). Three rotors, the blocking rotor (3) and twodisplacement rotors (4, 5), turn in synchronizedrelationship within the bores. The three rotors aresupported by bearing plates (6, 7). The ends of the rotorsprotrude through the bearing plates. Blocking rotor gear(8) is placed on the end of the blocking rotor. Displacementrotor gears (9, 10) are placed on the ends of thedisplacement rotors. These gears create the synchronizedtimed relationship between the three rotors.

As fluid moves through the meter housing, the rotorassembly turns. The liquid is broken into uniform sectionsby the turning rotors. Fluid displacement happenssimultaneously. As fluid enters, another portion of thefluid is being partitioned and measured. At the same time,the fluid ahead of it is being displaced out of the meter andinto the discharge line. Since the volume of the bores isknown, and the same amount of fluid passes through themeter during each revolution of the blocking rotor, the exactvolume of liquid that has passed through the meter can beaccurately determined.

This true rotary motion is transmitted through the packinggland, the face gear, the adjuster drive shaft, and theadjuster to the register stack and counter. True rotarymotion output means consistent accuracy since theregister indication is in precise agreement with the actualvolume throughput at any given instant.

At any position in the cycle, the meter body, the blockingrotor, and at least one of the displacement rotors form acontinuous capillary seal between the un-metered upstreamproduct and the metered downstream product.

Capillary seals mean no metal-to-metal contact withinthe metering element. This means no wear. No wearmeans no increase in slippage, and no increase in slippagemeans no deterioration in accuracy.

Throughout the metering element, the mating surfaces areeither flat surfaces or cylindrical faces and sections thatare accurately machined. These relatively simplemachining operations, plus the fact that there is nooscillating or reciprocating motion within the device,permits extremely close and consistent tolerances withinthe LC meter.

The product flowing through the meter exerts a dynamicforce that is at right angles to the faces of the displacementrotors. The meter is designed so that the rotor shafts arealways in a horizontal plane. These two facts result in noaxial thrust. Therefore, with no need for thrust washers orthrust bearings, the rotors automatically seek the centerof the stream between the two bearing plates eliminatingwear between the ends of the rotors and the bearing plates.Once again, no wear results in no metal fatigue and nofriction.

The Liquid Controls meters are made of a variety of materialsto suit a variety of products. Because of our no-weardesign, capillary seals, and unique rotary metering, LCmeters provide unequalled accuracy, long operating life,and unusual dependability.

Meter Element Exploded Line Drawing

44444


1.1.1.1.1. Is all your documentation included with yourIs all your documentation included with yourIs all your documentation included with yourIs all your documentation included with yourIs all your documentation included with yourmeter? meter? meter? meter? meter? LC meters come in many variations. Theinformation sent to you depends on the accessoriesyou have ordered with your meter. Make an inventoryof your owner�s information packet. First, find yourLC packing slip with the computer printout. Locatethe serial number and the meter model number onthis printout. Cross reference the packing slip numberwith the actual meter numbers. The illustration onthis page will help you locate the Specification andSerial Number Plates on the meter and its accessories.

2.2.2.2.2. Record your meter serial number Record your meter serial number Record your meter serial number Record your meter serial number Record your meter serial number in the spaceprovided on the inside cover of this manual. The insidecover also provides a space for your full-servicedistributor�s name and telephone number. Fill in thisinformation and keep it handy. You will always needyour meter serial number and model number whencalling for service or parts! See �How to OrderReplacement Parts� in this manual.

55555

3.3.3.3.3. Identify your meterIdentify your meterIdentify your meterIdentify your meterIdentify your meter��s model-accessory letters model-accessory letters model-accessory letters model-accessory letters model-accessory letter. . . . . Usethe charts shown above to familiarize yourself withmeter accessories. Find the meter and letter on thechart which represents your meter, then check withthe chart below to see that your red owner�s informationpacket is complete. Not all accessory levels areavailable for every model of LC meter.

4.4.4.4.4. Check your owner�s information packet Check your owner�s information packet Check your owner�s information packet Check your owner�s information packet Check your owner�s information packet with thechart shown above to make sure that all thedocumentation needed for your meter and accessoriesis in your red information packet. If documentation ismissing, call your full-service distributor or LiquidControls for replacement materials.


66666

InstInstInstInstInstallation Requirementallation Requirementallation Requirementallation Requirementallation Requirementsssss

Make sure that all necessary safety precautions have beentaken. Provide for proper ventilation, temperature control,fire prevention, evacuation and fire management.


Read this manual as well as all the literature provided inyour owner�s manual. If you have any questions, consultwith your full-service distributor or call the ServiceDepartment at Liquid Controls.

Install the meter and accessories in conformance withapplicable state and federal construction, electrical andsafety codes.

NOTE: NOTE: NOTE: NOTE: NOTE: Class 10 LPG meters must be installed inaccordance with the requirements of ANSI-NFPA 58 inaddition to all other state and local codes.

WWWWWARNING: ARNING: ARNING: ARNING: ARNING: Under normal operation, do not expose anyportion of the LP-Gas system to pressures in excess ofrated working pressures without an automatic safety valveto vent the over pressure discharge to a place of safetyaway from the operator and other people. Failure to providesuch a safety relief may result in leakage or rupture of oneor more of the components in the system. This can resultin injury of death from the gas, a fire, or pieces of flyingdebris from the rupture.

Before shipment, protective thread caps were placed in allmeter and accessory openings. They should remain inplace until you are ready to attach piping.

Prior to meter installation, the entire piping system shouldbe thoroughly flushed of all debris, with a liquid that iscompatible with the construction of the meter.

Keep external surfaces of the meter clean.

The meter must always be securely bolted to a platform orsupporting member, regardless of the mounting positionof the meter. Never �hang� a meter on the connecting piping.

Install meter only on the discharge side (downstream) ofthe system pump.

Apply pipe compound to male threads only.

Position the meter with service in mind. Provide amplework space. Removing covers can be difficult when workspace is not available. Always supply a platform or supportfor the meter mounting.

A meter is metallurgically designed to be physicallycompatible with a given type of liquid, as originally specifiedby the customer, and as indicated on the Serial NumberPlate. A meter should not be used with a liquid differentfrom the liquid originally specified, unless the physicalcharacteristics and pH rating are similar and the applicationhas been checked with LC Sales and Engineering throughyour full-service distributor.

Install a strainer on the meter inlet to avoid damage fromforeign matter, such as weld slag, from entering the system.The strainer must always be located on the inlet side.

All meters are tagged identifying their direction of flow.Meters are set with a flow direction of left to right asstandard. However, when a meter is ordered, the customercan specify that the flow be set from either direction. If themeter register counts in reverse, the meter is reading thedirection of flow in reverse. If this occurs, the meterregistration must be reset. See �Reversing the MeterRegistration� in this manual for mechanical output meters.Refer to your accessory manual for electrical output meters(such as meters equipped with a pulser).


Always request up-to-date, engineering approved,dimensional drawings before starting any construction.Do not rely on catalog pictures or drawings which arefor reference only. After receiving prints, check to seethat all equipment ordered is shown and that any extrapressure taps, plugs, etc. are noted and their sizespecified.

77777

Operation RequirementOperation RequirementOperation RequirementOperation RequirementOperation Requirementsssss

The meter must remain full of product at all times.The meter must remain full of product at all times.The meter must remain full of product at all times.The meter must remain full of product at all times.The meter must remain full of product at all times.An easy way to accomplish this is to put the meterassembly in the line below the piping center-line (a sumpposition). This requires adding elbows and flanges prior toinstalling the meter. The meter should be installed in abypass loop, below the pipe center-line, with block valvesupstream and downstream. A block valve should be locatedin the mainstream, labeled as the bypass valve.

Caution: Caution: Caution: Caution: Caution: Any portion of pipe system that might isolate orblock flow should be provided with a pressure relief toprevent damage from thermal expansion. There areexcellent benefits to this type of installation. First, themeter is kept full. Second, this type of installation allowsthe meter to be isolated for servicing and calibration whilecontinuing flow through the bypass valve.

Upstream lines must be maintained fullUpstream lines must be maintained fullUpstream lines must be maintained fullUpstream lines must be maintained fullUpstream lines must be maintained full to prevent airfrom entering the meter. If upstream or inlet lines areconstructed in a manner which allows reverse flow, footvalves or back checks must be installed.

Underground tanks Underground tanks Underground tanks Underground tanks Underground tanks that are furnished with a submersiblepump will eliminate many problems that occur with positivedisplacement pumps (suction pumps) when suction pipingis incorrectly sized or when the lift is too great.

Every meter should be calibrated Every meter should be calibrated Every meter should be calibrated Every meter should be calibrated Every meter should be calibrated under actual serviceand installation conditions per the API Manual of PetroleumMeasurement Standards:

Chapter 4 - Proving SystemsChapter 5 - MeteringChapter 6 - Metering AssembliesChapter 11 Section 2.3 -Water Calibration of Volumetric ProversChapter 12 Section 2 -Calculation of Petroleum Quantities

These chapters of the API Manual of PetroleumMeasurement Standards supersedes the API standard1101.

Provide a means Provide a means Provide a means Provide a means Provide a means of conveniently diverting liquid forcalibration purposes.

Give careful attention to your system�s pumpingGive careful attention to your system�s pumpingGive careful attention to your system�s pumpingGive careful attention to your system�s pumpingGive careful attention to your system�s pumpingequipment and piping equipment and piping equipment and piping equipment and piping equipment and piping because of their influence on liquidbeing measured as it enters the metering assembly.Systems should be made free of conditions that cause orintroduce entrained air or vapor.

Follow the manufacturer�s recommendation fullyFollow the manufacturer�s recommendation fullyFollow the manufacturer�s recommendation fullyFollow the manufacturer�s recommendation fullyFollow the manufacturer�s recommendation fullywhen installing pumps. when installing pumps. when installing pumps. when installing pumps. when installing pumps. Give particular attention tofactors like: use of foot valves, pipe size to the inlet andconformance to net positive suction head (NPSH)conditions when suction pumping is required. Followingthe manufacturer�s recommendations will minimize air andvapor elimination problems.

For liquids such as light hydrocarbons For liquids such as light hydrocarbons For liquids such as light hydrocarbons For liquids such as light hydrocarbons For liquids such as light hydrocarbons that tend toflash or vaporize easily at higher ambient temperatures, itis desirable to use flooded suctions and piping sized largerthan the nominal pump size.

On systems such as vehicle tank installations, On systems such as vehicle tank installations, On systems such as vehicle tank installations, On systems such as vehicle tank installations, On systems such as vehicle tank installations, pipinglayout is important in preventing problems with splitcompartment test conformance. Piping should slope awayfrom a P.D. pump to prevent resurgent re-priming of thepump due to drain back.

Hydraulic shock is harmful to all componentsHydraulic shock is harmful to all componentsHydraulic shock is harmful to all componentsHydraulic shock is harmful to all componentsHydraulic shock is harmful to all components of anoperating system including valves, meter and the pump.In particular, meters must be afforded protection from shockbecause of their need to measure with high precision.Generally the best protection is prevention, which can bereadily accomplished by adjusting valve closing rates insuch a manner that shock does not occur.

Thermal expansion like hydraulic shock is aThermal expansion like hydraulic shock is aThermal expansion like hydraulic shock is aThermal expansion like hydraulic shock is aThermal expansion like hydraulic shock is aphenomenon that can easily damage meters phenomenon that can easily damage meters phenomenon that can easily damage meters phenomenon that can easily damage meters phenomenon that can easily damage meters andsystems in general. Care should be taken in designingthe system to include pressure relief valves in any portionor branch of the system that might be closed off by closureof operating valves or block valves.

88888

Meter SMeter SMeter SMeter SMeter Stttttart Up and Operationart Up and Operationart Up and Operationart Up and Operationart Up and Operation

Prior to meter start upPrior to meter start upPrior to meter start upPrior to meter start upPrior to meter start up, use extreme caution. Makesure that:

1. The meter is properly secured2. All connections are tight3. All valves are in the closed position

Placing your meter in operation: Placing your meter in operation: Placing your meter in operation: Placing your meter in operation: Placing your meter in operation: When placing yourmeter in operation, the meter and system must be filledslowly with liquid and be free of air prior to start-up. Extremecare must be taken to avoid damaging the meter duringthis time. The system may be filled by gravity (preferred)or by use of the pump (if required) when filling the systemwith liquid for the first time.

Gravity filling - Gravity filling - Gravity filling - Gravity filling - Gravity filling - systems with positive head pressurefrom product storage above the inlet port of the meter.

1. Make sure all valves (up stream and down stream ofthe meter) in the system are closed.

2. Crack open the valve located at the storage tank. Themeter�s register/counter will start to move and thenstop, provided there is not a valve between the tankand the meter inlet. If there is another valve betweenthe tank and meter, repeat this process with each valveuntil the meter is exposed to the liquid.

3. Once you are assured that the meter has registeredsome volume and stopped, continue to fully open thetank valve.

4. With the valve(s) open between the tank and the meter,now go to the valve located down stream of the meter.Open the down stream valve slowly until the meter�sregister/counter starts to move. Do not run the meterany faster than 25% of its rated flow during start-up.Once the product is flowing out the end of your system,the outlet valve can be opened all the way providedthat the system is designed not to exceed the flowrate marked on the meter.

NOTENOTENOTENOTENOTE: If the valves are not manual, consult the valvemanufacturer for slow flow start-up.


Make sure that your pump can operate against aMake sure that your pump can operate against aMake sure that your pump can operate against aMake sure that your pump can operate against aMake sure that your pump can operate against adead head pressure. If NOTdead head pressure. If NOTdead head pressure. If NOTdead head pressure. If NOTdead head pressure. If NOT, consult the factory, consult the factory, consult the factory, consult the factory, consult the factoryfor assistance.for assistance.for assistance.for assistance.for assistance.



Filling the system with a pump - Filling the system with a pump - Filling the system with a pump - Filling the system with a pump - Filling the system with a pump - Consult the pumpmanufacturer for proper pump priming. Once the pump isprimed with product, proceed as follows:

� Follow steps one through four above for proper meterstart-up.

Never operate the meter or system when partiallyNever operate the meter or system when partiallyNever operate the meter or system when partiallyNever operate the meter or system when partiallyNever operate the meter or system when partiallyfilled with liquid, or with pockets of compressed airfilled with liquid, or with pockets of compressed airfilled with liquid, or with pockets of compressed airfilled with liquid, or with pockets of compressed airfilled with liquid, or with pockets of compressed airor vapor present. If these conditions cannot beor vapor present. If these conditions cannot beor vapor present. If these conditions cannot beor vapor present. If these conditions cannot beor vapor present. If these conditions cannot beavoided, air and vapor elimination systems may beavoided, air and vapor elimination systems may beavoided, air and vapor elimination systems may beavoided, air and vapor elimination systems may beavoided, air and vapor elimination systems may berequired. If you cannot fill the meter slowly byrequired. If you cannot fill the meter slowly byrequired. If you cannot fill the meter slowly byrequired. If you cannot fill the meter slowly byrequired. If you cannot fill the meter slowly bygravity or by using a valve to throttle back the flow,gravity or by using a valve to throttle back the flow,gravity or by using a valve to throttle back the flow,gravity or by using a valve to throttle back the flow,gravity or by using a valve to throttle back the flow,consult the factoryconsult the factoryconsult the factoryconsult the factoryconsult the factory.....

Do not operate the meter at a pressure exceeding thatmarked on the Serial Number Plate. Under any and allpressure producing circumstances, for instance, thermalexpansion and hydraulic shock, the working pressuremust not exceed the indicated maximum.

If the meter is operated at a rate greater than themaximum recommended GPM, excessive wear andpremature failure may occur.

The meter can be calibrated for flows below minimumratings if the flow remains constant and varies withinnarrow limits or if the product is viscous. A meter shouldnever be run beyond the maximum flow rate determinedfor that class meter and/or liquid measured.

99999

Reversing the Meter RegistrationReversing the Meter RegistrationReversing the Meter RegistrationReversing the Meter RegistrationReversing the Meter Registration

The direction of flow is specified by the customer whenthe meter is ordered. The standard direction of flow isfrom left to right when facing the front of the meter. A redpressure sensitive label indicating inlet is affixed to themeter at time of shipment.

If the meter is equipped with a strainer and/or valve, thestrainer (and/or valve) MUSTMUSTMUSTMUSTMUST be moved when reversing thedirection of flow through the meter. The strainer shouldThe strainer shouldThe strainer shouldThe strainer shouldThe strainer shouldalways be located on the inlet side of the meteralways be located on the inlet side of the meteralways be located on the inlet side of the meteralways be located on the inlet side of the meteralways be located on the inlet side of the meter..... Whenthe meter is equipped with a valve, it is moved to the outletside of the meter. Some repositioning of the valvecomponents may be required. See the Valve Manual inthe Owner�s Information Packet.

When the meter is first installed, check the register. If theregister counts DOWN,DOWN,DOWN,DOWN,DOWN, meaning that the register numbersdecrease rather than increase, you must reverse thedirection of registration by reversing the position of theadjuster drive gear.

Reversing the drive to the register is accomplished byreversing the position of the adjuster drive gear relative tothe pinion gear of the packing gland, as shown to the left.See below for step-by-step instructions.


2. Remove the retaining ring (4) with a screwdriver orpliers.

3. Remove the two retaining spring screws (1) with astandard screwdriver. Note: For M-15, M-25, M-30,Note: For M-15, M-25, M-30,Note: For M-15, M-25, M-30,Note: For M-15, M-25, M-30,Note: For M-15, M-25, M-30,and M-40 modelsand M-40 modelsand M-40 modelsand M-40 modelsand M-40 models loosen the single set screw.

4. Remove the retaining spring (2).

5. Remove the drive shaft (3) mounted with the adjusterdrive gear assembly including (4) Retaining Ring and(5) Adjuster Drive Gear.

6. Remove the adjuster drive gear (5) and turn it 180° sothat it is upside down from the original installationposition. The bushing (7) supports the adjuster drivegear in the lower position. The retaining ring (4)supports the adjuster drive gear in the upper position.

Adjuster drive gearengaged from the top.

Adjuster drive gearengaged from thebottom.

7. Reassemble the parts in reverse order. Make surethat the adjuster drive gear meshes with the packinggland�s pinion gear (6) without being too tight. Makesure there is a little play in the gear teeth. The retainingring (4) should be placed in the groove provided on thedrive shaft (3), regardless of the adjuster drive gearposition. The packing gland pinion gear to adjusterdrive gear ratio is either 1:1 or 2:1. In the 2:1 ratio, thepinion of the packing gland is smaller in diameter.

Packing Gland

1010101010

Setting the SSetting the SSetting the SSetting the SSetting the Stttttandard andard andard andard andard AdjusterAdjusterAdjusterAdjusterAdjuster

NOTE:NOTE:NOTE:NOTE:NOTE: These instructions apply to meters equipped withmechanical output accessories only. If your meter isequipped with an electrical output (i.e., electronic pulser)refer to your accessory manual, such as the Pulser Manualsupplied in your owner�s information packet.


2. Check meter registration by delivering product to areliable, accurate prover. Perform multiple delivery teststo verify the meter repeatability.

3. Record the setting indicated on the adjuster:

4. Note the difference between the volume of the proverand the volume indicated on the meter counter.Calculate the % correction required, as follows:

5. Loosen the adjuster clamp screw.

6. When the prover volume is less than the meter countervolume, add the percentage to the original adjustersetting by turning the thimble towards the arrow markedlarger (volume). Correct the original setting byapproaching the number desired from the next largernumber. For example, if the desired adjuster settingis 2.4, turn the adjuster thimble to the left to number5, then to the right to obtain the 2.4 setting. Adjusteris currently set at 2.3 in the illustration to the right.

7. When the prover volume is moremoremoremoremore than the metercounter volume, subtract the percentage from theoriginal adjuster setting by turning the thimble in thedirection of the arrow marked smaller volume percent.

8. Retighten the adjuster clamp screw. Run productthrough the meter to allow the adjuster to take a set.Then make several prover runs to check for accuracy

Meter Maintenance andMeter Maintenance andMeter Maintenance andMeter Maintenance andMeter Maintenance andrepeatrepeatrepeatrepeatrepeatabilityabilityabilityabilityability.....Prevent pipe strain or stress Prevent pipe strain or stress Prevent pipe strain or stress Prevent pipe strain or stress Prevent pipe strain or stress from occurring when makingmeter or accessory repairs. Pipe strain and stress occurswhen the pipes are not supported or are not alignedcorrectly to the meter. The weight of the pipes must alwaysbe supported independent of the meter. This means thatthe meter and accessories can be easily removed withoutaffecting the pipes or the pipe alignment. Never leave anyof the pipes hanging.

Seasonal meter storageSeasonal meter storageSeasonal meter storageSeasonal meter storageSeasonal meter storage If the meter is used for seasonalwork, at the end of each season the meter should beremoved from the system and thoroughly flushed with acompatible liquid. This includes removing the drain on thefront and rear covers. Then flush the product from the frontand rear covers. If flushing with water is preferred, extracare should be taken to drain the meter completely anddry all internal parts. Immediate refilling with a compatibleliquid (or oil misting) is essential to prevent corrosion aswell as ice damage to parts from moisture that wasoverlooked after flushing and drying.

VVVVVolume in prover - volume on meter counterolume in prover - volume on meter counterolume in prover - volume on meter counterolume in prover - volume on meter counterolume in prover - volume on meter counter % correction = X 100 % correction = X 100 % correction = X 100 % correction = X 100 % correction = X 100

volume in provervolume in provervolume in provervolume in provervolume in prover

1111111111

Meter MaintenanceMeter MaintenanceMeter MaintenanceMeter MaintenanceMeter Maintenance

Do not mar or scratch Do not mar or scratch Do not mar or scratch Do not mar or scratch Do not mar or scratch any of the precision machinedsurfaces by prying or sanding parts.

TTTTTorque orque orque orque orque all fasteners such as screws and bolts inaccordance with specifications listed in the �Torque Chart�in this manual (page 22).

Stone the machined surfaces Stone the machined surfaces Stone the machined surfaces Stone the machined surfaces Stone the machined surfaces when reassembling themeter to assure that the machined surfaces are free ofburrs and mars.

Repair pulled threads Repair pulled threads Repair pulled threads Repair pulled threads Repair pulled threads with threaded insert fasteners.These can be used in many instances. Contact your full-service distributor for advice if this occurs.

Coat threads Coat threads Coat threads Coat threads Coat threads with anti-seize when removing and replacingbolts and castings in a meter.

Removing flange gaskets Removing flange gaskets Removing flange gaskets Removing flange gaskets Removing flange gaskets When removing the flangeassembly, always carefully scrape off the flange gaskets.Make sure that the flange surface has been scraped clean.Discard the old flange gasket and install a new flangegasket. Never reuse old flange gaskets.

Examine all fasteners Examine all fasteners Examine all fasteners Examine all fasteners Examine all fasteners to make sure they are not bent,rusted, or have pulled threads. The threads should all

appear evenly placed. If the bolts are bent, check thehousing and cover for flatness. Use a straight edge todetermine flatness.

Look for gapLook for gapLook for gapLook for gapLook for gaps s s s s when disassembling a meter. Use a feelergauge to check for gaps between the bearing plate andhousing. If you do find gaps, check the bearing plates forflatness with a straight edge. Gaps can be caused byshock problems that must be resolved. Contact your full-service distributor for assistance if this occurs.

Check the O-rings Check the O-rings Check the O-rings Check the O-rings Check the O-rings for damage. Cracked, rough, or wornO-rings should be replaced. However, a more seriousproblem of shock may be indicated if the O-rings looknibbled. Shock problems must be verified and resolved.Contact your full-service distributor for assistance if thisoccurs.

Check the bearing plates Check the bearing plates Check the bearing plates Check the bearing plates Check the bearing plates for flatness. Use a straightedge. Warped bearing plates can be caused by shockproblems that must be resolved. Contact your full-servicedistributor for assistance if this occurs.

Check with regulatory agencyCheck with regulatory agencyCheck with regulatory agencyCheck with regulatory agencyCheck with regulatory agency that governs Weights &Measures in your area. Removing the dust cover sealwire or other maintenance procedures may require Weights& Measures recalibration.

WARNING

Relieving Internal PressureRelieving Internal PressureRelieving Internal PressureRelieving Internal PressureRelieving Internal PressureAll internal pressure must be relieved to zero pressureAll internal pressure must be relieved to zero pressureAll internal pressure must be relieved to zero pressureAll internal pressure must be relieved to zero pressureAll internal pressure must be relieved to zero pressure

before disassembly or inspection of the strainer, air eliminator any valves in the system,the packing gland, and the front or rear covers.

Serious injury or death from fire or explosion could result from maintenance of anSerious injury or death from fire or explosion could result from maintenance of anSerious injury or death from fire or explosion could result from maintenance of anSerious injury or death from fire or explosion could result from maintenance of anSerious injury or death from fire or explosion could result from maintenance of animproperly depressurized and evacuated system.improperly depressurized and evacuated system.improperly depressurized and evacuated system.improperly depressurized and evacuated system.improperly depressurized and evacuated system.


4. Slowly open the valve/nozzle at the end of the supplyline.

5. After product has bled off, close the valve/nozzle atthe end of the supply line.

6. Slowly crack the fitting on top of the differential valveto relieve product pressure in the system. Productwill drain from the meter system.

7. As product is bleeding from the differential valve, slowlyreopen and close the valve/nozzle on the dischargeline. Repeat this step until the product stops drainingfrom the differential valve and discharge line valve/nozzle.

8. Leave the discharge line valve/nozzle open whileworking on the system.

Procedure for Non-LPG Meters1. Turn off pump pressure to the system.2. Close valves before and after the meter.3. Remove pressure by removing the drain plugs and

draining the meter.

Procedure for LPG Meters1. Close the belly valve of the supply tank.2. Close the valve on the vapor return line.3. Close the manual valve in the supply line on the inlet

side of the meter. If no manual valve exists on theinlet side, consult the truck manufacturer forprocedures to depressurize the system.

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Removing the Dust CoverRemoving the Dust CoverRemoving the Dust CoverRemoving the Dust CoverRemoving the Dust Cover1. Cut the dust cover seal wire with a side cutters.

Remove the dust cover screws with a 5/16� wrench orslotted screwdriver and then remove the dust cover.See �Relieving Internal Pressure� �Relieving Internal Pressure� �Relieving Internal Pressure� �Relieving Internal Pressure� �Relieving Internal Pressure� and �Regulatory �Regulatory �Regulatory �Regulatory �RegulatoryAgency� Agency� Agency� Agency� Agency� in the �Meter Maintenance� section (page11) of this manual.

Removing the Removing the Removing the Removing the Removing the Adjuster and Adjuster and Adjuster and Adjuster and Adjuster and Adjuster Drive Adjuster Drive Adjuster Drive Adjuster Drive Adjuster Drive AssemblyAssemblyAssemblyAssemblyAssembly

1. Record the adjuster micrometer setting.

2. Carefully note the adjuster drive gear position. Thegear engages the packing gland pinion from below orabove. This gear must be reinstalled in its originalposition or the meter counter will run backwards.

1313131313


3. Use a standard screwdriver to loosen (or remove) thetwo retaining spring screws.

4. Swing the retaining spring off the adjuster drive bushing.

5. Loosen the adjuster mounting clamp screw with aphillips head screwdriver.

Removing the adjuster from the top of the meter when topaccess is easiest. Front access instructions are on thenext page.

6. Remove screws that secure adjuster mounting plateto counter adapter.

7. Lift adjuster mounting bracket with adjuster out of thecounter adapter.


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Removing the adjuster from the front of the meter whenfront access is easiest. Top access instructions are onthe previous page.


10. Remove the slotted head screw that secures theadjuster to the mounting plate.

11. Bring the adjuster out through the front of the meterby rotating it from left to right to clear the adjustermounting plate and then pull down to remove from themeter.

Servicing the Packing GlandServicing the Packing GlandServicing the Packing GlandServicing the Packing GlandServicing the Packing GlandThe packing gland is affected by the liquid being metered,the operating temperature, and other system conditions.After prolonged use, the gland may show leakage fromthe metering chamber. This is a sign of wear. The glandshould be replaced or repaired if this occurs. It can beserviced in the field.

1. Remove the two packing gland retaining plate screwswith a 5/16� socket and ratchet drive extension or5/16� nut driver.

2. Pull out the packing gland.

3. Take apart the packing gland by gently prying off theretaining ring with a standard screwdriver.

4. Pull the driver out from the assembly.



1515151515

Buna/VBuna/VBuna/VBuna/VBuna/Viton/Titon/Titon/Titon/Titon/Teflon Packing Glandeflon Packing Glandeflon Packing Glandeflon Packing Glandeflon Packing Gland

1. Driver2. Shaft3. Stainless steel thrust washer4. Rulon thrust washer5. Buna/Viton/Teflon �U� Cup 6. Aluminum/stainless housing 7. Washer - Nylon 8. Output gear 2:1 9. Retaining ring10. Bushing11. Retaining plate12. Buna/Viton/Teflon O-ring13. Two retaining plate screws14. Output gear 1:115. Carbon Guide Bearing16. Washer - Stainless Steel

Packing Gland RetPacking Gland RetPacking Gland RetPacking Gland RetPacking Gland Retaining Plateaining Plateaining Plateaining Plateaining PlateThe retaining plate has four holes: two that are drilled 1-1/2� on center and two that are drilled 1-5/8� on center. Ifyour meter has a counter adapter dust cover (Item #0366)shaped like the illustration shown below, use the holesdrilled 1- 5/8� on center to mount the packing gland retainingplate.

If your meter does notnotnotnotnot have the counter adapter dust covershaped like the illustration shown on the right, use the twoholes drilled 1-1/2� on center to mount the packing glandretaining plate.

Packing Gland ComponentPacking Gland ComponentPacking Gland ComponentPacking Gland ComponentPacking Gland Componentsssss

Adapter Dust Cover for holesdrilled 1-5/8� on center

Standard Packing Gland

LPG Packing Gland

Item 11 (above)

1616161616


Mechanical Output Meters*Mechanical Output Meters*Mechanical Output Meters*Mechanical Output Meters*Mechanical Output Meters*

* For electrical output meters refer to the Pulser Manualsupplied in your owner�s information packet.

1. Remove the counter bracket screws with a box wrenchor socket driver. The counter bracket can be removedwith or without removing the adjuster assembly.

NOTE: For Aluminum M-30 and M-40 modelsNOTE: For Aluminum M-30 and M-40 modelsNOTE: For Aluminum M-30 and M-40 modelsNOTE: For Aluminum M-30 and M-40 modelsNOTE: For Aluminum M-30 and M-40 models the counterbracket and front cover are one piece. Go to step 2.

2. Turn the meter on either the inlet or outlet side. Let itstand to allow the product to drain from the meterchamber.

3. Locate the drain plugs on the front and rear covers.Remove the drain plugs using an allen wrench. Let themeter stand to allow product to drain from the frontand rear covers.



1717171717

4. Use a socket wrench or box end wrench to removethe screws securing the front cover. Remove thescrews that hold the rear cover. The number of screwswill vary depending on meter size.

5. Remove the front and rear covers. MA-4, M-5, andMA-4, M-5, andMA-4, M-5, andMA-4, M-5, andMA-4, M-5, andMA-5 old style models, M-60 and M-80 currentMA-5 old style models, M-60 and M-80 currentMA-5 old style models, M-60 and M-80 currentMA-5 old style models, M-60 and M-80 currentMA-5 old style models, M-60 and M-80 currentmodelsmodelsmodelsmodelsmodels have a driven reduction gear attached with ashoulder bolt to the center of the front bearing plate.

6. Carefully remove the O-rings / flat gaskets from frontand rear of the housing. Undamaged Buna or Viton O-rings may be reused. Flat gaskets and Teflon O-ringsshould always be replaced and never reused.

7. Hold a spare displacement rotor gear between the rightdisplacement rotor gear and the blocking rotor gear tokeep them from turning (if unavailable, use a shop ragbetween gear teeth). Use the rotor gear wrench orsocket to remove the right displacement rotor gearscrew and washer.

MA-4, M-5, and MA-5 old style models, M-60 and M-80MA-4, M-5, and MA-5 old style models, M-60 and M-80MA-4, M-5, and MA-5 old style models, M-60 and M-80MA-4, M-5, and MA-5 old style models, M-60 and M-80MA-4, M-5, and MA-5 old style models, M-60 and M-80current models:current models:current models:current models:current models:Rotor gears are on the meter back.

All other models:All other models:All other models:All other models:All other models:Rotor gears are on the front.

8. Hold the spare gear between the left displacementrotor gear and blocking rotor gear. Use the rotor gearwrench or socket to remove the screw and the packinggland driver held by the screw.

9. Hold the spare gear between the right displacementrotor gear and the blocking rotor gear. Use the rotorgear wrench or socket to remove the left displacementrotor gear screw and washer.


1818181818


1. Insert two standard screwdrivers behind the blockingrotor gear: Gently pry the gear off its rotor taperedend. If the gears show signs of corrosion, or do notpry off easily, use the alternative method described insteps 5-8.

2. Use the same method to remove the left rotor gearand the right rotor gear. Remember, if the gear doesnot pry off easily, or feels stuck, use the alternativemethod described in steps 5-8.

3. As each gear comes off the rotor remove the key (1)from the rotor keyway (2). Save the key to use whenreassembling the meter.

4. Use the bearing plate wrench to remove the screwsthat hold the front bearing plate to the meter housing.On the back of the meter housing, remove the screwsthat hold the rear bearing plate to the housing. Go tostep 1, Removing the Bearing Plates.

Removing Corroded Rotor GearsRemoving Corroded Rotor GearsRemoving Corroded Rotor GearsRemoving Corroded Rotor GearsRemoving Corroded Rotor Gears5. Replace all three rotor gear screws, without washers,

halfway onto each of the rotor ends.

6. On the back of the meter housing, remove the screwsthat hold the rear bearing plate to the housing usingthe bearing plate wrench or socket. The number ofscrews varies with the size of meter.

Removing Non-Corroded Rotor GearsRemoving Non-Corroded Rotor GearsRemoving Non-Corroded Rotor GearsRemoving Non-Corroded Rotor GearsRemoving Non-Corroded Rotor Gears

1919191919


7. With a plastic or non-metallic mallet, tap on the headsof the screws lightly and equally. As you tap on thescrew heads, the gears are driven off the rotors. Asthe rotors are driven in, the rear bearing plate and therotor assembly are pushed away from the housing.

NOTENOTENOTENOTENOTE: For carbon insert bearing plates, remove therear plate first and then each rotor as it is handsupported.

8. Use the bearing plate wrench or socket to remove thescrews that hold the front bearing plate to the meterhousing. The number of screws varies between differentmeter sizes.

Removing the Bearing PlatesRemoving the Bearing PlatesRemoving the Bearing PlatesRemoving the Bearing PlatesRemoving the Bearing Platesand Rotorsand Rotorsand Rotorsand Rotorsand Rotors1. Insert a screwdriver into each of the two notches near

the dowel pins. Be careful not to mar any of thesurfaces. Gently pry the front bearing plate off the dowelpins.

2. Remove the front bearing plate and rotor assembly bypulling a rotor straight out from the housing. Be carefulnot to mar any of the surfaces. MA-4, M-5, and MA-5MA-4, M-5, and MA-5MA-4, M-5, and MA-5MA-4, M-5, and MA-5MA-4, M-5, and MA-5old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:Pull the rotor from the rear bearing plate. This will alsoremove the drive reduction gear which is attached tothe blocking rotor.

3. Remove the remaining bearing plate from the otherside by inserting a screwdriver into each of the twonotches near the dowel pins. Be careful not to marany surfaces. Gently pry the front bearing plate off thedowel pins. NOTE: MA-4, M-5, and MA-5 old styleNOTE: MA-4, M-5, and MA-5 old styleNOTE: MA-4, M-5, and MA-5 old styleNOTE: MA-4, M-5, and MA-5 old styleNOTE: MA-4, M-5, and MA-5 old stylemodels, M-60 and M-80 current models models, M-60 and M-80 current models models, M-60 and M-80 current models models, M-60 and M-80 current models models, M-60 and M-80 current models have adriven reduction gear in attached with a shoulder boltto the center of the front bearing plate.

4. Inspect and clean all critical surfaces like gear teeth,rotors and internal housing faces. Remove anycrystalline formations using fine emery cloth or a finewire brush. Be careful not to mar or alter the shape ofany of the parts. Changing the shape of the parts mayinterfere with their operation. Remove nicks and burrson metal parts with a stone. Remove all grit and otherforeign particles. These may also damage parts andinterfere with proper operation. Replace all parts thatappear worn or damaged.

2020202020


1. MA-4, M-5, and MA-5 old style models, M-60 andMA-4, M-5, and MA-5 old style models, M-60 andMA-4, M-5, and MA-5 old style models, M-60 andMA-4, M-5, and MA-5 old style models, M-60 andMA-4, M-5, and MA-5 old style models, M-60 andM-80 current models:M-80 current models:M-80 current models:M-80 current models:M-80 current models: Rotor gears are on the rearbearing plate. All other models: Rotor gears are onthe front bearing plate. Install the non-rotor gear bearingplate using the bearing plate screws and wrench.

2. Insert the non-tapered ends on the three rotors intothe housing. Place each rotor into its respective borein the installed bearing plate. MA-4, M-5, and MA-5MA-4, M-5, and MA-5MA-4, M-5, and MA-5MA-4, M-5, and MA-5MA-4, M-5, and MA-5old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:old style models, M-60 and M-80 current models:Make sure that the teeth of the driving reduction gearmesh with the teeth of the driven reduction gear.

3. Place the remaining bearing plate over the three taperedrotor ends and fasten it with the bearing plate screws.Use the bearing plate wrench. The number of screwsvaries with meter size.

4. The rotors should have a small amount of end-playand be easy to turn. Test each rotor, one at a time.Turn the rotors to make sure that they revolve freely.Jog the rotors from end to end to check for end-play.If they do not move easily in both tests, remove therotors and check for burrs and corrosion deposits.Clean them thoroughly.

Repeat Steps 2, 3 and 4.

5. The rotor key is a small wedge of metal. Each rotorhas a notch, or �keyway�, to hold a key. Position akey into each one of the three rotors. Press the keysinto the rotor keyways with your thumb and forefinger.

6. Slide the blocking rotor gear on its tapered rotor end.Slide the right displacement rotor gear on its taperedrotor end so that the timing marks line up between thetwo gears. See �Timing the Rotor Gears� on the nextpage. Hint: Before you place the right displacementrotor gear on its tapered end, hold the right rotor gearin position. Turn the blocking rotor gear. Try to line upthe timing marks before you place the rightdisplacement rotor gear on its tapered rotor end.

7. Position the left displacement rotor gear on its taperedrotor end so that its timing mark lines up with theblocking rotor gear. See �Timing the Rotor Gears�.

2121212121


Timing the Rotor GearsTiming the Rotor GearsTiming the Rotor GearsTiming the Rotor GearsTiming the Rotor GearsRotor gears are timed by lining up the timing marks. Theblocking rotor gear has a tooth directly in frontdirectly in frontdirectly in frontdirectly in frontdirectly in front of itstiming mark. On the displacement rotor gears, the timingmark falls in front of the space betweenin front of the space betweenin front of the space betweenin front of the space betweenin front of the space between two gearteeth. Make sure that the tooth in front of the timing markon the blocking rotor gear connects with the space infront of the timing mark on the displacement rotor gear.You may need to remove the gears and reposition themseveral times on their rotor ends in order to get the timingmarks to line up correctly. For more information, See�Troubleshooting�.

1. Position the spare displacement rotor gear betweenthe left displacement rotor gear and the blocking rotorgear to prevent the gears from moving. Attach the rightdisplacement gear washer and screw using the rotorgear wrench. Tighten the screw to the torquespecification listed in the Torque Chart (page 22).

2. Keep the spare displacement rotor gear positioned bythe left displacement rotor gear. Attach the leftdisplacement gear washer and screw using the rotorgear wrench. Tighten the screw to the torquespecification listed in the Torque Chart.

3. Position the spare displacement rotor gear betweenthe right displacement rotor gear and the blocking rotorgear. Attach the blocking rotor gear with the packinggland driver and screw using the rotor gear wrench.Tighten the screw to the torque specification listed inthe Torque Chart.

4. Rotate the gears to make sure that the rotors turnfreely. Burrs, foreign material, or marred surfaces canrestrict the rotor movements. It may be necessary toremove the gears and rotors and deburr and clean thesurfaces again.

5. Install an O-ring (1) into the groove (2) on the front ofthe meter housing. The M-60 and M-80 modelsM-60 and M-80 modelsM-60 and M-80 modelsM-60 and M-80 modelsM-60 and M-80 models use aflat gasket.

6. Fasten the front cover (3) with the cover screws (4)using the cover socket or open end/box end wrench.NOTE: 6A.NOTE: 6A.NOTE: 6A.NOTE: 6A.NOTE: 6A. LC recommends tightening the front coverscrews in a criss-cross or �star� pattern with a minimumof two passes. First pass should be at half-torque,with final pass(es) at full torque. This will ensureuniform seal compression on cover O-ring or gasket.See M-7 pattern on page 22 for reference.

Meter Assembly Exploded View

7. Install the front drain plug (6) in the front drain plughole (7) using the drain plug allen wrench.

8. Install an O-ring (8) into the groove (9) on the rear ofthe meter housing. The M-60 and M-80 modelsM-60 and M-80 modelsM-60 and M-80 modelsM-60 and M-80 modelsM-60 and M-80 models usea flat gasket.

9. Fasten the rear cover (10) with the cover screws (11)using the cover socket or open end/box end wrench.NOTE: 9ANOTE: 9ANOTE: 9ANOTE: 9ANOTE: 9A. LC recommends tightening the rear coverscrews in a criss-cross or �star� pattern with a minimumof two passes. First pass should be at half torque,with final pass(es) at full torque. This will ensureuniform seal compression on cover O-ring or gasket.See M-7 pattern on page 22 reference.

10. Install the rear drain plug (12) in the rear drain plughole (13) using the drain plug allen wrench.

11. If your meter is equipped with an electrical outputaccessory, such as a digital pulser, reinstall it accordingto the instructions outlined under �Reinstalling...� inyour accessory manual, such as the PulserInstallation, Operation and Maintenance Manualsupplied in your owner�s information packet. Installthe front drain plug (6) in the front drain plug hole (7)using the drain plug allen wrench.

2222222222



TTTTTORQUE PORQUE PORQUE PORQUE PORQUE PAAAAATTERN M-7 COVERSTTERN M-7 COVERSTTERN M-7 COVERSTTERN M-7 COVERSTTERN M-7 COVERS

*Torque Tolerance is ± 10%

2323232323

Wrench and Socket Size ChartWrench and Socket Size ChartWrench and Socket Size ChartWrench and Socket Size ChartWrench and Socket Size Chart

NOTE: FOR ROTOR GEAR SCREWSNOTE: FOR ROTOR GEAR SCREWSNOTE: FOR ROTOR GEAR SCREWSNOTE: FOR ROTOR GEAR SCREWSNOTE: FOR ROTOR GEAR SCREWS

Please apply these techniques when repairing meters in the field.

1. Prior to installation, apply a small amount of Locquic Primer N764 to each screw.2. Apply a light coat of Loctite 242 in three even strokes to each screw. The Loctite and Locquic primer are notto be applied to the female connection in the rotor.

2424242424


PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:Leakage past packing gland drive shaft housing from internal metering chamber.

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:Internal seal of packing gland assembly is worn. Replace packing gland and O-ring seal.

OPERAOPERAOPERAOPERAOPERATING NOTE:TING NOTE:TING NOTE:TING NOTE:TING NOTE:Two common causes of packing gland leakage are thermal expansion and hydraulic shock. If two valves in apiping system (on either side of the meter) are closed at one time, and if the temperature rises as little as 1°F inthe system, it could result in a rise in pressure within the system that would exceed the working pressure ratingof the meter. To avoid this hazard caused by thermal expansion, a pressure-relief valve of some kind must beinstalled in the system. Hydraulic shock occurs when a large volume (mass) of liquid is moving through a pipe lineat some flow rate and a valve is suddenly closed. When the flow is stopped, the entire mass of the liquid in thepiping system acts as a battering ram causing a shock effect within the meter. The greater the mass length of lineand/or velocity, the greater the hydraulic shock. Since the valve is usually located at the meter outlet, the meterhousing, packing gland and the meter internal members receive the full impact of such hydraulic shock. To preventthis hazard a slow closing two-stage valve should be used with the meter. On those systems where mass lengthof line, etc. are of such magnitude as to preclude the elimination of hydraulic shock with the use of a two-stageslow closing valve, an impact-absorbing air cushioning device should be used.

PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:Leakage from the cover gasket.

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:Gasket has been damaged due to shock pressure or cover bolts have not been tightened sufficiently.

PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:Product flows through meter but the register does not operate.

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:A.A.A.A.A. Check packing gland, and gear train.

B.B.B.B.B. If all meter parts are moving then problem is in register. Faulty register should be checked and repaired bytrained mechanic.

C.C.C.C.C. Remove register from meter. If all meter parts are moving but output shaft of adjuster assembly is not, adjusteris worn and must be replaced.

D.D.D.D.D. If totalizer numerals (small numbers) on register are recording, but the big numerals are not moving, registerneeds repair.

E.E.E.E.E. Packing gland gear not turning. For M-60 and M-80 meters, the drive blade may be sheared. Replace thepacking gland. This may be caused by starting the flow too rapidly.


All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in thesystem, the packing gland, and the front or rear covers. See �Relieving Internal Pressure� (page 11).

2525252525


PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:Breaking teeth on timing gears.

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:A.A.A.A.A. Starting or stopping flow in meter too rapidly.B.B.B.B.B. Pump bypass not adjusted properly.

PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:Product flows through meter but register does not record correctly.

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:A.A.A.A.A. Adjuster not properly calibrated.B.B.B.B.B. Incorrect gear plate or gear ratio has been installed.C. Air is in the system.

PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:No flow through meter.

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:A.A.A.A.A. Faulty non-functioning pump.B.B.B.B.B. Valve not open or not functioning.C.C.C.C.C. Meter �frozen� due to build-up of chemical �salts� or foreign material inside metering chamber. To correct,

clean the meter and inspect for damage.

PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:Meter runs too slowly.

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:A.A.A.A.A. Valve internal mechanism faulty. Valve does not open fully.B.B.B.B.B. Meter gears or rotors partially �salted� enough to slow up rotation of parts. To correct, clean the meter.C. Downstream restriction.D. Clogged strainer basket.

PROBLEM:PROBLEM:PROBLEM:PROBLEM:PROBLEM:The meter counts down in reverse (the meter numbers decrease).

PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:PROBABLE CAUSE AND SOLUTION:It is necessary to reverse the direction of flow by reversing the adjuster drive gear. See �M-7/MA-7 Meter Start Upand Operation: Reversing the Meter Registration� in this manual.

2626262626

How to Order Replacement PartHow to Order Replacement PartHow to Order Replacement PartHow to Order Replacement PartHow to Order Replacement Partsssss

1. Refer to the exploded view drawings on Pages 27-31.Find the four digit item number for the part you want toorder. The item numbers are listed on the explodeddrawings.

2. Find the computer printout titled Parts List that hasbeen inserted in the Owner�s Information Packet whichwas shipped with your order. Look up the item numberon the Parts List. The Parts List shows each itemnumber with a corresponding part number. Find thecorresponding five digit part number for the item youwant to order. The part number represents an individualpiece, a kit, or a complete assembly.

3. Inform your distributor of the part number that you need.The part number is the only number that allows thedistributor to find the correct component for your meter.

The Bills of Material for most meter classes are onThe Bills of Material for most meter classes are onThe Bills of Material for most meter classes are onThe Bills of Material for most meter classes are onThe Bills of Material for most meter classes are onthe LC public website. the LC public website. the LC public website. the LC public website. the LC public website. Always check the website forAlways check the website forAlways check the website forAlways check the website forAlways check the website forthe most current BOM.the most current BOM.the most current BOM.the most current BOM.the most current BOM.

2727272727


M5 through M25 Meters (including MA Meters)M5 through M25 Meters (including MA Meters)M5 through M25 Meters (including MA Meters)M5 through M25 Meters (including MA Meters)M5 through M25 Meters (including MA Meters)



2828282828


M30, M40 MetersM30, M40 MetersM30, M40 MetersM30, M40 MetersM30, M40 Meters



2929292929


M60, M80 Meter CoverM60, M80 Meter CoverM60, M80 Meter CoverM60, M80 Meter CoverM60, M80 Meter Cover



3030303030


M60, M80 Meter ElementM60, M80 Meter ElementM60, M80 Meter ElementM60, M80 Meter ElementM60, M80 Meter Element



3131313131

Quality SQuality SQuality SQuality SQuality Stttttatementatementatementatementatement

At Liquid Controls, we are dedicated to being the world leader in the field of liquid measurement.

Everyone associated with the enterprise must be committed to our quality effort and pursuing perfection.

To gain satisfaction in the eyes of our customers, we must accurately define and fulfill the customers� present andcontinuing needs.

We will strive to minimize the users� cost by providing products of high reliability, maintainability, serviceability, and no ofno planned obsolescence, which combine to give the customer superior value.

Our people are our greatest resource. We will create a positive, team-oriented environment which every person has trustand respect for one another, is recognized for achievement, and motivated toward excellence.

Absolute accountability for our efforts is determined by significant measures: our customers� level of satisfaction, thedevelopment of our people, and our contribution to the community.

Our goal is to be Simply the BestSimply the BestSimply the BestSimply the BestSimply the Best.

© 2004 Liquid Controls© 2004 Liquid Controls© 2004 Liquid Controls© 2004 Liquid Controls© 2004 Liquid ControlsPub. No. 48683Pub. No. 48683Pub. No. 48683Pub. No. 48683Pub. No. 48683

(05/04)(05/04)(05/04)(05/04)(05/04)

A Unit of IDEX Corporation105 Albrecht DriveLake Bluff, IL 60044-22421.800.458.5262 • 847.295.1050Fax: 847.295.1057www.lcmeter.com


P A R T S M A N U A L

M-7 ®, MA-7 ®

, M-10 ®Meters

Exploded View: M-7/MA-7/M-10 Meter Covers

0566 Plug,pipe-hex socket (2, one for each cover)

0627 Hex washer head screw(20, for both covers)

0125 Cover, rear

0126 Bracket, counter adapter

0202 Adjuster assembly

0364 Plate, adjuster mounting

0673 Screw (4)

0705 Washer, flat (4)

01

2

12 3 4

560

CAUTION

ALIGNCOUNTERDRIVESHAFTWITHSLOT

0603 Screw (2)

0382 Shaft, adjuster

0574 Ring,retaining

0165 Gear,packing gland

0366 Plate, dust cover

0630 Screw (2)

0780 Seal wire

0336 Gear

0250 PackingGland Assy.

0609 Screw, mounting plate (2)

0613 Screw, adjuster

LIQUID CONTROLS CORP. LAKE BLUFF, IL, USAMODEL NO.SERIAL NO.

MAX PRESSURE

VOL/REV

TEMP ERATURE

PRODUCT

FLOW RATE

®

ACCURACY

UK811783

Driveshaft bushing (2)

How to OrderReplacement Parts1. Find the item number listed on the exploded

drawing. The 4 digit item numbers are listed with a word description.

2. Find the computer printout titled Parts List that has been inserted in this manual. Look up the itemnumber on the Parts List. The Parts List shows eachitem number with a corresponding part number.Find the corresponding 5 digit part number for theitem you want to order. The part number representsan individual piece, a kit or a complete assembly.

3. Inform your distributor of the part number that youneed. The part number is the only number thatallows the distributor to find the correct componentfor your meter.

Exploded View: M-7/MA-7/M-10 Meter Housing

0672

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0153

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0163

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0528

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0673

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0318

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, dow

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4)

0771

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.

4


© 2001 Liquid Controls

SOLD AND SERVICED BY A NETWORK OF HIGHLY TRAINEDFULL SERVICE DISTRIBUTORS

Backed By Our Worldwide Reputation ForQuality, Accuracy and Advanced Design.

LIQUID CONTROLSA Unit of IDEX Corporation105 Albrecht DriveLake Bluff, IL 60044-2242(847) 295-1050FAX: (847) 295-1057Website: www.lcmeter.com

Bulletin #48496B $1Printed in U.S.A.(03/01)

Backed By Our Worldwide Reputation For Quality, Accuracy and Advanced Design.

Distributed By:

Printed with vegetable inks on recycled paper. Please Recycle!

WARRANTY:Liquid Controls (“Seller”) products are warranted againstdefects in material or workmanship for a period of one (1)year from date of installation, provided that the warranty shall not extend beyond twenty-four (24) monthsfrom the date of original shipment from Seller. Seller’s obligations, set forth below, shall apply only to failure(s) tomeet the foregoing obligations provided that Seller is givenwritten notice within thirty (30) days of any occurrencefrom which a claim of defect arises. If a warranty disputeoccurs, the Purchaser shall be required to provide Sellerwith proof of date of sale. The minimum requirement toestablish date of sale shall be a copy of the Seller’s invoice.In the event that a factory inspection by Seller or itsdesignee(s) supports the validity of a claim, at the discretion of Seller, repair, replacement or refund shall bethe sole remedy for defect and shall be made, free of

charge, ex-works factory. In no event shall Seller be liablefor any special, consequential, incidental, indirect or exemplary damages arising out of warranty, contract, tort(including negligence) or otherwise, including but not lim-ited to, loss of profit or revenue, loss of use of the product orany associated products and/orequipment, cost of substitutegoods or services, downtime costs or claims of or byPurchaser’s clients or customers. In any event, the total liability of Seller for any and all claims arising out of orresulting from the performance, non-performance or use ofthe product shall not exceed the purchase price of the indi-vidual product giving rise to the claim. All other guaranties,warranties, conditions and representations, either express orimplied, whether arising under any statute, common law,commercial usage or otherwise are excluded. ElectronicProducts require installation, start-up and servicing bylocal factory-trained service representatives. In the absence

of installation, start-up and servicing of Electronic Productsby Seller trained service representatives, this warranty isnull and void. Seller’s obligations as set forth above shallnot apply to any product, or, or any component or partthereof, which is not properly installed, used, maintained or repaired, or which is modified other than pursuant toSeller’s instructions or approval. NOTE: The above warranty applies only to products manufactured by LiquidControls, Lake Bluff, Illinois. Private label, OEM, and/orproducts manufactured by Liquid Controls licensee(s) arespecifically excluded from the above warranty. Consult factory for all non-Liquid Controls manufacturers’ warranties. NO IMPLIED OR STATUTORY WARRANTIESOF MERCHANTABILITY OR FITNESS FOR A PARTICULARPURPOSE SHALL APPLY.

VALUE 90 11/2"AUTOMATIC BULK FUELING NOZZLE

Catlow’s Value 90 Nozzle is an extra heavy duty, high flow, bulk fueling nozzle for marine, truck and bus or home fueloil delivery.The Value 90 has been designed for durability and yet economically priced. This rebuildable nozzle comes completewith automatic venturi shut-off and a dual position, hold-open mechanism.

Features:

Ordering Specifications:

CATLOW Inc. Sales Desk (800) 222-8569Sales Fax (937) 898-8631 Phone (937) 898-32362750 US RT 40, Tipp City, OH 45371©2006 CATLOW Inc. All Rights Reserved CV900306

• Curved lever design for easier gripping• Dual Poppet Assembly makes nozzle easier to open against high inlet pressure• Dash Pot minimizes line shock• Dual position hold-open mechanism for user friendly operation• BSPP and BSPT threads available upon request

• Strong body casting resists cracking• Venturi type automatic shut-off prevents accidental spillage • Spout assembly easily replaced• Nozzle design allows easy access to awkward fueling

positions• Lighter in weight

• CV90-001 11/2" Bulk Fueling Nozzle, New• CV90-002 11/2" Bulk Fueling Nozzle, New (ULC)• RV90 11/2" Bulk Fueling Nozzle, Rebuilt

Benefits:

Materials:• Body.......Aluminum• Weight....5.3 lbs.• Inlet........11/2" NPT• Spout.....Aluminum 1 3/8" OD• Seals......Viton and Buna

Accessories:• V90S Replacement spout assembly• V90SW 1 1/2" x 1 1/2" Swivel

BLACKMER TRUCK PUMPSINSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS

MODELS: TX, TXS, TXD, TXSD 1.5, 2A, 2.5A, 3E, 4ATXV 2.5B, 3B

and Discontinued TX(S) 2, 21/2, 3; TXV 2(A)(B), 21/2(A), 3(A) Models

960280INSTRUCTIONS NO. 201-A00Page 1 of 12Section 200Effective March 2003Replaces June 2001

TABLE OF CONTENTS Page

SAFETY DATA.................................................................1-2

PUMP DATA .........................................................................2Technical Data.......................................................2Initial Start Up Information .....................................2

INSTALLATION ...............................................................2-3Pre-Installation Cleaning .......................................2Location and Piping...............................................2Truck Mounting......................................................3Pump Drive............................................................3Pump Rotation.......................................................3To Change Pump Rotation ....................................3

OPERATION .....................................................................4-5Pre-Start Up Check List.........................................4Start Up Procedures ..............................................4Pump Speed..........................................................4Reverse Rotation...................................................4Flushing the Pump ................................................4Relief Valve ...........................................................4Relief Valve Setting and Adjustment .....................5

MAINTENANCE ...............................................................5-8Lubrication.............................................................5Vane Replacement ................................................5Pump Disassembly................................................6Pump Assembly ....................................................6

GENERAL PUMP TROUBLESHOOTING .................9-10

NOTICE:Blackmer truck pumps MUST only be installed insystems which have been designed by qualifiedengineering personnel. The system MUST conform toall applicable local and national regulations and safetystandards.

This manual is intended to assist in the installationand operation of the Blackmer truck pumps, andMUST be kept with the pump.

Blackmer truck pump service shall be performed byqualified technicians ONLY. Service shall conform toall applicable local and national regulations and safetystandards.

Thoroughly review this manual, all instructions andhazard warnings, BEFORE performing any work onthe Blackmer truck pumps.

Maintain ALL system and Blackmer truck pumpoperation and hazard warning decals.

SAFETY DATA

NOTE: Numbers in parentheses following individualparts indicate reference numbers on thecorresponding Blackmer Parts Lists.

This is a SAFETY ALERT SYMBOL.When you see this symbol on the product, or in the manual, look for

one of the following signal words and be alert to the potential forpersonal injury, death or major proper ty damage.

Warns of hazards that WILL cause serious personal injury, death or major proper ty damage.

Warns of hazards that CAN cause serious personal injury, death or major property damage.

Warns of hazards that CAN cause personal injuryor property damage.

NOTICE:Indicates special instructions which are very

impor tant and must be followed.

PRE-INSTALLATION CLEANINGForeign matter entering the pump WILL cause extensivedamage. The supply tank and intake piping MUST be cleanedand flushed prior to pump installation and operation.

LOCATION AND PIPINGAn improperly designed piping system or unit installation WILLsignificantly reduce pump performance and life. Blackmerrecommends the following piping system layout and unitinstallation.

1. To minimize intake losses, locate the pump as close aspossible to the source of supply.

2. Piping MUST be properly supported to prevent any pipingloads from being placed on the pump.

3. Intake piping and fittings MUST be at least as large indiameter as the pump intake connection.

SAFETY DATAFAILURE TO SET THE VEHICLE





DAMAGE.


property damage.
















PUMP DATA

* Optional materials of construction may be required to meet the operating limits listed above. Refer to Blackmer Material Specs 201/91-92 for TX(S)(D) models or 202/91-92 for TXV models.

1 780 RPM maximum pump speed for TX(S)(D)1.5, 2 and 2.5 models.500 RPM maximum pump speed for TX4A pump models.

TX(S)(D) TXV Models Models

Maximum Temperature* 300oF (149oC) 375oF (190oC)

Maximum Pump Speed 640 RPM1

Maximum Viscosity* 50,000 SSU (10,800 cSt)

Maximum Differential Pressure 125 psi (8.6 bar)

Maximum Working Pressure 175 psi (12.1 bar)(Inlet Pressure + Differential Pressure)

TECHNICAL DATA INITIAL START UP INFORMATION

Model No.

Serial No.

Date of Installation:

Pressure Gauge Reading:

Vacuum Gauge Reading:

Flow Rate:

INSTALLATION

NOTICE:BLACKMER TRUCK PUMPS MUST ONLY BEINSTALLED IN SYSTEMS DESIGNED BY QUALIFIEDENGINEERING PERSONNEL. SYSTEM DESIGN MUSTCONFORM WITH ALL APPLICABLE REGULATIONSAND CODES AND PROVIDE WARNING OF ALLSYSTEM HAZARDS.






DAMAGE.

Hazardous machinerycan cause severepersonal injury orproperty damage.

2

3

Figure 1 - Pump Drive

4. Minimize the number of intake line fittings (valves, elbows,etc.) and piping turns or bends.

5. Temporarily install vacuum and pressure gauges in the 1/4"NPT intake and discharge ports located on the pumpcylinder to check pump performance at start-up.

6. Install a strainer in the inlet line to protect the pump fromforeign matter. Placement of intake strainers shouldfacilitate frequent cleaning.

7. Intake and discharge piping MUST be free of all leaks.

TRUCK MOUNTINGThe pump will operate satisfactorily in any position. ConsultBlackmer factory for vertical shaft mounts. The pump can bebolted to the truck frame or on a saddle hung below the frame,and MUST be adequately supported. Mounting the pump withthe cylinder feet down, or with the intake port up, isrecommended for thorough draining of the pump.

PUMP DRIVE The pump may be driven by a power take-off through universaljoints. When using universal joints, a splined slip joint,properly lubricated, must be used on the connecting jack shaftto prevent end thrust on the pump shaft.

It is very important to install a proper drive line to avoidexcessive wear, vibration and noise (see Fig. 1 and Table 1).

General guidelines to follow for proper pump drive:

1. Do not use square slip joints.

2. Use the least number of jack shafts as is practical.

3. Use an even number of universal joints.

4. The pump shaft and power take-off shaft should be parallelin all respects. Use an angular level measuring device toensure the PTO and pump shaft are parallel to each other.If necessary, the pump can be shimmed to correct anymisalignment. The PTO shaft coming off at thetransmission does not need to be perfectly horizontal as

Table 1

Angle of Drive Shaft

1o through 5o 6o through 10o 11o through 15o

Very Good Good Fair

INSTALLATIONlong as the pump is shimmed to have its shaft parallel in allrespects to the PTO shaft.

5. The yokes of the universals at both ends of the jack shaftmust be parallel and in phase.

6. The maximum recommended angle between the jack shaftand the pump shaft is 15 degrees. Refer to Table 1.

Failure to follow any of these guidelines may result in a gallopor uneven turning of the pump rotor, which will in turn cause asurging vibration to the liquid stream and piping system.Contact the supplier of the drive line components for specificdesign assistance.

Hydraulic DriveThe pump may also be driven hydraulically. Hydraulic motorsmust be well supported with their shafts parallel to the pumpshaft in all respects. Blackmer provides an optional close-coupled hydraulic motor adapter. The adapter provides forstraight alignment of a hydraulic motor drive through a solidcoupling connected to a straight key pump shaft. Thiscoupling connection requires grease lubrication every threemonths at minimum. Refer to the "Lubrication" section of thismanual.

PUMP ROTATIONNOTICE:

CONFIRM CORRECT PUMP ROTATION BY CHECKINGTHE PUMP ROTATION ARROWS RESPECTIVE TO PUMPDRIVER ROTATION.

TO CHANGE PUMP ROTATION

TX(S)D and TXV ModelsThe TX(S)D and TXV pump models are equipped with adouble ended rotor and shaft, enabling them to be driven fromeither shaft end. To change rotation, rotate the pump 180degrees so that the opposite shaft becomes the driven shaft.On TX(S)D pump models, the shaft protector (186) MUST bemounted over the non-driven shaft end. On TXV pumpmodels, the outboard bearing cover (27) MUST be mountedover the non-driven shaft end.






TX1.5, TX4 Models and Discontinued TX(S) ModelsTo reverse the pump rotation, remove the bearing covers,locknuts/lockwashers or lock collars (if equipped), from bothinboard and outboard heads. Remove the inboard headassembly and reverse the rotor and shaft, so that the drivenend of the shaft protrudes from the outboard head. Removeand replace the vanes so that the relief grooves face in thedirection of pump rotation. Refer to the "Maintenance" Sectionof this manual for pump disassembly and assembly.

(Yokes must be in phase)

OPERATION

PRE-START UP CHECK LIST1. Check the alignment of the pipes to the pump. Pipes must

be supported so that they do not spring away or drop downwhen the pump flanges or union joints are disconnected.

2. Temporarily install vacuum and pressure gauges in the 1/4"NPT ports located on the pump cylinder. These can beused to check the actual suction and discharge conditionsafter pump start-up.

3. Inspect complete piping system to ensure that no pipingloads are being placed on the pump.

4. Secure appropriate hose connections.

START UP PROCEDURES

4

NOTICE:CONSULT THE "GENERAL PUMP TROUBLESHOOTING"SECTION OF THIS MANUAL IF DIFFICULTIES DURINGSTART UP ARE EXPERIENCED.

1. Start the pump. Priming should occur within one minute.

2. Check the vacuum and pressure gauges to ensure thesystem is operating within expected parameters. Recordthe gauge readings in the "Initial Start Up Information"section of this manual for future reference.

3. Inspect piping, fittings, and associated system equipmentfor leaks, noise, vibration and overheating.

4. Check the flow rate to ensure the pump is operating withinthe expected parameters.

5. Check the pressure sett ing of the relief valve bymomentarily closing a valve in the discharge line andreading the pressure gauge. This pressure should be 15 -20 psi (1.0 - 1.4 bar) higher than the maximum systemoperating pressure, or the external bypass valve setting (ifequipped). DO NOT operate the pump against a closeddischarge valve for more than 15 seconds. Ifadjustments need to be made, refer to the "Relief ValveSetting and Adjustment" section of this manual.

PUMP SPEEDPTO and hydraulically driven units MUST contain speedcontrol devices to prevent pump speeds above the maximumRPM specifications, regardless of the truck engine unloadingspeeds. Should fluid delivery be appreciably less thanexpected, see the "General Pump Troubleshooting" section.

PUMP OPERATING AGAINST A

CLOSED VALVE CAN CAUSE

SYSTEM COMPONENT FAILURE,

PERSONAL INJURY AND PROPERTY

DAMAGE.Hazardous pressurecan cause personal injury orproperty damage.

REVERSE ROTATION

NOTICE:PUMPS OPERATED IN REVERSE MUST HAVE ASEPARATE PRESSURE RELIEF VALVE INSTALLED TOPROTECT THE PUMP FROM EXCESSIVE PRESSURE.

It may be desirable to run the pump in reverse rotation forsystem maintenance. The pump will operate satisfactorily inreverse rotation to strip lines, at a reduced performance level.When operating the pump in reverse, a separate bypass valveMUST be installed to protect the pump from excessivepressure.

FLUSHING THE PUMP

NOTICE:IF FLUSHING FLUID IS TO BE LEFT IN THE PUMP FORAN EXTENDED TIME, IT MUST BE A LUBRICATING,NON-CORROSIVE FLUID. IF A CORROSIVE, NON-LUBRICATING FLUID IS USED, IT MUST BE FLUSHEDFROM THE PUMP IMMEDIATELY.

To flush the pump, use the following procedure:

1. Allow the pump to evacuate as much fluid as possible.

2. Run cleaning fluid through the pump intake. The cleaningfluid must be compatible with the pump O-rings and vanematerial. When handling "sticky" fluids that solidify withinthe pump (i.e., waxes, adhesives, resins, asphalts, etc.),use a fluid that will prevent solidification of the fluid beingtransferred and facilitate flushing.

3. Operate the pump against a closed discharge for 15seconds to allow the cleaning fluid to recirculate throughthe internal relief valve.

RELIEF VALVE

NOTICE:THE PUMP INTERNAL RELIEF VALVE IS DESIGNED TOPROTECT THE PUMP FROM EXCESSIVE PRESSUREAND MUST NOT BE USED AS A SYSTEM PRESSURECONTROL VALVE.

Pumping volati le l iquids under suction l i ft may causecavitation. Partial closing of the discharge valve WILL result ininternal relief valve chatter and must not be done. For theseapplications, install an external bypass valve, and anynecessary piping, back to the storage tank. This bypasssystem must be used when operating for extended periods(more than 1 minute) against a closed discharge valve.

RELIEF VALVE SETTING AND ADJUSTMENTThe relief valve pressure setting is marked on a metal tagattached to the valve cover. Generally, the relief valve shouldbe set at least 15 - 20 psi (1.0 - 1.4 bar) higher than theoperating pressure, or the external bypass valve setting (ifequipped).

OPERATION

5

Relief Valve Adjustment Procedure:

1. To INCREASE the pressure setting , remove the reliefvalve cap, loosen the locknut, and turn the adjusting screwinward, or clockwise. Replace the valve cap.

2. To DECREASE the pressure setting, remove the reliefvalve cap, loosen the locknut, and turn the adjusting screwoutward, or counterclockwise. Replace the valve cap.

Refer to the individual Blackmer pump parts lists for variousspring pressure ranges. The pumps are supplied from thefactory with the relief valve adjusted to the mid-point of thespring range. If the pump is equipped with a Blackmer airvalve, refer to setting and adjustment procedures covered inBlackmer Air Valve Instructions and Parts List No. 201-F00,286/F or 201-B00.

INCORRECT SETTINGS OF THE

PRESSURE RELIEF VALVE CAN

CAUSE SYSTEM COMPONENT

FAILURE, PERSONAL INJURY AND


MAINTENANCE






DAMAGE.


property damage.










NOTICE:MAINTENANCE SHALL BE PERFORMED BY QUALIFIED

TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE

PROCEDURES AND WARNINGS AS PRESENTED IN

THIS MANUAL.







LUBRICATIONBall bearings and hydraulic motor couplings (if equipped) mustbe lubricated every three months at a minimum. More frequentlubrication may be required, depending on the application andthe operating conditions. TXV pump model bearings MUSTbe replaced after each 1000 hours of service if f luidtemperature is greater than 250oF (120oC).

Recommended Grease:

TX(S)(D) Models - Exxon (Esso) - Ronex MP or Mobile -

Mobilith AW-2, or equivalent Lithium grease.

TXV Models - Exxon (Esso) - Polyres or Mobile - Mobile Poly372, or equivalent Polyurea grease.

Greasing Procedure:

1. Remove the grease relief fittings (76A) from the bearing covers (27 and 27A) or hydraulic motor adapter (135).

2. SLOWLY apply grease with a hand gun until grease beginsto escape from the grease relief fitting port. Discard excess grease in accordance with the proper codes and regulations.

3. Replace the grease relief fittings (76A).

DO NOT overgrease pump bearings. While it is normal forsome grease to escape from the grease tell-tale hole afterlubrication, excessive grease on pumps equipped withmechanical seals can cause seal failure.

VANE REPLACEMENTNOTICE:

MAINTENANCE SHALL BE PERFORMED BY QUALIFIEDTECHNICIANS ONLY, FOLLOWING THE APPROPRIATEPROCEDURES AND WARNINGS AS PRESENTED INTHIS MANUAL.

1. Remove the head assembly from the outboard (non-driven) side of the pump according to steps 2 - 6 in the"Pump Disassembly" section of this manual.

2. Turn the shaft by hand until a vane comes to the top (12o'clock) position of the rotor. Remove the vane.

3. Install a new vane, ensuring that the rounded edge is UP,

NOTICE:WHERE REGULATIONS REQUIRE, HOLES IN R/V CAP (1) ANDCAPSCREW W / HOLE (5C) ARE USED BY THE WEIGHTS ANDMEASURES OFFICIAL (S) TO APPLY A SECURITY SEAL OR TAG.

PUMP DISASSEMBLY

NOTICE:FOLLOW ALL HAZARD WARNINGS ANDINSTRUCTIONS PROVIDED IN THE "MAINTENANCE"SECTION OF THIS MANUAL.

1. Starting on the inboard (driven) end of the pump, clean thepump shaft thoroughly, making sure the shaft is free ofnicks and burrs. This wil l prevent damage to themechanical seal or lip seal when the inboard headassembly is removed.

2. Remove the inboard bearing cover capscrews (28) andslide the inboard bearing cover (27A) and gasket (26) offthe shaft. Discard the bearing cover gasket. On the 1.5, 2,2.5, and 3-inch pump models, the dirt shield (123A) willcome off with the bearing cover.

3. Remove the outboard bearing cover capscrews (28) andslide the outboard bearing cover (27) and gasket (26) offthe shaft. Discard the bearing cover gasket.

4. If equipped with locknuts and lockwashers (24A and 24B):

Figure 3 - Vane Installation - TXV Models**NOTE: 2-inch pump models have four (4) vanes.

Figure 2 - Vane Installation - TX(S)(D) Models**NOTE: 1.5 and 2-inch pump models have four (4) vanes.

MAINTENANCE

6

and the relief grooves are facing towards the direction ofrotation. See Figures 2 and 3.

4. Repeat steps 2 and 3 until all vanes have been replaced.

5. Reassemble the pump according to steps 2 - 7 and 12 - 17of the "Pump Assembly." section of this manual.

a. Bend up the engaged lockwasher tang and rotate thelocknut counterclockwise to remove it from the shaft

b. Slide the lockwasher off the shaft. Inspect thelockwasher for damage and replace as required.


5. The TX(S)4-inch pump model is equipped with bearing lockcollars (24A). To remove:

a. Remove the jam nuts (24C) and loosen the two setscrews (24B).

b. Slide the lock collar off the shaft.


6. Remove the head capscrews (21) and carefully pry thehead (20) away from the cylinder (12).

7. Slide the head off the shaft. The head O-ring (72), bearing(24), and mechanical seal (153) or lip seal (152) will comeoff with the head assembly. Remove and discard the headO-ring.

a. Pull the bearing (24) from the housing in the head (20).

b.To remove the mechanical seal (153), use two screwdrivers to gently push the backside of the seal jacket topush the seal from the head (see Figure 4). Use carewhen placing the screw drivers to prevent damage tothe seal faces. Remove and discard mechanical sealO-rings.

Figure 4 - Mechanical Seal Removal

c. To remove the lip seal assembly (152), use a thin prybar against the lip seal retaining ring to gently push thehousing (152B) out of the head (20). Use care not todamage the lip seal (152A). To remove the lip seal(152A), remove the retaining ring (152D) from thehousing, and gently pry the lip seal from the housing.Remove and discard the housing O-ring(s) (152C and152E).

8. Pull the rotor and shaft (13) from the cylinder (12). Whileone hand is pulling the shaft, the other hand should becupped underneath the rotor to prevent the vanes (14) andpush rods (77) from falling out. Carefully set the rotor andshaft aside for future vane replacement and reassembly.

9. Remove the remaining components from the outboard sideof the pump, as instructed in steps 6 and 7 above.

PUMP ASSEMBLYBefore reassembling the pump, inspect all componentparts for wear or damage, and replace as required. Washout the bearing/seal recess of the head and remove anyburrs or nicks from the rotor and shaft.

MAINTENANCE

7

1. Reassemble the OUTBOARD side of the pump first:

a. For a CLOCKWISE rotation pump, position the pumpcylinder with the INTAKE port to the left.

b. For a COUNTERCLOCKWISE rotation pump, positionthe pump cylinder with the INTAKE port to the right.

2. Install a new head O-ring (72) in the groove on the insideface of the head (20). Lay the O-ring flat and start in onone side of the groove, stretching ahead with the fingers,as shown in Figure 5.

Figure 5 - Head O-ring Installation

3. Install the head (20) on the outboard side of the cylinder(12). Install and uniformly tighten four head capscrews(21) 90o apart, torquing to 25 lbs ft (34 Nm).

4. MECHANICAL SEAL (If equipped)Apply a small amount of motor oil in the head recess. Pushthe mechanical seal assembly (153) into the recess of thehead with seal jacket drive tangs inward. The pin in thestationary seat must be between the lugs in the back of thehead recess.

5. LIP SEAL ASSEMBLY (if equipped)

The lip seal assembly (152) consists of a metal housingwith elastomer(s) around its outer diameter(s), and a teflonlip seal in its inner diameter. TXV “A” model pumps areequipped with spacer washers. Refer to Figures 6 and 7.

a. Apply a small amount of light motor oil on the innerdiameter of the lip seal housing (152B) to facilitate lipseal (152A) installation.Note: When installing the lip seal, be careful not to damage the lip seal O-ring.

b. On TXV “B” model pumps, push the lip seal (152A)squarely into the housing (152B) with the pin in the lipseal aligned with the hole in the back of the housing.The lip seal should seat flush or slightly recessed in thehousing, around its entire diameter.

c. On TXV “A” model pumps, insert the spacer washers(152F) into the housing, then push the lip seal (152A)squarely into the housing (152B) with flat side of the lipseal against the spacer washers. The lip seal shouldseat flush or slightly recessed in the housing, around itsentire diameter. Note: If necessary, the spacerwashers can also be located after the lip seal, as shownin Figure 7, to re-position the lip seal on the pump shaft.

d. Insert the retaining ring (152D) into the groove in thehousing.

e. Install new housing O-ring(s) (152C and 152E) in thegroove(s) of the housing. Lightly grease the housing O-ring(s) and push the lip seal and housing assembly intothe head recess with the lip seal inward. The lips of thelip seal will face the rotor when the housing is installed.Make sure the housing is bottomed out in the back ofthe head (20).

Figure 6 - Lip Seal - TXV “B” Models

Figure 7 - Lip Seal - Discontinued TXV “A” Models

6. Hand pack the ball bearing (24) with grease. Refer to the"Lubrication" section for the recommended grease.

7. Install the bearing (24) into the head recess. The bearingballs must face outward, with the grease shield inward.Ensure the bearing is fully and squarely seated against thelip seal housing (152B) or mechanical seal (153). On TXVpump models, install two 3/8" (10 mm) washers and twobearing cover capscrews (28) to clamp the bearing andcompress the lip seal housing inner O-ring (152E) forproper bearing locknut adjustment (see Figure 8). Thewashers and capscrews will be removed after the locknutsare adjusted.

Figure 8 - Clamping the Bearing

MAINTENANCE

8

c. Loosen both locknuts (24A) one complete turn.

d. Tighten one locknut (24A) until a slight rotor drag is feltwhen turning the shaft by hand.

e. Back off the nut the width of one lockwasher tang "B".Secure the nut by bending the closest al ignedlockwasher tang into the slot in the locknut. The pumpshould turn freely when rotated by hand.

f. Tighten the opposite locknut (24A) by hand until it issnug against the bearing (24). Then, using a spannerwrench, tighten the nut the width of one lockwashertang. Tighten just past the desired tang, then back offthe nut to align the tang with the locknut slot. Securethe nut by bending the aligned lockwasher tang into theslot in the locknut. The pump should continue to turnfreely when rotated by hand.

g. To check adjustment, grasp the nut and washer withfingers and rotate back and forth. If this cannot bedone, one or both locknuts (24A) are too tight andshould be alternately loosened one stop at a time(.001") (25 microns). Begin by loosening the locknutadjusted last.

h. On TXV pumps, after adjustment is complete, removethe bearing cover capscrews (28) and 3/8" washers fromboth ends of the pump.

13. LOCK COLLAR INSTALLATION - TX(S)4 Pump Modelsa. Slide the lock collar (24A) over the shaft and against the

bearing (24), with the counterbored side towards thebearing.

b. Push the collar (24A) forcibly against the bearing (24)by hand, while tightening the two setscrews (24B).Install and tighten the two jam nuts (24C) against thecollar.

c. Repeat this procedure on the opposite pump end. Afterinstalling both lock collars, verify the shaft turns freelywhen rotated by hand.

14. Inspect the grease seal (104) for wear or damage andreplace as required. Grease the outside diameter of thegrease seal and push it into the bearing cover (27 or 27A)with the lip of the seal inward. The lip will face outwardwhen the bearing cover is installed on the head.

15.Attach a new bearing cover gasket (26) and the bearingcover (27 or 27A) to the head (20). Install and torque thebearing cover capscrews (28) to 15 lbs ft (20 Nm).

16.Follow steps 14 and 15 to install the grease seal (104) andbearing cover (27 or 27A ) on the opposite side of thepump. On TXV pump models, the outboard bearing cover(27) is also a shaft protector and must be installed on thenon-driven shaft end.

17.On 1.5, 2 and 2.5-inch pump models, push the dirt shield(123A) over the inboard shaft and firmly against thebearing cover (27).

18.On TX(S)D pump models, attach the shaft protector (186)on the non-driven shaft end.

8. Turn the pump cylinder (12) around and begin assembly onthe opposite, inboard end.

9. Remove the vanes (14) and push rods (77) from the rotorand shaft assembly (13). Inspect for wear and damage,and replace as follows:

a. Partially install the non-driven end of the rotor and shaft(13) into the open side of the pump cylinder (12).

b. Leave part of the rotor outside of the cylinder so that thebottom vanes (14) can be installed and held in place asthe push rods (77) are installed in the push rod holes ofthe rotor. Insert the new vanes into the rotor slots withthe rounded edges outward, and the vane reliefgrooves facing TOWARDS the direction of rotation.Refer to Figures 2 and 3.

c. After the bottom vanes (14) and push rods (77) areinstalled, insert the rotor and shaft (13) fully into thecylinder (12).

d. Install the remaining vanes (14) into the top positions ofthe rotor. If equipped with a mechanical seal (153),rotate the shaft by hand to engage the drive tangsof the seal jacket in the rotor slots.

10. Install the inboard head (20), mechanical seal (153) or lipseal (152), and bearing (24) as instructed in steps 2through 7. Apply a thin coating of motor oil on the inboardshaft to aid installation.

11. Rotate the shaft by hand to engage the mechanical sealdrive tangs (if equipped), and to test for binding or tightspots. If the rotor does not turn freely, lightly tap the rims ofthe heads (20) with a soft faced mallet until the correctposition is found. Install all of the remaining headcapscrews (21) for each head (20) and uniformly torque to25 lbs ft (34 Nm).

12.LOCKNUT INSTALLATION (if equipped)

It is important that the bearing locknuts (24A) andlockwashers (24B) be installed and adjusted properly.Overtightening locknuts can cause bearing (24) failure or abroken lockwasher tang. Loose locknuts will allow the rotor(13) to shift against the heads, causing wear. See Figure 9.

a. On both ends of the pump shaft, Install a lockwasher(24B) with the tangs facing outward, followed by alocknut (24A) with the tapered end inward. Ensure theinner tang "A" of the lockwasher is located in the slot inthe shaft threads, bending it slightly, if necessary.

b. Tighten both locknuts (24A) to ensure that the bearings(24) are bottomed in the head recess. DO NOTovertighten and bend or shear the lockwasher innertang.

Figure 9 - Locknut Adjustment






9


NOTICE:MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANSONLY, FOLLOWING THE APPROPRIATE PROCEDURES ANDWARNINGS AS PRESENTED IN THIS MANUAL.


Pump Not Priming 1. Pump not wetted.2. Worn vanes.3. Suction valve closed.4. Leaks in the suction line.5. Strainer clogged.6. Suction line or valves clogged or too restrictive.7. Broken drive train.8. Pump vapor-locked.9. Pump speed too low for priming.

10. Relief valve partially open, worn or not seating properly.

Reduced Capacity 1. Pump speed too low.2. Suction valves not fully open.3. Leaks in the suction line.4. Excessive restriction in the suction line (i.e.: undersized piping, too many elbows

& fittings, clogged strainer, etc.).5. Damaged or worn parts.6. Excessive restriction in discharge line causing partial flow through the relief valve.7. Relief Valve worn, set too low, or not seating properly.8. Vanes installed incorrectly (see "Vane Replacement").

Noise 1. Excessive vacuum on the pump due to:

a. Undersized or restricted fittings in the suction line.b. Pump speed too fast for the viscosity or volatility of the liquid.c. Pump too far from fluid source.

2. Running the pump with a closed discharge line.3. Pump not securely mounted.4. Improper drive line (see "Pump Drive").5. Bearings worn or damaged.6. Vibration from improperly anchored piping.7. Bent shaft, or drive coupling misaligned.8. Excessively worn rotor.9. Malfunctioning valve in the system.

10. Relief valve setting too low.11. Damaged vanes (see following category).

Damaged Vanes 1. Foreign objects entering the pump.2. Running the pump dry.3. Cavitation.4. Viscosity too high for the vanes and/or the pump speed.5. Incompatibility with the liquids pumped.6. Excessive heat.7. Worn or bent push rods, or worn push rod holes.8. Settled or solidified material in the pump at start-up.9. Hydraulic hammer - pressure spikes.

10. Vanes installed incorrectly (see"Vane Replacement").

Troubleshooting continued on page 10.


Broken Shaft 1. Foreign objects entering the pump.2. Viscosity too high for the pump speed.3. Relief valve not opening.4. Hydraulic hammer - pressure spikes.5. Pump/driver misalignment.6. Excessively worn vanes or vane slots.7. Settled or solidified material in the pump at start-up.

Lip Seal / Mechanical Seal Leakage 1. O-rings not compatible with the liquids pumped.2. O-rings nicked, cut or twisted.3. Shaft at seal area damaged, worn or dirty.4. Ball bearings overgreased.5. Excessive cavitation.6. Lip seal not seated properly.7. Corrosion on lip seal housing.8. Mechanical seal faces cracked, scratched, pitted or dirty.


10

NOTES

11

1809 Century Avenue, Grand Rapids, Michigan 49509-1595, U.S.A.Telephone: (616) 241-1611 • Fax: (616) 241-3752

E-mail: [email protected] • Internet Address: www.blackmer.com Litho in U.S.A • © Copyright 2003

INSTALLATION INSTRUCTIONS

The RCI Technologies water sensor and indicator have been designed to operate when the RCI Technologies Fuel Purifier is in need of purging. A buzzer followed by a red indicator light will come on when the water level in the purifier reaches the sensor level. The buzzer will last 10 seconds. The light will stay on until the unit is purged.

466 W. Arrow Hwy, Ste D

San Dimas, CA 91773 Tel: 800-868-2088 Fax: 909-305-1245

Email: [email protected] International Email: [email protected]

NOTE: First determine power supply – 12 volt or 24 volt. Installation:

Remove heater from package. Apply Teflon tape (or other approved thread sealant) to the threads of the heater. Insert heater into the heater coupling and tighten into the body of the purifier.


1. Connect the two black leads together and attach to the negative side of a switch controlled fused circuit (using appropriate wire connectors).

2. Connect the common lead (white with black tracer) to the positive

side of the switch controlled fused circuit (again using the appropriate wire connectors).


1. Remove excess wire from the common lead (white with black tracer) leaving 1 to 2 inches of wire. Cap common lead with appropriate wire cap and crimp.

2. Connect the two black leads to the 24-volt switched fused power

supply (using the appropriate connectors).

For Assistance or Technical support call: (800) 868-2088

12 Volt – 6 amps 24 Volt – 3 amps

INSTALLATION AND WIRING INSTRUCTIONS


TM

May 1999 Section 29 Page 1A

Ø.56 HOLE

7.26

1.071.64

(5) Ø.28 HOLES

1.97.75

1.00

1.91

2.75

.75

Operator Accessories

Description Part No. Material Weight (lb) Remote Control Assy. 35603SL 1.10

Cable Clamp only 9Q1660 Stainless

.10 New design provides greater stroke (2-1/8”) and leverage. Stainless steel to resist corrosion. Remote attaches to trip lever on operator using cable. Pulling remote lever rotates operator trip lever and bar assembly, causing all open emergency valves to close. Per 49CFR178.345-11, remote must be located at least 10 feet away from loading/unloading outlet (where vehicle length allows) or on the end of the cargo tank farthest from the loading/unloading outlet. Test cable remote controls and operators at least once a day to insure proper functioning.

Part No. Material Weight (lb) 21050A Steel .17

Heavy duty fusible cable links are designed to attach the cable to the emergency valve cable lever arm and to provide thermal activation at the emergency valve. Fusible element melts at not more than 250°F, releasing the cable tension and allowing the emergency valve to close. Uses same non-slip, adjustable cable attachment as on Betts operators.

Fusible Link 3.86

Ø.31 x .75CLEVIS PIN

1.71

.47 COTTER PIN

.40

.60

716-20 UNFHEX NUT

.28

VEEDER-ROOT INSTALLATION, OPERATION AND SERVICE INSTRUCTIONS

SERIES 7886SERIES 7886 HIGHHIGH--CAPCAPACITYACITY & SERIES 7887& SERIES 7887

METER REGISTERSMETER REGISTERS Manual No. 251325 (REV. B)

VEEDER-ROOT Petroleum Products

Installation, Operation and Service Manual Series 7886 High-Capacity & 7887 Meter Registers TABLE OF CONTENTS SECTION 1. INTRODUCTION A. General ..................................... I SECTION 2. SERIES 7887 DESCRIPTION A. General ..................................... I B. Specifications ................................ 2 SECTION 3. SERIES 7886 DESCRIPTION A. General ..................................... 3 B. Specifications ................................ 3 SECTION 4. PERIODIC INSPECTION A. General ..................................... 5 B. Disassembly Prior to Cleaning ............... 5 C. Cleaning .................................... 5 D. Inspection ................................... 5 E. Lubrication .................................. 5 F. Troubleshooting .............................. 7 SECTION 5. DISASSEMBLY AND ASSEMBLY A. General ..................................... 8 B. Removal of Major Groups ...................... 8 C. Individual Parts Replacement .................. 10 D. Installation of Major Groups .................... 10 E. Final Checks and Adjustments ............. 15 F. Operational Check ............................ 16 SECTION 6. DAMAGE CLAIMS AND WARRANTY A. Damage Claims ............................... 16 B. Return Shipping .............................. 16 C. Warranty and Conditions ...................... 16

SECTION 1. INTRODUCTION A. GENERAL. These instructions are for servicing the Series 7886 High-Capacity and Series 7887 Meter Registers designed and manufactured by the Veeder-Root Company, 6th Avenue at Burns Crossing. P.O@ Box 1673, Altoona, PA 16603. Phone: (814) 695-4476. When a vertical bar I appears adjacent to text orILlu strations, information has been added or changed at the last issue date. Note- Consult Veeder-Root on any unusual application, installation or possible modification of this basic design. Every Meter Register is thoroughly tested at the Veeder-Root factory and by the meter manufacturer when installed on the meter. However, like any precision mechanism, it requires periodic care to ensure maximum service. This manual is for use in areas where factory rebuilding facilities and adequate exchange stocks are not readily accessible.

Where manufacturer's replacement stocks are available, it is important that no attempt be made to repair any meter register defective within the terms of the warranty as by doing so, the warranty is void and the user is deprived of the protection provided by the warranty. It is recommended that, when possible, meter registers be replaced and the defective unit returned to the meter manufacturer. Note: See Section 6 for complete Damage Claims and Warranty.

IMPORTANT! The instructions, photographs and drawings in Sec tions 4 and 5 are based on the Series 7887 Meter Register. With the exception of an additional counting wheel, the Series 7886 High-Capacity Meter Register is physically similar and the same procedures should be followed.

SECTION 2. SERIES 7887 DESCRIPTION A. GENERAL. 1. Physical. The Series 7887 Meter Register, Figure 1, displays a running account, final total and accumulated total of the quantity of liquid product delivery. Contained in a 4'x I O'diecast enclosure, individual delivery data is displayed on five 3/4' high flgures while totalizer information is recorded on eight 1/8' high figures. Reset of the Meter Register is accomplished through a reset knob on the right-hand side of the unit. 2. Operational. The Meter Register is operated by a drive shaft connected to a group of gears on the gear plate which converts the drive revolutions to the appropriate ratio. The output bevel gear of the group drives a bevel gear, Figure 5, which is connected to the drive shaft and clutch assembly. In rotating, this shaft drives a gear on the

clutch assembly which in turn drives a gear on the right (unit)wheel assembly. Revolutions are then accumulated on the wheels. In addition, this rotating shaft drives the bracket group connected to the accumulative totalizer shaft, thus both displays are driven from the same source, assuring accurate recording of information. During the reset operation, the clutch is disconnected from the drive shaft, a shutter moves into place covering the display wheels and reset fingers engage heart-shaped cams on the individual wheels to move them back to a zero position. In addition, a set of anti-topping fingers engages the wheels to preventjamming. At the completion of reset, the display wheels will read all zeros, and the shutter will rise to the normal operating position. The clutch will engage the drive shaft to transfer the information from the next delivery. The totalizer wheels will be unaffected by this reset operation, thus displaying an accurate measure of the accumulated totals of many deliveries.

B. SPECIFICATIONS. Specifications listed are standard unless otherwise noted. Optional features are available at additional cost. Speed: 250 rpm. Torque: Average running torque at room temperature with 1: I input: 4 oz-in. During display wheel transfer from all 9's to all O's, the instantaneous peak torque may reach 40 oz-in. Operating Temperature Range: -40' to +710C (-400 to + I 60'F). Number of Figures: Meter Register: 5. Accumulative Totalizer: 8 Size of Figures: Meter Register: 0.750' high x 0.400' wide (I 9.05 x 10. 16 mm). Totalizer: 0. 1 25' high x 0.078' wide (3.175 x 1.98 mm). Color of Figures: White on black, except right-hand totalizer wheel which is black on white when recording tenths of units, and white on black when recording whole units.

Style of Figures: Veeder-Root/Cornell for optimum read- ability. Character Configuration: 0 to 9 (options available). Reset: Single handle on register. Designed for one-handed operation. Mounting: Eight 1/4 x 28 tapped holes with steel inserts on a 6.625' (168.28 mm) diameter. Special adaptors are available for nearly all meters. Construction: Cover: cast aluminum. Case and sub frame: cast Zamak. Wheels, pinions, and clutch: acetal resin. Gearing: 1:1 is standard. 1:1 through 42:1 are available. Lubrication: Periodic. OPTIONS Nonreset Pulser: Meter Register with Series 1871 or 7671 Pulse Transmitter.

SECTION 3. SERIES 7886 DESCRIPTION A. GENERAL. 1. Physical. The Series 7886 High-Capacity Meter Register, Figure 3, displays a running account, final total and accumulated total of the quantity of liquid product delivery. Contained in a 4' x 10' die cast enclosure, individual delivery data is displayed on six 5/8' high figures while totalizer information is recorded on eight 1/8' high figures. Reset of the Meter Register is accomplished through a reset knob on the right-hand side of the unit. 2. Operational. The Meter Register is operated by a drive shaft connected to a group of gears on the gear plate which converts the drive revolutions to the appropriate ratio. The output bevel gear of the group drives a bevel gear, Figure 5, which is connected to the drive shaft and clutch assembly. In rotating, this shaft drives a gear on the clutch assembly which in turn drives a gear on the right (unit) wheel assembly. Revolutions are then accumulated on the wheels. In addition, this rotating shaft also drives the bracket group connected to the accumulative totalizer shaft, thus both displays are driven from the same source, assuring accurate recording of information. During the reset operation, the clutch is disconnected from the drive shaft, a shutter moves into place covering the display wheels and reset fingers engage heart-shaped cams on the individual wheels to move them back to a zero position. In addition, a set of anti-topping fingers engages the wheels to prevent jamming. At the completion of reset, the display wheels will read all zeros, and the shutter will rise to the normal operating position. The clutch will engage the drive shaft to transfer the information from the next delivery. The totalizer wheels will be unaffected by this reset operation, thus displaying an accurate measure of the accumulated totals of many deliveries.

B. SPECIFICATIONS. Specifications listed are standard unless otherwise noted. Optional features are available at additional cost. Speed: 250 rpm. Torque: Average running torque at room temperature with 1:1 input: 4oz-in. During displaywheeltransfer from all 9s to all O's, the instantaneous peak torque may reach 40 oz-in. Operating Temperature Range: -40' to +71'C (-40' to + 160'F). Number of Figures: Meter Register: 6. Accumulative Totalizer: 8 Size of Figures: Meter Register: 0.625' high x 0.300' wide (15.87 x 7.62 mm). Totalizer: 0.125' high x 0.078' wide (3.175 x 1.98 mm). Colorof Figures: White on black, except right-hand totalizer wheel which is black on white when recording tenths of units, and white on black when recording whole units. Style of Figures: Veeder-Hoot/Cornell for optimum read- ability. Character Configuration: 0 to 9 (options available). Reset: Single handle on register. Designed for one-handed operation. Mounting: Eight 1/4 x 28 tapped holes with steel inserts on a 6.625' (168.28 mm) diameter. Special adaptors are available for nearly all meters. Construction: Cover: cast aluminum. Case and sub frame: cast Zarnak. Wheels, pinions, and clutch: acetal resin. Gearing: 1:1 is standard. 1:1 through 42:1 are available. Lubrication: Periodic. OPTIONS Nonreset Pulser: Meter Register with Series 1871 or 7671 Pulse Transmitter.

SECTION 4. PERIODIC INSPECTION (For Series 7886 High-Capacity and Series 7887 Meter Registers) A. GENERAL The Meter Register is fully lubricated and property adjusted at manufacture. However, periodic cleaning and lubrication are required. Judgment of the intervals at which the meter register requires such service must necessarily be left to the individual user due to varying conditions of service. Under normal conditions, this will be at least once a year, or after each 2-1/2 million units of measure delivered, whichever comes first. B. DISASSEMBLY PRIOR TO CLEANING. Remove the meter register from its housing as follows: I .Remove the bolts securing the cover (if present) to the top of the housing. These bolts are hex head and are located at the four corners of the bottom of the housing. Remove the cover. 2. Remove the three button-head bolts securing the meter register to the housing. Remove the meter register. 3. Remove the screws securing the gear plate to the bottom of the housing. Remove the gear plate. C. CLEANING. CAUTION: DO NOT USE A WIRE BRUSH. 1. Wipe bezel crystal with a clean lint-free rag. 2. If the wheel faces are dirty, gently clean with a clean lint-free rag dipped in mild soapy water. 3. Clean the gears on the base plate by flushing or with a brush dipped in solvent. Blow dry with compressed air. 4. Clean housing by dipping, flushing or brushing with solvent. Blow dry with compressed air. D. INSPECTION. A periodic inspection of the entire meter register, housing and gear plate is required to make sure that they function property, parts are in place, and no binding or excessive side-to-side motion of shafts occurs. A checklist on such procedures follows: 1. Check the following shafts for perceptible side-to-side motion. Note: Remove the meter register from the housing before checking shaft freedom. a. Wheel Shaft b. Anti-Topping Finger Group Shaft c. Reset Finger Group Shaft d. Clutch Group Shaft e. Pinion Shaft 2. Temporarily install the base plate and meter register in the housing and check for proper engagement and freedom of movement of: a. All gears on gear plate. b. Output bevel gear on gear plate with the bevel drive gear on drive shaft.

c. 57 tooth gear on clutch assembly with gear on right wheel assembly. d. Gear drive shaft with gear train that operates the totalizer, and gear connecting the drive train to the totalizer. 3. Rotate drive shaft by hand to see that unit operates freely and then reset, checking for proper reset and shutter action. Adjust pointer after reset as required. 4. Check all screws, retaining rings and groove pins to see that they are tight and seated properly. E. LUBRICATION. 1. Recommended Lubricants Note: Chelae and Vischem products are manufactured by Ultrachem Inc., 1400 N. Walnut St., P.O. Box 2053 Wilmington, DE 19899 Oil: Chemlube 201 or equivalent with a temperature range of -65F to + 275F (-54'C to + 135'C). Grease: Vischem 352 or equivalent with a temperature range of -65'F to +300'F (-54'C to + 149'C). Note: All lubricants used in the register must be of a type

which remains fluid over the full temperature range to which the register will be subjected. Also, they should not oxidize or dry out leaving a gummy or perceptible residue.

If the Chemlube 201 oil lubricant is not available, a substitute with equivalent properties may be used. To assist field personnel in obtaining suitable lubricants for the meter register and ticket printers, the following list showing equivalent lubricants has been prepared:

OIL AEROSHELL FLUID NO. 3 REGENT SPINTEX OIL 60 GARGOYLE ARCTIC OIL LIGHT CASTROL HYSPIN 40 ANDEROL 401D

GREASE AEROSHELL 14 ESSO BEACON 325 ANDEROL 795 2. Points to Lubricate Oil: All points indicated as "Oil" on Figure 6 should be lubricated with oil as described above. This includes all shafts, studs, and bosses on which a moving part bears. Grease: Grease should be applied to all points indicated as "Grease' on Figure 6. This includes gears and the no-back ratchet and pinion. Note: The oil and grease should be applied with a small

brush to make certain that all areas will he properly lubricated. In this manner, the amount of lubrican t being used will be more easily controlled.

TROUBLE POSSIBLE CAUSE CORRECTION 1. Drive shaft hard to turn. Pointer or brake rubbing on first wheel

Dirt or pieces of foreign material in teeth of drive gears, gear plate, totalizer or bevel gear train driving totalizer.

Check pointer and break positioning. Adjust as required. Remove case. Check all gears, clean and lubricate as necessary. See Sect 4.

2. Binding occurs during reset cycle Missing washers on outside of clutch shaft. Pinion jam, anti-topping finger(s) broken or spring(s) missing

Check end play and washer as required. Check end play of wheel shaft. Replace broken anti-topping finger(s) or missing spring(s)

3. Reset knob turns hard Reset knob flange on the case binds on reset shaft. Wheel shaft group is bent. Reset fingers rubbing on wheel or retaining rings.

Remove reset knob. Loosen flange screws, center the flange on the shaft and tighten the screws. Replace wheel shaft. Check for missing retaining rings on reset finger and wheel shafts. Replace as required.

4. Any one wheel will not reset to zero Broken reset finger. Locking disc pin out of wheel groove.

Replace reset fingers as required. Disassemble wheel group and insert locking disc pin into groove in wheel.

5. Incomplete reset cycle. Knob turns but reset does not occur.

Key in large multiple cam broken. Reset actuating lever not engaged in cam or reset arm broken.

Replace cam with new cam and key. Remove cam, inspect and replace parts as required, and assemble properly.

6. Shutter partially obscured wheels at completion of reset cycle or completely covers wheels at reset cycle.

Shutter disconnected from reset lever. Connect shutter to reset lever.

7. Shutter will not drop into place or loss of detent action during reset.

Detent lever spring missing or broken. Install new spring.

8. Pointer not aligned with unit wheel. Improper adjustment of brake or pointer. Adjust brake to proper clearance. Adjust pointer to center mark.

9. Unit wheel can be turned in reverse by hand.

Dirty drive shaft clutch assembly. Clean clutch group and lubricate. See Section 4.

10. Cannot drive meter register. Pinion jam, reset fingers are engaged, heart cams hit on detent lever shutter stud, clutch not engaged.

Check washers on pinion shaft. Check and play of shafts. Clean and lubricate clutch.

F. TROUBLESHOOTING. Tabel 1 is used to assist in locating problems and making repairs and corrections. In some problems, similar defects can be produced by several causes of an entirely different nature. Cause of trouble must be determined and the correction made.

Table 1. Troubleshooting

SECTION 5. DISASSEMBLY AND ASSEMBLY (For Series 7886 High-Capacity and Series 7887 Meter Registers) A. GENERAL. When disassembling the meter register, be extremely careful not to lose or intermix any of the washers found on the shafts. By doing so, potential problems with end-play and backlash adjustments will be greatly lessened. When removing retaining rings or other parts from shafts, do not hold the shaft with any tool that might gouge or create burrs on the shaft. B. REMOVAL OF MAJOR GROUPS. Instructions for removal of all shaft groups are provided.

1. If present, remove the retaining ring securing the reset idler gear to the reset idler gear shaft. 2. Remove retaining rings and washers securing the pinion, reset, anti-topping and clutch shafts to the right-hand side plate (Figure 7). Remove screws and lockwasher securing the totalizer group and rear mounting bar from right-hand side plate. 3. Remove side plate. CAUTION: DO NOT LOSE OR INTERMIX WASHERS FROM EACH SHAFT. Note: Remove only those shaft groups necessary to gain access to parts being replaced.

4. Clutch Shaft Group Removal. a. Remove retaining ring and washers securing the clutch shaft group to the left-hand side plate. See Figure 8. b. Move clutch lever group so clutch is free. See Figure 9. Remove clutch shaft group. See Paragraph C, 1 for parts replacement. 5. Reset Finger Group Removal. a. Remove retaining ring and washer securing the reset group to the left-hand side plate. See Figure 8. b. Disengage the reset fingers and no-back pawl from th wheels. SeeFigure 10. Rernovethegroup. See Paragraph C, 2 for parts replacement. 6. Stop Shaft Removal. a. Remove the springs from between the anti-topping fingers and the stop shaft. b. Remove the spring from between the detent lever group and the stop shaft. c. Remove the stop shaft. 7. Anti-Topping Finger Group Removal. a. Remove the retaining ring and washers securing the anti- topping finger group shaft to the left-hand side plate. See Figure 8. b. Disengage the anti-topping fingers and the clutch lever group from the wheels. See Figure I 1. c. Remove the group from the side plate. See Paragraph C, 3 for parts replacement. 8. Totalizer Group Removal. a. Remove the screws securing the totalizer group to the left-hand and right-hand side plates. See Figures 7 and 8. b. Remove the totalizer group. c. No additional disassembly of the totalizer is possible. If the totalizer is inoperable, replace the group.

Note: If the inoperable totalizer has a small bevel gear (approx. 11/32 inch dia.) on the drive shaft, replace the bracket group on the left side frame as well as the totalizer group (see Figure 31 and Paragraph D, 7 and E, 5). Remove the screw holding the pointer onto the old totalizer and save for installation on new totalizer. 9. Pinion Removal. a. Remove retaining ring securing pinion shaft to the left- hand side plate. See Figure 8. b. Rotate the detent lever group so it will clear the reset cam. Remove shaft. c. Remove pinions, detent lever group washers and retaining rings from shaft. 10. Wheel Group Removal. a. Mark relationship of reset gear to wheel group shaft to assure proper positioning during assembly. b. Remove pin securing reset gear to the wheel group shaft. c. Remove gear, retaining ring and washer. Remove shaft. See Paragraph C, 4 for parts replacement.

C. INDIVIDUAL PARTS REPIACEMENT 1. Clutch Shaft Parts Replacement. See Figure 12. a. Totalizer and Drive Bevel Gears.

(1) Drift out pin securing gear to shaft. (2) Remove gear. (3) Remove retaining rings and washers that position drive gear. Do not change the order of the rings and washers. (4) Drift out pin holding drive gear and remove gear.

(5) Install new gear, pin, retaining rings and washers. Use new pin if required. (6) Install totalizer bevel gear and secure with pin.

CAUTION: CHECK SHAFT FOR STRAIGHTNESS AFFER PINNING. A BENT SHAFT WILL CAUSE BINDING DURING DRIVING OF METER REGISTER. CLUTCH MUST NOT BE DISASSEMBLED OR REPLACED AS AN INDIVIDUAL GROUP. IF CLUTCH IS BROKEN OR MALFUNCTIONS, REPLACE COMPLETE SHAFT AND CLUTCH AS AN ASSEMBLY. 2. Reset Finger Group Parts Replacement. See Figure 13. Individual reset fingers, reset arm, no-back pawl and pawl spring may be replaced as required. a. Remove retaining rings and appropriate washer to reach particular part. b. Replace defective items with new part. Assemble remaining parts on shaft. Install retaining rings and washers. Check end play per Figure 28. 3. Anti-ToppingFingerGroupPartsReplacement.SeeFigure 14. Individual anti-topping fingers, reset lever and clutch lever may be replaced as required. a. Remove retaining rings, washers and parts as required to get to part that is to be replaced. b. Install parts, retaining rings and washers in the sequence shown in Figure 14. Be sure to install parts so they are in the proper direction. Check end play per Figure 28. 4. Wheel Group Parts Replacement. See Figures 15, 16, 17 and 18. The reset cam, individual wheels, locking discs and eccentrics may be replaced as required. a. Remove retaining rings, washers and key as required to remove reset cam, wheels, locking discs and eccentrics. b. Install parts, retaining rings, washers and key in the sequence shown in Figure 17. When installing wheels, be sure the pin on the locking disc engages the groove in the wheel as shown in Figure 18. Check end play per Figure 28. D. INSTALLATION OF MAJOR GROUPS Prior to installing each shaft, lubricate per Paragraph E in Section 4. During assembly, do not intermix washers from one shaft to another. 1. Wheel Group Installation. a. lfnotpresent,installaO.030inchthickwasheroverthe end of the wheel group shaft opposite the cam. b. Install the shaft into the proper hole in the left-hand side plate. See Figure S. 2. Anti-Topping Finger Group Installation. See Figure 19. a. Hold wheel and side plate assembly upside down. b. Install anti-topping finger group in proper hole in left- hand side plate (see Figure 8). Be sure all fingers and clutch lever are free of wheels and the pin on the reset ievel, engages the track on the cam.

c. Seat the shaft, install washers and retaining ring to secure shaft to left-hand side plate. d. See that all fingers are free to engage wheels. 3. Stop Shaft Installation. a. Install retaining rings on ends of shaft. b. Insert stop shaft into proper hole in left-hand side plate. See Figure 8. 4. Reset Finger Shaft Group Installation. a. Rotate no-back pawl so that spring puts pawl under tension. Slip an elastic band over the reset fingers and pawl to hold pawl in position. See Figure 20. b. Install shaft into left-hand side plate and secure with retaining ring and washers. See Figure 8. c. Engage pin on reset lever group with slot in reset arm. See Figure 22. 5. Clutch Shaft Group Installation. a. Install shaft in proper hole in left-hand side plate. Add washers and secure with retaining ring. See Figure 8. b. Make sure that bevel gears that drive the totalizer are free to turn.

6. Right-Hand Side Plate Installation a. Hold meter register assembly as shown in Figure 22 and place a rubber band around the assembly to hold it together. Be sure the pin in the reset lever group remains engaged in the slot in the reset arm. b. Install side plate over wheel shaft first, then engage the other shafts. c. Temporarilysecure the side plate to the rear mounting bar with screws. 7. Bracket Group (if required) and Totalizer Installation. a. If required, install new bracket group to inside of left side frame and secure with two screws and lockwashers. See Figure 31. b. Install pointer with screw (saved from old totalizer) onto new totalizer group but do not tighten screw securely. Pointer position must be adjusted after totalizer group is installed. See Paragraph F, 2. c. Install the totalizer group so that the bevel gear is in mesh with the top bevel gear on the bracket group and secure with retaining screws. For adjustment of bevel gear drive, see Paragraph E, 5.

8. Spring Installation. a. See Figure 23 for identification of springs. b. Install the five anti-topping finger springs between the anti-topping fingers and the stop shaft. See Figure 24. c. Install the reset spring between the reset lever and the pinion shaft. d. Install the detent spring between the detent lever group and the stop shaft. e. Install the clutch spring between the clutch lever group and the pinion shaft. 9. Pinion Shaft Assembly Installation a. If not previously accomplished, remove all parts from pinion shaft. b. Rotate wheel shaft so reset fingers are fully engaged in the heart-shaped cams on each wheel. c. Place pinions, with short finger up, in between each wheel as shown in Figure 25. d. Install the end of the shaft closest to the two retaining ring slots into the left-hand side plate and through each pinion.

e. Install washers and detent lever group onto shaft and engage shutter with tab on detent lever. f. Push shaft through the right-hand side plate and secure with washer and retaining ring. g. Secure detent lever group into position with retaining rings. h. After assembly, rotate wheel shaft to make sure all pinions have been positioned properly. If binding occurs, reposition pinions per step c. 10. Reset Gear Installation. a. Install reset gear on wheel shaft, aligning orientation mark made at disassembly. b. Secure gear to shaft with pin. II. Reset Idler Gear Installation. a. If present, install reset idler gear on the reset idler gear shaft. See Figure 8. b. Secure with retaining ring. Note: This gear will be tirned when the meter duplicator and meter register are assembled together.

E. FINAL CHECKS AND ADJUSTMENTS. 1. End Play Check: Check end play (back and forth motion) of shafts and parts as follows: a. For proper measurement, the meter register must be installed in the TD-42383 mounting fixture, Figure 26, to constrain the frame into the same position that it is when installed in the housing. b. Secure the meter register to the fixture with two 1/4-28 button- head bolts. See Figure 27. c. Take end play measurements of each shaft. Add or subtract washers as necessary to obtain correct end play. 2. Input Drive Bevel Gear Engagement Adjustment. a. Install the gear plate onto the fixture using the appropriate hardware. b. Remove the retaining ring behind the bevel gear and add or subtract washers as required for proper rnesh between the bevel gear on the gear plate and the drive bevel gear on the clutch shaft. The shaft end play must be maintained as specified in Figure 28. c. Replace the retaining ring after adjustment. 3. Clutch Lever Positioning Adjustment. a. Rotate the reset gear until the clutch is fully disengaged. b. Measure the clearances as shown in Figure 29. c. If the dimensions cannot be obtained, add or remove washers as required, or replace the clutch and shaft. d. The amount of face engagement between the spur gear on the input clutch and the first wheel should be 75% + 20%. 4. Wheel Brake Adjustment. a. Rotate reset gear to position earn as shown in Figure 30. b. Measure clearance between brake and first wheel. If clearance is not within the dimensions given, adjust brake by loosening screw and moving brake into position. c. Remove the meter register from the fixture by removing the two button-head screws. Remove the gear plate from the fixture. 5. Gearing Adjustment for Totalizer. See Figure 31. Loosen set screw on bottom bevel gear. Mesh the top bevel gear tightly with the totalizer bevel gear. Press the register clutch shaft toward the left side frame. Adjust the bottom bevel gear such that it has 0.012 - 0.015 end play when meshing with the clutch shaft bevel gear. Tighten set screw and secure with a sealant (Loctite 222 or equivalent) to prevent loosening. 6. ApplyAnderoIL-795orequivalentgreaseonteethofbevel gears. 7. Backlash Compensating Mechanism Adjustment for EEC UNITS ONLY. While unit is running at 100-200 RPM, adjust screw so that pawl is approximately in the middle of clip as shown in Figure 32 (on Page 16). Oscillation of pawl is permissible. To check for proper operation, use a 1: I gear plate and operate register at 100-200 RPM. Stop counting, hold input shaft of gear plate and reset register. Wheel should reset so that some part of graduation at zero always aligns with pointer.

F. OPERATIONAL CHECK. Before returning the meter register to normal service, check that it operates properly as follows: 1. Rotate the input bevel gear and see that the totalizer and individual delivery wheels are driven and that they record the same amount. There should be no binding or drag. 2. Rotate the reset gear and see that the shutter drops into place, the wheels all reset and that there is no binding or drag. At the completion of reset, the zeros should align with the pointer. 3. See Troubleshooting, Table 1. Page 5, if there are any problems. SECTION 6. DAMAGE CLAIMS AND WARRANTY A. DAMAGE CLAIMS 1. Thoroughly examine the enclosure as soon as it is received. If damaged, write on the face of the freight bill a complete and detailed description of the damage. Have the carrier's agent sign the description. Note: Insist that the carrier's agent verify the inspection and sign the description. 2. Immediately notify the delivering carrier of damage or loss. This notification may be given either in person or by telephone. Written confirmation must be mailed within 48 hours. Railroads and motor carriers are understandably reluctant to make adjustments for damaged merchandise unless inspected and reported promptly. 3. Riskoflossofordamagetomerchandiseremainswiththe liuyer. It is the liuyer's responsibility to file a claim with,,the carrier involved. 4. Imniediately advise your Veeder-Root representative, distributor, oi, the factory so that we may assist you.

B. RETURN SHIPPING. All shipments of Veeder-Root products must be prepaid. Equipment must be packed in a strong exterior container and surrounded by shock absorbing material. Veeder-Root will accept no liability foi- damage caused by improper packing. It is suggested that the original shipping containei- be used if it is available. Address shipment to Veeder-Root Co., 6t]i Avenue at Burns Crossing, 11.0. liox 1673, Altoona, I'A 16603. C. WARRANTY AND CONDITIONS 1. WARRANTY. We warrant that our products shall he free from defects in material and workmanship for a period of one year from the date of shipment thereof or the product's total rated life, whichever first occurs. Within the warranty period we shall repair or replace such products which are returned to us with shipping charges prepaid and which are deter- inined by us to be defective. This warranty will not apply to any product which has been subjected to misuse, negligence, or accident; or misapplied; or used in violation of product manuals, instructions, or warnings; or modified or repaired by unauthorized persons; or improperly installed. 2. INSPECTION. You shall inspect the produ(-t promptly after i-eceipt and shall notify us at oui- Altoona office, in wi-iting,ofanyclaims,includingclaii-nsofbreactiofwarraiity, within thirty days aftei- you discover or should have dis- (-ovei-edtliefactsuponwliielitlieclaimishased.Yourfailtire to give written notice of a (-Iaiin within the time period shall be deeiiie(i to be a waivei- of sii(-Ii claim. 3. LIMITATION OF REMEDY AND WARRANTY. The provisions of Paragraph I are our sole obligation and exclude all other remedies or warranties, express or implied, including warranties of MERCHANTA-BILITY and FITNESS FOR A PARTICULAR PURPOSE, whether or not purposes or specifications are described herein. We further disclaim any responsibility whatsoever to you or to any other person for injury to person or damage to or loss of property or value caused by any product which has been subjected to misuse, negligence, or accident; or misapplied; or used in violation of product manuals, instructions, or warnings; or modified or repaired by unauthorized persons; or improperly installed. 4. LIMITATION OF DAMAGES. Under no circumstances shall we be liable for any incidental, consequential or special damages, losses or expenses arising from this contract or its performance or in connection with the use of, or inability to use, our product for any purpose whatsoever. 5. LIMITATION OF ACTIONS. No action regardless of form arising out of this contract may be commenced more than one year after- the cause of action has accrued, except an action for nonpayment. 6. COLLATERAL PROMISES. There are no representations, warranties, or conditions express or implied, statutory or otherwise except those herein contained, and no agreements or waivers collateral hereto shall be binding on either party unless in writing and signed by you and accepted by us at our Altoona office. 7. INTERPRETATION. Rights and liabilities arising out of any contract with us shall be determined under the Uniform Commercial Code as enacted in Connecticut.

VEEDERVEEDER--ROOTROOT Petroleum Products

6th Avenue at Burns Crossing

P.O. Box 1673 Altoona, PA 16603-1673 Phone (800) 873-3313

Fax (800) 234-5350 or

Phone (814) 695-4476 Fax (814) 695-7605

Copied from

Veeder-Root Technical Manual 8-014

Issued:12/95 Supersedes: 5/93

Compiled by:

Michael Leffew, Isometrics, Inc. Reidsville, NC


TM

Feb 1995

Section 20 Page 1A

INSTALLATION: The Wet-R-Dri Valve may be mounted in any position with handle located for easy operation. Valve, as assembled, opens by turning handle 1/4 turn counter clockwise (right hand operation). If clockwise rotation is desired (left hand operation) please specify. Care should be taken when mounting valve to be sure the I.D. of adjoining flanges or pipe is large enough to allow disc of valve to open freely. We suggest using our accompanying flanges and adapters shown in Section 20, Page 5A.

NOTE: Standard drilling fits TTMA recommended standards. Valves are available with the following options: Stainless steel liners and shafts, grease fittings installed in the drive and bearing shafts, and “E” Coating of aluminum valves (recommended for aluminum valves used in water service). For repair kit, see Section 20, Page 5B.

O.D.

I.D.

A

B

Wet-R-Dri Valve LIGHTWEIGHT

COMPACT

VERSATILE

Standard Model Detent Model Standard Material Size Assembly No.

Wt. Assembly No.

Wt. Body Disc

Max. Working Pressure

Temperature Range


Buna-N 75 PSI


Buna-N 75 PSI

WD400 AL V 4.5 WD401 AL V 4.5 Aluminum 4” WD400 GI V 8.3 WD401 GI V 8.3 Grey Iron

Viton 75 PSI

5” WD500 AL V 7.9 WD501 AL V 7.9 Aluminum Viton 50 PSI 6” WD600 AL U 11.8 WD601 AL U 11.8 Aluminum Urethane 50 PSI 8” WD800 AL U 17.3 WD801 AL U 17.3 Aluminum Urethane 50 PSI

See

Cha

rt B

elow

Dimensions Suffix for Disc Material

Buna-N Urethane Size A B C I.D. O.D. B.C. Holes Black White

Viton Black White

EPDM

2” 63/4 41/4 11/8 21/4 33/4 33/4 6-7/16 B WB V U WU E 3” 63/4 45/8 11/8 33/8 55/8 47/8 8-7/16 -40°F -40°F -0°F -40°F -40°F -50°F 4” 63/4 51/8 11/8 43/8 65/8 57/8 8-7/16 +200°F +200°F +400°F +200°F +200°F +300°F 5” 63/4 63/8 21/8 57/16 75/8 7 12-7/16 6” 12 7 21/8 61/8 85/8 81/8 12-7/16 8” 12 8 21/2 8 107/8 101/8 16-7/16

NOTE: Temperature ranges based on published information and may vary due to actual operating conditions.

TTMA STYLE


TM

Jan 1993

Section 20 Page 1B

WARNING Use only genuine Betts Industries Inc. replacement parts. Use of substitute parts can impair the proper functioning of the Wet-R-Dri Valve.

STANDARD MODEL

7

9

4

WD101-3

92

BU

8

1

6

2

DETENT MODEL

WD101-3

7

9

5

92

BU

8

1

6

101211

2

Wet-R-Dri VALVE

2” Size 3” Size 4” Size 5” Size 6” Size 8” Size No. Description Material Part No. Part No. Part No. Part No. Part No. Part No.

Buna-N WD101-2 BN WD101-3 BN WD101-4 BN WD101-5 BN WD101-6 BN WD101-8 BN Viton WD101-2 VT WD101-3 VT WD101-4 VT WD101-5 VT WD101-6 VT WD101-8 VT Urethane WD101-2 PY WD101-3 PY WD101-4 PY WD101-5 PY WD101-6 PY WD101-8 PY

1 Disc

EPDM WD101-2 EP WD101-3 EP WD101-4 EP WD101-5 EP WD101-6 EP WD101-8 EP Handle Mall. “E” Coated 25884EY 25884EY 25884EY 25884EY 25933AL 25933AL Cap Screw Steel Zinc Plt. 9Q5813 9Q5813 9Q5813 9Q5813 9Q5898 9Q5898 2 Hex. Nut Steel Zinc Plt. 9Q5808 9Q5808 9Q5808 9Q5808 9Q5808 9Q5808

4 Drive Shaft Steel 27053MS 27050MS 27050MS 27051MS 16229MS 16229MS002 5 Drive Shaft Steel 27053MS001 27050MS001 27050MS001 27051MS001 16229MS 16229MS002 6 O-Ring To Match Disc Mat’l. 17889** 17889** 17889** 17889** 18831** 18831** 7 Bearing Shaft Steel 16006MS 15913MS 15913MS 15913MS 16230MS 16230MS002 8 O-Ring To Match Disc Mat’l. 17781** 18141** 18141** 18141** 18831** 18831** 9 Driv-Lok-Pin Steel Zinc Plt. 9Q4893 9Q4893 9Q4893 9Q4925 9Q4926 9Q4938 10 Detent Ball 440 Stnls 9Z4856 9Z4856 9Z4856 9Z4856 9Z4856 9Z4856 11 Detent Spring 304 Stnls 15229SL 15229SL 15229SL 15229SL 15229SL 15229SL 12 Ret. Screw 304 Stnls 9Q5838 9Q5838 9Q5838 9Q5838 9Q5838 9Q5838

PARTS LIST

** O-Ring material suffix to match Disc suffix (i.e.-17889VT)

Documents

2009 C300 Operators and Maintenance Manual