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
CHAPTER 1. INTRODUCTION 1-1. Scope 1-2. Physical Description 1-3. Functional Description 1-4. Warranty Information 1-5. Shipping, Handling and Storage Data 1-6. Preparation for Use CHAPTER 2. OPERATING INSTRUCTIONS 2-1. Scope 2-2. Safety Interlocks 2-3. Bonding 2-4. Prefueling Check 2-5. Bottom Loading 2-6. Top Loading 2-7. Gravity Drain, Unmetered 2-8. Fueling Procedure 2-9. Tank Loading using the Truck Pump, Unmetered 2-10. Defueling 2-11. Gravity Drain, Metered CHAPTER 3. MAINTENANCE AND SERVICING 3-1. Scope 3-2. Cleaning 3-3. Lubrication 3-4. Inspection 3-5. Troubleshooting 3-6. Component Repair 3.7. Service 3.8. Ready for Air Transport CHAPTER 4. PARTS LIST AND COMMERCIAL LITERATURE 4-1. General 4-2. Parts List CHAPTER 5. SCULLY OVERFILL PREVENTION LIST OF ILLUSTRATIONS Title Piping Schematic Pumping Compartment Pump/PTO Diagram Top of Tank Cable Diagram Electrical Schematic (Lights) Scully System Schematic LIST OF TABLES Table 3-1 3-2 3-3 Title Daily Inspection Periodic Checks and Services Troubleshooting

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3 3 3 3 5 5 5 6 6 6 6 6 7 8 9 10 11 12 13 15 15 15 15 15 15 15 15 16 20 20 20 23

Figure 2-1 4-1 4-2 4-3 4-3 4-5 4-6

page 14 21 21 22 22 22 23 page 18 18 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 2. 3. 4. 5. 4x2 Tare Weight: 16,700 LBS. Dimensions: 270"L X 96"W X 96"H Shipping Cube: 1440 Cu. Ft. Environmental Conditions: -20 to 125 degrees F 4x4 17,700 LBS. 270"L X 96"W X 99"H 1485 Cu. Ft.

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. to shipment. The vehicle has been completely serviced and adjusted prior

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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. perform the following checks:

Prior to filling the tank or performing any fueling operation,

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-pressureization 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. the following procedures: Fuel can be gravity drained from the tank by performing

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. truck is to be accomplished. WARNING

Perform the following procedures when fueling from the tank

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. procedures when self-loading the truck tank is required. Perform the following

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. the following procedures:

Fuel can be gravity drained from the tank by performing

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. DANGER 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.

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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.

Connect this end to chain wrapped around axle/spring

This end hooks over frame rail

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

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c. Dump air from air bumper under cab.

DISCONNECT THIS LINKAGE FROM LEVER

AFTER DISCONNECTING LINKAGE, USE THIS LEVER TO RELEASE

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Table 3-1 Daily Inspections Before Operation X During Operation X After Operation Item Fuel System Plumbing and Components Sump Drain Valve Check Check plumbing and components for leaks while the unit is operating.

X

X

X

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. Fueling Hose and Check that all detachable Nozzles equipment is present and properly stored. Fire Extinguishers Check that all fire extinguishers are charged and inspections are up to date. Table 3-2 Periodic Checks Weekly X

Checks and Services 1. Clean and inspect nozzle, bottom loading adaptor and fuel strainer. 2. Check tank for operation of manhole fill cover latch, debris or foreign matter in tank and operation of vent(s). 3. Service Lube Points (see paragraph 3-3). 4. Check accuracy of meter and register using a graduated container. 5. Calibrate Meter

Other Intervals

x

X Annually When material being pumped is changed, when maintenance is performed on meter or register or when unit is obviously not measuring correctly. Monthly

6. Check tightness of bolts on valve flanges. Visual inspection will not verify tightness, physically put a wrench on these bolts. 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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Malfunction 1. Pump operates, but system will not pump fuel

Table 3-3 Troubleshooting Probable Cause 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

2. Pump operates, but output is below normal

1. Partially clogged strainer 2. Engine Speed too slow 3. Emergency Valve Cable stretched 1. Vent valve closed or clogged

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

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

5. Meter does not register 6. Meter registers erratically

7. Pump pressure too high or too low

1. Valves not positioned correctly 2. Pump to motor coupling defective 3. Defective pump 1. Rotor Shaft pin sheared 2. Broken Rotor 1. Stripped gear teeth or broken teeth in the gear. 2. Worn gear plate ass’y shafts 1. By Pass Valve out of adjustment

Corrective Action 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 1. Clean or replace strainer 2. Increase engine speed 3. Check underneath truck for cable travel. Adjust or replace cable as needed 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 1. Reset valve settings, insure that valve settings are correct. 2. Replace defective coupling 3. Repair or replace pump. 1. Replace pin 2. Replace Rotor 1. Replace defective gears 2. Replace gear plate ass’y or gears 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. & INDEX NO. 4-1-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 4-2-1 -2 -3 -4 -5 4-3-1 -2 -3 -4 4-4-1 -2 -3 -4 4-5-1 -2 -3 -4 -5 -6 DESCRIPTION Valve, B/F, 3-inch API Bottom Loading Adapter D-1 Bottom Loading Adapter Brake Interlock Valve Valve, Check, 1/2" (inside tank) Hose Reel Nozzle Valve, B/F, 2-inch (Victaulic) Flow Meter 2-inch Faucet Dust Cap 2-1/2 inch Faucet Dust Cap Static Reel Valve, Faucet Scully Shut-Off System Powerise Air-Springs Pump End Yoke Driveshaft End Yoke PTO Hood, Vapor Recovery Vent Manhole Cover, 20" Probe, Scully Shut-off Kit Remote Trip Handle Valve, Water Drain Valve, Emergency / Bottom Load Operator, EV Light, Cabinet Light, Clearance Light, Stop, Turn, Tail Light, Back-up Light, I.D. Junction Box PART NUMBER WD301ALV F5000-001 61528BC 3418 61-103-01 C1115-25-15L CV90-001 700 M7C1 MS27028-11 MS27028-13 DMI-75G40-20 WD201ALV 09356 GSS-18-21UB TXD02A 10-4-123 N10270-SF 10-4-103 CS20-41006-H1BX VR45962BU AV46850ALFTS PPVL863BXB346 09356 35603SL 3721X1 64055A 41158-A 570006 500012 400017 500011 200013 470041 QTY 3 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 3 1 1 1 2 4 2 2 1 1

20

1 5
IN TANK

2

8

7

4

6 3

9

10

Fig. 4-1 Pumping Compartment

Fig. 4-2 Pump/PTO Diagram

21

1 3

4 2

Fig. 4-3 Top of Tank

Fig. 4-4 Cable Diagram

Fig. 4-5 Electrical (Lights)

22

Fig.4-6 Scully System Schematic

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.

23

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.

24

Carter Ground Fueling Division
Argo-Tech Corporation 671 West Seventeenth Street Costa Mesa, CA USA 92627-3605 Ph: (949) 764-2200 • Fax: (949) 631-2673 Email: cgf_sales@jccarter.com

Web: www.argo-tech.com

SM64055 MAINTENANCE MANUAL FOR CARTER PART NUMBERS 64055 & 64143 4” INTERNAL/BOTTOM LOADING VALVES,

March 1, 2001, New Release

SM64055

March 1, 2001

SUMMARY OF REVISIONS
DATE OF CHANGE 3/1/2001 E.O. NO. REV. PARA. OR PAGE NO. DESCRIPTION APPROVED

-

NEW RELEASE

-2-

SM64055

March 1, 2001

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 3, 64143 PARTS BREAKDOWN ............................................................ 13 FIGURE 4, PILOT VALVE PARTS BREAKDOWN ............................................ 14 FIGURE 5 - DIAPHRAGM INSTALLATION POSITION .................................... 15 FIGURE 6 - DIAPHRAGM TORQUE SEQUENCE .............................................. 15

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SM64055

March 1, 2001

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

1.0

INTRODUCTION B can also be used with optic probe (s) using solenoid valve (s) to effect the control of the pilot valve (s). If so service manuals for these components should be requested from the manufacturer of the items used. Carter does not provide such items.

This manual furnishes detailed instructions covering the maintenance and overhaul of Carter Part Numbers 64055, and 64143 4” Internal/Bottom Loading Valves. This manual assumes that the valves will be used with a Carter 64079 Level Sensor, however the 64055A, B, 64143A or 2.0 EQUIPMENT DESCRIPTION

The Carter 64055 family of 4” valves can be used either as a straight internal valve or for bottom loading control. The 64055 mounts directly into a 4” TTMA Tank Sump Ring. The 64055A is used with the Carter 64079 Level Sensor for bottom loading control with a single control pilot valve. Option “B” adds two-stage level control with two pilot valves. (Note: Early units contained provisions for only single pilot valves with the dual capability available at a later date.) Option “B” requires either the use of 64079B, C or two 64079 Level Sensors. A Carter Vent, 64078, is also available to complete the system requirements. A straight 64055 Internal Valve can be converted to a bottom loading valve, 64055A, by adding a pilot valve. The 64143 4” Bottom Loading Valve is used only for bottom loading. The difference between the 64055 and the 64143 is the absence of an off-loading cylinder on the 64143 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 piston chamber through a two-staged orifice in the center of the piston. If the piston chamber has no exit, the areas inside the piston chamber (outer diameter of the piston) is larger than 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 pilot valve, options A or B, the pressure drop across the inlet orifice reduces the piston chamber pressure significantly. The resultant balance of forces will cause the piston to open, hence the valve. When the piston chamber is once again closed [pilot valve (s) closes], the balance of forces again causes the valve to close. The 64055 or 64143 A or B is normally utilized with the 64079 Level Sensor. If so desired, a solenoid valve (s) can be used in the system to provide or deprive the pilot valve of pressure (usually routed from the bottom loading adapter) to cause the opening and closing of the valve. In this way the valve can be used with any optic type sensing probe to detect the desired tank level for closure. On the 64055, a separate air operated piston is provided to effect off-loading as desired. The direction of air pressure to this piston will cause it to pull open the main piston to allow for off-loading flow. When the air pressure is depleted, the spring forces will close both the air and main pistons.

3.0

AVAILABLE OPTIONS The “B” option (64055B or 64143B) adds two pilot valves to the basic unit to close the valve in two-stages. An orifice in the secondary pilot valve will continue to vent the piston chamber after the primary pilot valve has closed. This orifice restricts the pressure escaping from the piston chamber to maintain the piston in a partially open position hence flow into the tank is reduced significantly. This provides a more accurate final shutoff and also helps control surge pressure on final shutoff.

The 64055 Basic Valve is designed for use as an internal valve and has no other functional controls. The 64055 can be opened for off-loading by application of air pressure to the cylinder provided. The 64143 can only be used as option A (64143A) since it has no off-loading capability. The “A” option (64055A or 64143A) adds a pilot valve to the basic unit making it a bottom loading control valve. Again the 64055A can also be used for off-loading by the application of air pressure to the provided cylinder.

-4-

SM64055 4.0 4.1 4.2 4.3 DISASSEMBLY Refer to Figures 1, 2 or 3 for exploded views of the unit. Remove the six Screws (8) and Washers (9) from the Bonnet (23) or (24) and put a side for reuse. Rotate the bonnet slightly in either direction and pull it from the Body (28). On the 64055 the Piston (12) and its attaching parts will come out of the Body (28) with the bonnet as Piston Assembly (10).. Continue on with the next paragraph if the unit being disassembled is the 64055. Ship to paragraph 4.5 if it is a 64143. 64055: 4.9

March 1, 2001

4.5.3 Unless replacement is needed it is recommended that Set Screw (27) and Nut (26) in the face of the piston not be removed. 4.6 4.7 64055 & 64143 - Remove and discard O-ring (29) and Seal (30) from Body (28). Unless the Screen (33) is damaged and needs replacement, do not remove it from the Body (28). If it needs replacing then remove Screws (31) and Nuts (32) to do so. On the basic unit, remove the Plug (3) only if it has been leaking. If it is removed, then discard Gasket (4). On 64055 or 64143A - Unscrew Pilot Valve Assy (2) from Bonnet (23) or (24) and remove and discard Gasket (4). On “B” option to either unit, remove secondary Pilot Valve Assy (2). Orifice (5) and Gasket (6) will be found under the secondary Pilot Valve Assy (2). Remove them and discard Gasket (6).

4.8

4.4

4.4.1 Find the Pin (17B) in the Shaft Assembly (17). Use the spring pin to hold the shaft in place and remove Rod (11) by unscrewing it, being careful not to drop 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) and discard it. 4.4.3 Using the pin used in paragraph 4.4.1 hold the Shaft Assembly (17) while unscrewing Housing (18). Pull Housing (18) off of Bonnet (23). 4.4.4 Remove Wipe Ring (20) and Quad-Ring (21) from Bonnet (23). Discard both items. Skip to paragraph 4.6. 4.5 64143:

4.10 Pilot Valve Assy (2) may be replaced as a complete 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 the flanged surface of either metal part holding the diaphragms 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) and Washer (41) in place. This will free up the remaining parts for removal.

4.5.1 Remove Bonnet (24) then remove Spring (13). Remove O-ring (22) from Bonnet (24) and discard it. 4.5.2 Reach into body (28) opening and carefully extract the Piston Assy (25).

5.0

INSPECTION the Shaft (17A) and the Piston (12) can be polished to remove minor scratches by using a very fine emery cloth while the parts are rotated. Do not polish local areas of these diameters. Unless proper equipment is available to accomplish this task and to polish the inner diameter of the Housing (18) it is recommended that the parts be replace, If polishing is attempted, do not break through the hard anodized surface of the Piston (12). If scratches are too pronounced, the parts should be replaced. Replace any part with damage exceeding 15% of local wall thickness. Use Alodine 1200, or similar chem film treatment, to touch up bared aluminum.

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

-5-

SM64055 The flat surfaces of the Fitting (43) and Cover (36) may be polished to remove minor scratches by using a flat plate and very fine emery cloth. Be careful to keep the

March 1, 2001 parts flat during polishing and to not raise any burrs on the inside diameters that bare on the diaphragms.

6.0

REASSEMBLY the number 1 screw to 1.6 in-lbs. (1.8 Kg-cm), followed by tightening screws number 5, 3, 6 and 4 in that order. Then repeat the tightening sequence to 3.2 in-lbs. (2.1 Kg-cm) and then 5.3 in-lbs. (6.1 Kg-cm) respectively. Let the assembly stand for a minimum of 15 hours retighten the screws as above to the 5.3 in-lbs. (6.1 Kgcm) setting. 6.1.4 When installing the Seal (30) onto O-ring (29) in Body (28) be sure to smooth the surface evenly with a finger. See note on Figures 2 and 3. 6.1.5 On the 64055 - Use Locktite 24221 (17C) on the thread of Shaft (17A) before screwing on Housing (18). Note the thread of both parts should be cleaned with the recommended Locktite cleaning solution prior to using 24221. Read the instructions on 24221 before using. 6.1.6 Once the Piston/Bonnet Assy (10) has been inserted into the Body (28) the Rod (11) must be adjusted to provide a gap of 0.012±0.005 (.305±.127 mm) between the under side of the hex head of the rod and the mating flat surface of the Piston (12). A feeler gage should be used for this purpose. This will assure that the proper surge control during shutoff will be effective. On the 64143 if the Set Screw (27) and Nut (26) were removed it will be necessary to adjust the face of the Set Screw (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, the replacement will be provided in a flat condition and it will be necessary to carefully shape it to fit the Body (28).

6.1 Reassembly is accomplished in essentially the reverse order of disassembly noting the following: 6.1.2 Light lubrication of all O-rings and seals, using petroleum jelly is recommended to facilitate installation. 6.1.3 When reassembling the Pilot Valve Assy (2) use the following procedure to assure proper diaphragm retention: 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 smaller end placed onto the shaft first. The larger flat surface should be facing away from the shaft. 6.1.3.2 The two Diaphragms (37) are placed such that the loops in the diaphragms are facing the Pressure Pad (38).See Figure 5 for an illustration. [In operation, the loops always face in the direction in which the pressure from 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. Carefully place the Cover (36) onto this assembly aligning the holes. 6.1.3.3 Start the six Screws (34) with the Washers (35) in place by hand until resistance is met. Note that if no resistance is met in attempting to hand tighten the screws, it is recommended that the Screws (34) be replaced. They are 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 number the holes in a clockwise direction from one to six. Refer top Figure 6. Using a properly set torque wrench, tighten

7.0

TEST procedures will be Tee off the inlet pressure line to the primary pilot valve and to the secondary pilot valve on “B” option units. Install a small ball valve between the inlet pressure source and each pilot valves. Install a bleed valve between the pilot valve (s) and the ball valve. Gauges should be installed in the pressure line to the main valve’s inlet and in the line to the pilot valve (s). 7.3.2 On the 64055 connect the air port to a 100-psig air pressure source with a gauge in the line.

7.1 The following test accomplished after overhaul: 7.2 Test conditions

7.2.1 Test media shall be odorless kerosene, Jet A or equivalent at 75° + 15°F. 7.3 Functional Test - If testing prior to reinstalling the unit in the refueler is desired conduct the following tests: 7.3.1 Connect the inlet of the unit to a test media pressure source with a minimum of 150-psig available.

-6-

SM64055 7.3.3 Bleed all air from the valve by applying 10-psig test media pressure to the inlet and opening the bleed valve (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 all liquid trapped in the line (s). 7.3.4 Increase the pressure to the valve to approximately 25-psig for one minute and then increase it to 150-psig for one minute. Observe for external leakage during the test period. No leakage except from the main piston shall be allowed. This leakage should be limited to 100 cc/minute.

March 1, 2001 7.3.5 On the 64055, following the above test with the valve still full of liquid apply air pressure to the unit starting at 35-psig and slowly increasing slowly until the valve opens. The valve should open at an air pressure of 50-psig maximum. If testing the 64143 skip this paragraph and go on to 7.3.6. Shutoff the air pressure and bleed it to atmosphere. The valve should return to the closed position. 7.3.6 Apply liquid pressure slowly to the valve inlet and simultaneously to the pilot (s). Observe when the main piston opens. The valve shall open with an inlet pressure of 15-psig or less.

8.0

ILLUSTRATED PARTS CATALOG

Table 1.0 tabulates the parts and sub-assemblies comprising the various versions of both the 64055 and 64143 Valves with all options. The item numbers of the

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

TABLE 1.0 64055 & 64143 Bottom Loading Valves & Options Refer to Figures 1A and 1B Figure 1A 1A Item 1 3 4 2 3 4 2 4 5 6 1 3 4 2 2 5 6 Part Number 64055 GF814-10D MS29512-10 47097 GF814-10D MS29512-10 47097 MS29512-10 221087 MS29512-08 64143 GF814-10D MS29512-10 47097 47097 221087 MS29512-08 Description Internal Valve, Bottom Loading and Off-loading (Figure 1A).................... Plug................................................... Gasket ............................................... Pilot Valve, Primary (FIGURE 4) .... Plug................................................... Gasket ............................................... Pilot Valve, Secondary (FIGURE 4) Gasket ............................................... Orifice............................................... Gasket ............................................... Internal Valve, Bottom Loading Only (Figure 1B) ....................................... Plug................................................... Gasket ............................................... Pilot Valve, Primary (FIGURE 4) .... Pilot Valve, Secondary (FIGURE 4) Orifice............................................... Gasket ............................................... Units Per Assembly 1 2 2 1 1 2 2 2 1 1 1 1 2 1 2 1 1 Option Spares/10 Units/Yr. 20 20 20 10 20 10

Basic Basic A A A B B B B A A, B A B B B

1B

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SM64055 TABLE 2.0 Parts Breakdown, 64055 & 64143 Basic Valves Figure 2, 3 2 Item 8 9 10 11 12 13 14 15 16 17 17A 17B 17C 18 19 20 21 22 23 22 24 25 12 26 27 13 28 29 30 31 32 33 Part Number GF35275-265 GF35338-138 No number 220447 47096 220436 GF16633-4050 220438 220437 47095 220448 GF16562-238 24221 220450 MS29513-112 220453 Q4325-366Y MS29513-157 47099 MS29513-157 221108 47284 47096 GF51971-3 221109 220436 220458 MS29513-248 220456 GF515C4-5 GF20365D440 220431 Description Screws............................................... Washers ............................................ Piston/Bonnet Assy........................... Rod........................................... Piston ....................................... Spring....................................... Ring.......................................... Spring Pad................................ Spring....................................... Shaft Assembly ........................ Shaft.................................. Pin..................................... Locktite .................................... Housing .................................... O-ring....................................... Wipe Ring ................................ Quad Ring ................................ O-ring....................................... Bonnet...................................... O-ring ............................................... Bonnet .............................................. Piston Assy ....................................... Piston ....................................... Nut ........................................... Set Screw, Orifice .................... Spring ............................................... Body ................................................. O-ring ............................................... Seal ................................................... Screw ................................................ Nut .................................................... Screen ............................................... Units Per Assembly 8 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 Option All All 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64143 64143 64143 64143 64143 64143 64143 All All All All All All

March 1, 2001

Spares/10 Units/Yr. 1 10 10 10 10 10 1 1 10 10 -

3

2, 3

-8-

SM64055

March 1, 2001

TABLE 3.0 Pilot Valve Parts Breakdown Figure 1A, 1B 4 Item 2 34 35 36 37 38 39 40 41 42 43 5 34 35 36 37 38 39 40 41 42 43 Part Number 47097 LP35275-230 GF620C6 220441 220445 220443 GF16633-4018 220434 220442 220444 220433 47097 LP35275-230 GF620C6 220441 220445 220443 GF16633-4018 220434 220442 220444 220433 Description Pilot Valve Assy, Primary................. Screw........................................ Washer ..................................... Cover........................................ Diaphragm................................ Pressure Pad ............................. Ring.......................................... Poppet ...................................... Washer ..................................... Spring....................................... Fitting....................................... Pilot Valve Assy, Secondary............. Screw........................................ Washer ..................................... Cover........................................ Diaphragm................................ Pressure Pad ............................. Ring.......................................... Poppet ...................................... Washer ..................................... Spring....................................... Fitting....................................... Units Per Assembly 1 6 6 1 2 1 1 1 1 1 1 1 6 6 1 2 1 1 1 1 1 1 Option A&B A&B A&B A&B A&B A&B A&B A&B A&B A&B A&B B B B B B B B B B B B Spares/10 Units/Yr. 20 20 -

1 4

There are several kits of parts designed to provide the necessary items to overhaul the units as described below. DESCRIPTION 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. 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 interchangeable with an "MS" part of the same number. The recommended spare parts shown Above Are the number required to support 10 units for one year or each overhaul whichever is sooner. These quantities do not include replacement spares for intermediate replacement of parts required by Abuse or misuse of the equipment. The recommended quantities are based on the ratio of spare parts sold for each unit during A one-year period of time. The actual quantity required will vary from location to location. KIT NUMBER KD64055-1

Notes: 1.

2.

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SM64055

March 1, 2001

FIGURE 1A 64055 & OPTIONS

- 10 -

SM64055

March 1, 2001

FIGURE 1B - 64143A & OPTIONS

- 11 -

SM64055

March 1, 2001

FIGURE 2 64055 PARTS BREAKDOWN

- 12 -

SM64055

March 1, 2001

FIGURE 3 64143 PARTS BREAKDOWN

- 13 -

SM64055

March 1, 2001

FIGURE 4 PILOT VALVE PARTS BREAKDOWN

- 14 -

SM64055

March 1, 2001

FIGURE 5 DIAPHRAGE INSTLLATION POSITION

FIGURE 6 DIAPHRAGM TORQUE SEQUENCE

- 15 -

Carter Ground Fueling Division
Argo-Tech Corporation

4” BOTTOM LOADING COMPONENTS
MODELS 64055, 64079, 64143
The Carter 4” family of Bottom Loading Valves and accompanying Level Sensor are designed for use in refuelers where bottom loading/off-loading rates of up to 800 gpm are desired. There are two internal valves in the family, one for use in loading and off-loading while the other is strictly used for loading. Off-loading requires the use of air pressure to open the internal valve. Both are used with the Carter 64079 Level Sensor or as an alternative they can be used with an optic probe control. Bottom loading control is accomplished automatically, as in all Carter units when the tank liquid level reaches the pre-set level sensor. See accompanying brochure 64055 for detail information on the operation of all Carter bottom loading units. Both of the available internal valves can be purchased to use with either a single or dual level sensor as explained below. 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 Sensor provides better shutoff level accuracy and lower surge pressures resulting from closing at very high rates of flow. ❏ 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 gpm Off-loading - 1.5 psi at 600 gpm
64055A 4” Internal Valve

64079A Level Sensor

Bulletin 64143 9/2000

671 W. 17th St., Costa Mesa, CA 92627 • Ph (949) 764-2200 • Fax (949) 631-2673 • E-mail cgf_sales@jccarter.com www.argo-tech.com • 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 offloading capability. One or more of the following options may be added to change the function or configuration of the units above: OPTION A B DESCRIPTION Adds pilot valve to basic unit (64055 only, 64143A only unit available) to provide bottom loading control when used with Carter 64079 Jet Level Sensor or optic sensing probe system. Adds dual pilot valves to either unit for use with either two 64079 or one 64079B Level Sensors to improve accuracy 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 64143A Bottom Loading Valve will provide high level bottom loading control. There are no wearing parts in the unit hence it lasts indefinitely. Truck vibration will have no affect on the unit, unlike float valves, which are 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 and precheck feature are provided as standard equipment. One of the following options may be added to the basic 64079 part number to achieve the degree of customization desired when used with either the 64055A or 64143A: OPTION A B DESCRIPTION . Adds stud to basic unit to provide mounting and level adjustment., ½-13 UNC-2B thread Adds second Level Sensor with accompanying single mounting stud for use with 64055B or 64143B, ½-13 UNC2B thread.

EQUIVALENT PART NUMBERS – WHITTAKER TO CARTER The following table presents the equivalent part numbers for Carter units to replace Whittaker units:
ITEM DESCRIPTION WHITTAKER PART NO. CARTER PART NO. COMMENTS – APPLICABLE TO CARTER UNITS

4” Internal Valve for Off-loading only 4” Internal Valve for Loading and Off-loading 4” Internal Valve Loading only. for Bottom Bottom

F614 F614A or B None F613 F613A

64055 64055A or B 64143A 64079 64079A

Air pressure required for off-loading. Either single or dual pilots available. Air required for off-loading No off-loading capability, a separate internal valve has to be used. Precheck and collector drain cans standard on Carter unit. Mounting stud located outside of precheck and drain cans for better control. Same comment as above.

Level Sensor, no options Level Sensor with mounting stud

Dual Level Sensor with mounting stud

F613B

64079B

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

ALTERNATIVE BOTTOM LOADING UNITS Carter also provides bottom loading equipment for 3” and 6” installations. See Brochure 64055 for complete information 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 the level 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 should be routed from a port on the bottom loading adapter, such as Carter’s 6958, or 61528 that have ports designed for this application. (See brochure 60373 for adapter choices). Routing the inlet pressure source closer to the internal valve may not allow sufficient pressure for the system to function correctly. If the optional mounting stud (option A) 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 surging may 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 64079 although the same affect can be achieved by installing a 3/8” spring loaded normally open ball valve in the inlet pressure line. It will be necessary to adjust the precheck gate in the bottom of the 64079 to make the precheck effective in either case. This is a trial and error adjustment. Note that there are no “tuning” plugs on the Carter 64079 as on the Whittaker F613. A simple “gate” type valve in the bottom of the precheck can provides adjusting of the precheck flow. ❐ It is essential for safety reasons to install a plastic tube to the drain fitting on the bottom of the 64079 Level Sensor. Draining fuel from the Level Sensor if not collected and drained properly could generate a static discharge, which could lead to a fire. ❐ The optional mounting stud is located outside of the precheck and drain cans on the Carter unit. Unlike the Whittaker F613 there is not holes to plug with loose o-rings if the stud is used. If not used the can on the Carter unit is already sealed and there are no plugs to install. If installed correctly the level in the tank can be adjusted over 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 installed in the pressure line from the adapter. When the tank level is below the probe the inlet pressure should be routed to the pilot on the internal valve to cause it to open. When the optic probe is sensing fuel (level below the probe) the pilot on the internal valve must be vented to tank and the inlet pressure shutoff. This will cause the internal valve to close and stop the bottom loading process.

ENVELOPE DIMENSIONS 64055 INTERNAL VALVE

64079 LEVEL SENSOR

Carter Ground Fueling Division
Argo-Tech Corporation 671 West Seventeenth Street Costa Mesa, CA USA 92627-3605 Ph: (949) 764-2200 • Fax: (949) 631-2673 Email: cgf_sales@jccarter.com

Web: www.argo-tech.com

SM6958 MAINTENANCE MANUAL FOR CARTER PART 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 2.0 3.0 4.0 5.0 6.0 7.0 8.0

INTRODUCTION ........................................................................3 EQUIPMENT DESCRIPTION .....................................................3 TABLE OF OPTIONS ..................................................................3 DISASSEMBLY ...........................................................................4 INSPECTION................................................................................4 REASSEMBLY ............................................................................4 TEST .............................................................................................4 ILLUSTRATED PARTS LIST .....................................................5

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

SM6958

December 1, 1994

MAINTENANCE, OVERHAUL & TEST INSTRUCTIONS CARTER PART NUMBERS 6958, 61272, 61409, 61528, 64040 & 61529 BOTTOM LOADING & RECIRCULATION ADAPTERS
1.0 INTRODUCTION This manual furnishes detailed instructions covering the maintenance and overhaul of Carter Part Number 6958, 61272, 61409, 61528, 64040 & 61529 Bottom Loading and Recirculation Adapters. These units all utilize the MS24484 type refueling modular adapter.

2.0

EQUIPMENT DESCRIPTION These Carter units are all of similar design in that they all utilize the 2½ inch MS24484 type refueling modular adapter. This type of adapter is only suited for bottom loading and recirculation or other relatively low pressure type applications. For Hydrant System applications one should use Carter 60195 or 60373 for 2½ inch installations or 60505 or 61526 Adapters for the 4 inch API type applications. These adapters consist of a cast aluminum housing in which is mounted either the commercial version, MS24484-2, or the current QPL version, MS24484-5, refueling modular adapter. Both of these MS24484 units are dimensionally identical. The only differences lie in two areas, both related to high temperature applications normally seen in fighter aircraft applications: to 350°F. The seal on the MS24484-2 is suitable for temperatures up 160°F.

• The bayonet flange to which the nozzle connects
on the MS24484-5, has a greater tensile strength requirement required by the 350°F requirement. Again, the MS24484-2 was designed for service at temperatures up to 160°F. The MS24484-5 is only manufactured by specifically qualified suppliers, among which is our parent company, J. C. Carter. The MS24484-2, a previously listed qualified product is made by Carter Ground Fueling Co. All of the models discussed herein, except for the basic module, 61529, are similar, varying mainly in the outlet mounting configuration.

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

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 in the table below.

Option Letter A B C

Description Adds Pressure Dust Cap (61531) Adds Plastic Dust Cap (41607) Adds Commercial MS24484-2 Adapter

Comments In lieu of Option B on all models. In lieu of Option A on all models. In lieu of Option D on all models except 61529. (Either C or D must be specified to obtain a complete unit). In lieu of Option C on all models except 61529. (Either C or D must be specified to obtain a complete unit). In lieu of Option H on 6958 only. (Either G or H must be specified to obtain a complete unit). In lieu of Option G on 6958 only (Either G or H must be specified to obtain a complete unit).

D

Adds Military MS24484-5 Adapter

G H

Adds 2-1/2" - 8 NPT Female Outlet Adds 2-1/2" - BSPP Female Outlet

SM6958

December 1, 1994

4.0

DISASSEMBLY Refer to Figure 1 for an exploded view of the Unit. 4.3 Noting the warning below, carefully remove the six Screws (6) from the Adapter Module (2 or 2A).

4.1

Remove six Screws (1). Pull Adapter Module (2 or 2A) from Housing (3) and remove and discard Oring (4). Remove Cap (11 or 11A) from Adapter Module (2 or 2A). If present (available only on some units), do not remove the two pipe Plugs (5) from the Housing (3) unless replacement is required. Spare parts for the Cap (11 or 11A) are not available. If it is faulty replace as a complete unit. INSPECTION Special Tools - Use Adapter Wear Gauge, 61657-2 to check the Flange (9 or 9A) of Adapter Module (2 or 2A) for suitability for continued use. Refer to Service Manual SM61657 for instructions on its use. This gauge will indicate whether the slots and lugs of the Flange (9 or 9A) of Adapter Module (2 or 2A) are worn beyond safe use. Check the seal on Cap (11A) for deterioration, cuts or nicks. Replace the Cap (11A) if such aberrations are apparent.

WARNING The Spider (7 or 7A) is spring loaded and care should be exercised in removing the attaching Screws (6).

4.2

5.0 5.1

5.3

Check Cap (11) for aging cracks or other damage. Replace as needed. Inspect Poppet (8 or 8A) for damage to the seal. The seal is bonded into the metal poppet and is not removable. Replace Poppet (8 or 8A) as needed.

5.4

5.2

6.0 6.1 6.2

REASSEMBLY Reassembly is accomplished in essentially the reverse order of disassembly noting the following: Light lubrication of all O-rings and seals, using petroleum jelly is recommended to facilitate installation. Reassemble Adapter Module (2 or 2A). 6.4 Place the O-ring (4) in the groove in Adapter Module (2 or 2A) before installing in the Housing (3). Torque Screws (1) to 20 ± 2 in-lbs (.23 m-kg). Reattach Cap (11 or 11A) to tab on Adapter Module (2 or 2A) if utilized.

6.5

6.3

7.0

TEST procedures will be 7.3.1 Attach adapter to a 120 psi fluid pressure source through the outlet (flanged or threaded end). Attach a Carter 60427 or 61428 type nozzle to the inlet Adapter Module (2 or 2A). The nozzle shall be plugged at the inlet end with a plug and a small petcock or hand valve. With the nozzle and petcock open, slowly increase the pressure into the adapter outlet to fully bleed the air from the test unit. Close the petcock and increase the test -4-

7.1 The following test accomplished after overhaul: 7.2 Test conditions

7.2.1 Test media shall be Stoddard Solvent (Federal Specification P-D-680), JP-4 per MIL-J-5624D at 75° + 15°F, Jet A or equivalent. 7.3 Functional Test

SM6958

December 1, 1994

pressure to 120 psi. Check for external leakage from the joint between the nozzle and adapter and from the adapter housing and joints. 7.3.2 Bleed the pressure from the test unit and remove the nozzle.

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

8.0

ILLUSTRATED PARTS CATALOG Table 1.0 tabulates the parts and sub-assemblies comprising the various adapters covered by this manual. The item numbers of the table are keyed to the exploded views of the Units diagrammed in Figure 1. TABLE 1.0 Number Description Required Screw ........................................ 6 Adapter Module (MS24484-2) . 1 Screw ................................. 6 Spider................................. 1 Spring ................................ 1 Flange ................................ 1 Poppet................................ 1 Adapter Module (MS24484-5) . 1 Screw ................................. 6 Spider................................. 1 Spring ................................ 1 Flange ................................ 1 Poppet................................ 1 Body, 2½" NPT ........................ 1 Body, 2½" BSPP...................... 1 Body, 4" TTMA........................ 1 Body, 4" ANSI.......................... 1 Body, 3" TTMA........................ 1 O-ring........................................ 1 Body, 3" ANSI Plug........................................... Cap, Plastic ............................... Cap, Metal Sealing.................... 1 2 1 1

Item 1 2 6 7 8 9 10 2A 6 7 8 9A 10A 3A 3B 3C 3D 3E 4 3F 5 11 11A Notes:

Part Number GF24693C73 61529 LP500-6-5 20876 2753 20748-2 20780 61247 LP500-6-5 20876 2753 20748-1 208197 24176 204563 210201 210136 210216 MS29513-153 220288 210462 41607 61531 1.

Spares/10 Units/Yr. 6 6 1 2 6 1 2 10 3 1

Used on All except 61529 All except Option D All All All All except Option D All except Option D Option D only All All All Option D only Option D only 6958 Option G only 6958 Option H only 61272 only 61409 only 61528 only All (not furnished with 61529) 64040 only Some 6958, 61272 and 61528 only Option B only Option A only

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 it is interchangeable with an "MS" part of the same number. 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 year period of time. The actual quantity required will vary from location to location.

2.

-5-

Fig. 507 Emergency Valve Operator
Specification Sheet
DESCRIPTION
Remote control of emergency valves through flexible cable. Maximum 3/ 6" cable. Replaceable fuse adaptor releases at 210°F. 1 Threaded take-up for cable slack adjusts conveniently in place. Choice of 15/8 " or 23/ " cable travel positions. Dual trip levers provide 8 shutoff of emergency valves from two locations. Figure 507

Morrison Bros. Co.

www.morbros.com

Figure 507AO

SPECIFICATION OPTIONS:
I.D. NUMBER 507---0100 AO 507---0200 AO 507---0300 AO 507---0400 AO 507---0500 AO 507AO-0100 AO 507AO-0200 AO 507AO-0300 AO 507AO-0400 AO 507AO-0500 AO A 1 2 3 4 5 1 2 3 4 5 B N N N N N Y Y Y Y Y C P P P P P P P P P P D 16 3/4 16 3/4 16 3/4 16 3/4 16 3/4 20 1/2 20 1/2 20 1/2 20 1/2 20 1/2 E 4 13/16 4 13/16 8 3/8 8 3/8 8 3/8 6 3/16 6 3/16 9 3/4 9 3/4 9 3/4 F 12 1/8 12 1/8 12 1/8 12 1/8 12 1/8 12 1/8 12 1/8 12 1/8 12 1/8 12 1/8 WT. 6 8 11.5 13.25 15 7 10 13 15 17

CHART KEY: A—Compartment: 1, 2, 3, 4, 5 B—Air Operated: Y for Yes, N for No C—Material/Coating: P for Powder Coated. D—Length E—Width F—Height Weight—Shipping Weight

P.O. Box 238 • Dubuque, Iowa 52004-0238

563.583.5701 (tel) • 800.553.4840 • 563.583.5028 (fax)
w w w . m o r b r o s . c o m

AIR ELIMINATOR FROM PUMP

TO PIPING

HEATER

JUNCTION BOX
SENSOR

FILTERS

R

20” PAF 406-98 OFFSET MANHOLE With Integral Relief Valve/10” Fill INTEGRAL RELIEF VALVE/10” FILL LESS THAN 1 LITER LEAKAGE SET PRESSURE ADJUSTMENT INCREASED FLOW RATE SECONDARY SAFETY LATCH

MEETS DOT 178.345-5 TEST PRESSURE 36 PSIG

BETTS INDUSTRIES, INC. WARREN, PA. U.S.A.

COVERED BY PATENTS ISSUED AND PENDING

CT-0040

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

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. Note: 3 /2” Vent and Liquid Level Switch not included in assembly. Clamping Ring, Cover Relief Clamping Ring Bolt, Washer, Plate Valve Nut Strongback, & Latch Steel Zinc Plt. Alum. Steel Zinc Plt. Brass Stnls 304 Alum. Stnls 304 Stnls 304 Stnls 316 Alum. Stnls 304 Stnls 304
1

Normal Vent Alum. Alum. Alum.

Wt. (lb.) 29.7 30.2 30.2

Assembly No. PPVL820BXB PPVL820CXB PPVL820DXB

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.
TM

INDUSTRIES, INC.
WARREN, PA.

Sept 1999

Section 86 Page 19A

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

A B C D E F G H

PLAN VIEW DIMENSIONS 1 4 /4” Dia. (107.95mm) 7 8 Holes-.390 Dia. (9.90mm) on 4 /8” (123.83mm) B.C. 3 2 /8” Dia. (60.325mm) Hole 1 /4” N.P.T. Coupling 7” Rad. (177.8mm) 3 6 /8” (161.93mm) 3 4 /4” (120.65mm) 1 3 /4” (82.55mm)

No. 1 1a 2 2a 3 4 5 6

Description Fill Cover Fill Cover (O-Ring Grvd.) Gasket Integral Relief Valve O-Ring Bolt-Clamp Ring Nut-Clamp Ring Washer-Clamp Ring Clamping Ring

7

Manhole Gasket Channel Type

8

Manhole Collar Channel Type

Material Alum/E-Coated Alum/E-Coated Buna-N Viton Wh. Hypalon Tef-Sil Steel Zinc Plt. Stnls 304 Brass Stnls 304 Steel Zinc Plt. Stnls 304 Steel Steel Zinc Plt. Stnls 304 Buna-N Viton Wh. Hypalon Teflon Env. w/ Wh. Hypalon Steel Aluminum Stnls 304 Stnls 316

Part No. 8297ALEY 8297ALEY389 3119BN 3119VT 3119WH 3902TS 3029ZC 3029SL 3030BR 9Q5809 3031ZC 3031SL 3036MS 3036ZC 3036SL 3560BN 3560VT 3560WH 3033TF 3176MS 3176AE 3176SL 3176SS

No. 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26

Description Vent Assembly Gasket Cylinder Assembly Piston Stem Spring 1 /2” NPT Plug Zinc Plt. Stem O-Ring -112 Cylinder O-Ring –137 Piston O-Ring –137 O-Ring Retainer Retainer Ring Bellows 7 Lockwasher Ext. Tooth /16” 7 Nut Hex /16x20 Plastic Plug 3 /8-16 Hex Nut w/ Insert

Material Aluminum Buna-N Aluminum Aluminum Stnls 304 Steel Steel Zinc Plt. Buna-N Buna-N Tef-Sil Alum/E-Coated Stnls 304 EPDM Stnls 304 Stnls 304 Polyethylene Steel Zinc Plt.

Part No. 6496ALB 3716BN 6657AL 6654AL 6688SL 4122MS 9V4907 4118BN 4015BN 4015TS 4117ALEY 9Q4961 4020EPDM 9Q5961 9Q5960 9Z6163 9Q5896

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

250°F 400°F 250°F 400°F 250°F

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. 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.
TM

INDUSTRIES, INC.
WARREN, PA.

Sept 1999

Section 86 Page 19B

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

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

SECTION 1:

IDENTIFICATION OF ADJUSTABLE PAF S URGE 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”

HEX
PLASTIC CAP

DETAIL

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 Ecoated cover.

BLACK E-COATED COVER

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

SECTION 2:

MAINTENANCE AND TESTING FOR PAF S URGE 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 External Visual Inspection Leakage Test Pressure Retest 1. Interval Period 1 year 1 year 5 year Code Paragraph 49CFR180.407(d) 49CFR180.407(h) 49CFR180.407(g)

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. COVER (9) Inspect CYLINDER (10)

Inspect & clean GASKET (24)

Inspect & clean NORMAL VENT (8) Inspect SEAT (25) STRONGBACK (5)

Inspect GASKET (26) for leakage

Figure 1

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

Retest Fixture (Part No. 6556LCB)

Inspect for Leakage Here

Clamp Channel Inside of 10” Fill

Figure 2

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

Tubing

Pressure Release
Reducer Bushing

Pressure Release

Test Tank 6687AL
Seal

Air in from regulator

Air out to manometer or gage.

Air in from regulator

Air out to manometer or gage.

Water Jar

Bubbles Indicate Leakage

PRESSURE TEST Figure 3A

VACUUM TEST Figure 3B

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

SET PRESSURE ADJUSTMENT OF PAF S URGE 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.

SECTION 3:

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.

Loosen Nut

Increase Set Pressure

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.

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

REMOVAL OF PAF S URGE 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.

SECTION 4:

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 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.
DISASSEMBLE

DISASSEMBLE

SUPPORT HERE

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

SECTION 5:

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

Ø

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.

3/8 Female Thread of Tool

Screw Tool to End of STEM (4)

NOTE: Tool is Shown Shorter Than Actual Length

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 Hold Shaft Stationary

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.

NOTE: Tool is Shown Shorter Than Actual Length

Unscrew Nut

Grip Cylinder On This End

Hold Shaft Stationary

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).

Betts Industries, Inc.
Warren, PA 16365 Phone: 814-723-1250 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.
Apply petroleum jelly here during re-assembly.

Slice Gasket as Shown & Pry Out with Screwdriver.

For maintenance or assembly instructions consult appropriate procedures.

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

SECTION 6:

ASSEMBLY OF PAF S URGE 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 cle aned 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 petroleum jelly here. Apply never-seize here.

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

Betts Industries, Inc.
Warren, PA 16365 Phone: 814-723-1250
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). NO Oil in this Chamber

Ensure NO Gap

Fill the Bottom Chamber Completely

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.

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)

1

TABLE OF CONTENTS TITLE
CHAPTER 1. INTRODUCTION 1-1. Scope 1-2. Physical Description 1-3. Functional Description 1-4. Warranty Information 1-5. Shipping, Handling and Storage Data 1-6. Preparation for Use CHAPTER 2. OPERATING INSTRUCTIONS 2-1. Scope 2-2. Safety Interlocks 2-3. Bonding 2-4. Prefueling Check 2-5. Bottom Loading 2-6. Top Loading 2-7. Gravity Drain, Unmetered 2-8. Fueling Procedure 2-9. Tank Loading using the Truck Pump, Unmetered 2-10. Defueling 2-11. Gravity Drain, Metered 3-1. Procedure CHAPTER 3. MAINTENANCE AND SERVICING 3-1. Scope 3-2. Cleaning 3-3. Lubrication 3-4. Inspection 3-5. Troubleshooting 3-6. Component Repair 3.7. Service 3.8. Ready for Air Transport CHAPTER 4. PARTS LIST AND COMMERCIAL LITERATURE 4-1. General 4-2. Parts List CHAPTER 5. SCULLY OVERFILL PREVENTION LIST OF ILLUSTRATIONS Title Piping Schematic (for Trucks with Filters) Piping Schematic (for Trucks without Filters) Pumping Compartment Pump/PTO Diagram Cable Diagram Electrical Schematic (Lights) Scully System Schematic LIST OF TABLES Table 3-1 3-2 3-3 Title Daily Inspection Periodic Checks and Services Troubleshooting

PAGE 3 3 3 3 5 5 5
6 6 6 6 6 7 8 9 10 11 12 14 16 17 17 17 17 17 17 17 17 18 23 22 22 25

Figure 2-1 A 2-1 B 4-1 4-2 4-3 4-5 4-6

page 15 15 23 23 24 24 25 page 20 20 21

2

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 2. 3. 4. 5. 4x2 Tare Weight: 16,700 LBS. Dimensions: 270"L X 96"W X 96"H Shipping Cube: 1440 Cu. Ft. Environmental Conditions: -20 to 125 degrees F 4x4 17,700 LBS. 270"L X 96"W X 99"H 1485 Cu. Ft.

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.

3

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.

4

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. to shipment. The vehicle has been completely serviced and adjusted prior

5

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. perform the following checks:

Prior to filling the tank or performing any fueling operation,

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.

6

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.

7

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-pressureization 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.

8

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. the following procedures: Fuel can be gravity drained from the tank by performing

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.

9

2-8. FUELING PROCEDURE. truck is to be accomplished. WARNING

Perform the following procedures when fueling from the tank

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).

10

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. procedures when self-loading the truck tank is required. Perform the following

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.

11

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.

12

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.

13

2-11. GRAVITY DRAIN - METERED. the following procedures:

Fuel can be gravity drained from the tank by performing

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.

14

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

15

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

16

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. DANGER 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.

17

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.

Connect this end to chain wrapped around axle/spring

This end hooks over frame rail

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

18

c. Dump air from air bumper under cab.

DISCONNECT THIS LINKAGE FROM LEVER

AFTER DISCONNECTING LINKAGE, USE THIS LEVER TO RELEASE

19

Table 3-1 Daily Inspections Before Operation X During Operation X After Operation Item Fuel System Plumbing and Components Sump Drain Valve Check Check plumbing and components for leaks while the unit is operating.

X

X

X

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. Fueling Hose and Check that all detachable Nozzles equipment is present and properly stored. Fire Extinguishers Check that all fire extinguishers are charged and inspections are up to date.

Table 3-2 Periodic Checks Checks and Services Weekly 1. Clean and inspect nozzle, bottom loading adaptor and fuel X strainer. 2. Check tank for operation of manhole fill cover latch, debris or x foreign matter in tank and operation of vent(s). 3. Service Lube Points (see paragraph 3-3). X 4. Check accuracy of meter and register using a graduated container. 5. Calibrate Meter

Other Intervals

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

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

20

Malfunction 1. Pump operates, but system will not pump fuel

Table 3-3 Troubleshooting Probable Cause 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

2. Pump operates, but output is below normal

1. Partially clogged strainer 2. Engine Speed too slow 3. Emergency Valve Cable stretched 1. Vent valve closed or clogged

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

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

5. Meter does not register 6. Meter registers erratically

7. Pump pressure too high or too low

1. Valves not positioned correctly 2. Pump to motor coupling defective 3. Defective pump 1. Rotor Shaft pin sheared 2. Broken Rotor 1. Stripped gear teeth or broken teeth in the gear. 2. Worn gear plate ass’y shafts 1. By Pass Valve out of adjustment

Corrective Action 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 1. Clean or replace strainer 2. Increase engine speed 3. Check underneath truck for cable travel. Adjust or replace cable as needed 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 1. Reset valve settings, insure that valve settings are correct. 2. Replace defective coupling 3. Repair or replace pump. 1. Replace pin 2. Replace Rotor 1. Replace defective gears 2. Replace gear plate ass’y or gears 1. Adjust to correct pressure by turning screw on top of valve. Turn in to increase pressure, turn out to decrease pressure.

21

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

22

1 5
IN TANK

2

8

7

4

6 3

9

10

Fig. 4-1 Pumping Compartment

Fig. 4-2 Pump/PTO Diagra

23

1 3

4 2

Fig. 4-3 Top of Tank

Fig. 4-4 Cable Diagram

Fig. 4-5 Electrical (Lights)

24

Fig.4-6 Scully System Schematic

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.

25

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.

26

Carter Ground Fueling Division
Argo-Tech Corporation 671 West Seventeenth Street Costa Mesa, CA USA 92627-3605 Ph: (949) 764-2200 • Fax: (949) 631-2673 Email: cgf_sales@jccarter.com

Web: www.argo-tech.com

SM64055 MAINTENANCE MANUAL FOR CARTER PART NUMBERS 64055 & 64143 4” INTERNAL/BOTTOM LOADING VALVES,

March 1, 2001, New Release

SM64055

March 1, 2001

SUMMARY OF REVISIONS
DATE OF CHANGE 3/1/2001 E.O. NO. REV. PARA. OR PAGE NO. DESCRIPTION APPROVED

-

NEW RELEASE

-2-

SM64055

March 1, 2001

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 3, 64143 PARTS BREAKDOWN ............................................................ 13 FIGURE 4, PILOT VALVE PARTS BREAKDOWN ............................................ 14 FIGURE 5 - DIAPHRAGM INSTALLATION POSITION .................................... 15 FIGURE 6 - DIAPHRAGM TORQUE SEQUENCE .............................................. 15

-3-

SM64055

March 1, 2001

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

1.0

INTRODUCTION B can also be used with optic probe (s) using solenoid valve (s) to effect the control of the pilot valve (s). If so service manuals for these components should be requested from the manufacturer of the items used. Carter does not provide such items.

This manual furnishes detailed instructions covering the maintenance and overhaul of Carter Part Numbers 64055, and 64143 4” Internal/Bottom Loading Valves. This manual assumes that the valves will be used with a Carter 64079 Level Sensor, however the 64055A, B, 64143A or 2.0 EQUIPMENT DESCRIPTION

The Carter 64055 family of 4” valves can be used either as a straight internal valve or for bottom loading control. The 64055 mounts directly into a 4” TTMA Tank Sump Ring. The 64055A is used with the Carter 64079 Level Sensor for bottom loading control with a single control pilot valve. Option “B” adds two-stage level control with two pilot valves. (Note: Early units contained provisions for only single pilot valves with the dual capability available at a later date.) Option “B” requires either the use of 64079B, C or two 64079 Level Sensors. A Carter Vent, 64078, is also available to complete the system requirements. A straight 64055 Internal Valve can be converted to a bottom loading valve, 64055A, by adding a pilot valve. The 64143 4” Bottom Loading Valve is used only for bottom loading. The difference between the 64055 and the 64143 is the absence of an off-loading cylinder on the 64143 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 piston chamber through a two-staged orifice in the center of the piston. If the piston chamber has no exit, the areas inside the piston chamber (outer diameter of the piston) is larger than 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 pilot valve, options A or B, the pressure drop across the inlet orifice reduces the piston chamber pressure significantly. The resultant balance of forces will cause the piston to open, hence the valve. When the piston chamber is once again closed [pilot valve (s) closes], the balance of forces again causes the valve to close. The 64055 or 64143 A or B is normally utilized with the 64079 Level Sensor. If so desired, a solenoid valve (s) can be used in the system to provide or deprive the pilot valve of pressure (usually routed from the bottom loading adapter) to cause the opening and closing of the valve. In this way the valve can be used with any optic type sensing probe to detect the desired tank level for closure. On the 64055, a separate air operated piston is provided to effect off-loading as desired. The direction of air pressure to this piston will cause it to pull open the main piston to allow for off-loading flow. When the air pressure is depleted, the spring forces will close both the air and main pistons.

3.0

AVAILABLE OPTIONS The “B” option (64055B or 64143B) adds two pilot valves to the basic unit to close the valve in two-stages. An orifice in the secondary pilot valve will continue to vent the piston chamber after the primary pilot valve has closed. This orifice restricts the pressure escaping from the piston chamber to maintain the piston in a partially open position hence flow into the tank is reduced significantly. This provides a more accurate final shutoff and also helps control surge pressure on final shutoff.

The 64055 Basic Valve is designed for use as an internal valve and has no other functional controls. The 64055 can be opened for off-loading by application of air pressure to the cylinder provided. The 64143 can only be used as option A (64143A) since it has no off-loading capability. The “A” option (64055A or 64143A) adds a pilot valve to the basic unit making it a bottom loading control valve. Again the 64055A can also be used for off-loading by the application of air pressure to the provided cylinder.

-4-

SM64055 4.0 4.1 4.2 4.3 DISASSEMBLY Refer to Figures 1, 2 or 3 for exploded views of the unit. Remove the six Screws (8) and Washers (9) from the Bonnet (23) or (24) and put a side for reuse. Rotate the bonnet slightly in either direction and pull it from the Body (28). On the 64055 the Piston (12) and its attaching parts will come out of the Body (28) with the bonnet as Piston Assembly (10).. Continue on with the next paragraph if the unit being disassembled is the 64055. Ship to paragraph 4.5 if it is a 64143. 64055: 4.9

March 1, 2001

4.5.3 Unless replacement is needed it is recommended that Set Screw (27) and Nut (26) in the face of the piston not be removed. 4.6 4.7 64055 & 64143 - Remove and discard O-ring (29) and Seal (30) from Body (28). Unless the Screen (33) is damaged and needs replacement, do not remove it from the Body (28). If it needs replacing then remove Screws (31) and Nuts (32) to do so. On the basic unit, remove the Plug (3) only if it has been leaking. If it is removed, then discard Gasket (4). On 64055 or 64143A - Unscrew Pilot Valve Assy (2) from Bonnet (23) or (24) and remove and discard Gasket (4). On “B” option to either unit, remove secondary Pilot Valve Assy (2). Orifice (5) and Gasket (6) will be found under the secondary Pilot Valve Assy (2). Remove them and discard Gasket (6).

4.8

4.4

4.4.1 Find the Pin (17B) in the Shaft Assembly (17). Use the spring pin to hold the shaft in place and remove Rod (11) by unscrewing it, being careful not to drop 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) and discard it. 4.4.3 Using the pin used in paragraph 4.4.1 hold the Shaft Assembly (17) while unscrewing Housing (18). Pull Housing (18) off of Bonnet (23). 4.4.4 Remove Wipe Ring (20) and Quad-Ring (21) from Bonnet (23). Discard both items. Skip to paragraph 4.6. 4.5 64143:

4.10 Pilot Valve Assy (2) may be replaced as a complete 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 the flanged surface of either metal part holding the diaphragms 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) and Washer (41) in place. This will free up the remaining parts for removal.

4.5.1 Remove Bonnet (24) then remove Spring (13). Remove O-ring (22) from Bonnet (24) and discard it. 4.5.2 Reach into body (28) opening and carefully extract the Piston Assy (25).

5.0

INSPECTION the Shaft (17A) and the Piston (12) can be polished to remove minor scratches by using a very fine emery cloth while the parts are rotated. Do not polish local areas of these diameters. Unless proper equipment is available to accomplish this task and to polish the inner diameter of the Housing (18) it is recommended that the parts be replace, If polishing is attempted, do not break through the hard anodized surface of the Piston (12). If scratches are too pronounced, the parts should be replaced. Replace any part with damage exceeding 15% of local wall thickness. Use Alodine 1200, or similar chem film treatment, to touch up bared aluminum.

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

-5-

SM64055 The flat surfaces of the Fitting (43) and Cover (36) may be polished to remove minor scratches by using a flat plate and very fine emery cloth. Be careful to keep the

March 1, 2001 parts flat during polishing and to not raise any burrs on the inside diameters that bare on the diaphragms.

6.0

REASSEMBLY the number 1 screw to 1.6 in-lbs. (1.8 Kg-cm), followed by tightening screws number 5, 3, 6 and 4 in that order. Then repeat the tightening sequence to 3.2 in-lbs. (2.1 Kg-cm) and then 5.3 in-lbs. (6.1 Kg-cm) respectively. Let the assembly stand for a minimum of 15 hours retighten the screws as above to the 5.3 in-lbs. (6.1 Kgcm) setting. 6.1.4 When installing the Seal (30) onto O-ring (29) in Body (28) be sure to smooth the surface evenly with a finger. See note on Figures 2 and 3. 6.1.5 On the 64055 - Use Locktite 24221 (17C) on the thread of Shaft (17A) before screwing on Housing (18). Note the thread of both parts should be cleaned with the recommended Locktite cleaning solution prior to using 24221. Read the instructions on 24221 before using. 6.1.6 Once the Piston/Bonnet Assy (10) has been inserted into the Body (28) the Rod (11) must be adjusted to provide a gap of 0.012±0.005 (.305±.127 mm) between the under side of the hex head of the rod and the mating flat surface of the Piston (12). A feeler gage should be used for this purpose. This will assure that the proper surge control during shutoff will be effective. On the 64143 if the Set Screw (27) and Nut (26) were removed it will be necessary to adjust the face of the Set Screw (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, the replacement will be provided in a flat condition and it will be necessary to carefully shape it to fit the Body (28).

6.1 Reassembly is accomplished in essentially the reverse order of disassembly noting the following: 6.1.2 Light lubrication of all O-rings and seals, using petroleum jelly is recommended to facilitate installation. 6.1.3 When reassembling the Pilot Valve Assy (2) use the following procedure to assure proper diaphragm retention: 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 smaller end placed onto the shaft first. The larger flat surface should be facing away from the shaft. 6.1.3.2 The two Diaphragms (37) are placed such that the loops in the diaphragms are facing the Pressure Pad (38).See Figure 5 for an illustration. [In operation, the loops always face in the direction in which the pressure from 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. Carefully place the Cover (36) onto this assembly aligning the holes. 6.1.3.3 Start the six Screws (34) with the Washers (35) in place by hand until resistance is met. Note that if no resistance is met in attempting to hand tighten the screws, it is recommended that the Screws (34) be replaced. They are 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 number the holes in a clockwise direction from one to six. Refer top Figure 6. Using a properly set torque wrench, tighten

7.0

TEST procedures will be Tee off the inlet pressure line to the primary pilot valve and to the secondary pilot valve on “B” option units. Install a small ball valve between the inlet pressure source and each pilot valves. Install a bleed valve between the pilot valve (s) and the ball valve. Gauges should be installed in the pressure line to the main valve’s inlet and in the line to the pilot valve (s). 7.3.2 On the 64055 connect the air port to a 100-psig air pressure source with a gauge in the line.

7.1 The following test accomplished after overhaul: 7.2 Test conditions

7.2.1 Test media shall be odorless kerosene, Jet A or equivalent at 75° + 15°F. 7.3 Functional Test - If testing prior to reinstalling the unit in the refueler is desired conduct the following tests: 7.3.1 Connect the inlet of the unit to a test media pressure source with a minimum of 150-psig available.

-6-

SM64055 7.3.3 Bleed all air from the valve by applying 10-psig test media pressure to the inlet and opening the bleed valve (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 all liquid trapped in the line (s). 7.3.4 Increase the pressure to the valve to approximately 25-psig for one minute and then increase it to 150-psig for one minute. Observe for external leakage during the test period. No leakage except from the main piston shall be allowed. This leakage should be limited to 100 cc/minute.

March 1, 2001 7.3.5 On the 64055, following the above test with the valve still full of liquid apply air pressure to the unit starting at 35-psig and slowly increasing slowly until the valve opens. The valve should open at an air pressure of 50-psig maximum. If testing the 64143 skip this paragraph and go on to 7.3.6. Shutoff the air pressure and bleed it to atmosphere. The valve should return to the closed position. 7.3.6 Apply liquid pressure slowly to the valve inlet and simultaneously to the pilot (s). Observe when the main piston opens. The valve shall open with an inlet pressure of 15-psig or less.

8.0

ILLUSTRATED PARTS CATALOG

Table 1.0 tabulates the parts and sub-assemblies comprising the various versions of both the 64055 and 64143 Valves with all options. The item numbers of the

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

TABLE 1.0 64055 & 64143 Bottom Loading Valves & Options Refer to Figures 1A and 1B Figure 1A 1A Item 1 3 4 2 3 4 2 4 5 6 1 3 4 2 2 5 6 Part Number 64055 GF814-10D MS29512-10 47097 GF814-10D MS29512-10 47097 MS29512-10 221087 MS29512-08 64143 GF814-10D MS29512-10 47097 47097 221087 MS29512-08 Description Internal Valve, Bottom Loading and Off-loading (Figure 1A).................... Plug................................................... Gasket ............................................... Pilot Valve, Primary (FIGURE 4) .... Plug................................................... Gasket ............................................... Pilot Valve, Secondary (FIGURE 4) Gasket ............................................... Orifice............................................... Gasket ............................................... Internal Valve, Bottom Loading Only (Figure 1B) ....................................... Plug................................................... Gasket ............................................... Pilot Valve, Primary (FIGURE 4) .... Pilot Valve, Secondary (FIGURE 4) Orifice............................................... Gasket ............................................... Units Per Assembly 1 2 2 1 1 2 2 2 1 1 1 1 2 1 2 1 1 Option Spares/10 Units/Yr. 20 20 20 10 20 10

Basic Basic A A A B B B B A A, B A B B B

1B

-7-

SM64055 TABLE 2.0 Parts Breakdown, 64055 & 64143 Basic Valves Figure 2, 3 2 Item 8 9 10 11 12 13 14 15 16 17 17A 17B 17C 18 19 20 21 22 23 22 24 25 12 26 27 13 28 29 30 31 32 33 Part Number GF35275-265 GF35338-138 No number 220447 47096 220436 GF16633-4050 220438 220437 47095 220448 GF16562-238 24221 220450 MS29513-112 220453 Q4325-366Y MS29513-157 47099 MS29513-157 221108 47284 47096 GF51971-3 221109 220436 220458 MS29513-248 220456 GF515C4-5 GF20365D440 220431 Description Screws............................................... Washers ............................................ Piston/Bonnet Assy........................... Rod........................................... Piston ....................................... Spring....................................... Ring.......................................... Spring Pad................................ Spring....................................... Shaft Assembly ........................ Shaft.................................. Pin..................................... Locktite .................................... Housing .................................... O-ring....................................... Wipe Ring ................................ Quad Ring ................................ O-ring....................................... Bonnet...................................... O-ring ............................................... Bonnet .............................................. Piston Assy ....................................... Piston ....................................... Nut ........................................... Set Screw, Orifice .................... Spring ............................................... Body ................................................. O-ring ............................................... Seal ................................................... Screw ................................................ Nut .................................................... Screen ............................................... Units Per Assembly 8 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 Option All All 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64055 64143 64143 64143 64143 64143 64143 64143 All All All All All All

March 1, 2001

Spares/10 Units/Yr. 1 10 10 10 10 10 1 1 10 10 -

3

2, 3

-8-

SM64055

March 1, 2001

TABLE 3.0 Pilot Valve Parts Breakdown Figure 1A, 1B 4 Item 2 34 35 36 37 38 39 40 41 42 43 5 34 35 36 37 38 39 40 41 42 43 Part Number 47097 LP35275-230 GF620C6 220441 220445 220443 GF16633-4018 220434 220442 220444 220433 47097 LP35275-230 GF620C6 220441 220445 220443 GF16633-4018 220434 220442 220444 220433 Description Pilot Valve Assy, Primary................. Screw........................................ Washer ..................................... Cover........................................ Diaphragm................................ Pressure Pad ............................. Ring.......................................... Poppet ...................................... Washer ..................................... Spring....................................... Fitting....................................... Pilot Valve Assy, Secondary............. Screw........................................ Washer ..................................... Cover........................................ Diaphragm................................ Pressure Pad ............................. Ring.......................................... Poppet ...................................... Washer ..................................... Spring....................................... Fitting....................................... Units Per Assembly 1 6 6 1 2 1 1 1 1 1 1 1 6 6 1 2 1 1 1 1 1 1 Option A&B A&B A&B A&B A&B A&B A&B A&B A&B A&B A&B B B B B B B B B B B B Spares/10 Units/Yr. 20 20 -

1 4

There are several kits of parts designed to provide the necessary items to overhaul the units as described below. DESCRIPTION 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. 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 interchangeable with an "MS" part of the same number. The recommended spare parts shown Above Are the number required to support 10 units for one year or each overhaul whichever is sooner. These quantities do not include replacement spares for intermediate replacement of parts required by Abuse or misuse of the equipment. The recommended quantities are based on the ratio of spare parts sold for each unit during A one-year period of time. The actual quantity required will vary from location to location. KIT NUMBER KD64055-1

Notes: 1.

2.

-9-

SM64055

March 1, 2001

FIGURE 1A 64055 & OPTIONS

- 10 -

SM64055

March 1, 2001

FIGURE 1B - 64143A & OPTIONS

- 11 -

SM64055

March 1, 2001

FIGURE 2 64055 PARTS BREAKDOWN

- 12 -

SM64055

March 1, 2001

FIGURE 3 64143 PARTS BREAKDOWN

- 13 -

SM64055

March 1, 2001

FIGURE 4 PILOT VALVE PARTS BREAKDOWN

- 14 -

SM64055

March 1, 2001

FIGURE 5 DIAPHRAGE INSTLLATION POSITION

FIGURE 6 DIAPHRAGM TORQUE SEQUENCE

- 15 -

Carter Ground Fueling Division
Argo-Tech Corporation

4” BOTTOM LOADING COMPONENTS
MODELS 64055, 64079, 64143
The Carter 4” family of Bottom Loading Valves and accompanying Level Sensor are designed for use in refuelers where bottom loading/off-loading rates of up to 800 gpm are desired. There are two internal valves in the family, one for use in loading and off-loading while the other is strictly used for loading. Off-loading requires the use of air pressure to open the internal valve. Both are used with the Carter 64079 Level Sensor or as an alternative they can be used with an optic probe control. Bottom loading control is accomplished automatically, as in all Carter units when the tank liquid level reaches the pre-set level sensor. See accompanying brochure 64055 for detail information on the operation of all Carter bottom loading units. Both of the available internal valves can be purchased to use with either a single or dual level sensor as explained below. 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 Sensor provides better shutoff level accuracy and lower surge pressures resulting from closing at very high rates of flow. ❏ 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 gpm Off-loading - 1.5 psi at 600 gpm
64055A 4” Internal Valve

64079A Level Sensor

Bulletin 64143 9/2000

671 W. 17th St., Costa Mesa, CA 92627 • Ph (949) 764-2200 • Fax (949) 631-2673 • E-mail cgf_sales@jccarter.com www.argo-tech.com • 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 offloading capability. One or more of the following options may be added to change the function or configuration of the units above: OPTION A B DESCRIPTION Adds pilot valve to basic unit (64055 only, 64143A only unit available) to provide bottom loading control when used with Carter 64079 Jet Level Sensor or optic sensing probe system. Adds dual pilot valves to either unit for use with either two 64079 or one 64079B Level Sensors to improve accuracy 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 64143A Bottom Loading Valve will provide high level bottom loading control. There are no wearing parts in the unit hence it lasts indefinitely. Truck vibration will have no affect on the unit, unlike float valves, which are 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 and precheck feature are provided as standard equipment. One of the following options may be added to the basic 64079 part number to achieve the degree of customization desired when used with either the 64055A or 64143A: OPTION A B DESCRIPTION . Adds stud to basic unit to provide mounting and level adjustment., ½-13 UNC-2B thread Adds second Level Sensor with accompanying single mounting stud for use with 64055B or 64143B, ½-13 UNC2B thread.

EQUIVALENT PART NUMBERS – WHITTAKER TO CARTER The following table presents the equivalent part numbers for Carter units to replace Whittaker units:
ITEM DESCRIPTION WHITTAKER PART NO. CARTER PART NO. COMMENTS – APPLICABLE TO CARTER UNITS

4” Internal Valve for Off-loading only 4” Internal Valve for Loading and Off-loading 4” Internal Valve Loading only. for Bottom Bottom

F614 F614A or B None F613 F613A

64055 64055A or B 64143A 64079 64079A

Air pressure required for off-loading. Either single or dual pilots available. Air required for off-loading No off-loading capability, a separate internal valve has to be used. Precheck and collector drain cans standard on Carter unit. Mounting stud located outside of precheck and drain cans for better control. Same comment as above.

Level Sensor, no options Level Sensor with mounting stud

Dual Level Sensor with mounting stud

F613B

64079B

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

ALTERNATIVE BOTTOM LOADING UNITS Carter also provides bottom loading equipment for 3” and 6” installations. See Brochure 64055 for complete information 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 the level 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 should be routed from a port on the bottom loading adapter, such as Carter’s 6958, or 61528 that have ports designed for this application. (See brochure 60373 for adapter choices). Routing the inlet pressure source closer to the internal valve may not allow sufficient pressure for the system to function correctly. If the optional mounting stud (option A) 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 surging may 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 64079 although the same affect can be achieved by installing a 3/8” spring loaded normally open ball valve in the inlet pressure line. It will be necessary to adjust the precheck gate in the bottom of the 64079 to make the precheck effective in either case. This is a trial and error adjustment. Note that there are no “tuning” plugs on the Carter 64079 as on the Whittaker F613. A simple “gate” type valve in the bottom of the precheck can provides adjusting of the precheck flow. ❐ It is essential for safety reasons to install a plastic tube to the drain fitting on the bottom of the 64079 Level Sensor. Draining fuel from the Level Sensor if not collected and drained properly could generate a static discharge, which could lead to a fire. ❐ The optional mounting stud is located outside of the precheck and drain cans on the Carter unit. Unlike the Whittaker F613 there is not holes to plug with loose o-rings if the stud is used. If not used the can on the Carter unit is already sealed and there are no plugs to install. If installed correctly the level in the tank can be adjusted over 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 installed in the pressure line from the adapter. When the tank level is below the probe the inlet pressure should be routed to the pilot on the internal valve to cause it to open. When the optic probe is sensing fuel (level below the probe) the pilot on the internal valve must be vented to tank and the inlet pressure shutoff. This will cause the internal valve to close and stop the bottom loading process.

ENVELOPE DIMENSIONS 64055 INTERNAL VALVE

64079 LEVEL SENSOR

Carter Ground Fueling Division
Argo-Tech Corporation 671 West Seventeenth Street Costa Mesa, CA USA 92627-3605 Ph: (949) 764-2200 • Fax: (949) 631-2673 Email: cgf_sales@jccarter.com

Web: www.argo-tech.com

SM6958 MAINTENANCE MANUAL FOR CARTER PART 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 2.0 3.0 4.0 5.0 6.0 7.0 8.0

INTRODUCTION ........................................................................3 EQUIPMENT DESCRIPTION .....................................................3 TABLE OF OPTIONS ..................................................................3 DISASSEMBLY ...........................................................................4 INSPECTION................................................................................4 REASSEMBLY ............................................................................4 TEST .............................................................................................4 ILLUSTRATED PARTS LIST .....................................................5

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

SM6958

December 1, 1994

MAINTENANCE, OVERHAUL & TEST INSTRUCTIONS CARTER PART NUMBERS 6958, 61272, 61409, 61528, 64040 & 61529 BOTTOM LOADING & RECIRCULATION ADAPTERS
1.0 INTRODUCTION This manual furnishes detailed instructions covering the maintenance and overhaul of Carter Part Number 6958, 61272, 61409, 61528, 64040 & 61529 Bottom Loading and Recirculation Adapters. These units all utilize the MS24484 type refueling modular adapter.

2.0

EQUIPMENT DESCRIPTION These Carter units are all of similar design in that they all utilize the 2½ inch MS24484 type refueling modular adapter. This type of adapter is only suited for bottom loading and recirculation or other relatively low pressure type applications. For Hydrant System applications one should use Carter 60195 or 60373 for 2½ inch installations or 60505 or 61526 Adapters for the 4 inch API type applications. These adapters consist of a cast aluminum housing in which is mounted either the commercial version, MS24484-2, or the current QPL version, MS24484-5, refueling modular adapter. Both of these MS24484 units are dimensionally identical. The only differences lie in two areas, both related to high temperature applications normally seen in fighter aircraft applications: to 350°F. The seal on the MS24484-2 is suitable for temperatures up 160°F.

• The bayonet flange to which the nozzle connects
on the MS24484-5, has a greater tensile strength requirement required by the 350°F requirement. Again, the MS24484-2 was designed for service at temperatures up to 160°F. The MS24484-5 is only manufactured by specifically qualified suppliers, among which is our parent company, J. C. Carter. The MS24484-2, a previously listed qualified product is made by Carter Ground Fueling Co. All of the models discussed herein, except for the basic module, 61529, are similar, varying mainly in the outlet mounting configuration.

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

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 in the table below.

Option Letter A B C

Description Adds Pressure Dust Cap (61531) Adds Plastic Dust Cap (41607) Adds Commercial MS24484-2 Adapter

Comments In lieu of Option B on all models. In lieu of Option A on all models. In lieu of Option D on all models except 61529. (Either C or D must be specified to obtain a complete unit). In lieu of Option C on all models except 61529. (Either C or D must be specified to obtain a complete unit). In lieu of Option H on 6958 only. (Either G or H must be specified to obtain a complete unit). In lieu of Option G on 6958 only (Either G or H must be specified to obtain a complete unit).

D

Adds Military MS24484-5 Adapter

G H

Adds 2-1/2" - 8 NPT Female Outlet Adds 2-1/2" - BSPP Female Outlet

SM6958

December 1, 1994

4.0

DISASSEMBLY Refer to Figure 1 for an exploded view of the Unit. 4.3 Noting the warning below, carefully remove the six Screws (6) from the Adapter Module (2 or 2A).

4.1

Remove six Screws (1). Pull Adapter Module (2 or 2A) from Housing (3) and remove and discard Oring (4). Remove Cap (11 or 11A) from Adapter Module (2 or 2A). If present (available only on some units), do not remove the two pipe Plugs (5) from the Housing (3) unless replacement is required. Spare parts for the Cap (11 or 11A) are not available. If it is faulty replace as a complete unit. INSPECTION Special Tools - Use Adapter Wear Gauge, 61657-2 to check the Flange (9 or 9A) of Adapter Module (2 or 2A) for suitability for continued use. Refer to Service Manual SM61657 for instructions on its use. This gauge will indicate whether the slots and lugs of the Flange (9 or 9A) of Adapter Module (2 or 2A) are worn beyond safe use. Check the seal on Cap (11A) for deterioration, cuts or nicks. Replace the Cap (11A) if such aberrations are apparent.

WARNING The Spider (7 or 7A) is spring loaded and care should be exercised in removing the attaching Screws (6).

4.2

5.0 5.1

5.3

Check Cap (11) for aging cracks or other damage. Replace as needed. Inspect Poppet (8 or 8A) for damage to the seal. The seal is bonded into the metal poppet and is not removable. Replace Poppet (8 or 8A) as needed.

5.4

5.2

6.0 6.1 6.2

REASSEMBLY Reassembly is accomplished in essentially the reverse order of disassembly noting the following: Light lubrication of all O-rings and seals, using petroleum jelly is recommended to facilitate installation. Reassemble Adapter Module (2 or 2A). 6.4 Place the O-ring (4) in the groove in Adapter Module (2 or 2A) before installing in the Housing (3). Torque Screws (1) to 20 ± 2 in-lbs (.23 m-kg). Reattach Cap (11 or 11A) to tab on Adapter Module (2 or 2A) if utilized.

6.5

6.3

7.0

TEST procedures will be 7.3.1 Attach adapter to a 120 psi fluid pressure source through the outlet (flanged or threaded end). Attach a Carter 60427 or 61428 type nozzle to the inlet Adapter Module (2 or 2A). The nozzle shall be plugged at the inlet end with a plug and a small petcock or hand valve. With the nozzle and petcock open, slowly increase the pressure into the adapter outlet to fully bleed the air from the test unit. Close the petcock and increase the test -4-

7.1 The following test accomplished after overhaul: 7.2 Test conditions

7.2.1 Test media shall be Stoddard Solvent (Federal Specification P-D-680), JP-4 per MIL-J-5624D at 75° + 15°F, Jet A or equivalent. 7.3 Functional Test

SM6958

December 1, 1994

pressure to 120 psi. Check for external leakage from the joint between the nozzle and adapter and from the adapter housing and joints. 7.3.2 Bleed the pressure from the test unit and remove the nozzle.

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

8.0

ILLUSTRATED PARTS CATALOG Table 1.0 tabulates the parts and sub-assemblies comprising the various adapters covered by this manual. The item numbers of the table are keyed to the exploded views of the Units diagrammed in Figure 1. TABLE 1.0 Number Description Required Screw ........................................ 6 Adapter Module (MS24484-2) . 1 Screw ................................. 6 Spider................................. 1 Spring ................................ 1 Flange ................................ 1 Poppet................................ 1 Adapter Module (MS24484-5) . 1 Screw ................................. 6 Spider................................. 1 Spring ................................ 1 Flange ................................ 1 Poppet................................ 1 Body, 2½" NPT ........................ 1 Body, 2½" BSPP...................... 1 Body, 4" TTMA........................ 1 Body, 4" ANSI.......................... 1 Body, 3" TTMA........................ 1 O-ring........................................ 1 Body, 3" ANSI Plug........................................... Cap, Plastic ............................... Cap, Metal Sealing.................... 1 2 1 1

Item 1 2 6 7 8 9 10 2A 6 7 8 9A 10A 3A 3B 3C 3D 3E 4 3F 5 11 11A Notes:

Part Number GF24693C73 61529 LP500-6-5 20876 2753 20748-2 20780 61247 LP500-6-5 20876 2753 20748-1 208197 24176 204563 210201 210136 210216 MS29513-153 220288 210462 41607 61531 1.

Spares/10 Units/Yr. 6 6 1 2 6 1 2 10 3 1

Used on All except 61529 All except Option D All All All All except Option D All except Option D Option D only All All All Option D only Option D only 6958 Option G only 6958 Option H only 61272 only 61409 only 61528 only All (not furnished with 61529) 64040 only Some 6958, 61272 and 61528 only Option B only Option A only

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 it is interchangeable with an "MS" part of the same number. 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 year period of time. The actual quantity required will vary from location to location.

2.

-5-

Fig. 507 Emergency Valve Operator
Specification Sheet
DESCRIPTION
Remote control of emergency valves through flexible cable. Maximum 3/ 6" cable. Replaceable fuse adaptor releases at 210°F. 1 Threaded take-up for cable slack adjusts conveniently in place. Choice of 15/8 " or 23/ " cable travel positions. Dual trip levers provide 8 shutoff of emergency valves from two locations. Figure 507

Morrison Bros. Co.

www.morbros.com

Figure 507AO

SPECIFICATION OPTIONS:
I.D. NUMBER 507---0100 AO 507---0200 AO 507---0300 AO 507---0400 AO 507---0500 AO 507AO-0100 AO 507AO-0200 AO 507AO-0300 AO 507AO-0400 AO 507AO-0500 AO A 1 2 3 4 5 1 2 3 4 5 B N N N N N Y Y Y Y Y C P P P P P P P P P P D 16 3/4 16 3/4 16 3/4 16 3/4 16 3/4 20 1/2 20 1/2 20 1/2 20 1/2 20 1/2 E 4 13/16 4 13/16 8 3/8 8 3/8 8 3/8 6 3/16 6 3/16 9 3/4 9 3/4 9 3/4 F 12 1/8 12 1/8 12 1/8 12 1/8 12 1/8 12 1/8 12 1/8 12 1/8 12 1/8 12 1/8 WT. 6 8 11.5 13.25 15 7 10 13 15 17

CHART KEY: A—Compartment: 1, 2, 3, 4, 5 B—Air Operated: Y for Yes, N for No C—Material/Coating: P for Powder Coated. D—Length E—Width F—Height Weight—Shipping Weight

P.O. Box 238 • Dubuque, Iowa 52004-0238

563.583.5701 (tel) • 800.553.4840 • 563.583.5028 (fax)
w w w . m o r b r o s . c o m

AIR ELIMINATOR FROM PUMP

TO PIPING

HEATER

JUNCTION BOX
SENSOR

FILTERS

R

20” PAF 406-98 OFFSET MANHOLE With Integral Relief Valve/10” Fill INTEGRAL RELIEF VALVE/10” FILL LESS THAN 1 LITER LEAKAGE SET PRESSURE ADJUSTMENT INCREASED FLOW RATE SECONDARY SAFETY LATCH

MEETS DOT 178.345-5 TEST PRESSURE 36 PSIG

BETTS INDUSTRIES, INC. WARREN, PA. U.S.A.

COVERED BY PATENTS ISSUED AND PENDING

CT-0040

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

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. Note: 3 /2” Vent and Liquid Level Switch not included in assembly. Clamping Ring, Cover Relief Clamping Ring Bolt, Washer, Plate Valve Nut Strongback, & Latch Steel Zinc Plt. Alum. Steel Zinc Plt. Brass Stnls 304 Alum. Stnls 304 Stnls 304 Stnls 316 Alum. Stnls 304 Stnls 304
1

Normal Vent Alum. Alum. Alum.

Wt. (lb.) 29.7 30.2 30.2

Assembly No. PPVL820BXB PPVL820CXB PPVL820DXB

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.
TM

INDUSTRIES, INC.
WARREN, PA.

Sept 1999

Section 86 Page 19A

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

A B C D E F G H

PLAN VIEW DIMENSIONS 1 4 /4” Dia. (107.95mm) 7 8 Holes-.390 Dia. (9.90mm) on 4 /8” (123.83mm) B.C. 3 2 /8” Dia. (60.325mm) Hole 1 /4” N.P.T. Coupling 7” Rad. (177.8mm) 3 6 /8” (161.93mm) 3 4 /4” (120.65mm) 1 3 /4” (82.55mm)

No. 1 1a 2 2a 3 4 5 6

Description Fill Cover Fill Cover (O-Ring Grvd.) Gasket Integral Relief Valve O-Ring Bolt-Clamp Ring Nut-Clamp Ring Washer-Clamp Ring Clamping Ring

7

Manhole Gasket Channel Type

8

Manhole Collar Channel Type

Material Alum/E-Coated Alum/E-Coated Buna-N Viton Wh. Hypalon Tef-Sil Steel Zinc Plt. Stnls 304 Brass Stnls 304 Steel Zinc Plt. Stnls 304 Steel Steel Zinc Plt. Stnls 304 Buna-N Viton Wh. Hypalon Teflon Env. w/ Wh. Hypalon Steel Aluminum Stnls 304 Stnls 316

Part No. 8297ALEY 8297ALEY389 3119BN 3119VT 3119WH 3902TS 3029ZC 3029SL 3030BR 9Q5809 3031ZC 3031SL 3036MS 3036ZC 3036SL 3560BN 3560VT 3560WH 3033TF 3176MS 3176AE 3176SL 3176SS

No. 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26

Description Vent Assembly Gasket Cylinder Assembly Piston Stem Spring 1 /2” NPT Plug Zinc Plt. Stem O-Ring -112 Cylinder O-Ring –137 Piston O-Ring –137 O-Ring Retainer Retainer Ring Bellows 7 Lockwasher Ext. Tooth /16” 7 Nut Hex /16x20 Plastic Plug 3 /8-16 Hex Nut w/ Insert

Material Aluminum Buna-N Aluminum Aluminum Stnls 304 Steel Steel Zinc Plt. Buna-N Buna-N Tef-Sil Alum/E-Coated Stnls 304 EPDM Stnls 304 Stnls 304 Polyethylene Steel Zinc Plt.

Part No. 6496ALB 3716BN 6657AL 6654AL 6688SL 4122MS 9V4907 4118BN 4015BN 4015TS 4117ALEY 9Q4961 4020EPDM 9Q5961 9Q5960 9Z6163 9Q5896

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

250°F 400°F 250°F 400°F 250°F

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. 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.
TM

INDUSTRIES, INC.
WARREN, PA.

Sept 1999

Section 86 Page 19B

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

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

SECTION 1:

IDENTIFICATION OF ADJUSTABLE PAF S URGE 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”

HEX
PLASTIC CAP

DETAIL

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 Ecoated cover.

BLACK E-COATED COVER

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

SECTION 2:

MAINTENANCE AND TESTING FOR PAF S URGE 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 External Visual Inspection Leakage Test Pressure Retest 1. Interval Period 1 year 1 year 5 year Code Paragraph 49CFR180.407(d) 49CFR180.407(h) 49CFR180.407(g)

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. COVER (9) Inspect CYLINDER (10)

Inspect & clean GASKET (24)

Inspect & clean NORMAL VENT (8) Inspect SEAT (25) STRONGBACK (5)

Inspect GASKET (26) for leakage

Figure 1

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

Retest Fixture (Part No. 6556LCB)

Inspect for Leakage Here

Clamp Channel Inside of 10” Fill

Figure 2

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

Tubing

Pressure Release
Reducer Bushing

Pressure Release

Test Tank 6687AL
Seal

Air in from regulator

Air out to manometer or gage.

Air in from regulator

Air out to manometer or gage.

Water Jar

Bubbles Indicate Leakage

PRESSURE TEST Figure 3A

VACUUM TEST Figure 3B

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

SET PRESSURE ADJUSTMENT OF PAF S URGE 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.

SECTION 3:

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.

Loosen Nut

Increase Set Pressure

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.

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

REMOVAL OF PAF S URGE 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.

SECTION 4:

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 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.
DISASSEMBLE

DISASSEMBLE

SUPPORT HERE

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

SECTION 5:

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

Ø

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.

3/8 Female Thread of Tool

Screw Tool to End of STEM (4)

NOTE: Tool is Shown Shorter Than Actual Length

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 Hold Shaft Stationary

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.

NOTE: Tool is Shown Shorter Than Actual Length

Unscrew Nut

Grip Cylinder On This End

Hold Shaft Stationary

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).

Betts Industries, Inc.
Warren, PA 16365 Phone: 814-723-1250 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.
Apply petroleum jelly here during re-assembly.

Slice Gasket as Shown & Pry Out with Screwdriver.

For maintenance or assembly instructions consult appropriate procedures.

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

SECTION 6:

ASSEMBLY OF PAF S URGE 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 cle aned 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 petroleum jelly here. Apply never-seize here.

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

Betts Industries, Inc.
Warren, PA 16365 Phone: 814-723-1250
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). NO Oil in this Chamber

Ensure NO Gap

Fill the Bottom Chamber Completely

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.

Installation Parts Installation & Parts Manual
M/MA Meters

Installation: M100-10

Contents Table of Contents and Safety Procedures Safety Procedures
Description Page Number How LC Meters Work ........................................... 3 Owner’s Information Packet ................................. 4 Installation Requirements ..................................... 6 Operation Requirements ....................................... 7 Meter Start Up and Operation .............................. 8 Reversing the Meter Registration ......................... 9 Setting the Standard Adjuster .............................. 10 Meter Maintenance ............................................... 10 Relieving Internal Pressure ................................... 11 Servicing the Drive Components ........................... 12 Removing the Dust Cover ..................................... 12 Removing the Adjuster and Adjuster Drive Assembly ...................................... 12 Buna/Viton/Teflon Packing Gland ......................... 15 The Retaining Plate .............................................. 15 Disassembling the Meter ...................................... 16 Removing the Non-Corroded Rotor Gears .......................................................... 18 Removing Corroded Rotor Gears .......................... 18 Reassembling the Meter ...................................... 20 Timing the Rotor Gears ........................................ 21 Torque Chart ......................................................... 22 Wrench and Socket Size Chart ........................... 23 Troubleshooting .................................................... 24 How to Order Replacement Parts ........................ 26 Illustrated Parts Breakdown ................................. 27-30 Quality Statement ................................................ 31 Please have the following information available when you make inquires, order replacement parts, or schedule service. If a specific meter accessory is involved, please provide the model and serial number of the accessory in question (see page 4). Your Meter’s Serial Number: ________________________ Your Full-Service Distributor: _______________________ Your Full-Service Distributor’s Telephone Number: _______________________________

WARNING ! WARNING
All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in the system, the packing gland, and the front or rear covers. See “Relieving Internal Pressure” (page 11).

Prepared Be Prepared
Make sure that all necessary safety precautions have been taken. Provide for proper ventilation, temperature control, fire prevention, evacuation and fire management. Provide easy access to the appropriate fire extinguishers for your product. Consult with your local fire department and state and local codes to make sure that you are adequately prepared. Read this manual as well as all the literature provided in your owner’s packet.

In the Event of a Gas Leak
In the event of a large gas leak: Evacuate the area and notify the fire department. 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 the buildings. Some gases, such as LPG, seek lower levels, while other gases seek higher levels. 3. Evacuate all people from the danger zone. 4. See that the gas is dispersed before resuming business and operating motors. If in doubt, notify your local fire department.

In the Event of a Gas Fire
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 can safely control: Stop the leakage if you can safely reach the equipment. Then use the appropriate extinguisher: Class B fire extinguisher, water, fog, etc., depending on the materials. If in doubt, call your local fire department.

NOTICE
This manual provides warnings and procedures that are intended to inform the owner and/or operator of the hazards present when using the Liquid Controls Meter on LP-Gas and other products. The reading of these warnings and the avoidance of such hazards is strictly in the hands of the owner-operators of the equipment. Neglect of that responsibility is not within the control of the manufacturer of the meter.

2

How LC Meters Work
Liquid Controls meters are positive displacement meters. They are designed for liquid measurement in both custody transfer and process control applications. They can be installed in pump or gravity flow systems. Because of their simple design, they are easy to maintain, and easy to adapt to a variety of systems. The meter housing (1) is designed with three cylindrical bores (2). Three rotors, the blocking rotor (3) and two displacement rotors (4, 5), turn in synchronized relationship within the bores. The three rotors are supported by bearing plates (6, 7). The ends of the rotors protrude through the bearing plates. Blocking rotor gear (8) is placed on the end of the blocking rotor. Displacement rotor gears (9, 10) are placed on the ends of the displacement rotors. These gears create the synchronized timed relationship between the three rotors. As fluid moves through the meter housing, the rotor assembly turns. The liquid is broken into uniform sections by the turning rotors. Fluid displacement happens simultaneously. As fluid enters, another portion of the fluid is being partitioned and measured. At the same time, the fluid ahead of it is being displaced out of the meter and into the discharge line. Since the volume of the bores is known, and the same amount of fluid passes through the meter during each revolution of the blocking rotor, the exact volume of liquid that has passed through the meter can be accurately determined. This true rotary motion is transmitted through the packing gland, the face gear, the adjuster drive shaft, and the adjuster to the register stack and counter. True rotary motion output means consistent accuracy since the register indication is in precise agreement with the actual volume throughput at any given instant. At any position in the cycle, the meter body, the blocking rotor, and at least one of the displacement rotors form a continuous capillary seal between the un-metered upstream product and the metered downstream product.

Meter Element Exploded Line Drawing Capillary seals mean no metal-to-metal contact within the metering element. This means no wear. No wear means no increase in slippage, and no increase in slippage means no deterioration in accuracy. Throughout the metering element, the mating surfaces are either flat surfaces or cylindrical faces and sections that are accurately machined. These relatively simple machining operations, plus the fact that there is no oscillating or reciprocating motion within the device, permits extremely close and consistent tolerances within the LC meter. The product flowing through the meter exerts a dynamic force that is at right angles to the faces of the displacement rotors. The meter is designed so that the rotor shafts are always in a horizontal plane. These two facts result in no axial thrust. Therefore, with no need for thrust washers or thrust bearings, the rotors automatically seek the center of the stream between the two bearing plates eliminating wear between the ends of the rotors and the bearing plates. Once again, no wear results in no metal fatigue and no friction. The Liquid Controls meters are made of a variety of materials to suit a variety of products. Because of our no-wear design, capillary seals, and unique rotary metering, LC meters provide unequalled accuracy, long operating life, and unusual dependability.

3

Owner’ Owner ’s Information Packet

1. Is all your documentation included with your meter? LC meters come in many variations. The information sent to you depends on the accessories you have ordered with your meter. Make an inventory of your owner’s information packet. First, find your LC packing slip with the computer printout. Locate the serial number and the meter model number on this printout. Cross reference the packing slip number with the actual meter numbers. The illustration on this page will help you locate the Specification and Serial Number Plates on the meter and its accessories.

2. Record your meter serial number in the space provided on the inside cover of this manual. The inside cover also provides a space for your full-service distributor’s name and telephone number. Fill in this information and keep it handy. You will always need your meter serial number and model number when calling for service or parts! See ‘How to Order Replacement Parts’ in this manual.

4

Owner’ Owner ’s Information Packet
meter’ letter. 3. Identify your meter ’s model-accessory letter. Use the charts shown above to familiarize yourself with meter accessories. Find the meter and letter on the chart which represents your meter, then check with the chart below to see that your red owner’s information packet is complete. Not all accessory levels are available for every model of LC meter.

4. Check your owner’s information packet with the chart shown above to make sure that all the documentation needed for your meter and accessories is in your red information packet. If documentation is missing, call your full-service distributor or Liquid Controls for replacement materials.

5

Installation Requirements Installation Requirements
Make sure that all necessary safety precautions have been taken. Provide for proper ventilation, temperature control, fire prevention, evacuation and fire management. Provide easy access to the appropriate fire extinguishers for your product. Consult with your local fire department and state and local codes to make sure that you are adequately prepared. Read this manual as well as all the literature provided in your owner’s manual. If you have any questions, consult with your full-service distributor or call the Service Department at Liquid Controls. Install the meter and accessories in conformance with applicable state and federal construction, electrical and safety codes. NOTE: Class 10 LPG meters must be installed in accordance with the requirements of ANSI-NFPA 58 in addition to all other state and local codes. WARNING: Under normal operation, do not expose any portion of the LP-Gas system to pressures in excess of rated working pressures without an automatic safety valve to vent the over pressure discharge to a place of safety away from the operator and other people. Failure to provide such a safety relief may result in leakage or rupture of one or more of the components in the system. This can result in injury of death from the gas, a fire, or pieces of flying debris from the rupture. Before shipment, protective thread caps were placed in all meter and accessory openings. They should remain in place until you are ready to attach piping. Prior to meter installation, the entire piping system should be thoroughly flushed of all debris, with a liquid that is compatible with the construction of the meter. Keep external surfaces of the meter clean. The meter must always be securely bolted to a platform or supporting member, regardless of the mounting position of the meter. Never ‘hang’ a meter on the connecting piping. Install meter only on the discharge side (downstream) of the system pump. Apply pipe compound to male threads only. Position the meter with service in mind. Provide ample work space. Removing covers can be difficult when work space is not available. Always supply a platform or support for the meter mounting. A meter is metallurgically designed to be physically compatible with a given type of liquid, as originally specified by the customer, and as indicated on the Serial Number Plate. A meter should not be used with a liquid different from the liquid originally specified, unless the physical characteristics and pH rating are similar and the application has been checked with LC Sales and Engineering through your full-service distributor. Install a strainer on the meter inlet to avoid damage from foreign 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 as standard. However, when a meter is ordered, the customer can specify that the flow be set from either direction. If the meter register counts in reverse, the meter is reading the direction of flow in reverse. If this occurs, the meter registration must be reset. See ‘Reversing the Meter Registration’ in this manual for mechanical output meters. Refer to your accessory manual for electrical output meters (such as meters equipped with a pulser).

NOTE
Always request up-to-date, engineering approved, dimensional drawings before starting any construction. Do not rely on catalog pictures or drawings which are for reference only. After receiving prints, check to see that all equipment ordered is shown and that any extra pressure taps, plugs, etc. are noted and their size specified.

6

Requirements Operation Requirements
The meter must remain full of product at all times. An easy way to accomplish this is to put the meter assembly in the line below the piping center-line (a sump position). This requires adding elbows and flanges prior to installing the meter. The meter should be installed in a bypass loop, below the pipe center-line, with block valves upstream and downstream. A block valve should be located in the mainstream, labeled as the bypass valve. Caution: Any portion of pipe system that might isolate or block flow should be provided with a pressure relief to prevent damage from thermal expansion. There are excellent benefits to this type of installation. First, the meter is kept full. Second, this type of installation allows the meter to be isolated for servicing and calibration while continuing flow through the bypass valve. Upstream lines must be maintained full to prevent air from entering the meter. If upstream or inlet lines are constructed in a manner which allows reverse flow, foot valves or back checks must be installed. Underground tanks that are furnished with a submersible pump will eliminate many problems that occur with positive displacement pumps (suction pumps) when suction piping is incorrectly sized or when the lift is too great. Every meter should be calibrated under actual service and installation conditions per the API Manual of Petroleum Measurement Standards: Chapter 4 - Proving Systems Chapter 5 - Metering Chapter 6 - Metering Assemblies Chapter 11 Section 2.3 Water Calibration of Volumetric Provers Chapter 12 Section 2 Calculation of Petroleum Quantities These chapters of the API Manual of Petroleum Measurement Standards supersedes the API standard 1101. Provide a means of conveniently diverting liquid for calibration purposes. Give careful attention to your system’s pumping equipment and piping because of their influence on liquid being measured as it enters the metering assembly. Systems should be made free of conditions that cause or introduce entrained air or vapor. Follow the manufacturer’s recommendation fully when installing pumps. Give particular attention to factors like: use of foot valves, pipe size to the inlet and conformance to net positive suction head (NPSH) conditions when suction pumping is required. Following the manufacturer’s recommendations will minimize air and vapor elimination problems. For liquids such as light hydrocarbons that tend to flash or vaporize easily at higher ambient temperatures, it is desirable to use flooded suctions and piping sized larger than the nominal pump size. On systems such as vehicle tank installations, piping layout is important in preventing problems with split compartment test conformance. Piping should slope away from a P.D. pump to prevent resurgent re-priming of the pump due to drain back. Hydraulic shock is harmful to all components of an operating system including valves, meter and the pump. In particular, meters must be afforded protection from shock because of their need to measure with high precision. Generally the best protection is prevention, which can be readily accomplished by adjusting valve closing rates in such a manner that shock does not occur. Thermal expansion like hydraulic shock is a phenomenon that can easily damage meters and systems in general. Care should be taken in designing the system to include pressure relief valves in any portion or branch of the system that might be closed off by closure of operating valves or block valves.

7

St Meter Start Up and Operation
Prior to meter start up, use extreme caution. Make up sure that: 1. The meter is properly secured 2. All connections are tight 3. All valves are in the closed position Placing your meter in operation: When placing your meter in operation, the meter and system must be filled slowly with liquid and be free of air prior to start-up. Extreme care must be taken to avoid damaging the meter during this time. The system may be filled by gravity (preferred) or by use of the pump (if required) when filling the system with liquid for the first time. Gravity filling - systems with positive head pressure from product storage above the inlet port of the meter. 1. Make sure all valves (up stream and down stream of the meter) in the system are closed. 2. Crack open the valve located at the storage tank. The meter’s register/counter will start to move and then stop, provided there is not a valve between the tank and the meter inlet. If there is another valve between the tank and meter, repeat this process with each valve until the meter is exposed to the liquid. 3. Once you are assured that the meter has registered some volume and stopped, continue to fully open the tank 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’s register/counter starts to move. Do not run the meter any 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 provided that the system is designed not to exceed the flow rate marked on the meter. NOTE: NOTE If the valves are not manual, consult the valve manufacturer for slow flow start-up. Filling the system with a pump - Consult the pump manufacturer for proper pump priming. Once the pump is primed with product, proceed as follows: • Follow steps one through four above for proper meter start-up.

NOTE
Make sure that your dead head pressure. for assistance. pump can operate against a If NOT, consult the factory NOT,

Never operate the meter or system when partially filled with liquid, or with pockets of compressed air or vapor present. If these conditions cannot be avoided, air and vapor elimination systems may be required. If you cannot fill the meter slowly by gravity or by using a valve to throttle back the flow, factory. consult the factory. Do not operate the meter at a pressure exceeding that marked on the Serial Number Plate. Under any and all pressure producing circumstances, for instance, thermal expansion and hydraulic shock, the working pressure must not exceed the indicated maximum. If the meter is operated at a rate greater than the maximum recommended GPM, excessive wear and premature failure may occur. The meter can be calibrated for flows below minimum ratings if the flow remains constant and varies within narrow limits or if the product is viscous. A meter should never be run beyond the maximum flow rate determined for that class meter and/or liquid measured.

WARNING ! WARNING
All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in the system, the packing gland, and the front or rear covers. See “Relieving Internal Pressure” (page 11).

8

Reversing the Meter Registration
The direction of flow is specified by the customer when the meter is ordered. The standard direction of flow is from left to right when facing the front of the meter. A red pressure sensitive label indicating inlet is affixed to the meter at time of shipment. If the meter is equipped with a strainer and/or valve, the strainer (and/or valve) MUST be moved when reversing the direction of flow through the meter. The strainer should meter. always be located on the inlet side of the meter. When the meter is equipped with a valve, it is moved to the outlet side of the meter. Some repositioning of the valve components may be required. See the Valve Manual in the Owner’s Information Packet. When the meter is first installed, check the register. If the register counts DOWN, meaning that the register numbers decrease rather than increase, you must reverse the direction of registration by reversing the position of the adjuster drive gear. Reversing the drive to the register is accomplished by reversing the position of the adjuster drive gear relative to the 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 to remove the dust cover (page 12). 2. Remove the retaining ring (4) with a screwdriver or pliers. 3. Remove the two retaining spring screws (1) with a standard screwdriver. Note: For M-15, M-25, M-30, and M-40 models loosen the single set screw. 4. Remove the retaining spring (2). 5. Remove the drive shaft (3) mounted with the adjuster drive gear assembly including (4) Retaining Ring and (5) Adjuster Drive Gear. 6. Remove the adjuster drive gear (5) and turn it 180° so that it is upside down from the original installation position. The bushing (7) supports the adjuster drive gear in the lower position. The retaining ring (4) supports the adjuster drive gear in the upper position.

Adjuster drive gear engaged from the top.

Adjuster drive gear engaged from the bottom.

7. Reassemble the parts in reverse order. Make sure that the adjuster drive gear meshes with the packing gland’s pinion gear (6) without being too tight. Make sure there is a little play in the gear teeth. The retaining ring (4) should be placed in the groove provided on the drive shaft (3), regardless of the adjuster drive gear position. The packing gland pinion gear to adjuster drive gear ratio is either 1:1 or 2:1. In the 2:1 ratio, the pinion of the packing gland is smaller in diameter.

Packing Gland

9

St Setting the Standard Adjuster
NOTE: These instructions apply to meters equipped with mechanical output accessories only. If your meter is equipped with an electrical output (i.e., electronic pulser) refer to your accessory manual, such as the Pulser Manual supplied in your owner’s information packet. 1. Refer to “Servicing the Drive Components”, Step 1 to remove the dust cover (page 12). 2. Check meter registration by delivering product to a reliable, accurate prover. Perform multiple delivery tests to verify the meter repeatability. 3. Record the setting indicated on the adjuster: 4. Note the difference between the volume of the prover and the volume indicated on the meter counter. Calculate the % correction required, as follows: Volume in prover - volume on meter counter % correction = volume in prover 5. Loosen the adjuster clamp screw. 6. When the prover volume is less than the meter counter volume, add the percentage to the original adjuster setting by turning the thimble towards the arrow marked larger (volume). Correct the original setting by approaching the number desired from the next larger number. For example, if the desired adjuster setting is 2.4, turn the adjuster thimble to the left to number 5, then to the right to obtain the 2.4 setting. Adjuster is currently set at 2.3 in the illustration to the right. 7. When the prover volume is more than the meter counter volume, subtract the percentage from the original adjuster setting by turning the thimble in the direction of the arrow marked smaller volume percent. 8. Retighten the adjuster clamp screw. Run product through the meter to allow the adjuster to take a set. Then make several prover runs to check for accuracy X 100

Meter Maintenance and repeatability ability. repeat ability.
Prevent pipe strain or stress from occurring when making meter or accessory repairs. Pipe strain and stress occurs when the pipes are not supported or are not aligned correctly to the meter. The weight of the pipes must always be supported independent of the meter. This means that the meter and accessories can be easily removed without affecting the pipes or the pipe alignment. Never leave any of the pipes hanging.

Seasonal meter storage If the meter is used for seasonal work, at the end of each season the meter should be removed from the system and thoroughly flushed with a compatible liquid. This includes removing the drain on the front and rear covers. Then flush the product from the front and rear covers. If flushing with water is preferred, extra care should be taken to drain the meter completely and dry all internal parts. Immediate refilling with a compatible liquid (or oil misting) is essential to prevent corrosion as well as ice damage to parts from moisture that was overlooked after flushing and drying.

10

Meter Maintenance
Do not mar or scratch any of the precision machined surfaces by prying or sanding parts. Torque all fasteners such as screws and bolts in accordance with specifications listed in the ‘Torque Chart’ in this manual (page 22). Stone the machined surfaces when reassembling the meter to assure that the machined surfaces are free of burrs and mars. Repair pulled threads with threaded insert fasteners. These can be used in many instances. Contact your fullservice distributor for advice if this occurs. Coat threads with anti-seize when removing and replacing bolts and castings in a meter. Removing flange gaskets When removing the flange assembly, 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 flange gasket. Never reuse old flange gaskets. 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 the housing and cover for flatness. Use a straight edge to determine flatness. gaps Look for gaps when disassembling a meter. Use a feeler gauge to check for gaps between the bearing plate and housing. If you do find gaps, check the bearing plates for flatness with a straight edge. Gaps can be caused by shock problems that must be resolved. Contact your fullservice distributor for assistance if this occurs. Check the O-rings for damage. Cracked, rough, or worn O-rings should be replaced. However, a more serious problem of shock may be indicated if the O-rings look nibbled. Shock problems must be verified and resolved. Contact your full-service distributor for assistance if this occurs. Check the bearing plates for flatness. Use a straight edge. Warped bearing plates can be caused by shock problems that must be resolved. Contact your full-service distributor for assistance if this occurs. Check with regulatory agency that governs Weights & Measures in your area. Removing the dust cover seal wire or other maintenance procedures may require Weights & Measures recalibration.

WARNING ! WARNING Relieving Internal Pressure
All 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.

WARNING

Serious injury or death from fire or explosion could result from maintenance of an improperly depressurized and evacuated system.
4. Slowly open the valve/nozzle at the end of the supply line. 5. After product has bled off, close the valve/nozzle at the end of the supply line. 6. Slowly crack the fitting on top of the differential valve to relieve product pressure in the system. Product will drain from the meter system. 7. As product is bleeding from the differential valve, slowly reopen and close the valve/nozzle on the discharge line. Repeat this step until the product stops draining from the differential valve and discharge line valve/ nozzle. 8. Leave the discharge line valve/nozzle open while working on the system.

Procedure for Non-LPG Meters 1. 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 Meters 1. 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 the inlet side, consult the truck manufacturer for procedures to depressurize the system.

11

Components Servicing the Drive Components
Removing the Dust Cover
1. Cut the dust cover seal wire with a side cutters. Remove the dust cover screws with a 5/16’ wrench or slotted screwdriver and then remove the dust cover. See “Relieving Internal Pressure” and “Regulatory Agency” in the ‘Meter Maintenance’ section (page 11) of this manual.

Removing the Adjuster and Adjuster Drive Assembly
1. Record the adjuster micrometer setting.

2. Carefully note the adjuster drive gear position. The gear engages the packing gland pinion from below or above. This gear must be reinstalled in its original position or the meter counter will run backwards.

12

Components Servicing the Drive Components
3. Use a standard screwdriver to loosen (or remove) the two retaining spring screws. 4. Swing the retaining spring off the adjuster drive bushing. 5. Loosen the adjuster mounting clamp screw with a phillips head screwdriver.

Removing the adjuster from the top of the meter when top access is easiest. Front access instructions are on the next page. 6. Remove screws that secure adjuster mounting plate to counter adapter. 7. Lift adjuster mounting bracket with adjuster out of the counter adapter. 8. Remove the adjuster drive assembly from the housing.

13

Components Servicing the Drive Components
Removing the adjuster from the front of the meter when front access is easiest. Top access instructions are on the previous page. 9. Remove the adjuster drive assembly from the housing. 10. Remove the slotted head screw that secures the adjuster to the mounting plate. 11. Bring the adjuster out through the front of the meter by rotating it from left to right to clear the adjuster mounting plate and then pull down to remove from the meter.

WARNING ! WARNING
All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in the system, the packing gland, and the front or rear covers. See “Relieving Internal Pressure” (page 11).

Servicing the Packing Gland
The packing gland is affected by the liquid being metered, the operating temperature, and other system conditions. After prolonged use, the gland may show leakage from the metering chamber. This is a sign of wear. The gland should be replaced or repaired if this occurs. It can be serviced in the field. 1. Remove the two packing gland retaining plate screws with a 5/16” socket and ratchet drive extension or 5/16” nut driver. 2. Pull out the packing gland. 3. Take apart the packing gland by gently prying off the retaining ring with a standard screwdriver. 4. Pull the driver out from the assembly.

14

Buna/Viton/T iton/Teflon Buna/Viton/Teflon Packing Gland
Components Packing Gland Component s
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Driver Shaft Stainless steel thrust washer Rulon thrust washer Buna/Viton/Teflon “U” Cup Aluminum/stainless housing Washer - Nylon Output gear 2:1 Retaining ring Bushing Retaining plate Buna/Viton/Teflon O-ring Two retaining plate screws Output gear 1:1 Carbon Guide Bearing Washer - Stainless Steel

Standard Packing Gland

LPG Packing Gland

Retaining Packing Gland Retaining Plate
The retaining plate has four holes: two that are drilled 1-1/ 2” on center and two that are drilled 1-5/8” on center. If your meter has a counter adapter dust cover (Item #0366) shaped like the illustration shown below, use the holes drilled 1- 5/8” on center to mount the packing gland retaining plate. If your meter does not have the counter adapter dust cover shaped like the illustration shown on the right, use the two holes drilled 1-1/2” on center to mount the packing gland retaining plate.

Item 11 (above)

Adapter Dust Cover for holes drilled 1-5/8” on center

15

Disassembling the Meter
Mechanical Output Meters*
WARNING ! WARNING
All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in the system, the packing gland, and the front or rear covers. See “Relieving Internal Pressure” (page 11). * For electrical output meters refer to the Pulser Manual supplied in your owner’s information packet. 1. Remove the counter bracket screws with a box wrench or socket driver. The counter bracket can be removed with or without removing the adjuster assembly. NOTE: For Aluminum M-30 and M-40 models the counter bracket and front cover are one piece. Go to step 2. 2. Turn the meter on either the inlet or outlet side. Let it stand to allow the product to drain from the meter chamber. 3. Locate the drain plugs on the front and rear covers. Remove the drain plugs using an allen wrench. Let the meter stand to allow product to drain from the front and rear covers.

16

Disassembling the Meter
4. Use a socket wrench or box end wrench to remove the screws securing the front cover. Remove the screws that hold the rear cover. The number of screws will vary depending on meter size. 5. Remove the front and rear covers. MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models have a driven reduction gear attached with a shoulder bolt to the center of the front bearing plate.

6. Carefully remove the O-rings / flat gaskets from front and rear of the housing. Undamaged Buna or Viton Orings may be reused. Flat gaskets and Teflon O-rings should always be replaced and never reused.

7. Hold a spare displacement rotor gear between the right displacement rotor gear and the blocking rotor gear to keep them from turning (if unavailable, use a shop rag between gear teeth). Use the rotor gear wrench or socket to remove the right displacement rotor gear screw and washer. MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models: Rotor gears are on the meter back. All other models: Rotor gears are on the front. 8. Hold the spare gear between the left displacement rotor gear and blocking rotor gear. Use the rotor gear wrench or socket to remove the screw and the packing gland driver held by the screw. 9. Hold the spare gear between the right displacement rotor gear and the blocking rotor gear. Use the rotor gear wrench or socket to remove the left displacement rotor gear screw and washer.

17

Disassembling the Meter
Removing Non-Corroded Rotor Gears
1. Insert two standard screwdrivers behind the blocking rotor gear: Gently pry the gear off its rotor tapered end. If the gears show signs of corrosion, or do not pry off easily, use the alternative method described in steps 5-8. 2. Use the same method to remove the left rotor gear and the right rotor gear. Remember, if the gear does not pry off easily, or feels stuck, use the alternative method 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 when reassembling the meter.

4. Use the bearing plate wrench to remove the screws that hold the front bearing plate to the meter housing. On the back of the meter housing, remove the screws that hold the rear bearing plate to the housing. Go to step 1, Removing the Bearing Plates.

Removing Corroded Rotor Gears
5. 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 screws that hold the rear bearing plate to the housing using the bearing plate wrench or socket. The number of screws varies with the size of meter.

18

Disassembling the Meter
7. With a plastic or non-metallic mallet, tap on the heads of the screws lightly and equally. As you tap on the screw heads, the gears are driven off the rotors. As the rotors are driven in, the rear bearing plate and the rotor assembly are pushed away from the housing. NOTE: NOTE For carbon insert bearing plates, remove the rear plate first and then each rotor as it is hand supported. 8. Use the bearing plate wrench or socket to remove the screws that hold the front bearing plate to the meter housing. The number of screws varies between different meter sizes.

Removing the Bearing Plates and Rotors
1. Insert a screwdriver into each of the two notches near the dowel pins. Be careful not to mar any of the surfaces. Gently pry the front bearing plate off the dowel pins. 2. Remove the front bearing plate and rotor assembly by pulling a rotor straight out from the housing. Be careful not to mar any of the surfaces. MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models: Pull the rotor from the rear bearing plate. This will also remove the drive reduction gear which is attached to the blocking rotor. 3. Remove the remaining bearing plate from the other side by inserting a screwdriver into each of the two notches near the dowel pins. Be careful not to mar any surfaces. Gently pry the front bearing plate off the dowel pins. NOTE: MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models have a driven reduction gear in attached with a shoulder bolt to the center of the front bearing plate. 4. Inspect and clean all critical surfaces like gear teeth, rotors and internal housing faces. Remove any crystalline formations using fine emery cloth or a fine wire brush. Be careful not to mar or alter the shape of any of the parts. Changing the shape of the parts may interfere with their operation. Remove nicks and burrs on metal parts with a stone. Remove all grit and other foreign particles. These may also damage parts and interfere with proper operation. Replace all parts that appear worn or damaged.

19

Reassembling the Meter
1. MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models: Rotor gears are on the rear bearing plate. All other models: Rotor gears are on the front bearing plate. Install the non-rotor gear bearing plate using the bearing plate screws and wrench. 2. Insert the non-tapered ends on the three rotors into the housing. Place each rotor into its respective bore in the installed bearing plate. MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models: Make sure that the teeth of the driving reduction gear mesh with the teeth of the driven reduction gear. 3. Place the remaining bearing plate over the three tapered rotor ends and fasten it with the bearing plate screws. Use the bearing plate wrench. The number of screws varies with meter size. 4. The rotors should have a small amount of end-play and 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 the rotors 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 rotor has a notch, or “keyway”, to hold a key. Position a key into each one of the three rotors. Press the keys into 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 tapered rotor end so that the timing marks line up between the two gears. See ‘Timing the Rotor Gears’ on the next page. Hint: Before you place the right displacement rotor gear on its tapered end, hold the right rotor gear in position. Turn the blocking rotor gear. Try to line up the timing marks before you place the right displacement rotor gear on its tapered rotor end. 7. Position the left displacement rotor gear on its tapered rotor end so that its timing mark lines up with the blocking rotor gear. See ‘Timing the Rotor Gears’.

20

Reassembling the Meter
Timing the Rotor Gears
Rotor gears are timed by lining up the timing marks. The blocking rotor gear has a tooth directly in front of its timing mark. On the displacement rotor gears, the timing mark falls in front of the space between two gear teeth. Make sure that the tooth in front of the timing mark on the blocking rotor gear connects with the space in front of the timing mark on the displacement rotor gear. You may need to remove the gears and reposition them several times on their rotor ends in order to get the timing marks to line up correctly. For more information, See ‘Troubleshooting’. 1. Position the spare displacement rotor gear between the left displacement rotor gear and the blocking rotor gear to prevent the gears from moving. Attach the right displacement gear washer and screw using the rotor gear wrench. Tighten the screw to the torque specification listed in the Torque Chart (page 22). 2. Keep the spare displacement rotor gear positioned by the left displacement rotor gear. Attach the left displacement gear washer and screw using the rotor gear wrench. Tighten the screw to the torque specification listed in the Torque Chart. 3. Position the spare displacement rotor gear between the right displacement rotor gear and the blocking rotor gear. Attach the blocking rotor gear with the packing gland driver and screw using the rotor gear wrench. Tighten the screw to the torque specification listed in the Torque Chart. 4. Rotate the gears to make sure that the rotors turn freely. Burrs, foreign material, or marred surfaces can restrict the rotor movements. It may be necessary to remove the gears and rotors and deburr and clean the surfaces again. 5. Install an O-ring (1) into the groove (2) on the front of the meter housing. The M-60 and M-80 models use a flat gasket. 6. Fasten the front cover (3) with the cover screws (4) using the cover socket or open end/box end wrench. NOTE: 6A. LC recommends tightening the front cover screws in a criss-cross or “star” pattern with a minimum of two passes. First pass should be at half-torque, with final pass(es) at full torque. This will ensure uniform seal compression on cover O-ring or gasket. See M-7 pattern on page 22 for reference. 7. Install the front drain plug (6) in the front drain plug hole (7) using the drain plug allen wrench. 8. Install an O-ring (8) into the groove (9) on the rear of the meter housing. The M-60 and M-80 models use a flat gasket. 9. Fasten the rear cover (10) with the cover screws (11) using the cover socket or open end/box end wrench. NOTE: 9A. LC recommends tightening the rear cover 9A screws in a criss-cross or “star” pattern with a minimum of two passes. First pass should be at half torque, with final pass(es) at full torque. This will ensure uniform 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 plug hole (13) using the drain plug allen wrench. 11. If your meter is equipped with an electrical output accessory, such as a digital pulser, reinstall it according to the instructions outlined under ‘Reinstalling...’ in your accessory manual, such as the Pulser Installation, Operation and Maintenance Manual supplied in your owner’s information packet. Install the front drain plug (6) in the front drain plug hole (7) using the drain plug allen wrench.

Meter Assembly Exploded View

21

Torque Chart
PA TORQUE PATTERN M-7 COVERS

Torque Chart

*Torque Tolerance is ± 10%

22

Wrench and Socket Size Chart

NOTE: 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 not to be applied to the female connection in the rotor.

23

Troubleshooting
WARNING ! WARNING
All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in the system, the packing gland, and the front or rear covers. See “Relieving Internal Pressure” (page 11). PROBLEM: Leakage past packing gland drive shaft housing from internal metering chamber. PROBABLE CAUSE AND SOLUTION: Internal seal of packing gland assembly is worn. Replace packing gland and O-ring seal. OPERATING OPERATING NOTE: Two common causes of packing gland leakage are thermal expansion and hydraulic shock. If two valves in a piping system (on either side of the meter) are closed at one time, and if the temperature rises as little as 1°F in the system, it could result in a rise in pressure within the system that would exceed the working pressure rating of the meter. To avoid this hazard caused by thermal expansion, a pressure-relief valve of some kind must be installed in the system. Hydraulic shock occurs when a large volume (mass) of liquid is moving through a pipe line at some flow rate and a valve is suddenly closed. When the flow is stopped, the entire mass of the liquid in the piping system acts as a battering ram causing a shock effect within the meter. The greater the mass length of line and/or velocity, the greater the hydraulic shock. Since the valve is usually located at the meter outlet, the meter housing, packing gland and the meter internal members receive the full impact of such hydraulic shock. To prevent this hazard a slow closing two-stage valve should be used with the meter. On those systems where mass length of line, etc. are of such magnitude as to preclude the elimination of hydraulic shock with the use of a two-stage slow closing valve, an impact-absorbing air cushioning device should be used. PROBLEM: Leakage from the cover gasket. PROBABLE CAUSE AND SOLUTION: Gasket has been damaged due to shock pressure or cover bolts have not been tightened sufficiently. PROBLEM: Product flows through meter but the register does not operate. PROBABLE CAUSE AND SOLUTION: A. Check packing gland, and gear train. B. If all meter parts are moving then problem is in register. Faulty register should be checked and repaired by trained mechanic. C. Remove register from meter. If all meter parts are moving but output shaft of adjuster assembly is not, adjuster is worn and must be replaced. D. If totalizer numerals (small numbers) on register are recording, but the big numerals are not moving, register needs repair. E. Packing gland gear not turning. For M-60 and M-80 meters, the drive blade may be sheared. Replace the packing gland. This may be caused by starting the flow too rapidly.

24

Troubleshooting
PROBLEM: Breaking teeth on timing gears. PROBABLE CAUSE AND SOLUTION: A. Starting or stopping flow in meter too rapidly. B. Pump bypass not adjusted properly. PROBLEM: Product flows through meter but register does not record correctly. PROBABLE CAUSE AND SOLUTION: A. Adjuster not properly calibrated. B. Incorrect gear plate or gear ratio has been installed. C. Air is in the system. PROBLEM: No flow through meter. PROBABLE CAUSE AND SOLUTION: A. Faulty non-functioning pump. B. Valve not open or not functioning. 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: Meter runs too slowly. PROBABLE CAUSE AND SOLUTION: A. Valve internal mechanism faulty. Valve does not open fully. 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: The meter counts down in reverse (the meter numbers decrease). 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 Up and Operation: Reversing the Meter Registration’ in this manual.

25

Parts How to Order Replacement Parts
1. Refer to the exploded view drawings on Pages 27-31. Find the four digit item number for the part you want to order. The item numbers are listed on the exploded drawings. 2. Find the computer printout titled Parts List that has been inserted in the Owner’s Information Packet which was shipped with your order. Look up the item number on the Parts List. The Parts List shows each item number with a corresponding part number. Find the corresponding five digit part number for the item you want to order. The part number represents an individual piece, 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 the distributor to find the correct component for your meter. The Bills of Material for most meter classes are on the LC public website. Always check the website for the most current BOM.

26

Parts Illustrated Parts Breakdown
M5 through M25 Meters (including MA Meters)

NOTE: NOTE Numbers shown are ITEM numbers, not Part Numbers. Refer to the Bill of Materials supplied in the red Owner’s Information Packet to locate the PART NUMBER associated with these ITEM NUMBERS ART NUMBERS. NOTE: NOTE Meter components may appear different between models.

27

Parts Illustrated Parts Breakdown
M30, M40 Meters

NOTE: NOTE Numbers shown are ITEM numbers, not Part Numbers. Refer to the Bill of Materials supplied in the red Owner’s Information Packet to locate the PART NUMBER associated with these ITEM NUMBERS ART NUMBERS. NOTE: NOTE Meter components may appear different between models.

28

Parts Illustrated Parts Breakdown
M60, M80 Meter Cover

NOTE: NOTE Numbers shown are ITEM numbers, not Part Numbers. Refer to the Bill of Materials supplied in the red Owner’s Information Packet to locate the PART NUMBER associated with these ITEM NUMBERS ART NUMBERS. NOTE: NOTE Meter components may appear different between models.

29

Parts Illustrated Parts Breakdown
M60, M80 Meter Element

NOTE: NOTE Numbers shown are ITEM numbers, not Part Numbers. Refer to the Bill of Materials supplied in the red Owner’s Information Packet to locate the PART NUMBER associated with these ITEM NUMBERS ART NUMBERS. NOTE: NOTE Meter components may appear different between models.

30

St Quality Statement
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 and continuing needs. We will strive to minimize the users’ cost by providing products of high reliability, maintainability, serviceability, and no of no 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 trust and 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, the development of our people, and our contribution to the community. Our goal is to be Simply the Best Best.

31

A Unit of IDEX Corporation 105 Albrecht Drive Lake Bluff, IL 60044-2242 1.800.458.5262 • 847.295.1050 Fax: 847.295.1057 www.lcmeter.com

© 2004 Liquid Controls Pub. No. 48683 (05/04)

PARTS MANUAL

M-7, MA-7, M-10

®

®

®

Meters

LIQUID CONTROLS
A Unit of IDEX Corporation

Exploded View: M-7/MA-7/M-10 Meter Covers
CAUTION
IGN COUNTER D AL RIV E T WITH S SHA F LO T

0 2
0

1

6
5
3

1

2

4

0202 Adjuster assembly

0609 Screw, mounting plate (2)

0364 Plate, adjuster mounting

0613 Screw, adjuster 0366 Plate, dust cover 0382 Shaft, adjuster 0336 Gear 0574 Ring, retaining

0126 Bracket, counter adapter

MODEL NO. SERIAL NO.
®

LIQUID CONTRO LS CO LAKE BL UFF, IL, RP. USA

ACCURA FLOW

VOL/REV
CY

RATE

TEMP ER

ATURE SURE

UK81 1783

PRODUC

T

MAX PRES

0165 Gear, packing gland 0250 Packing Gland Assy. 0705 Washer, flat (4) 0673 Screw (4)

0780 Seal wire Driveshaft bushing (2) 0630 Screw (2) 0603 Screw (2)

How to Order Replacement Parts
1. 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 item number on the Parts List. The Parts List shows each item number with a corresponding part number. Find the corresponding 5 digit part number for the item you want to order. The part number represents an individual piece, 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 the distributor to find the correct component for your meter.

0566 Plug, pipe-hex socket (2, one for each cover)

0125 Cover, rear 0627 Hex washer head screw (20, for both covers)

When placing order for replacement parts please reference the meter's serial number.

®

Front cover
Rear cover
0570 Pipe plug (optional) 0153 Rotor, blocking 0611 Screw, hex head w/lockwasher (6 per plate) 4 0528 Key (3) (1 per rotor)

0161 Gear, blocking rotor

0326 Driver, packing gland

*0675 Screw, cap socket head

. CORP ROLS A CONT US LIQUID BLUFF, IL, LAKE L NO. MODE NO. SERIAL
®

0765 Washer, Lock

0673 Screw, hex washer head (2) 0163 Gear, displacement pinion (2)

0318 Pin, dowel (4)
0372 Plate, serial number
0144 Plate, bearing (2)

0771 Bellevue washer, rotor gear (2)

0155 Rotor, displacement (2)

0110 Housing

Exploded View: M-7/MA-7/M-10 Meter Housing

0430 O-Ring (2)

*For M-10 Meter Blocking Rotor, #0672 Shown HereReplaces #0675

0672 Screw, blocking rotor

SOLD AND SERVICED BY A NETWORK OF HIGHLY TRAINED FULL SERVICE DISTRIBUTORS

Backed By Our Worldwide Reputation For Quality, Accuracy and Advanced Design.
WARRANTY: Liquid Controls (“Seller”) products are warranted against defects 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) months from the date of original shipment from Seller. Seller’s obligations, set forth below, shall apply only to failure(s) to meet the foregoing obligations provided that Seller is given written notice within thirty (30) days of any occurrence from which a claim of defect arises. If a warranty dispute occurs, the Purchaser shall be required to provide Seller with proof of date of sale. The minimum requirement to establish date of sale shall be a copy of the Seller’s invoice. In the event that a factory inspection by Seller or its designee(s) supports the validity of a claim, at the discretion of Seller, repair, replacement or refund shall be the sole remedy for defect and shall be made, free of charge, ex-works factory. In no event shall Seller be liable for any special, consequential, incidental, indirect or exemplary damages arising out of warranty, contract, tort (including negligence) or otherwise, including but not limited to, loss of profit or revenue, loss of use of the product or any associated products and/orequipment, cost of substitute goods or services, downtime costs or claims of or by Purchaser’s clients or customers. In any event, the total liability of Seller for any and all claims arising out of or resulting from the performance, non-performance or use of the product shall not exceed the purchase price of the individual product giving rise to the claim. All other guaranties, warranties, conditions and representations, either express or implied, whether arising under any statute, common law, commercial usage or otherwise are excluded. Electronic Products require installation, start-up and servicing by local factory-trained service representatives. In the absence of installation, start-up and servicing of Electronic Products by Seller trained service representatives, this warranty is null and void. Seller’s obligations as set forth above shall not apply to any product, or, or any component or part thereof, which is not properly installed, used, maintained or repaired, or which is modified other than pursuant to Seller’s instructions or approval. NOTE: The above warranty applies only to products manufactured by Liquid Controls, Lake Bluff, Illinois. Private label, OEM, and/or products manufactured by Liquid Controls licensee(s) are specifically excluded from the above warranty. Consult factory for all non-Liquid Controls manufacturers’ warranties. NO IMPLIED OR STATUTORY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL APPLY.

Backed By Our Worldwide Reputation For Quality, Accuracy and Advanced Design.

LIQUID CONTROLS
A Unit of IDEX Corporation

LIQUID CONTROLS A Unit of IDEX Corporation 105 Albrecht Drive Lake Bluff, IL 60044-2242 (847) 295-1050 FAX: (847) 295-1057 Website: www.lcmeter.com

Distributed By:

Printed with vegetable inks on recycled paper. Please Recycle!

© 2001 Liquid Controls

Printed in U.S.A.(03/01)

Bulletin #48496B $1

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 fuel oil delivery. The Value 90 has been designed for durability and yet economically priced. This rebuildable nozzle comes complete with automatic venturi shut-off and a dual position, hold-open mechanism.

Features:
• 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

Benefits:
• 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

Materials:
• • • • • Body.......Aluminum Weight....5.3 lbs. Inlet........11/2" NPT Spout.....Aluminum 1 3/8" OD Seals......Viton and Buna

Ordering Specifications:
• CV90-001 11/2" Bulk Fueling Nozzle, New • CV90-002 11/2" Bulk Fueling Nozzle, New (ULC) • RV90 11/2" Bulk Fueling Nozzle, Rebuilt

Accessories:
• V90S Replacement spout assembly • V90SW 1 1/2" x 1 1/2" Swivel

CATLOW Inc. Sales Desk (800) 222-8569 Sales Fax (937) 898-8631 Phone (937) 898-3236 2750 US RT 40, Tipp City, OH 45371
© 2006 CATLOW Inc. All Rights Reserved

CV900306

BLACKMER TRUCK PUMPS
INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS

MODELS: TX, TXS, TXD, TXSD 1.5, 2A, 2.5A, 3E, 4A TXV 2.5B, 3B
and Discontinued TX(S) 2, 21/2, 3; TXV 2(A)(B), 21/2(A), 3(A) Models

960280 INSTRUCTIONS NO. 201-A00 Page 1 of 12 Section Effective Replaces 200 March 2003 June 2001

SAFETY DATA

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 for personal injury, death or major proper ty damage.

TABLE OF CONTENTS

Page

Warns of hazards that WILL cause serious personal injury, death or major proper ty damage.

SAFETY DATA .................................................................1-2 PUMP DATA .........................................................................2 Technical Data.......................................................2 Initial Start Up Information .....................................2 INSTALLATION ...............................................................2-3 Pre-Installation Cleaning .......................................2 Location and Piping...............................................2 Truck Mounting......................................................3 Pump Drive............................................................3 Pump Rotation.......................................................3 To Change Pump Rotation ....................................3 OPERATION .....................................................................4-5 Pre-Start Up Check List.........................................4 Start Up Procedures ..............................................4 Pump Speed..........................................................4 Reverse Rotation...................................................4 Flushing the Pump ................................................4 Relief Valve ...........................................................4 Relief Valve Setting and Adjustment .....................5 MAINTENANCE ...............................................................5-8 Lubrication.............................................................5 Vane Replacement ................................................5 Pump Disassembly................................................6 Pump Assembly ....................................................6 GENERAL PUMP TROUBLESHOOTING .................9-10

Warns of hazards that CAN cause serious personal injury, death or major property damage.

Warns of hazards that CAN cause personal injury or property damage.

NOTICE:
Indicates special instructions which are very impor tant and must be followed.

NOTICE: Blackmer truck pumps MUST only be installed in systems which have been designed by qualified engineering personnel. The system MUST conform to all applicable local and national regulations and safety standards. This manual is intended to assist in the installation and operation of the Blackmer truck pumps, and MUST be kept with the pump. Blackmer truck pump service shall be performed by qualified technicians ONLY. Service shall conform to all applicable local and national regulations and safety standards. Thoroughly review this manual, all instructions and hazard warnings, BEFORE performing any work on the Blackmer truck pumps. Maintain ALL system and Blackmer truck pump operation and hazard warning decals.

NOTE: Numbers in parentheses following individual parts indicate reference numbers on the corresponding Blackmer Parts Lists.

SAFETY DATA
FAILURE TO SET THE VEHICLE EMERGENCY BRAKE AND CHOCK WHEELS BEFORE PERFORMING SERVICE CAN CAUSE SEVERE
Hazardous machinery can cause severe personal injury or property damage.

DISCONNECTING FLUID OR PRESSURE CONTAINMENT COMPONENTS DURING PUMP OPERATION CAN CAUSE SERIOUS
Hazardous pressure can cause personal injury or property damage.

PERSONAL INJURY OR PROPERTY DAMAGE.

PERSONAL INJURY, DEATH OR MAJOR PROPERTY DAMAGE.

FAILURE TO RELIEVE SYSTEM PRESSURE PRIOR TO PERFORMING PUMP SERVICE OR MAINTENANCE CAN CAUSE PERSONAL INJURY OR
Hazardous pressure can cause personal injury or property damage.

IF PUMPING HAZARDOUS FLUIDS SYSTEM MUST BE FLUSHED PRIOR TO PERFORMING SERVICE.
Hazardous or toxic fluids can cause serious injury.

PROPERTY DAMAGE.

PUMP DATA
TECHNICAL DATA
TX(S)(D) Models Maximum Temperature* Maximum Pump Speed Maximum Viscosity* Maximum Differential Pressure Maximum Working Pressure
(Inlet Pressure + Differential Pressure)

INITIAL START UP INFORMATION
TXV Models 375oF (190oC)

Model No. Serial No. Date of Installation: Pressure Gauge Reading: Vacuum Gauge Reading: Flow Rate:

300oF (149oC)

640 RPM1 50,000 SSU (10,800 cSt) 125 psi (8.6 bar) 175 psi (12.1 bar)

* 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.

INSTALLATION
NOTICE: BLACKMER TRUCK PUMPS MUST ONLY BE INSTALLED IN SYSTEMS DESIGNED BY QUALIFIED ENGINEERING PERSONNEL. SYSTEM DESIGN MUST CONFORM WITH ALL APPLICABLE REGULATIONS AND CODES AND PROVIDE WARNING OF ALL SYSTEM HAZARDS.

PRE-INSTALLATION CLEANING
Foreign matter entering the pump WILL cause extensive damage. The supply tank and intake piping MUST be cleaned and flushed prior to pump installation and operation.

LOCATION AND PIPING
An improperly designed piping system or unit installation WILL significantly reduce pump performance and life. Blackmer recommends the following piping system layout and unit installation. 1. To minimize intake losses, locate the pump as close as possible to the source of supply. 2. Piping MUST be properly supported to prevent any piping loads from being placed on the pump. 3. Intake piping and fittings MUST be at least as large in diameter as the pump intake connection. 2

FAILURE TO SET THE VEHICLE EMERGENCY BRAKE AND CHOCK WHEELS BEFORE PERFORMING SERVICE CAN CAUSE SEVERE
Hazardous machinery can cause severe personal injury or property damage.

PERSONAL INJURY OR PROPERTY DAMAGE.

INSTALLATION
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 pump cylinder to check pump performance at start-up. 6. Install a strainer in the inlet line to protect the pump from foreign matter. Placement of intake strainers should facilitate frequent cleaning. 7. Intake and discharge piping MUST be free of all leaks. long as the pump is shimmed to have its shaft parallel in all respects to the PTO shaft. 5. The yokes of the universals at both ends of the jack shaft must be parallel and in phase. 6. The maximum recommended angle between the jack shaft and the pump shaft is 15 degrees. Refer to Table 1. Failure to follow any of these guidelines may result in a gallop or uneven turning of the pump rotor, which will in turn cause a surging vibration to the liquid stream and piping system. Contact the supplier of the drive line components for specific design assistance.

TRUCK MOUNTING
The pump will operate satisfactorily in any position. Consult Blackmer factory for vertical shaft mounts. The pump can be bolted to the truck frame or on a saddle hung below the frame, and MUST be adequately supported. Mounting the pump with the cylinder feet down, or with the intake port up, is recommended for thorough draining of the pump.

Hydraulic Drive
The pump may also be driven hydraulically. Hydraulic motors must be well supported with their shafts parallel to the pump shaft in all respects. Blackmer provides an optional closecoupled hydraulic motor adapter. The adapter provides for straight alignment of a hydraulic motor drive through a solid coupling connected to a straight key pump shaft. This coupling connection requires grease lubrication every three months at minimum. Refer to the "Lubrication" section of this manual.

PUMP DRIVE
The pump may be driven by a power take-off through universal joints. When using universal joints, a splined slip joint, properly lubricated, must be used on the connecting jack shaft to prevent end thrust on the pump shaft. It is very important to install a proper drive line to avoid excessive wear, vibration and noise (see Fig. 1 and Table 1).

PUMP ROTATION

NOTICE: CONFIRM CORRECT PUMP ROTATION BY CHECKING THE PUMP ROTATION ARROWS RESPECTIVE TO PUMP DRIVER ROTATION.

TO CHANGE PUMP ROTATION TX(S)D and TXV Models
The TX(S)D and TXV pump models are equipped with a double ended rotor and shaft, enabling them to be driven from either shaft end. To change rotation, rotate the pump 180 degrees so that the opposite shaft becomes the driven shaft. On TX(S)D pump models, the shaft protector (186) MUST be mounted over the non-driven shaft end. On TXV pump models, the outboard bearing cover (27) MUST be mounted over the non-driven shaft end. OPERATION WITHOUT SHAFT 11o through 15o Fair
Do not operate without guard in place.

(Yokes must be in phase)

Figure 1 - Pump Drive

Angle of Drive Shaft 1o through 5o Very Good 6o through 10o Good 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 parallel in all respects. Use an angular level measuring device to ensure the PTO and pump shaft are parallel to each other. If necessary, the pump can be shimmed to correct any misalignment. The PTO shaft coming off at the transmission does not need to be perfectly horizontal as 3

PROTECTOR CAN CAUSE SERIOUS PERSONAL INJURY, MAJOR PROPERTY DAMAGE, OR DEATH.

TX1.5, TX4 Models and Discontinued TX(S) Models
To reverse the pump rotation, remove the bearing covers, locknuts/lockwashers or lock collars (if equipped), from both inboard and outboard heads. Remove the inboard head assembly and reverse the rotor and shaft, so that the driven end of the shaft protrudes from the outboard head. Remove and replace the vanes so that the relief grooves face in the direction of pump rotation. Refer to the "Maintenance" Section of this manual for pump disassembly and assembly.

OPERATION
PRE-START UP CHECK LIST
1. Check the alignment of the pipes to the pump. Pipes must be supported so that they do not spring away or drop down when 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 be used to check the actual suction and discharge conditions after pump start-up. 3. Inspect complete piping system to ensure that no piping loads are being placed on the pump. 4. Secure appropriate hose connections.

REVERSE ROTATION
NOTICE: PUMPS OPERATED IN REVERSE MUST HAVE A SEPARATE PRESSURE RELIEF VALVE INSTALLED TO PROTECT THE PUMP FROM EXCESSIVE PRESSURE. It may be desirable to run the pump in reverse rotation for system maintenance. The pump will operate satisfactorily in reverse rotation to strip lines, at a reduced performance level. When operating the pump in reverse, a separate bypass valve MUST be installed to protect the pump from excessive pressure.

START UP PROCEDURES
PUMP OPERATING AGAINST A CLOSED VALVE CAN CAUSE SYSTEM COMPONENT FAILURE, PERSONAL INJURY AND PROPERTY
Hazardous pressure can cause personal injury or property damage.

FLUSHING THE PUMP
NOTICE: IF FLUSHING FLUID IS TO BE LEFT IN THE PUMP FOR AN EXTENDED TIME, IT MUST BE A LUBRICATING, NON-CORROSIVE FLUID. IF A CORROSIVE, NONLUBRICATING FLUID IS USED, IT MUST BE FLUSHED FROM THE PUMP IMMEDIATELY. To flush the pump, use the following procedure: 1. Allow the pump to evacuate as much fluid as possible.

DAMAGE.

NOTICE: CONSULT THE "GENERAL PUMP TROUBLESHOOTING" SECTION OF THIS MANUAL IF DIFFICULTIES DURING START UP ARE EXPERIENCED. 1. Start the pump. Priming should occur within one minute. 2. Check the vacuum and pressure gauges to ensure the system is operating within expected parameters. Record the gauge readings in the "Initial Start Up Information" section of this manual for future reference. 3. Inspect piping, fittings, and associated system equipment for leaks, noise, vibration and overheating. 4. Check the flow rate to ensure the pump is operating within the expected parameters. 5. Check the pressure setting of the relief valve by momentarily closing a valve in the discharge line and reading the pressure gauge. This pressure should be 15 20 psi (1.0 - 1.4 bar) higher than the maximum system operating pressure, or the external bypass valve setting (if equipped). DO NOT operate the pump against a closed discharge valve for more than 15 seconds. If adjustments need to be made, refer to the "Relief Valve Setting and Adjustment" section of this manual.

2. Run cleaning fluid through the pump intake. The cleaning fluid must be compatible with the pump O-rings and vane material. When handling "sticky" fluids that solidify within the pump (i.e., waxes, adhesives, resins, asphalts, etc.), use a fluid that will prevent solidification of the fluid being transferred and facilitate flushing. 3. Operate the pump against a closed discharge for 15 seconds to allow the cleaning fluid to recirculate through the internal relief valve.

RELIEF VALVE
NOTICE: THE PUMP INTERNAL RELIEF VALVE IS DESIGNED TO PROTECT THE PUMP FROM EXCESSIVE PRESSURE AND MUST NOT BE USED AS A SYSTEM PRESSURE CONTROL VALVE. Pumping volatile liquids under suction lift may cause cavitation. Partial closing of the discharge valve WILL result in internal relief valve chatter and must not be done. For these applications, install an external bypass valve, and any necessary piping, back to the storage tank. This bypass system must be used when operating for extended periods (more than 1 minute) against a closed discharge valve.

PUMP SPEED
PTO and hydraulically driven units MUST contain speed control devices to prevent pump speeds above the maximum RPM specifications, regardless of the truck engine unloading speeds. Should fluid delivery be appreciably less than expected, see the "General Pump Troubleshooting" section.

RELIEF VALVE SETTING AND ADJUSTMENT
The relief valve pressure setting is marked on a metal tag attached to the valve cover. Generally, the relief valve should be set at least 15 - 20 psi (1.0 - 1.4 bar) higher than the operating pressure, or the external bypass valve setting (if equipped). 4

OPERATION
Relief Valve Adjustment Procedure: 1. To INCREASE the pressure setting , remove the relief valve cap, loosen the locknut, and turn the adjusting screw inward, or clockwise. Replace the valve cap. 2. To DECREASE the pressure setting, remove the relief valve cap, loosen the locknut, and turn the adjusting screw outward, or counterclockwise. Replace the valve cap. Refer to the individual Blackmer pump parts lists for various spring pressure ranges. The pumps are supplied from the factory with the relief valve adjusted to the mid-point of the spring range. If the pump is equipped with a Blackmer air valve, refer to setting and adjustment procedures covered in Blackmer Air Valve Instructions and Parts List No. 201-F00, 286/F or 201-B00. NOTICE: WHERE REGULATIONS REQUIRE, HOLES IN R/V CAP (1) AND CAPSCREW W / HOLE (5C) ARE USED BY THE WEIGHTS AND MEASURES OFFICIAL (S) TO APPLY A SECURITY SEAL OR TAG.

INCORRECT SETTINGS OF THE PRESSURE RELIEF VALVE CAN CAUSE SYSTEM COMPONENT FAILURE, PERSONAL INJURY AND
Hazardous pressure can cause personal injury or property damage.

PROPERTY DAMAGE.

MAINTENANCE
NOTICE: MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE PROCEDURES AND WARNINGS AS PRESENTED IN THIS MANUAL. FAILURE TO SET THE VEHICLE EMERGENCY BRAKE AND CHOCK WHEELS BEFORE PERFORMING SERVICE CAN CAUSE SEVERE
Hazardous machinery can cause severe personal injury or property damage.

LUBRICATION
Ball bearings and hydraulic motor couplings (if equipped) must be lubricated every three months at a minimum. More frequent lubrication may be required, depending on the application and the operating conditions. TXV pump model bearings MUST be replaced after each 1000 hours of service if fluid temperature 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 Poly 372, or equivalent Polyurea grease. Greasing Procedure:

PERSONAL INJURY OR PROPERTY DAMAGE.

FAILURE TO RELIEVE SYSTEM PRESSURE PRIOR TO PERFORMING PUMP SERVICE OR MAINTENANCE CAN CAUSE PERSONAL INJURY OR
Hazardous pressure can cause personal injury or property damage.

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 begins to 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 for some grease to escape from the grease tell-tale hole after lubrication, excessive grease on pumps equipped with mechanical seals can cause seal failure.

PROPERTY DAMAGE.

DISCONNECTING FLUID OR PRESSURE CONTAINMENT COMPONENTS DURING PUMP OPERATION CAN CAUSE SERIOUS
Hazardous pressure can cause personal injury or property damage.

VANE REPLACEMENT
NOTICE: MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE PROCEDURES AND WARNINGS AS PRESENTED IN THIS MANUAL. 1. Remove the head assembly from the outboard (nondriven) 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 (12 o'clock) position of the rotor. Remove the vane. 3. Install a new vane, ensuring that the rounded edge is UP, 5

PERSONAL INJURY, DEATH OR MAJOR PROPERTY DAMAGE.

IF PUMPING HAZARDOUS FLUIDS SYSTEM MUST BE FLUSHED PRIOR TO PERFORMING SERVICE.
Hazardous or toxic fluids can cause serious injury.

MAINTENANCE
and the relief grooves are facing towards the direction of rotation. 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 - 17 of the "Pump Assembly." section of this manual. a. Bend up the engaged lockwasher tang and rotate the locknut counterclockwise to remove it from the shaft b. Slide the lockwasher off the shaft. Inspect the lockwasher 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 lock collars (24A). To remove: a. Remove the jam nuts (24C) and loosen the two set screws (24B). b. Slide the lock collar off the shaft. c. Repeat steps a and b on the opposite shaft end. 6. Remove the head capscrews (21) and carefully pry the head (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 come off with the head assembly. Remove and discard the head O-ring. a. Pull the bearing (24) from the housing in the head (20). b.To remove the mechanical seal (153), use two screw drivers to gently push the backside of the seal jacket to push the seal from the head (see Figure 4). Use care when placing the screw drivers to prevent damage to the seal faces. Remove and discard mechanical seal O-rings.

Figure 2 - Vane Installation - TX(S)(D) Models*
*NOTE: 1.5 and 2-inch pump models have four (4) vanes.

Figure 3 - Vane Installation - TXV Models*
*NOTE: 2-inch pump models have four (4) vanes.

Figure 4 - Mechanical Seal Removal c. To remove the lip seal assembly (152), use a thin pry bar against the lip seal retaining ring to gently push the housing (152B) out of the head (20). Use care not to damage the lip seal (152A). To remove the lip seal (152A), remove the retaining ring (152D) from the housing, and gently pry the lip seal from the housing. Remove and discard the housing O-ring(s) (152C and 152E). 8. Pull the rotor and shaft (13) from the cylinder (12). While one hand is pulling the shaft, the other hand should be cupped underneath the rotor to prevent the vanes (14) and push rods (77) from falling out. Carefully set the rotor and shaft aside for future vane replacement and reassembly. 9. Remove the remaining components from the outboard side of the pump, as instructed in steps 6 and 7 above.

PUMP DISASSEMBLY
NOTICE: FOLLOW ALL HAZARD WARNINGS AND INSTRUCTIONS PROVIDED IN THE "MAINTENANCE" SECTION OF THIS MANUAL. 1. Starting on the inboard (driven) end of the pump, clean the pump shaft thoroughly, making sure the shaft is free of nicks and burrs. This will prevent damage to the mechanical seal or lip seal when the inboard head assembly is removed. 2. Remove the inboard bearing cover capscrews (28) and slide the inboard bearing cover (27A) and gasket (26) off the shaft. Discard the bearing cover gasket. On the 1.5, 2, 2.5, and 3-inch pump models, the dirt shield (123A) will come off with the bearing cover. 3. Remove the outboard bearing cover capscrews (28) and slide the outboard bearing cover (27) and gasket (26) off the shaft. Discard the bearing cover gasket. 4. If equipped with locknuts and lockwashers (24A and 24B): 6

PUMP ASSEMBLY
Before reassembling the pump, inspect all component parts for wear or damage, and replace as required. Wash out the bearing /seal recess of the head and remove any burrs or nicks from the rotor and shaft.

MAINTENANCE
1. Reassemble the OUTBOARD side of the pump first: a. For a CLOCKWISE rotation pump, position the pump cylinder with the INTAKE port to the left. b. For a COUNTERCLOCKWISE rotation pump, position the pump cylinder with the INTAKE port to the right. 2. Install a new head O-ring (72) in the groove on the inside face of the head (20). Lay the O-ring flat and start in on one side of the groove, stretching ahead with the fingers, as shown in Figure 5. e. Install new housing O-ring(s) (152C and 152E) in the groove(s) of the housing. Lightly grease the housing Oring(s) and push the lip seal and housing assembly into the head recess with the lip seal inward. The lips of the lip seal will face the rotor when the housing is installed. Make sure the housing is bottomed out in the back of the head (20).

Figure 6 - Lip Seal - TXV “B” Models 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. Push the mechanical seal assembly (153) into the recess of the head with seal jacket drive tangs inward. The pin in the stationary seat must be between the lugs in the back of the head recess. 5. LIP SEAL ASSEMBLY (if equipped) The lip seal assembly (152) consists of a metal housing with elastomer(s) around its outer diameter(s), and a teflon lip seal in its inner diameter. TXV “A” model pumps are equipped with spacer washers. Refer to Figures 6 and 7. a. Apply a small amount of light motor oil on the inner diameter of the lip seal housing (152B) to facilitate lip seal (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 lip seal aligned with the hole in the back of the housing. The lip seal should seat flush or slightly recessed in the housing, 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 lip seal against the spacer washers. The lip seal should seat flush or slightly recessed in the housing, around its entire diameter. Note: If necessary, the spacer washers can also be located after the lip seal, as shown in Figure 7, to re-position the lip seal on the pump shaft. d. Insert the retaining ring (152D) into the groove in the housing. 7 Figure 8 - Clamping the Bearing 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 bearing balls must face outward, with the grease shield inward. Ensure the bearing is fully and squarely seated against the lip seal housing (152B) or mechanical seal (153). On TXV pump models, install two 3/8" (10 mm) washers and two bearing cover capscrews (28) to clamp the bearing and compress the lip seal housing inner O-ring (152E) for proper bearing locknut adjustment (see Figure 8). The washers and capscrews will be removed after the locknuts are adjusted.

MAINTENANCE
8. Turn the pump cylinder (12) around and begin assembly on the opposite, inboard end. 9. Remove the vanes (14) and push rods (77) from the rotor and 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 the bottom vanes (14) can be installed and held in place as the push rods (77) are installed in the push rod holes of the rotor. Insert the new vanes into the rotor slots with the rounded edges outward, and the vane relief grooves facing TOWARDS the direction of rotation. Refer to Figures 2 and 3. c. After the bottom vanes (14) and push rods (77) are installed, insert the rotor and shaft (13) fully into the cylinder (12). d. Install the remaining vanes (14) into the top positions of the rotor. If equipped with a mechanical seal (153), rotate the shaft by hand to engage the drive tangs of the seal jacket in the rotor slots. 10. Install the inboard head (20), mechanical seal (153) or lip seal (152), and bearing (24) as instructed in steps 2 through 7. Apply a thin coating of motor oil on the inboard shaft to aid installation. 11. Rotate the shaft by hand to engage the mechanical seal drive tangs (if equipped), and to test for binding or tight spots. If the rotor does not turn freely, lightly tap the rims of the heads (20) with a soft faced mallet until the correct position is found. Install all of the remaining head capscrews (21) for each head (20) and uniformly torque to 25 lbs ft (34 Nm). 12. LOCKNUT INSTALLATION (if equipped) It is important that the bearing locknuts (24A) and lockwashers (24B) be installed and adjusted properly. Overtightening locknuts can cause bearing (24) failure or a broken lockwasher tang. Loose locknuts will allow the rotor (13) to shift against the heads, causing wear. See Figure 9. c. Loosen both locknuts (24A) one complete turn. d. Tighten one locknut (24A) until a slight rotor drag is felt when turning the shaft by hand. e. Back off the nut the width of one lockwasher tang "B". Secure the nut by bending the closest aligned lockwasher tang into the slot in the locknut. The pump should turn freely when rotated by hand. f. Tighten the opposite locknut (24A) by hand until it is snug against the bearing (24). Then, using a spanner wrench, tighten the nut the width of one lockwasher tang. Tighten just past the desired tang, then back off the nut to align the tang with the locknut slot. Secure the nut by bending the aligned lockwasher tang into the slot in the locknut. The pump should continue to turn freely when rotated by hand. g. To check adjustment, grasp the nut and washer with fingers and rotate back and forth. If this cannot be done, one or both locknuts (24A) are too tight and should be alternately loosened one stop at a time (.001") (25 microns). Begin by loosening the locknut adjusted last. h. On TXV pumps, after adjustment is complete, remove the bearing cover capscrews (28) and 3/8" washers from both ends of the pump. 13. LOCK COLLAR INSTALLATION - TX(S)4 Pump Models a. Slide the lock collar (24A) over the shaft and against the bearing (24), with the counterbored side towards the bearing. 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 the collar. c. Repeat this procedure on the opposite pump end. After installing both lock collars, verify the shaft turns freely when rotated by hand. 14. Inspect the grease seal (104) for wear or damage and replace as required. Grease the outside diameter of the grease seal and push it into the bearing cover (27 or 27A) with the lip of the seal inward. The lip will face outward when the bearing cover is installed on the head. 15. Attach a new bearing cover gasket (26) and the bearing cover (27 or 27A) to the head (20). Install and torque the bearing cover capscrews (28) to 15 lbs ft (20 Nm). 16. Follow steps 14 and 15 to install the grease seal (104) and bearing cover (27 or 27A ) on the opposite side of the pump. On TXV pump models, the outboard bearing cover (27) is also a shaft protector and must be installed on the non-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 the bearing cover (27). 18. On TX(S)D pump models, attach the shaft protector (186) on the non-driven shaft end. OPERATION WITHOUT SHAFT PROTECTOR CAN CAUSE SERIOUS PERSONAL INJURY, MAJOR PROPERTY DAMAGE, OR DEATH.
Do not operate without guard in place.

Figure 9 - Locknut Adjustment a. On both ends of the pump shaft, Install a lockwasher (24B) with the tangs facing outward, followed by a locknut (24A) with the tapered end inward. Ensure the inner tang "A" of the lockwasher is located in the slot in the 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 NOT overtighten and bend or shear the lockwasher inner tang.

8

GENERAL PUMP TROUBLESHOOTING
NOTICE: MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE PROCEDURES AND WARNINGS AS PRESENTED IN THIS MANUAL.

SYMPTOM Pump Not Priming

PROBABLE CAUSE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 1. 2. 3. 4. 5. 6. 7. 8. Pump not wetted. Worn vanes. Suction valve closed. Leaks in the suction line. Strainer clogged. Suction line or valves clogged or too restrictive. Broken drive train. Pump vapor-locked. Pump speed too low for priming. Relief valve partially open, worn or not seating properly. Pump speed too low. Suction valves not fully open. Leaks in the suction line. Excessive restriction in the suction line (i.e.: undersized piping, too many elbows & fittings, clogged strainer, etc.). Damaged or worn parts. Excessive restriction in discharge line causing partial flow through the relief valve. Relief Valve worn, set too low, or not seating properly. Vanes installed incorrectly (see "Vane Replacement").

Reduced Capacity

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. 3. 4. 5. 6. 7. 8. 9. 10. 11. Running the pump with a closed discharge line. Pump not securely mounted. Improper drive line (see "Pump Drive"). Bearings worn or damaged. Vibration from improperly anchored piping. Bent shaft, or drive coupling misaligned. Excessively worn rotor. Malfunctioning valve in the system. Relief valve setting too low. Damaged vanes (see following category). Foreign objects entering the pump. Running the pump dry. Cavitation. Viscosity too high for the vanes and /or the pump speed. Incompatibility with the liquids pumped. Excessive heat. Worn or bent push rods, or worn push rod holes. Settled or solidified material in the pump at start-up. Hydraulic hammer - pressure spikes. Vanes installed incorrectly (see"Vane Replacement").

Damaged Vanes

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Troubleshooting continued on page 10.

9

GENERAL PUMP TROUBLESHOOTING

SYMPTOM Broken Shaft

PROBABLE CAUSE
1. 2. 3. 4. 5. 6. 7. 1. 2. 3. 4. 5. 6. 7. 8. Foreign objects entering the pump. Viscosity too high for the pump speed. Relief valve not opening. Hydraulic hammer - pressure spikes. Pump/driver misalignment. Excessively worn vanes or vane slots. Settled or solidified material in the pump at start-up. O-rings not compatible with the liquids pumped. O-rings nicked, cut or twisted. Shaft at seal area damaged, worn or dirty. Ball bearings overgreased. Excessive cavitation. Lip seal not seated properly. Corrosion on lip seal housing. Mechanical seal faces cracked, scratched, pitted or dirty.

Lip Seal / Mechanical Seal Leakage

10

NOTES

11

1809 Century Avenue, Grand Rapids, Michigan 49509-1595, U.S.A. Telephone: (616) 241-1611 • Fax: (616) 241-3752 E-mail: blackmer@blackmer.com • 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: rrandle@rcipurifier.com International Email: rrandle@az.uia.net

INSTALLATION AND WIRING INSTRUCTIONS
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).

Wiring 24 VDC Heater 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).
12 Volt – 6 amps 24 Volt – 3 amps

For Assistance or Technical support call: (800) 868-2088

Operator Accessories
1.00

2.75

.75 1.91

.75

1.97 7.26

1.64 1.07

Ø.56 HOLE

(5) Ø.28 HOLES

Description Remote Control Assy. Cable Clamp only

Part No. 35603SL 9Q1660

Material Stainless

Weight (lb) 1.10 .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.

3.86 Ø.31 x .75 CLEVIS PIN

.40

Fusible Link
.60

.28 1.71

.47

COTTER PIN

7 16-20 UNF HEX NUT

Part No. 21050A

Material Steel

Weight (lb) .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.
TM

INDUSTRIES, INC.
WARREN, PA.

May 1999

Section 29 Page 1A

VEEDER-ROOT INSTALLATION, OPERATION AND SERVICE INSTRUCTIONS

SERIES 7886 HIGH-CAPACITY HIGH-CAPACITY & SERIES 7887 METER 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 ..................................... B. Specifications ................................ SECTION 3. SERIES 7886 DESCRIPTION A. General ..................................... B. Specifications ................................ SECTION 4. PERIODIC INSPECTION A. B. C. D. E. F. General ..................................... Disassembly Prior to Cleaning ............... Cleaning .................................... Inspection ................................... Lubrication .................................. Troubleshooting .............................. 5 5 5 5 5 7 3 3 I 2

SECTION 5. DISASSEMBLY AND ASSEMBLY A. B. C. D. E. F. General ..................................... Removal of Major Groups ...................... Individual Parts Replacement .................. Installation of Major Groups .................... Final Checks and Adjustments ............. Operational Check ............................ 8 8 10 10 15 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 proce- dures 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 heartshaped 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 onehanded 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.

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

TROUBLE
1. Drive shaft hard to turn.

POSSIBLE CAUSE
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. Missing washers on outside of clutch shaft. Pinion jam, anti-topping finger(s) broken or spring(s) missing Reset knob flange on the case binds on reset shaft. Wheel shaft group is bent. Reset fingers rubbing on wheel or retaining rings.

CORRECTION
Check pointer and break positioning. Adjust as required. Remove case. Check all gears, clean and lubricate as necessary. See Sect 4. Check end play and washer as required. Check end play of wheel shaft. Replace broken anti-topping finger(s) or missing spring(s) 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. Replace reset fingers as required. Disassemble wheel group and insert locking disc pin into groove in wheel. Replace cam with new cam and key. Remove cam, inspect and replace parts as required, and assemble properly. Connect shutter to reset lever.

2. Binding occurs during reset cycle

3. Reset knob turns hard

4. Any one wheel will not reset to zero

Broken reset finger. Locking disc pin out of wheel groove. Key in large multiple cam broken. Reset actuating lever not engaged in cam or reset arm broken. Shutter disconnected from reset lever.

5. Incomplete reset cycle. Knob turns but reset does not occur. 6. Shutter partially obscured wheels at completion of reset cycle or completely covers wheels at reset cycle. 7. Shutter will not drop into place or loss of detent action during reset. 8. Pointer not aligned with unit wheel. 9. Unit wheel can be turned in reverse by hand. 10. Cannot drive meter register.

Detent lever spring missing or broken. Improper adjustment of brake or pointer. Dirty drive shaft clutch assembly. Pinion jam, reset fingers are engaged, heart cams hit on detent lever shutter stud, clutch not engaged.

Install new spring. Adjust brake to proper clearance. Adjust pointer to center mark. Clean clutch group and lubricate. See Section 4. Check washers on pinion shaft. Check and play of shafts. Clean and lubricate clutch.

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, side plate reset, anti-topping and clutch shafts to the right-hand (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 antitopping 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 lefthand 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 se- quence 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 lock- washers. 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 antitopping 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 buttonhead 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.

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 deterinined 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 wiiting,ofanyclaims,includingclaii-nsofbreactiofwarraiity, within thirty days aftei- you discover or should have dis- (-oveiedtliefactsuponwliielitlieclaimishased.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.

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.

VEEDER-ROOT VEEDERPetroleum 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

Wet-R-Dri Valve
A

TTMA STYLE

LIGHTWEIGHT COMPACT VERSATILE
B

I.D.

O.D.

Size 2” 3” 4” 5” 6” 8”

Standard Model Assembly No. WD200 AL B WD200 GI B WD300 AL B WD300 GI B WD400 AL V WD400 GI V WD500 AL V WD600 AL U WD800 AL U

Wt. 2.4 4.6 3.6 6.9 4.5 8.3 7.9 11.8 17.3

Detent Model Assembly No. WD201 AL B WD201 GI B WD301 AL B WD301 GI B WD401 AL V WD401 GI V WD501 AL V WD601 AL U WD801 AL U

Wt. 2.4 4.6 3.6 6.9 4.5 8.3 7.9 11.8 17.3

Standard Material Body Disc Aluminum Buna-N Grey Iron Aluminum Buna-N Grey Iron Aluminum Viton Grey Iron Aluminum Viton Aluminum Urethane Aluminum Urethane

Max. Working Pressure 75 PSI 75 PSI 75 PSI 50 PSI 50 PSI 50 PSI

Temperature Range See Chart Below EPDM E -50°F +300°F

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. Dimensions Size 2” 3” 4” 5” 6” 8” A 6 /4 3 6 /4 3 6 /4 3 6 /4 12 12
3

B 4 /4 5 4 /8 1 5 /8 3 6 /8 7 8
1

C 1 /8 1 1 /8 1 1 /8 1 2 /8 1 2 /8 1 2 /2
1

I.D. 2 /4 3 3 /8 3 4 /8 7 5 /16 1 6 /8 8
1

O.D. 3 /4 5 5 /8 5 6 /8 5 7 /8 5 8 /8 7 10 /8
3

B.C. 3 /4 7 4 /8 7 5 /8 7 1 8 /8 1 10 /8
3

Holes 6- /16 7 8- /16 7 8- /16 7 12- /16 7 12- /16 7 16- /16
7

Suffix for Disc Material Buna-N Urethane Viton Black White Black White B WB V U WU -40°F -40°F -0°F -40°F -40°F +200°F +200°F +400°F +200°F +200°F NOTE: Temperature ranges based on published information and may vary due to actual operating conditions.

INSTALLATION: The Wet-R-Dri Valve may be mounted in any position with handle located for easy operation. Valve, as assembled, opens by 1 turning handle /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.
TM

INDUSTRIES, INC.
WARREN, PA.

Feb 1995

Section 20 Page 1A

PARTS LIST

Wet-R-Dri VALVE
2 2 6

4

5

6

10 12 11

9
92

WD101-3

BU

1

9
92

WD101-3

BU

1

7 8

7 8

STANDARD MODEL

DETENT MODEL

No.

Description

Material Buna-N Viton Urethane EPDM Mall. “E” Coated Steel Zinc Plt. Steel Zinc Plt. Steel Steel To Match Disc Mat’l. Steel To Match Disc Mat’l. Steel Zinc Plt. 440 Stnls 304 Stnls 304 Stnls

1

Disc Handle Cap Screw Hex. Nut Drive Shaft Drive Shaft O-Ring Bearing Shaft O-Ring Driv-Lok-Pin Detent Ball Detent Spring Ret. Screw

2 4 5 6 7 8 9 10 11 12

2” Size Part No. WD101-2 BN WD101-2 VT WD101-2 PY WD101-2 EP 25884EY 9Q5813 9Q5808 27053MS 27053MS001 17889** 16006MS 17781** 9Q4893 9Z4856 15229SL 9Q5838

3” Size Part No. WD101-3 BN WD101-3 VT WD101-3 PY WD101-3 EP 25884EY 9Q5813 9Q5808 27050MS 27050MS001 17889** 15913MS 18141** 9Q4893 9Z4856 15229SL 9Q5838

4” Size Part No. WD101-4 BN WD101-4 VT WD101-4 PY WD101-4 EP 25884EY 9Q5813 9Q5808 27050MS 27050MS001 17889** 15913MS 18141** 9Q4893 9Z4856 15229SL 9Q5838

5” Size Part No. WD101-5 BN WD101-5 VT WD101-5 PY WD101-5 EP 25884EY 9Q5813 9Q5808 27051MS 27051MS001 17889** 15913MS 18141** 9Q4925 9Z4856 15229SL 9Q5838

6” Size Part No. WD101-6 BN WD101-6 VT WD101-6 PY WD101-6 EP 25933AL 9Q5898 9Q5808 16229MS 16229MS 18831** 16230MS 18831** 9Q4926 9Z4856 15229SL 9Q5838

8” Size Part No. WD101-8 BN WD101-8 VT WD101-8 PY WD101-8 EP 25933AL 9Q5898 9Q5808 16229MS002 16229MS002 18831** 16230MS002 18831** 9Q4938 9Z4856 15229SL 9Q5838

** O-Ring material suffix to match Disc suffix (i.e.-17889VT)

WARNING Use only genuine Betts Industries Inc. replacement parts. Use of substitute parts can impair the proper functioning of the Wet-R-Dri Valve.
TM

INDUSTRIES, INC.
WARREN, PA.

Jan 1993

Section 20 Page 1B

Installation Parts Installation & Parts Manual
M/MA Meters

Installation: M100-10

Contents Table of Contents and Safety Procedures Safety Procedures
Description Page Number How LC Meters Work ........................................... 3 Owner’s Information Packet ................................. 4 Installation Requirements ..................................... 6 Operation Requirements ....................................... 7 Meter Start Up and Operation .............................. 8 Reversing the Meter Registration ......................... 9 Setting the Standard Adjuster .............................. 10 Meter Maintenance ............................................... 10 Relieving Internal Pressure ................................... 11 Servicing the Drive Components ........................... 12 Removing the Dust Cover ..................................... 12 Removing the Adjuster and Adjuster Drive Assembly ...................................... 12 Buna/Viton/Teflon Packing Gland ......................... 15 The Retaining Plate .............................................. 15 Disassembling the Meter ...................................... 16 Removing the Non-Corroded Rotor Gears .......................................................... 18 Removing Corroded Rotor Gears .......................... 18 Reassembling the Meter ...................................... 20 Timing the Rotor Gears ........................................ 21 Torque Chart ......................................................... 22 Wrench and Socket Size Chart ........................... 23 Troubleshooting .................................................... 24 How to Order Replacement Parts ........................ 26 Illustrated Parts Breakdown ................................. 27-30 Quality Statement ................................................ 31 Please have the following information available when you make inquires, order replacement parts, or schedule service. If a specific meter accessory is involved, please provide the model and serial number of the accessory in question (see page 4). Your Meter’s Serial Number: ________________________ Your Full-Service Distributor: _______________________ Your Full-Service Distributor’s Telephone Number: _______________________________

WARNING ! WARNING
All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in the system, the packing gland, and the front or rear covers. See “Relieving Internal Pressure” (page 11).

Prepared Be Prepared
Make sure that all necessary safety precautions have been taken. Provide for proper ventilation, temperature control, fire prevention, evacuation and fire management. Provide easy access to the appropriate fire extinguishers for your product. Consult with your local fire department and state and local codes to make sure that you are adequately prepared. Read this manual as well as all the literature provided in your owner’s packet.

In the Event of a Gas Leak
In the event of a large gas leak: Evacuate the area and notify the fire department. 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 the buildings. Some gases, such as LPG, seek lower levels, while other gases seek higher levels. 3. Evacuate all people from the danger zone. 4. See that the gas is dispersed before resuming business and operating motors. If in doubt, notify your local fire department.

In the Event of a Gas Fire
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 can safely control: Stop the leakage if you can safely reach the equipment. Then use the appropriate extinguisher: Class B fire extinguisher, water, fog, etc., depending on the materials. If in doubt, call your local fire department.

NOTICE
This manual provides warnings and procedures that are intended to inform the owner and/or operator of the hazards present when using the Liquid Controls Meter on LP-Gas and other products. The reading of these warnings and the avoidance of such hazards is strictly in the hands of the owner-operators of the equipment. Neglect of that responsibility is not within the control of the manufacturer of the meter.

2

How LC Meters Work
Liquid Controls meters are positive displacement meters. They are designed for liquid measurement in both custody transfer and process control applications. They can be installed in pump or gravity flow systems. Because of their simple design, they are easy to maintain, and easy to adapt to a variety of systems. The meter housing (1) is designed with three cylindrical bores (2). Three rotors, the blocking rotor (3) and two displacement rotors (4, 5), turn in synchronized relationship within the bores. The three rotors are supported by bearing plates (6, 7). The ends of the rotors protrude through the bearing plates. Blocking rotor gear (8) is placed on the end of the blocking rotor. Displacement rotor gears (9, 10) are placed on the ends of the displacement rotors. These gears create the synchronized timed relationship between the three rotors. As fluid moves through the meter housing, the rotor assembly turns. The liquid is broken into uniform sections by the turning rotors. Fluid displacement happens simultaneously. As fluid enters, another portion of the fluid is being partitioned and measured. At the same time, the fluid ahead of it is being displaced out of the meter and into the discharge line. Since the volume of the bores is known, and the same amount of fluid passes through the meter during each revolution of the blocking rotor, the exact volume of liquid that has passed through the meter can be accurately determined. This true rotary motion is transmitted through the packing gland, the face gear, the adjuster drive shaft, and the adjuster to the register stack and counter. True rotary motion output means consistent accuracy since the register indication is in precise agreement with the actual volume throughput at any given instant. At any position in the cycle, the meter body, the blocking rotor, and at least one of the displacement rotors form a continuous capillary seal between the un-metered upstream product and the metered downstream product.

Meter Element Exploded Line Drawing Capillary seals mean no metal-to-metal contact within the metering element. This means no wear. No wear means no increase in slippage, and no increase in slippage means no deterioration in accuracy. Throughout the metering element, the mating surfaces are either flat surfaces or cylindrical faces and sections that are accurately machined. These relatively simple machining operations, plus the fact that there is no oscillating or reciprocating motion within the device, permits extremely close and consistent tolerances within the LC meter. The product flowing through the meter exerts a dynamic force that is at right angles to the faces of the displacement rotors. The meter is designed so that the rotor shafts are always in a horizontal plane. These two facts result in no axial thrust. Therefore, with no need for thrust washers or thrust bearings, the rotors automatically seek the center of the stream between the two bearing plates eliminating wear between the ends of the rotors and the bearing plates. Once again, no wear results in no metal fatigue and no friction. The Liquid Controls meters are made of a variety of materials to suit a variety of products. Because of our no-wear design, capillary seals, and unique rotary metering, LC meters provide unequalled accuracy, long operating life, and unusual dependability.

3

Owner’ Owner ’s Information Packet

1. Is all your documentation included with your meter? LC meters come in many variations. The information sent to you depends on the accessories you have ordered with your meter. Make an inventory of your owner’s information packet. First, find your LC packing slip with the computer printout. Locate the serial number and the meter model number on this printout. Cross reference the packing slip number with the actual meter numbers. The illustration on this page will help you locate the Specification and Serial Number Plates on the meter and its accessories.

2. Record your meter serial number in the space provided on the inside cover of this manual. The inside cover also provides a space for your full-service distributor’s name and telephone number. Fill in this information and keep it handy. You will always need your meter serial number and model number when calling for service or parts! See ‘How to Order Replacement Parts’ in this manual.

4

Owner’ Owner ’s Information Packet
meter’ letter. 3. Identify your meter ’s model-accessory letter. Use the charts shown above to familiarize yourself with meter accessories. Find the meter and letter on the chart which represents your meter, then check with the chart below to see that your red owner’s information packet is complete. Not all accessory levels are available for every model of LC meter.

4. Check your owner’s information packet with the chart shown above to make sure that all the documentation needed for your meter and accessories is in your red information packet. If documentation is missing, call your full-service distributor or Liquid Controls for replacement materials.

5

Installation Requirements Installation Requirements
Make sure that all necessary safety precautions have been taken. Provide for proper ventilation, temperature control, fire prevention, evacuation and fire management. Provide easy access to the appropriate fire extinguishers for your product. Consult with your local fire department and state and local codes to make sure that you are adequately prepared. Read this manual as well as all the literature provided in your owner’s manual. If you have any questions, consult with your full-service distributor or call the Service Department at Liquid Controls. Install the meter and accessories in conformance with applicable state and federal construction, electrical and safety codes. NOTE: Class 10 LPG meters must be installed in accordance with the requirements of ANSI-NFPA 58 in addition to all other state and local codes. WARNING: Under normal operation, do not expose any portion of the LP-Gas system to pressures in excess of rated working pressures without an automatic safety valve to vent the over pressure discharge to a place of safety away from the operator and other people. Failure to provide such a safety relief may result in leakage or rupture of one or more of the components in the system. This can result in injury of death from the gas, a fire, or pieces of flying debris from the rupture. Before shipment, protective thread caps were placed in all meter and accessory openings. They should remain in place until you are ready to attach piping. Prior to meter installation, the entire piping system should be thoroughly flushed of all debris, with a liquid that is compatible with the construction of the meter. Keep external surfaces of the meter clean. The meter must always be securely bolted to a platform or supporting member, regardless of the mounting position of the meter. Never ‘hang’ a meter on the connecting piping. Install meter only on the discharge side (downstream) of the system pump. Apply pipe compound to male threads only. Position the meter with service in mind. Provide ample work space. Removing covers can be difficult when work space is not available. Always supply a platform or support for the meter mounting. A meter is metallurgically designed to be physically compatible with a given type of liquid, as originally specified by the customer, and as indicated on the Serial Number Plate. A meter should not be used with a liquid different from the liquid originally specified, unless the physical characteristics and pH rating are similar and the application has been checked with LC Sales and Engineering through your full-service distributor. Install a strainer on the meter inlet to avoid damage from foreign 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 as standard. However, when a meter is ordered, the customer can specify that the flow be set from either direction. If the meter register counts in reverse, the meter is reading the direction of flow in reverse. If this occurs, the meter registration must be reset. See ‘Reversing the Meter Registration’ in this manual for mechanical output meters. Refer to your accessory manual for electrical output meters (such as meters equipped with a pulser).

NOTE
Always request up-to-date, engineering approved, dimensional drawings before starting any construction. Do not rely on catalog pictures or drawings which are for reference only. After receiving prints, check to see that all equipment ordered is shown and that any extra pressure taps, plugs, etc. are noted and their size specified.

6

Requirements Operation Requirements
The meter must remain full of product at all times. An easy way to accomplish this is to put the meter assembly in the line below the piping center-line (a sump position). This requires adding elbows and flanges prior to installing the meter. The meter should be installed in a bypass loop, below the pipe center-line, with block valves upstream and downstream. A block valve should be located in the mainstream, labeled as the bypass valve. Caution: Any portion of pipe system that might isolate or block flow should be provided with a pressure relief to prevent damage from thermal expansion. There are excellent benefits to this type of installation. First, the meter is kept full. Second, this type of installation allows the meter to be isolated for servicing and calibration while continuing flow through the bypass valve. Upstream lines must be maintained full to prevent air from entering the meter. If upstream or inlet lines are constructed in a manner which allows reverse flow, foot valves or back checks must be installed. Underground tanks that are furnished with a submersible pump will eliminate many problems that occur with positive displacement pumps (suction pumps) when suction piping is incorrectly sized or when the lift is too great. Every meter should be calibrated under actual service and installation conditions per the API Manual of Petroleum Measurement Standards: Chapter 4 - Proving Systems Chapter 5 - Metering Chapter 6 - Metering Assemblies Chapter 11 Section 2.3 Water Calibration of Volumetric Provers Chapter 12 Section 2 Calculation of Petroleum Quantities These chapters of the API Manual of Petroleum Measurement Standards supersedes the API standard 1101. Provide a means of conveniently diverting liquid for calibration purposes. Give careful attention to your system’s pumping equipment and piping because of their influence on liquid being measured as it enters the metering assembly. Systems should be made free of conditions that cause or introduce entrained air or vapor. Follow the manufacturer’s recommendation fully when installing pumps. Give particular attention to factors like: use of foot valves, pipe size to the inlet and conformance to net positive suction head (NPSH) conditions when suction pumping is required. Following the manufacturer’s recommendations will minimize air and vapor elimination problems. For liquids such as light hydrocarbons that tend to flash or vaporize easily at higher ambient temperatures, it is desirable to use flooded suctions and piping sized larger than the nominal pump size. On systems such as vehicle tank installations, piping layout is important in preventing problems with split compartment test conformance. Piping should slope away from a P.D. pump to prevent resurgent re-priming of the pump due to drain back. Hydraulic shock is harmful to all components of an operating system including valves, meter and the pump. In particular, meters must be afforded protection from shock because of their need to measure with high precision. Generally the best protection is prevention, which can be readily accomplished by adjusting valve closing rates in such a manner that shock does not occur. Thermal expansion like hydraulic shock is a phenomenon that can easily damage meters and systems in general. Care should be taken in designing the system to include pressure relief valves in any portion or branch of the system that might be closed off by closure of operating valves or block valves.

7

St Meter Start Up and Operation
Prior to meter start up, use extreme caution. Make up sure that: 1. The meter is properly secured 2. All connections are tight 3. All valves are in the closed position Placing your meter in operation: When placing your meter in operation, the meter and system must be filled slowly with liquid and be free of air prior to start-up. Extreme care must be taken to avoid damaging the meter during this time. The system may be filled by gravity (preferred) or by use of the pump (if required) when filling the system with liquid for the first time. Gravity filling - systems with positive head pressure from product storage above the inlet port of the meter. 1. Make sure all valves (up stream and down stream of the meter) in the system are closed. 2. Crack open the valve located at the storage tank. The meter’s register/counter will start to move and then stop, provided there is not a valve between the tank and the meter inlet. If there is another valve between the tank and meter, repeat this process with each valve until the meter is exposed to the liquid. 3. Once you are assured that the meter has registered some volume and stopped, continue to fully open the tank 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’s register/counter starts to move. Do not run the meter any 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 provided that the system is designed not to exceed the flow rate marked on the meter. NOTE: NOTE If the valves are not manual, consult the valve manufacturer for slow flow start-up. Filling the system with a pump - Consult the pump manufacturer for proper pump priming. Once the pump is primed with product, proceed as follows: • Follow steps one through four above for proper meter start-up.

NOTE
Make sure that your dead head pressure. for assistance. pump can operate against a If NOT, consult the factory NOT,

Never operate the meter or system when partially filled with liquid, or with pockets of compressed air or vapor present. If these conditions cannot be avoided, air and vapor elimination systems may be required. If you cannot fill the meter slowly by gravity or by using a valve to throttle back the flow, factory. consult the factory. Do not operate the meter at a pressure exceeding that marked on the Serial Number Plate. Under any and all pressure producing circumstances, for instance, thermal expansion and hydraulic shock, the working pressure must not exceed the indicated maximum. If the meter is operated at a rate greater than the maximum recommended GPM, excessive wear and premature failure may occur. The meter can be calibrated for flows below minimum ratings if the flow remains constant and varies within narrow limits or if the product is viscous. A meter should never be run beyond the maximum flow rate determined for that class meter and/or liquid measured.

WARNING ! WARNING
All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in the system, the packing gland, and the front or rear covers. See “Relieving Internal Pressure” (page 11).

8

Reversing the Meter Registration
The direction of flow is specified by the customer when the meter is ordered. The standard direction of flow is from left to right when facing the front of the meter. A red pressure sensitive label indicating inlet is affixed to the meter at time of shipment. If the meter is equipped with a strainer and/or valve, the strainer (and/or valve) MUST be moved when reversing the direction of flow through the meter. The strainer should meter. always be located on the inlet side of the meter. When the meter is equipped with a valve, it is moved to the outlet side of the meter. Some repositioning of the valve components may be required. See the Valve Manual in the Owner’s Information Packet. When the meter is first installed, check the register. If the register counts DOWN, meaning that the register numbers decrease rather than increase, you must reverse the direction of registration by reversing the position of the adjuster drive gear. Reversing the drive to the register is accomplished by reversing the position of the adjuster drive gear relative to the 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 to remove the dust cover (page 12). 2. Remove the retaining ring (4) with a screwdriver or pliers. 3. Remove the two retaining spring screws (1) with a standard screwdriver. Note: For M-15, M-25, M-30, and M-40 models loosen the single set screw. 4. Remove the retaining spring (2). 5. Remove the drive shaft (3) mounted with the adjuster drive gear assembly including (4) Retaining Ring and (5) Adjuster Drive Gear. 6. Remove the adjuster drive gear (5) and turn it 180° so that it is upside down from the original installation position. The bushing (7) supports the adjuster drive gear in the lower position. The retaining ring (4) supports the adjuster drive gear in the upper position.

Adjuster drive gear engaged from the top.

Adjuster drive gear engaged from the bottom.

7. Reassemble the parts in reverse order. Make sure that the adjuster drive gear meshes with the packing gland’s pinion gear (6) without being too tight. Make sure there is a little play in the gear teeth. The retaining ring (4) should be placed in the groove provided on the drive shaft (3), regardless of the adjuster drive gear position. The packing gland pinion gear to adjuster drive gear ratio is either 1:1 or 2:1. In the 2:1 ratio, the pinion of the packing gland is smaller in diameter.

Packing Gland

9

St Setting the Standard Adjuster
NOTE: These instructions apply to meters equipped with mechanical output accessories only. If your meter is equipped with an electrical output (i.e., electronic pulser) refer to your accessory manual, such as the Pulser Manual supplied in your owner’s information packet. 1. Refer to “Servicing the Drive Components”, Step 1 to remove the dust cover (page 12). 2. Check meter registration by delivering product to a reliable, accurate prover. Perform multiple delivery tests to verify the meter repeatability. 3. Record the setting indicated on the adjuster: 4. Note the difference between the volume of the prover and the volume indicated on the meter counter. Calculate the % correction required, as follows: Volume in prover - volume on meter counter % correction = volume in prover 5. Loosen the adjuster clamp screw. 6. When the prover volume is less than the meter counter volume, add the percentage to the original adjuster setting by turning the thimble towards the arrow marked larger (volume). Correct the original setting by approaching the number desired from the next larger number. For example, if the desired adjuster setting is 2.4, turn the adjuster thimble to the left to number 5, then to the right to obtain the 2.4 setting. Adjuster is currently set at 2.3 in the illustration to the right. 7. When the prover volume is more than the meter counter volume, subtract the percentage from the original adjuster setting by turning the thimble in the direction of the arrow marked smaller volume percent. 8. Retighten the adjuster clamp screw. Run product through the meter to allow the adjuster to take a set. Then make several prover runs to check for accuracy X 100

Meter Maintenance and repeatability ability. repeat ability.
Prevent pipe strain or stress from occurring when making meter or accessory repairs. Pipe strain and stress occurs when the pipes are not supported or are not aligned correctly to the meter. The weight of the pipes must always be supported independent of the meter. This means that the meter and accessories can be easily removed without affecting the pipes or the pipe alignment. Never leave any of the pipes hanging.

Seasonal meter storage If the meter is used for seasonal work, at the end of each season the meter should be removed from the system and thoroughly flushed with a compatible liquid. This includes removing the drain on the front and rear covers. Then flush the product from the front and rear covers. If flushing with water is preferred, extra care should be taken to drain the meter completely and dry all internal parts. Immediate refilling with a compatible liquid (or oil misting) is essential to prevent corrosion as well as ice damage to parts from moisture that was overlooked after flushing and drying.

10

Meter Maintenance
Do not mar or scratch any of the precision machined surfaces by prying or sanding parts. Torque all fasteners such as screws and bolts in accordance with specifications listed in the ‘Torque Chart’ in this manual (page 22). Stone the machined surfaces when reassembling the meter to assure that the machined surfaces are free of burrs and mars. Repair pulled threads with threaded insert fasteners. These can be used in many instances. Contact your fullservice distributor for advice if this occurs. Coat threads with anti-seize when removing and replacing bolts and castings in a meter. Removing flange gaskets When removing the flange assembly, 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 flange gasket. Never reuse old flange gaskets. 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 the housing and cover for flatness. Use a straight edge to determine flatness. gaps Look for gaps when disassembling a meter. Use a feeler gauge to check for gaps between the bearing plate and housing. If you do find gaps, check the bearing plates for flatness with a straight edge. Gaps can be caused by shock problems that must be resolved. Contact your fullservice distributor for assistance if this occurs. Check the O-rings for damage. Cracked, rough, or worn O-rings should be replaced. However, a more serious problem of shock may be indicated if the O-rings look nibbled. Shock problems must be verified and resolved. Contact your full-service distributor for assistance if this occurs. Check the bearing plates for flatness. Use a straight edge. Warped bearing plates can be caused by shock problems that must be resolved. Contact your full-service distributor for assistance if this occurs. Check with regulatory agency that governs Weights & Measures in your area. Removing the dust cover seal wire or other maintenance procedures may require Weights & Measures recalibration.

WARNING ! WARNING Relieving Internal Pressure
All 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.

WARNING

Serious injury or death from fire or explosion could result from maintenance of an improperly depressurized and evacuated system.
4. Slowly open the valve/nozzle at the end of the supply line. 5. After product has bled off, close the valve/nozzle at the end of the supply line. 6. Slowly crack the fitting on top of the differential valve to relieve product pressure in the system. Product will drain from the meter system. 7. As product is bleeding from the differential valve, slowly reopen and close the valve/nozzle on the discharge line. Repeat this step until the product stops draining from the differential valve and discharge line valve/ nozzle. 8. Leave the discharge line valve/nozzle open while working on the system.

Procedure for Non-LPG Meters 1. 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 Meters 1. 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 the inlet side, consult the truck manufacturer for procedures to depressurize the system.

11

Components Servicing the Drive Components
Removing the Dust Cover
1. Cut the dust cover seal wire with a side cutters. Remove the dust cover screws with a 5/16’ wrench or slotted screwdriver and then remove the dust cover. See “Relieving Internal Pressure” and “Regulatory Agency” in the ‘Meter Maintenance’ section (page 11) of this manual.

Removing the Adjuster and Adjuster Drive Assembly
1. Record the adjuster micrometer setting.

2. Carefully note the adjuster drive gear position. The gear engages the packing gland pinion from below or above. This gear must be reinstalled in its original position or the meter counter will run backwards.

12

Components Servicing the Drive Components
3. Use a standard screwdriver to loosen (or remove) the two retaining spring screws. 4. Swing the retaining spring off the adjuster drive bushing. 5. Loosen the adjuster mounting clamp screw with a phillips head screwdriver.

Removing the adjuster from the top of the meter when top access is easiest. Front access instructions are on the next page. 6. Remove screws that secure adjuster mounting plate to counter adapter. 7. Lift adjuster mounting bracket with adjuster out of the counter adapter. 8. Remove the adjuster drive assembly from the housing.

13

Components Servicing the Drive Components
Removing the adjuster from the front of the meter when front access is easiest. Top access instructions are on the previous page. 9. Remove the adjuster drive assembly from the housing. 10. Remove the slotted head screw that secures the adjuster to the mounting plate. 11. Bring the adjuster out through the front of the meter by rotating it from left to right to clear the adjuster mounting plate and then pull down to remove from the meter.

WARNING ! WARNING
All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in the system, the packing gland, and the front or rear covers. See “Relieving Internal Pressure” (page 11).

Servicing the Packing Gland
The packing gland is affected by the liquid being metered, the operating temperature, and other system conditions. After prolonged use, the gland may show leakage from the metering chamber. This is a sign of wear. The gland should be replaced or repaired if this occurs. It can be serviced in the field. 1. Remove the two packing gland retaining plate screws with a 5/16” socket and ratchet drive extension or 5/16” nut driver. 2. Pull out the packing gland. 3. Take apart the packing gland by gently prying off the retaining ring with a standard screwdriver. 4. Pull the driver out from the assembly.

14

Buna/Viton/T iton/Teflon Buna/Viton/Teflon Packing Gland
Components Packing Gland Component s
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Driver Shaft Stainless steel thrust washer Rulon thrust washer Buna/Viton/Teflon “U” Cup Aluminum/stainless housing Washer - Nylon Output gear 2:1 Retaining ring Bushing Retaining plate Buna/Viton/Teflon O-ring Two retaining plate screws Output gear 1:1 Carbon Guide Bearing Washer - Stainless Steel

Standard Packing Gland

LPG Packing Gland

Retaining Packing Gland Retaining Plate
The retaining plate has four holes: two that are drilled 1-1/ 2” on center and two that are drilled 1-5/8” on center. If your meter has a counter adapter dust cover (Item #0366) shaped like the illustration shown below, use the holes drilled 1- 5/8” on center to mount the packing gland retaining plate. If your meter does not have the counter adapter dust cover shaped like the illustration shown on the right, use the two holes drilled 1-1/2” on center to mount the packing gland retaining plate.

Item 11 (above)

Adapter Dust Cover for holes drilled 1-5/8” on center

15

Disassembling the Meter
Mechanical Output Meters*
WARNING ! WARNING
All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in the system, the packing gland, and the front or rear covers. See “Relieving Internal Pressure” (page 11). * For electrical output meters refer to the Pulser Manual supplied in your owner’s information packet. 1. Remove the counter bracket screws with a box wrench or socket driver. The counter bracket can be removed with or without removing the adjuster assembly. NOTE: For Aluminum M-30 and M-40 models the counter bracket and front cover are one piece. Go to step 2. 2. Turn the meter on either the inlet or outlet side. Let it stand to allow the product to drain from the meter chamber. 3. Locate the drain plugs on the front and rear covers. Remove the drain plugs using an allen wrench. Let the meter stand to allow product to drain from the front and rear covers.

16

Disassembling the Meter
4. Use a socket wrench or box end wrench to remove the screws securing the front cover. Remove the screws that hold the rear cover. The number of screws will vary depending on meter size. 5. Remove the front and rear covers. MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models have a driven reduction gear attached with a shoulder bolt to the center of the front bearing plate.

6. Carefully remove the O-rings / flat gaskets from front and rear of the housing. Undamaged Buna or Viton Orings may be reused. Flat gaskets and Teflon O-rings should always be replaced and never reused.

7. Hold a spare displacement rotor gear between the right displacement rotor gear and the blocking rotor gear to keep them from turning (if unavailable, use a shop rag between gear teeth). Use the rotor gear wrench or socket to remove the right displacement rotor gear screw and washer. MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models: Rotor gears are on the meter back. All other models: Rotor gears are on the front. 8. Hold the spare gear between the left displacement rotor gear and blocking rotor gear. Use the rotor gear wrench or socket to remove the screw and the packing gland driver held by the screw. 9. Hold the spare gear between the right displacement rotor gear and the blocking rotor gear. Use the rotor gear wrench or socket to remove the left displacement rotor gear screw and washer.

17

Disassembling the Meter
Removing Non-Corroded Rotor Gears
1. Insert two standard screwdrivers behind the blocking rotor gear: Gently pry the gear off its rotor tapered end. If the gears show signs of corrosion, or do not pry off easily, use the alternative method described in steps 5-8. 2. Use the same method to remove the left rotor gear and the right rotor gear. Remember, if the gear does not pry off easily, or feels stuck, use the alternative method 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 when reassembling the meter.

4. Use the bearing plate wrench to remove the screws that hold the front bearing plate to the meter housing. On the back of the meter housing, remove the screws that hold the rear bearing plate to the housing. Go to step 1, Removing the Bearing Plates.

Removing Corroded Rotor Gears
5. 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 screws that hold the rear bearing plate to the housing using the bearing plate wrench or socket. The number of screws varies with the size of meter.

18

Disassembling the Meter
7. With a plastic or non-metallic mallet, tap on the heads of the screws lightly and equally. As you tap on the screw heads, the gears are driven off the rotors. As the rotors are driven in, the rear bearing plate and the rotor assembly are pushed away from the housing. NOTE: NOTE For carbon insert bearing plates, remove the rear plate first and then each rotor as it is hand supported. 8. Use the bearing plate wrench or socket to remove the screws that hold the front bearing plate to the meter housing. The number of screws varies between different meter sizes.

Removing the Bearing Plates and Rotors
1. Insert a screwdriver into each of the two notches near the dowel pins. Be careful not to mar any of the surfaces. Gently pry the front bearing plate off the dowel pins. 2. Remove the front bearing plate and rotor assembly by pulling a rotor straight out from the housing. Be careful not to mar any of the surfaces. MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models: Pull the rotor from the rear bearing plate. This will also remove the drive reduction gear which is attached to the blocking rotor. 3. Remove the remaining bearing plate from the other side by inserting a screwdriver into each of the two notches near the dowel pins. Be careful not to mar any surfaces. Gently pry the front bearing plate off the dowel pins. NOTE: MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models have a driven reduction gear in attached with a shoulder bolt to the center of the front bearing plate. 4. Inspect and clean all critical surfaces like gear teeth, rotors and internal housing faces. Remove any crystalline formations using fine emery cloth or a fine wire brush. Be careful not to mar or alter the shape of any of the parts. Changing the shape of the parts may interfere with their operation. Remove nicks and burrs on metal parts with a stone. Remove all grit and other foreign particles. These may also damage parts and interfere with proper operation. Replace all parts that appear worn or damaged.

19

Reassembling the Meter
1. MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models: Rotor gears are on the rear bearing plate. All other models: Rotor gears are on the front bearing plate. Install the non-rotor gear bearing plate using the bearing plate screws and wrench. 2. Insert the non-tapered ends on the three rotors into the housing. Place each rotor into its respective bore in the installed bearing plate. MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models: Make sure that the teeth of the driving reduction gear mesh with the teeth of the driven reduction gear. 3. Place the remaining bearing plate over the three tapered rotor ends and fasten it with the bearing plate screws. Use the bearing plate wrench. The number of screws varies with meter size. 4. The rotors should have a small amount of end-play and 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 the rotors 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 rotor has a notch, or “keyway”, to hold a key. Position a key into each one of the three rotors. Press the keys into 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 tapered rotor end so that the timing marks line up between the two gears. See ‘Timing the Rotor Gears’ on the next page. Hint: Before you place the right displacement rotor gear on its tapered end, hold the right rotor gear in position. Turn the blocking rotor gear. Try to line up the timing marks before you place the right displacement rotor gear on its tapered rotor end. 7. Position the left displacement rotor gear on its tapered rotor end so that its timing mark lines up with the blocking rotor gear. See ‘Timing the Rotor Gears’.

20

Reassembling the Meter
Timing the Rotor Gears
Rotor gears are timed by lining up the timing marks. The blocking rotor gear has a tooth directly in front of its timing mark. On the displacement rotor gears, the timing mark falls in front of the space between two gear teeth. Make sure that the tooth in front of the timing mark on the blocking rotor gear connects with the space in front of the timing mark on the displacement rotor gear. You may need to remove the gears and reposition them several times on their rotor ends in order to get the timing marks to line up correctly. For more information, See ‘Troubleshooting’. 1. Position the spare displacement rotor gear between the left displacement rotor gear and the blocking rotor gear to prevent the gears from moving. Attach the right displacement gear washer and screw using the rotor gear wrench. Tighten the screw to the torque specification listed in the Torque Chart (page 22). 2. Keep the spare displacement rotor gear positioned by the left displacement rotor gear. Attach the left displacement gear washer and screw using the rotor gear wrench. Tighten the screw to the torque specification listed in the Torque Chart. 3. Position the spare displacement rotor gear between the right displacement rotor gear and the blocking rotor gear. Attach the blocking rotor gear with the packing gland driver and screw using the rotor gear wrench. Tighten the screw to the torque specification listed in the Torque Chart. 4. Rotate the gears to make sure that the rotors turn freely. Burrs, foreign material, or marred surfaces can restrict the rotor movements. It may be necessary to remove the gears and rotors and deburr and clean the surfaces again. 5. Install an O-ring (1) into the groove (2) on the front of the meter housing. The M-60 and M-80 models use a flat gasket. 6. Fasten the front cover (3) with the cover screws (4) using the cover socket or open end/box end wrench. NOTE: 6A. LC recommends tightening the front cover screws in a criss-cross or “star” pattern with a minimum of two passes. First pass should be at half-torque, with final pass(es) at full torque. This will ensure uniform seal compression on cover O-ring or gasket. See M-7 pattern on page 22 for reference. 7. Install the front drain plug (6) in the front drain plug hole (7) using the drain plug allen wrench. 8. Install an O-ring (8) into the groove (9) on the rear of the meter housing. The M-60 and M-80 models use a flat gasket. 9. Fasten the rear cover (10) with the cover screws (11) using the cover socket or open end/box end wrench. NOTE: 9A. LC recommends tightening the rear cover 9A screws in a criss-cross or “star” pattern with a minimum of two passes. First pass should be at half torque, with final pass(es) at full torque. This will ensure uniform 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 plug hole (13) using the drain plug allen wrench. 11. If your meter is equipped with an electrical output accessory, such as a digital pulser, reinstall it according to the instructions outlined under ‘Reinstalling...’ in your accessory manual, such as the Pulser Installation, Operation and Maintenance Manual supplied in your owner’s information packet. Install the front drain plug (6) in the front drain plug hole (7) using the drain plug allen wrench.

Meter Assembly Exploded View

21

Torque Chart
PA TORQUE PATTERN M-7 COVERS

Torque Chart

*Torque Tolerance is ± 10%

22

Wrench and Socket Size Chart

NOTE: 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 not to be applied to the female connection in the rotor.

23

Troubleshooting
WARNING ! WARNING
All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in the system, the packing gland, and the front or rear covers. See “Relieving Internal Pressure” (page 11). PROBLEM: Leakage past packing gland drive shaft housing from internal metering chamber. PROBABLE CAUSE AND SOLUTION: Internal seal of packing gland assembly is worn. Replace packing gland and O-ring seal. OPERATING OPERATING NOTE: Two common causes of packing gland leakage are thermal expansion and hydraulic shock. If two valves in a piping system (on either side of the meter) are closed at one time, and if the temperature rises as little as 1°F in the system, it could result in a rise in pressure within the system that would exceed the working pressure rating of the meter. To avoid this hazard caused by thermal expansion, a pressure-relief valve of some kind must be installed in the system. Hydraulic shock occurs when a large volume (mass) of liquid is moving through a pipe line at some flow rate and a valve is suddenly closed. When the flow is stopped, the entire mass of the liquid in the piping system acts as a battering ram causing a shock effect within the meter. The greater the mass length of line and/or velocity, the greater the hydraulic shock. Since the valve is usually located at the meter outlet, the meter housing, packing gland and the meter internal members receive the full impact of such hydraulic shock. To prevent this hazard a slow closing two-stage valve should be used with the meter. On those systems where mass length of line, etc. are of such magnitude as to preclude the elimination of hydraulic shock with the use of a two-stage slow closing valve, an impact-absorbing air cushioning device should be used. PROBLEM: Leakage from the cover gasket. PROBABLE CAUSE AND SOLUTION: Gasket has been damaged due to shock pressure or cover bolts have not been tightened sufficiently. PROBLEM: Product flows through meter but the register does not operate. PROBABLE CAUSE AND SOLUTION: A. Check packing gland, and gear train. B. If all meter parts are moving then problem is in register. Faulty register should be checked and repaired by trained mechanic. C. Remove register from meter. If all meter parts are moving but output shaft of adjuster assembly is not, adjuster is worn and must be replaced. D. If totalizer numerals (small numbers) on register are recording, but the big numerals are not moving, register needs repair. E. Packing gland gear not turning. For M-60 and M-80 meters, the drive blade may be sheared. Replace the packing gland. This may be caused by starting the flow too rapidly.

24

Troubleshooting
PROBLEM: Breaking teeth on timing gears. PROBABLE CAUSE AND SOLUTION: A. Starting or stopping flow in meter too rapidly. B. Pump bypass not adjusted properly. PROBLEM: Product flows through meter but register does not record correctly. PROBABLE CAUSE AND SOLUTION: A. Adjuster not properly calibrated. B. Incorrect gear plate or gear ratio has been installed. C. Air is in the system. PROBLEM: No flow through meter. PROBABLE CAUSE AND SOLUTION: A. Faulty non-functioning pump. B. Valve not open or not functioning. 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: Meter runs too slowly. PROBABLE CAUSE AND SOLUTION: A. Valve internal mechanism faulty. Valve does not open fully. 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: The meter counts down in reverse (the meter numbers decrease). 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 Up and Operation: Reversing the Meter Registration’ in this manual.

25

Parts How to Order Replacement Parts
1. Refer to the exploded view drawings on Pages 27-31. Find the four digit item number for the part you want to order. The item numbers are listed on the exploded drawings. 2. Find the computer printout titled Parts List that has been inserted in the Owner’s Information Packet which was shipped with your order. Look up the item number on the Parts List. The Parts List shows each item number with a corresponding part number. Find the corresponding five digit part number for the item you want to order. The part number represents an individual piece, 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 the distributor to find the correct component for your meter. The Bills of Material for most meter classes are on the LC public website. Always check the website for the most current BOM.

26

Parts Illustrated Parts Breakdown
M5 through M25 Meters (including MA Meters)

NOTE: NOTE Numbers shown are ITEM numbers, not Part Numbers. Refer to the Bill of Materials supplied in the red Owner’s Information Packet to locate the PART NUMBER associated with these ITEM NUMBERS ART NUMBERS. NOTE: NOTE Meter components may appear different between models.

27

Parts Illustrated Parts Breakdown
M30, M40 Meters

NOTE: NOTE Numbers shown are ITEM numbers, not Part Numbers. Refer to the Bill of Materials supplied in the red Owner’s Information Packet to locate the PART NUMBER associated with these ITEM NUMBERS ART NUMBERS. NOTE: NOTE Meter components may appear different between models.

28

Parts Illustrated Parts Breakdown
M60, M80 Meter Cover

NOTE: NOTE Numbers shown are ITEM numbers, not Part Numbers. Refer to the Bill of Materials supplied in the red Owner’s Information Packet to locate the PART NUMBER associated with these ITEM NUMBERS ART NUMBERS. NOTE: NOTE Meter components may appear different between models.

29

Parts Illustrated Parts Breakdown
M60, M80 Meter Element

NOTE: NOTE Numbers shown are ITEM numbers, not Part Numbers. Refer to the Bill of Materials supplied in the red Owner’s Information Packet to locate the PART NUMBER associated with these ITEM NUMBERS ART NUMBERS. NOTE: NOTE Meter components may appear different between models.

30

St Quality Statement
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 and continuing needs. We will strive to minimize the users’ cost by providing products of high reliability, maintainability, serviceability, and no of no 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 trust and 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, the development of our people, and our contribution to the community. Our goal is to be Simply the Best Best.

31

A Unit of IDEX Corporation 105 Albrecht Drive Lake Bluff, IL 60044-2242 1.800.458.5262 • 847.295.1050 Fax: 847.295.1057 www.lcmeter.com

© 2004 Liquid Controls Pub. No. 48683 (05/04)

PARTS MANUAL

M-7, MA-7, M-10

®

®

®

Meters

LIQUID CONTROLS
A Unit of IDEX Corporation

Exploded View: M-7/MA-7/M-10 Meter Covers
CAUTION
IGN COUNTER D AL RIV E T WITH S SHA F LO T

0 2
0

1

6
5
3

1

2

4

0202 Adjuster assembly

0609 Screw, mounting plate (2)

0364 Plate, adjuster mounting

0613 Screw, adjuster 0366 Plate, dust cover 0382 Shaft, adjuster 0336 Gear 0574 Ring, retaining

0126 Bracket, counter adapter

MODEL NO. SERIAL NO.
®

LIQUID CONTRO LS CO LAKE BL UFF, IL, RP. USA

ACCURA FLOW

VOL/REV
CY

RATE

TEMP ER

ATURE SURE

UK81 1783

PRODUC

T

MAX PRES

0165 Gear, packing gland 0250 Packing Gland Assy. 0705 Washer, flat (4) 0673 Screw (4)

0780 Seal wire Driveshaft bushing (2) 0630 Screw (2) 0603 Screw (2)

How to Order Replacement Parts
1. 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 item number on the Parts List. The Parts List shows each item number with a corresponding part number. Find the corresponding 5 digit part number for the item you want to order. The part number represents an individual piece, 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 the distributor to find the correct component for your meter.

0566 Plug, pipe-hex socket (2, one for each cover)

0125 Cover, rear 0627 Hex washer head screw (20, for both covers)

When placing order for replacement parts please reference the meter's serial number.

®

Front cover
Rear cover
0570 Pipe plug (optional) 0153 Rotor, blocking 0611 Screw, hex head w/lockwasher (6 per plate) 4 0528 Key (3) (1 per rotor)

0161 Gear, blocking rotor

0326 Driver, packing gland

*0675 Screw, cap socket head

. CORP ROLS A CONT US LIQUID BLUFF, IL, LAKE L NO. MODE NO. SERIAL
®

0765 Washer, Lock

0673 Screw, hex washer head (2) 0163 Gear, displacement pinion (2)

0318 Pin, dowel (4)
0372 Plate, serial number
0144 Plate, bearing (2)

0771 Bellevue washer, rotor gear (2)

0155 Rotor, displacement (2)

0110 Housing

Exploded View: M-7/MA-7/M-10 Meter Housing

0430 O-Ring (2)

*For M-10 Meter Blocking Rotor, #0672 Shown HereReplaces #0675

0672 Screw, blocking rotor

SOLD AND SERVICED BY A NETWORK OF HIGHLY TRAINED FULL SERVICE DISTRIBUTORS

Backed By Our Worldwide Reputation For Quality, Accuracy and Advanced Design.
WARRANTY: Liquid Controls (“Seller”) products are warranted against defects 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) months from the date of original shipment from Seller. Seller’s obligations, set forth below, shall apply only to failure(s) to meet the foregoing obligations provided that Seller is given written notice within thirty (30) days of any occurrence from which a claim of defect arises. If a warranty dispute occurs, the Purchaser shall be required to provide Seller with proof of date of sale. The minimum requirement to establish date of sale shall be a copy of the Seller’s invoice. In the event that a factory inspection by Seller or its designee(s) supports the validity of a claim, at the discretion of Seller, repair, replacement or refund shall be the sole remedy for defect and shall be made, free of charge, ex-works factory. In no event shall Seller be liable for any special, consequential, incidental, indirect or exemplary damages arising out of warranty, contract, tort (including negligence) or otherwise, including but not limited to, loss of profit or revenue, loss of use of the product or any associated products and/orequipment, cost of substitute goods or services, downtime costs or claims of or by Purchaser’s clients or customers. In any event, the total liability of Seller for any and all claims arising out of or resulting from the performance, non-performance or use of the product shall not exceed the purchase price of the individual product giving rise to the claim. All other guaranties, warranties, conditions and representations, either express or implied, whether arising under any statute, common law, commercial usage or otherwise are excluded. Electronic Products require installation, start-up and servicing by local factory-trained service representatives. In the absence of installation, start-up and servicing of Electronic Products by Seller trained service representatives, this warranty is null and void. Seller’s obligations as set forth above shall not apply to any product, or, or any component or part thereof, which is not properly installed, used, maintained or repaired, or which is modified other than pursuant to Seller’s instructions or approval. NOTE: The above warranty applies only to products manufactured by Liquid Controls, Lake Bluff, Illinois. Private label, OEM, and/or products manufactured by Liquid Controls licensee(s) are specifically excluded from the above warranty. Consult factory for all non-Liquid Controls manufacturers’ warranties. NO IMPLIED OR STATUTORY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL APPLY.

Backed By Our Worldwide Reputation For Quality, Accuracy and Advanced Design.

LIQUID CONTROLS
A Unit of IDEX Corporation

LIQUID CONTROLS A Unit of IDEX Corporation 105 Albrecht Drive Lake Bluff, IL 60044-2242 (847) 295-1050 FAX: (847) 295-1057 Website: www.lcmeter.com

Distributed By:

Printed with vegetable inks on recycled paper. Please Recycle!

© 2001 Liquid Controls

Printed in U.S.A.(03/01)

Bulletin #48496B $1

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 fuel oil delivery. The Value 90 has been designed for durability and yet economically priced. This rebuildable nozzle comes complete with automatic venturi shut-off and a dual position, hold-open mechanism.

Features:
• 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

Benefits:
• 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

Materials:
• • • • • Body.......Aluminum Weight....5.3 lbs. Inlet........11/2" NPT Spout.....Aluminum 1 3/8" OD Seals......Viton and Buna

Ordering Specifications:
• CV90-001 11/2" Bulk Fueling Nozzle, New • CV90-002 11/2" Bulk Fueling Nozzle, New (ULC) • RV90 11/2" Bulk Fueling Nozzle, Rebuilt

Accessories:
• V90S Replacement spout assembly • V90SW 1 1/2" x 1 1/2" Swivel

CATLOW Inc. Sales Desk (800) 222-8569 Sales Fax (937) 898-8631 Phone (937) 898-3236 2750 US RT 40, Tipp City, OH 45371
© 2006 CATLOW Inc. All Rights Reserved

CV900306

BLACKMER TRUCK PUMPS
INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS

MODELS: TX, TXS, TXD, TXSD 1.5, 2A, 2.5A, 3E, 4A TXV 2.5B, 3B
and Discontinued TX(S) 2, 21/2, 3; TXV 2(A)(B), 21/2(A), 3(A) Models

960280 INSTRUCTIONS NO. 201-A00 Page 1 of 12 Section Effective Replaces 200 March 2003 June 2001

SAFETY DATA

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 for personal injury, death or major proper ty damage.

TABLE OF CONTENTS

Page

Warns of hazards that WILL cause serious personal injury, death or major proper ty damage.

SAFETY DATA .................................................................1-2 PUMP DATA .........................................................................2 Technical Data.......................................................2 Initial Start Up Information .....................................2 INSTALLATION ...............................................................2-3 Pre-Installation Cleaning .......................................2 Location and Piping...............................................2 Truck Mounting......................................................3 Pump Drive............................................................3 Pump Rotation.......................................................3 To Change Pump Rotation ....................................3 OPERATION .....................................................................4-5 Pre-Start Up Check List.........................................4 Start Up Procedures ..............................................4 Pump Speed..........................................................4 Reverse Rotation...................................................4 Flushing the Pump ................................................4 Relief Valve ...........................................................4 Relief Valve Setting and Adjustment .....................5 MAINTENANCE ...............................................................5-8 Lubrication.............................................................5 Vane Replacement ................................................5 Pump Disassembly................................................6 Pump Assembly ....................................................6 GENERAL PUMP TROUBLESHOOTING .................9-10

Warns of hazards that CAN cause serious personal injury, death or major property damage.

Warns of hazards that CAN cause personal injury or property damage.

NOTICE:
Indicates special instructions which are very impor tant and must be followed.

NOTICE: Blackmer truck pumps MUST only be installed in systems which have been designed by qualified engineering personnel. The system MUST conform to all applicable local and national regulations and safety standards. This manual is intended to assist in the installation and operation of the Blackmer truck pumps, and MUST be kept with the pump. Blackmer truck pump service shall be performed by qualified technicians ONLY. Service shall conform to all applicable local and national regulations and safety standards. Thoroughly review this manual, all instructions and hazard warnings, BEFORE performing any work on the Blackmer truck pumps. Maintain ALL system and Blackmer truck pump operation and hazard warning decals.

NOTE: Numbers in parentheses following individual parts indicate reference numbers on the corresponding Blackmer Parts Lists.

SAFETY DATA
FAILURE TO SET THE VEHICLE EMERGENCY BRAKE AND CHOCK WHEELS BEFORE PERFORMING SERVICE CAN CAUSE SEVERE
Hazardous machinery can cause severe personal injury or property damage.

DISCONNECTING FLUID OR PRESSURE CONTAINMENT COMPONENTS DURING PUMP OPERATION CAN CAUSE SERIOUS
Hazardous pressure can cause personal injury or property damage.

PERSONAL INJURY OR PROPERTY DAMAGE.

PERSONAL INJURY, DEATH OR MAJOR PROPERTY DAMAGE.

FAILURE TO RELIEVE SYSTEM PRESSURE PRIOR TO PERFORMING PUMP SERVICE OR MAINTENANCE CAN CAUSE PERSONAL INJURY OR
Hazardous pressure can cause personal injury or property damage.

IF PUMPING HAZARDOUS FLUIDS SYSTEM MUST BE FLUSHED PRIOR TO PERFORMING SERVICE.
Hazardous or toxic fluids can cause serious injury.

PROPERTY DAMAGE.

PUMP DATA
TECHNICAL DATA
TX(S)(D) Models Maximum Temperature* Maximum Pump Speed Maximum Viscosity* Maximum Differential Pressure Maximum Working Pressure
(Inlet Pressure + Differential Pressure)

INITIAL START UP INFORMATION
TXV Models 375oF (190oC)

Model No. Serial No. Date of Installation: Pressure Gauge Reading: Vacuum Gauge Reading: Flow Rate:

300oF (149oC)

640 RPM1 50,000 SSU (10,800 cSt) 125 psi (8.6 bar) 175 psi (12.1 bar)

* 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.

INSTALLATION
NOTICE: BLACKMER TRUCK PUMPS MUST ONLY BE INSTALLED IN SYSTEMS DESIGNED BY QUALIFIED ENGINEERING PERSONNEL. SYSTEM DESIGN MUST CONFORM WITH ALL APPLICABLE REGULATIONS AND CODES AND PROVIDE WARNING OF ALL SYSTEM HAZARDS.

PRE-INSTALLATION CLEANING
Foreign matter entering the pump WILL cause extensive damage. The supply tank and intake piping MUST be cleaned and flushed prior to pump installation and operation.

LOCATION AND PIPING
An improperly designed piping system or unit installation WILL significantly reduce pump performance and life. Blackmer recommends the following piping system layout and unit installation. 1. To minimize intake losses, locate the pump as close as possible to the source of supply. 2. Piping MUST be properly supported to prevent any piping loads from being placed on the pump. 3. Intake piping and fittings MUST be at least as large in diameter as the pump intake connection. 2

FAILURE TO SET THE VEHICLE EMERGENCY BRAKE AND CHOCK WHEELS BEFORE PERFORMING SERVICE CAN CAUSE SEVERE
Hazardous machinery can cause severe personal injury or property damage.

PERSONAL INJURY OR PROPERTY DAMAGE.

INSTALLATION
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 pump cylinder to check pump performance at start-up. 6. Install a strainer in the inlet line to protect the pump from foreign matter. Placement of intake strainers should facilitate frequent cleaning. 7. Intake and discharge piping MUST be free of all leaks. long as the pump is shimmed to have its shaft parallel in all respects to the PTO shaft. 5. The yokes of the universals at both ends of the jack shaft must be parallel and in phase. 6. The maximum recommended angle between the jack shaft and the pump shaft is 15 degrees. Refer to Table 1. Failure to follow any of these guidelines may result in a gallop or uneven turning of the pump rotor, which will in turn cause a surging vibration to the liquid stream and piping system. Contact the supplier of the drive line components for specific design assistance.

TRUCK MOUNTING
The pump will operate satisfactorily in any position. Consult Blackmer factory for vertical shaft mounts. The pump can be bolted to the truck frame or on a saddle hung below the frame, and MUST be adequately supported. Mounting the pump with the cylinder feet down, or with the intake port up, is recommended for thorough draining of the pump.

Hydraulic Drive
The pump may also be driven hydraulically. Hydraulic motors must be well supported with their shafts parallel to the pump shaft in all respects. Blackmer provides an optional closecoupled hydraulic motor adapter. The adapter provides for straight alignment of a hydraulic motor drive through a solid coupling connected to a straight key pump shaft. This coupling connection requires grease lubrication every three months at minimum. Refer to the "Lubrication" section of this manual.

PUMP DRIVE
The pump may be driven by a power take-off through universal joints. When using universal joints, a splined slip joint, properly lubricated, must be used on the connecting jack shaft to prevent end thrust on the pump shaft. It is very important to install a proper drive line to avoid excessive wear, vibration and noise (see Fig. 1 and Table 1).

PUMP ROTATION

NOTICE: CONFIRM CORRECT PUMP ROTATION BY CHECKING THE PUMP ROTATION ARROWS RESPECTIVE TO PUMP DRIVER ROTATION.

TO CHANGE PUMP ROTATION TX(S)D and TXV Models
The TX(S)D and TXV pump models are equipped with a double ended rotor and shaft, enabling them to be driven from either shaft end. To change rotation, rotate the pump 180 degrees so that the opposite shaft becomes the driven shaft. On TX(S)D pump models, the shaft protector (186) MUST be mounted over the non-driven shaft end. On TXV pump models, the outboard bearing cover (27) MUST be mounted over the non-driven shaft end. OPERATION WITHOUT SHAFT 11o through 15o Fair
Do not operate without guard in place.

(Yokes must be in phase)

Figure 1 - Pump Drive

Angle of Drive Shaft 1o through 5o Very Good 6o through 10o Good 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 parallel in all respects. Use an angular level measuring device to ensure the PTO and pump shaft are parallel to each other. If necessary, the pump can be shimmed to correct any misalignment. The PTO shaft coming off at the transmission does not need to be perfectly horizontal as 3

PROTECTOR CAN CAUSE SERIOUS PERSONAL INJURY, MAJOR PROPERTY DAMAGE, OR DEATH.

TX1.5, TX4 Models and Discontinued TX(S) Models
To reverse the pump rotation, remove the bearing covers, locknuts/lockwashers or lock collars (if equipped), from both inboard and outboard heads. Remove the inboard head assembly and reverse the rotor and shaft, so that the driven end of the shaft protrudes from the outboard head. Remove and replace the vanes so that the relief grooves face in the direction of pump rotation. Refer to the "Maintenance" Section of this manual for pump disassembly and assembly.

OPERATION
PRE-START UP CHECK LIST
1. Check the alignment of the pipes to the pump. Pipes must be supported so that they do not spring away or drop down when 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 be used to check the actual suction and discharge conditions after pump start-up. 3. Inspect complete piping system to ensure that no piping loads are being placed on the pump. 4. Secure appropriate hose connections.

REVERSE ROTATION
NOTICE: PUMPS OPERATED IN REVERSE MUST HAVE A SEPARATE PRESSURE RELIEF VALVE INSTALLED TO PROTECT THE PUMP FROM EXCESSIVE PRESSURE. It may be desirable to run the pump in reverse rotation for system maintenance. The pump will operate satisfactorily in reverse rotation to strip lines, at a reduced performance level. When operating the pump in reverse, a separate bypass valve MUST be installed to protect the pump from excessive pressure.

START UP PROCEDURES
PUMP OPERATING AGAINST A CLOSED VALVE CAN CAUSE SYSTEM COMPONENT FAILURE, PERSONAL INJURY AND PROPERTY
Hazardous pressure can cause personal injury or property damage.

FLUSHING THE PUMP
NOTICE: IF FLUSHING FLUID IS TO BE LEFT IN THE PUMP FOR AN EXTENDED TIME, IT MUST BE A LUBRICATING, NON-CORROSIVE FLUID. IF A CORROSIVE, NONLUBRICATING FLUID IS USED, IT MUST BE FLUSHED FROM THE PUMP IMMEDIATELY. To flush the pump, use the following procedure: 1. Allow the pump to evacuate as much fluid as possible.

DAMAGE.

NOTICE: CONSULT THE "GENERAL PUMP TROUBLESHOOTING" SECTION OF THIS MANUAL IF DIFFICULTIES DURING START UP ARE EXPERIENCED. 1. Start the pump. Priming should occur within one minute. 2. Check the vacuum and pressure gauges to ensure the system is operating within expected parameters. Record the gauge readings in the "Initial Start Up Information" section of this manual for future reference. 3. Inspect piping, fittings, and associated system equipment for leaks, noise, vibration and overheating. 4. Check the flow rate to ensure the pump is operating within the expected parameters. 5. Check the pressure setting of the relief valve by momentarily closing a valve in the discharge line and reading the pressure gauge. This pressure should be 15 20 psi (1.0 - 1.4 bar) higher than the maximum system operating pressure, or the external bypass valve setting (if equipped). DO NOT operate the pump against a closed discharge valve for more than 15 seconds. If adjustments need to be made, refer to the "Relief Valve Setting and Adjustment" section of this manual.

2. Run cleaning fluid through the pump intake. The cleaning fluid must be compatible with the pump O-rings and vane material. When handling "sticky" fluids that solidify within the pump (i.e., waxes, adhesives, resins, asphalts, etc.), use a fluid that will prevent solidification of the fluid being transferred and facilitate flushing. 3. Operate the pump against a closed discharge for 15 seconds to allow the cleaning fluid to recirculate through the internal relief valve.

RELIEF VALVE
NOTICE: THE PUMP INTERNAL RELIEF VALVE IS DESIGNED TO PROTECT THE PUMP FROM EXCESSIVE PRESSURE AND MUST NOT BE USED AS A SYSTEM PRESSURE CONTROL VALVE. Pumping volatile liquids under suction lift may cause cavitation. Partial closing of the discharge valve WILL result in internal relief valve chatter and must not be done. For these applications, install an external bypass valve, and any necessary piping, back to the storage tank. This bypass system must be used when operating for extended periods (more than 1 minute) against a closed discharge valve.

PUMP SPEED
PTO and hydraulically driven units MUST contain speed control devices to prevent pump speeds above the maximum RPM specifications, regardless of the truck engine unloading speeds. Should fluid delivery be appreciably less than expected, see the "General Pump Troubleshooting" section.

RELIEF VALVE SETTING AND ADJUSTMENT
The relief valve pressure setting is marked on a metal tag attached to the valve cover. Generally, the relief valve should be set at least 15 - 20 psi (1.0 - 1.4 bar) higher than the operating pressure, or the external bypass valve setting (if equipped). 4

OPERATION
Relief Valve Adjustment Procedure: 1. To INCREASE the pressure setting , remove the relief valve cap, loosen the locknut, and turn the adjusting screw inward, or clockwise. Replace the valve cap. 2. To DECREASE the pressure setting, remove the relief valve cap, loosen the locknut, and turn the adjusting screw outward, or counterclockwise. Replace the valve cap. Refer to the individual Blackmer pump parts lists for various spring pressure ranges. The pumps are supplied from the factory with the relief valve adjusted to the mid-point of the spring range. If the pump is equipped with a Blackmer air valve, refer to setting and adjustment procedures covered in Blackmer Air Valve Instructions and Parts List No. 201-F00, 286/F or 201-B00. NOTICE: WHERE REGULATIONS REQUIRE, HOLES IN R/V CAP (1) AND CAPSCREW W / HOLE (5C) ARE USED BY THE WEIGHTS AND MEASURES OFFICIAL (S) TO APPLY A SECURITY SEAL OR TAG.

INCORRECT SETTINGS OF THE PRESSURE RELIEF VALVE CAN CAUSE SYSTEM COMPONENT FAILURE, PERSONAL INJURY AND
Hazardous pressure can cause personal injury or property damage.

PROPERTY DAMAGE.

MAINTENANCE
NOTICE: MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE PROCEDURES AND WARNINGS AS PRESENTED IN THIS MANUAL. FAILURE TO SET THE VEHICLE EMERGENCY BRAKE AND CHOCK WHEELS BEFORE PERFORMING SERVICE CAN CAUSE SEVERE
Hazardous machinery can cause severe personal injury or property damage.

LUBRICATION
Ball bearings and hydraulic motor couplings (if equipped) must be lubricated every three months at a minimum. More frequent lubrication may be required, depending on the application and the operating conditions. TXV pump model bearings MUST be replaced after each 1000 hours of service if fluid temperature 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 Poly 372, or equivalent Polyurea grease. Greasing Procedure:

PERSONAL INJURY OR PROPERTY DAMAGE.

FAILURE TO RELIEVE SYSTEM PRESSURE PRIOR TO PERFORMING PUMP SERVICE OR MAINTENANCE CAN CAUSE PERSONAL INJURY OR
Hazardous pressure can cause personal injury or property damage.

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 begins to 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 for some grease to escape from the grease tell-tale hole after lubrication, excessive grease on pumps equipped with mechanical seals can cause seal failure.

PROPERTY DAMAGE.

DISCONNECTING FLUID OR PRESSURE CONTAINMENT COMPONENTS DURING PUMP OPERATION CAN CAUSE SERIOUS
Hazardous pressure can cause personal injury or property damage.

VANE REPLACEMENT
NOTICE: MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE PROCEDURES AND WARNINGS AS PRESENTED IN THIS MANUAL. 1. Remove the head assembly from the outboard (nondriven) 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 (12 o'clock) position of the rotor. Remove the vane. 3. Install a new vane, ensuring that the rounded edge is UP, 5

PERSONAL INJURY, DEATH OR MAJOR PROPERTY DAMAGE.

IF PUMPING HAZARDOUS FLUIDS SYSTEM MUST BE FLUSHED PRIOR TO PERFORMING SERVICE.
Hazardous or toxic fluids can cause serious injury.

MAINTENANCE
and the relief grooves are facing towards the direction of rotation. 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 - 17 of the "Pump Assembly." section of this manual. a. Bend up the engaged lockwasher tang and rotate the locknut counterclockwise to remove it from the shaft b. Slide the lockwasher off the shaft. Inspect the lockwasher 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 lock collars (24A). To remove: a. Remove the jam nuts (24C) and loosen the two set screws (24B). b. Slide the lock collar off the shaft. c. Repeat steps a and b on the opposite shaft end. 6. Remove the head capscrews (21) and carefully pry the head (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 come off with the head assembly. Remove and discard the head O-ring. a. Pull the bearing (24) from the housing in the head (20). b.To remove the mechanical seal (153), use two screw drivers to gently push the backside of the seal jacket to push the seal from the head (see Figure 4). Use care when placing the screw drivers to prevent damage to the seal faces. Remove and discard mechanical seal O-rings.

Figure 2 - Vane Installation - TX(S)(D) Models*
*NOTE: 1.5 and 2-inch pump models have four (4) vanes.

Figure 3 - Vane Installation - TXV Models*
*NOTE: 2-inch pump models have four (4) vanes.

Figure 4 - Mechanical Seal Removal c. To remove the lip seal assembly (152), use a thin pry bar against the lip seal retaining ring to gently push the housing (152B) out of the head (20). Use care not to damage the lip seal (152A). To remove the lip seal (152A), remove the retaining ring (152D) from the housing, and gently pry the lip seal from the housing. Remove and discard the housing O-ring(s) (152C and 152E). 8. Pull the rotor and shaft (13) from the cylinder (12). While one hand is pulling the shaft, the other hand should be cupped underneath the rotor to prevent the vanes (14) and push rods (77) from falling out. Carefully set the rotor and shaft aside for future vane replacement and reassembly. 9. Remove the remaining components from the outboard side of the pump, as instructed in steps 6 and 7 above.

PUMP DISASSEMBLY
NOTICE: FOLLOW ALL HAZARD WARNINGS AND INSTRUCTIONS PROVIDED IN THE "MAINTENANCE" SECTION OF THIS MANUAL. 1. Starting on the inboard (driven) end of the pump, clean the pump shaft thoroughly, making sure the shaft is free of nicks and burrs. This will prevent damage to the mechanical seal or lip seal when the inboard head assembly is removed. 2. Remove the inboard bearing cover capscrews (28) and slide the inboard bearing cover (27A) and gasket (26) off the shaft. Discard the bearing cover gasket. On the 1.5, 2, 2.5, and 3-inch pump models, the dirt shield (123A) will come off with the bearing cover. 3. Remove the outboard bearing cover capscrews (28) and slide the outboard bearing cover (27) and gasket (26) off the shaft. Discard the bearing cover gasket. 4. If equipped with locknuts and lockwashers (24A and 24B): 6

PUMP ASSEMBLY
Before reassembling the pump, inspect all component parts for wear or damage, and replace as required. Wash out the bearing /seal recess of the head and remove any burrs or nicks from the rotor and shaft.

MAINTENANCE
1. Reassemble the OUTBOARD side of the pump first: a. For a CLOCKWISE rotation pump, position the pump cylinder with the INTAKE port to the left. b. For a COUNTERCLOCKWISE rotation pump, position the pump cylinder with the INTAKE port to the right. 2. Install a new head O-ring (72) in the groove on the inside face of the head (20). Lay the O-ring flat and start in on one side of the groove, stretching ahead with the fingers, as shown in Figure 5. e. Install new housing O-ring(s) (152C and 152E) in the groove(s) of the housing. Lightly grease the housing Oring(s) and push the lip seal and housing assembly into the head recess with the lip seal inward. The lips of the lip seal will face the rotor when the housing is installed. Make sure the housing is bottomed out in the back of the head (20).

Figure 6 - Lip Seal - TXV “B” Models 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. Push the mechanical seal assembly (153) into the recess of the head with seal jacket drive tangs inward. The pin in the stationary seat must be between the lugs in the back of the head recess. 5. LIP SEAL ASSEMBLY (if equipped) The lip seal assembly (152) consists of a metal housing with elastomer(s) around its outer diameter(s), and a teflon lip seal in its inner diameter. TXV “A” model pumps are equipped with spacer washers. Refer to Figures 6 and 7. a. Apply a small amount of light motor oil on the inner diameter of the lip seal housing (152B) to facilitate lip seal (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 lip seal aligned with the hole in the back of the housing. The lip seal should seat flush or slightly recessed in the housing, 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 lip seal against the spacer washers. The lip seal should seat flush or slightly recessed in the housing, around its entire diameter. Note: If necessary, the spacer washers can also be located after the lip seal, as shown in Figure 7, to re-position the lip seal on the pump shaft. d. Insert the retaining ring (152D) into the groove in the housing. 7 Figure 8 - Clamping the Bearing 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 bearing balls must face outward, with the grease shield inward. Ensure the bearing is fully and squarely seated against the lip seal housing (152B) or mechanical seal (153). On TXV pump models, install two 3/8" (10 mm) washers and two bearing cover capscrews (28) to clamp the bearing and compress the lip seal housing inner O-ring (152E) for proper bearing locknut adjustment (see Figure 8). The washers and capscrews will be removed after the locknuts are adjusted.

MAINTENANCE
8. Turn the pump cylinder (12) around and begin assembly on the opposite, inboard end. 9. Remove the vanes (14) and push rods (77) from the rotor and 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 the bottom vanes (14) can be installed and held in place as the push rods (77) are installed in the push rod holes of the rotor. Insert the new vanes into the rotor slots with the rounded edges outward, and the vane relief grooves facing TOWARDS the direction of rotation. Refer to Figures 2 and 3. c. After the bottom vanes (14) and push rods (77) are installed, insert the rotor and shaft (13) fully into the cylinder (12). d. Install the remaining vanes (14) into the top positions of the rotor. If equipped with a mechanical seal (153), rotate the shaft by hand to engage the drive tangs of the seal jacket in the rotor slots. 10. Install the inboard head (20), mechanical seal (153) or lip seal (152), and bearing (24) as instructed in steps 2 through 7. Apply a thin coating of motor oil on the inboard shaft to aid installation. 11. Rotate the shaft by hand to engage the mechanical seal drive tangs (if equipped), and to test for binding or tight spots. If the rotor does not turn freely, lightly tap the rims of the heads (20) with a soft faced mallet until the correct position is found. Install all of the remaining head capscrews (21) for each head (20) and uniformly torque to 25 lbs ft (34 Nm). 12. LOCKNUT INSTALLATION (if equipped) It is important that the bearing locknuts (24A) and lockwashers (24B) be installed and adjusted properly. Overtightening locknuts can cause bearing (24) failure or a broken lockwasher tang. Loose locknuts will allow the rotor (13) to shift against the heads, causing wear. See Figure 9. c. Loosen both locknuts (24A) one complete turn. d. Tighten one locknut (24A) until a slight rotor drag is felt when turning the shaft by hand. e. Back off the nut the width of one lockwasher tang "B". Secure the nut by bending the closest aligned lockwasher tang into the slot in the locknut. The pump should turn freely when rotated by hand. f. Tighten the opposite locknut (24A) by hand until it is snug against the bearing (24). Then, using a spanner wrench, tighten the nut the width of one lockwasher tang. Tighten just past the desired tang, then back off the nut to align the tang with the locknut slot. Secure the nut by bending the aligned lockwasher tang into the slot in the locknut. The pump should continue to turn freely when rotated by hand. g. To check adjustment, grasp the nut and washer with fingers and rotate back and forth. If this cannot be done, one or both locknuts (24A) are too tight and should be alternately loosened one stop at a time (.001") (25 microns). Begin by loosening the locknut adjusted last. h. On TXV pumps, after adjustment is complete, remove the bearing cover capscrews (28) and 3/8" washers from both ends of the pump. 13. LOCK COLLAR INSTALLATION - TX(S)4 Pump Models a. Slide the lock collar (24A) over the shaft and against the bearing (24), with the counterbored side towards the bearing. 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 the collar. c. Repeat this procedure on the opposite pump end. After installing both lock collars, verify the shaft turns freely when rotated by hand. 14. Inspect the grease seal (104) for wear or damage and replace as required. Grease the outside diameter of the grease seal and push it into the bearing cover (27 or 27A) with the lip of the seal inward. The lip will face outward when the bearing cover is installed on the head. 15. Attach a new bearing cover gasket (26) and the bearing cover (27 or 27A) to the head (20). Install and torque the bearing cover capscrews (28) to 15 lbs ft (20 Nm). 16. Follow steps 14 and 15 to install the grease seal (104) and bearing cover (27 or 27A ) on the opposite side of the pump. On TXV pump models, the outboard bearing cover (27) is also a shaft protector and must be installed on the non-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 the bearing cover (27). 18. On TX(S)D pump models, attach the shaft protector (186) on the non-driven shaft end. OPERATION WITHOUT SHAFT PROTECTOR CAN CAUSE SERIOUS PERSONAL INJURY, MAJOR PROPERTY DAMAGE, OR DEATH.
Do not operate without guard in place.

Figure 9 - Locknut Adjustment a. On both ends of the pump shaft, Install a lockwasher (24B) with the tangs facing outward, followed by a locknut (24A) with the tapered end inward. Ensure the inner tang "A" of the lockwasher is located in the slot in the 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 NOT overtighten and bend or shear the lockwasher inner tang.

8

GENERAL PUMP TROUBLESHOOTING
NOTICE: MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE PROCEDURES AND WARNINGS AS PRESENTED IN THIS MANUAL.

SYMPTOM Pump Not Priming

PROBABLE CAUSE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 1. 2. 3. 4. 5. 6. 7. 8. Pump not wetted. Worn vanes. Suction valve closed. Leaks in the suction line. Strainer clogged. Suction line or valves clogged or too restrictive. Broken drive train. Pump vapor-locked. Pump speed too low for priming. Relief valve partially open, worn or not seating properly. Pump speed too low. Suction valves not fully open. Leaks in the suction line. Excessive restriction in the suction line (i.e.: undersized piping, too many elbows & fittings, clogged strainer, etc.). Damaged or worn parts. Excessive restriction in discharge line causing partial flow through the relief valve. Relief Valve worn, set too low, or not seating properly. Vanes installed incorrectly (see "Vane Replacement").

Reduced Capacity

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. 3. 4. 5. 6. 7. 8. 9. 10. 11. Running the pump with a closed discharge line. Pump not securely mounted. Improper drive line (see "Pump Drive"). Bearings worn or damaged. Vibration from improperly anchored piping. Bent shaft, or drive coupling misaligned. Excessively worn rotor. Malfunctioning valve in the system. Relief valve setting too low. Damaged vanes (see following category). Foreign objects entering the pump. Running the pump dry. Cavitation. Viscosity too high for the vanes and /or the pump speed. Incompatibility with the liquids pumped. Excessive heat. Worn or bent push rods, or worn push rod holes. Settled or solidified material in the pump at start-up. Hydraulic hammer - pressure spikes. Vanes installed incorrectly (see"Vane Replacement").

Damaged Vanes

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Troubleshooting continued on page 10.

9

GENERAL PUMP TROUBLESHOOTING

SYMPTOM Broken Shaft

PROBABLE CAUSE
1. 2. 3. 4. 5. 6. 7. 1. 2. 3. 4. 5. 6. 7. 8. Foreign objects entering the pump. Viscosity too high for the pump speed. Relief valve not opening. Hydraulic hammer - pressure spikes. Pump/driver misalignment. Excessively worn vanes or vane slots. Settled or solidified material in the pump at start-up. O-rings not compatible with the liquids pumped. O-rings nicked, cut or twisted. Shaft at seal area damaged, worn or dirty. Ball bearings overgreased. Excessive cavitation. Lip seal not seated properly. Corrosion on lip seal housing. Mechanical seal faces cracked, scratched, pitted or dirty.

Lip Seal / Mechanical Seal Leakage

10

NOTES

11

1809 Century Avenue, Grand Rapids, Michigan 49509-1595, U.S.A. Telephone: (616) 241-1611 • Fax: (616) 241-3752 E-mail: blackmer@blackmer.com • 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: rrandle@rcipurifier.com International Email: rrandle@az.uia.net

INSTALLATION AND WIRING INSTRUCTIONS
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).

Wiring 24 VDC Heater 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).
12 Volt – 6 amps 24 Volt – 3 amps

For Assistance or Technical support call: (800) 868-2088

Operator Accessories
1.00

2.75

.75 1.91

.75

1.97 7.26

1.64 1.07

Ø.56 HOLE

(5) Ø.28 HOLES

Description Remote Control Assy. Cable Clamp only

Part No. 35603SL 9Q1660

Material Stainless

Weight (lb) 1.10 .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.

3.86 Ø.31 x .75 CLEVIS PIN

.40

Fusible Link
.60

.28 1.71

.47

COTTER PIN

7 16-20 UNF HEX NUT

Part No. 21050A

Material Steel

Weight (lb) .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.
TM

INDUSTRIES, INC.
WARREN, PA.

May 1999

Section 29 Page 1A

VEEDER-ROOT INSTALLATION, OPERATION AND SERVICE INSTRUCTIONS

SERIES 7886 HIGH-CAPACITY HIGH-CAPACITY & SERIES 7887 METER 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 ..................................... B. Specifications ................................ SECTION 3. SERIES 7886 DESCRIPTION A. General ..................................... B. Specifications ................................ SECTION 4. PERIODIC INSPECTION A. B. C. D. E. F. General ..................................... Disassembly Prior to Cleaning ............... Cleaning .................................... Inspection ................................... Lubrication .................................. Troubleshooting .............................. 5 5 5 5 5 7 3 3 I 2

SECTION 5. DISASSEMBLY AND ASSEMBLY A. B. C. D. E. F. General ..................................... Removal of Major Groups ...................... Individual Parts Replacement .................. Installation of Major Groups .................... Final Checks and Adjustments ............. Operational Check ............................ 8 8 10 10 15 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 proce- dures 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 heartshaped 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 onehanded 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.

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

TROUBLE
1. Drive shaft hard to turn.

POSSIBLE CAUSE
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. Missing washers on outside of clutch shaft. Pinion jam, anti-topping finger(s) broken or spring(s) missing Reset knob flange on the case binds on reset shaft. Wheel shaft group is bent. Reset fingers rubbing on wheel or retaining rings.

CORRECTION
Check pointer and break positioning. Adjust as required. Remove case. Check all gears, clean and lubricate as necessary. See Sect 4. Check end play and washer as required. Check end play of wheel shaft. Replace broken anti-topping finger(s) or missing spring(s) 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. Replace reset fingers as required. Disassemble wheel group and insert locking disc pin into groove in wheel. Replace cam with new cam and key. Remove cam, inspect and replace parts as required, and assemble properly. Connect shutter to reset lever.

2. Binding occurs during reset cycle

3. Reset knob turns hard

4. Any one wheel will not reset to zero

Broken reset finger. Locking disc pin out of wheel groove. Key in large multiple cam broken. Reset actuating lever not engaged in cam or reset arm broken. Shutter disconnected from reset lever.

5. Incomplete reset cycle. Knob turns but reset does not occur. 6. Shutter partially obscured wheels at completion of reset cycle or completely covers wheels at reset cycle. 7. Shutter will not drop into place or loss of detent action during reset. 8. Pointer not aligned with unit wheel. 9. Unit wheel can be turned in reverse by hand. 10. Cannot drive meter register.

Detent lever spring missing or broken. Improper adjustment of brake or pointer. Dirty drive shaft clutch assembly. Pinion jam, reset fingers are engaged, heart cams hit on detent lever shutter stud, clutch not engaged.

Install new spring. Adjust brake to proper clearance. Adjust pointer to center mark. Clean clutch group and lubricate. See Section 4. Check washers on pinion shaft. Check and play of shafts. Clean and lubricate clutch.

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, side plate reset, anti-topping and clutch shafts to the right-hand (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 antitopping 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 lefthand 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 se- quence 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 lock- washers. 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 antitopping 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 buttonhead 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.

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 deterinined 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 wiiting,ofanyclaims,includingclaii-nsofbreactiofwarraiity, within thirty days aftei- you discover or should have dis- (-oveiedtliefactsuponwliielitlieclaimishased.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.

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.

VEEDER-ROOT VEEDERPetroleum 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

Wet-R-Dri Valve
A

TTMA STYLE

LIGHTWEIGHT COMPACT VERSATILE
B

I.D.

O.D.

Size 2” 3” 4” 5” 6” 8”

Standard Model Assembly No. WD200 AL B WD200 GI B WD300 AL B WD300 GI B WD400 AL V WD400 GI V WD500 AL V WD600 AL U WD800 AL U

Wt. 2.4 4.6 3.6 6.9 4.5 8.3 7.9 11.8 17.3

Detent Model Assembly No. WD201 AL B WD201 GI B WD301 AL B WD301 GI B WD401 AL V WD401 GI V WD501 AL V WD601 AL U WD801 AL U

Wt. 2.4 4.6 3.6 6.9 4.5 8.3 7.9 11.8 17.3

Standard Material Body Disc Aluminum Buna-N Grey Iron Aluminum Buna-N Grey Iron Aluminum Viton Grey Iron Aluminum Viton Aluminum Urethane Aluminum Urethane

Max. Working Pressure 75 PSI 75 PSI 75 PSI 50 PSI 50 PSI 50 PSI

Temperature Range See Chart Below EPDM E -50°F +300°F

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. Dimensions Size 2” 3” 4” 5” 6” 8” A 6 /4 3 6 /4 3 6 /4 3 6 /4 12 12
3

B 4 /4 5 4 /8 1 5 /8 3 6 /8 7 8
1

C 1 /8 1 1 /8 1 1 /8 1 2 /8 1 2 /8 1 2 /2
1

I.D. 2 /4 3 3 /8 3 4 /8 7 5 /16 1 6 /8 8
1

O.D. 3 /4 5 5 /8 5 6 /8 5 7 /8 5 8 /8 7 10 /8
3

B.C. 3 /4 7 4 /8 7 5 /8 7 1 8 /8 1 10 /8
3

Holes 6- /16 7 8- /16 7 8- /16 7 12- /16 7 12- /16 7 16- /16
7

Suffix for Disc Material Buna-N Urethane Viton Black White Black White B WB V U WU -40°F -40°F -0°F -40°F -40°F +200°F +200°F +400°F +200°F +200°F NOTE: Temperature ranges based on published information and may vary due to actual operating conditions.

INSTALLATION: The Wet-R-Dri Valve may be mounted in any position with handle located for easy operation. Valve, as assembled, opens by 1 turning handle /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.
TM

INDUSTRIES, INC.
WARREN, PA.

Feb 1995

Section 20 Page 1A

PARTS LIST

Wet-R-Dri VALVE
2 2 6

4

5

6

10 12 11

9
92

WD101-3

BU

1

9
92

WD101-3

BU

1

7 8

7 8

STANDARD MODEL

DETENT MODEL

No.

Description

Material Buna-N Viton Urethane EPDM Mall. “E” Coated Steel Zinc Plt. Steel Zinc Plt. Steel Steel To Match Disc Mat’l. Steel To Match Disc Mat’l. Steel Zinc Plt. 440 Stnls 304 Stnls 304 Stnls

1

Disc Handle Cap Screw Hex. Nut Drive Shaft Drive Shaft O-Ring Bearing Shaft O-Ring Driv-Lok-Pin Detent Ball Detent Spring Ret. Screw

2 4 5 6 7 8 9 10 11 12

2” Size Part No. WD101-2 BN WD101-2 VT WD101-2 PY WD101-2 EP 25884EY 9Q5813 9Q5808 27053MS 27053MS001 17889** 16006MS 17781** 9Q4893 9Z4856 15229SL 9Q5838

3” Size Part No. WD101-3 BN WD101-3 VT WD101-3 PY WD101-3 EP 25884EY 9Q5813 9Q5808 27050MS 27050MS001 17889** 15913MS 18141** 9Q4893 9Z4856 15229SL 9Q5838

4” Size Part No. WD101-4 BN WD101-4 VT WD101-4 PY WD101-4 EP 25884EY 9Q5813 9Q5808 27050MS 27050MS001 17889** 15913MS 18141** 9Q4893 9Z4856 15229SL 9Q5838

5” Size Part No. WD101-5 BN WD101-5 VT WD101-5 PY WD101-5 EP 25884EY 9Q5813 9Q5808 27051MS 27051MS001 17889** 15913MS 18141** 9Q4925 9Z4856 15229SL 9Q5838

6” Size Part No. WD101-6 BN WD101-6 VT WD101-6 PY WD101-6 EP 25933AL 9Q5898 9Q5808 16229MS 16229MS 18831** 16230MS 18831** 9Q4926 9Z4856 15229SL 9Q5838

8” Size Part No. WD101-8 BN WD101-8 VT WD101-8 PY WD101-8 EP 25933AL 9Q5898 9Q5808 16229MS002 16229MS002 18831** 16230MS002 18831** 9Q4938 9Z4856 15229SL 9Q5838

** O-Ring material suffix to match Disc suffix (i.e.-17889VT)

WARNING Use only genuine Betts Industries Inc. replacement parts. Use of substitute parts can impair the proper functioning of the Wet-R-Dri Valve.
TM

INDUSTRIES, INC.
WARREN, PA.

Jan 1993

Section 20 Page 1B

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