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MODEL 92021 GAUGE HEAD

INSTRUCTION MANUAL 92-221-3

5911 Butterfield Road, Hillside, IL 60162
Phone: 708-236-6000, Fax: 708-236-6006
http://www.ljtechnologies.com

Printed in the United States of America in 2003 by Shand &
Jurs, Hillside, IL
© 2003 by Shand & Jurs
Any copy of this book issued by the publisher is subject to
the condition that it shall not by way of trade or otherwise be
lent, resold, hired out or otherwise circulated without the
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other than that in which it is published and without a similar
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subsequent purchaser.
All Rights Reserved. No part of this publication may be
reproduced or transmitted in any form or by any means,
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Printed in USA

Page 2

Instruction Manual Number 92-221-3 Rev. 2.0 8/27/09

........................................................................0 INSTALLATION OF GAUGE HEAD ..................................................................... 13 (TANK OUT OF SERVICE) .................................................................. 19 6.......................................................................5 USING THE MANUAL ........................................................... 7 2.............. 9 3.......................................................................................................................................................................... 4 1................................4 TAPE REPLACEMENT ........................................2 TANK CLEANING ........................................... SHELL ENTRY .................. 5 1......................................................................................................INSTALLATION FOR CONE ROOF TANKS. 18 6............................................. 19 6..................... 5 1......................................................................................................................1 NORMAL OPERATION .1 GENERAL PREPARATION ......................................6 COUNTER W HEEL REPLACEMENT......................TABLE OF CONTENTS SAFETY INSTRUCTION ADDENDUM .......0 8/27/09 ..........................................0 TYPICAL MAINTENANCE PROCEDURES ................... GROUND READING.............................. 5 1.....................2 BACKGROUND OF THE USER: .........................7 HAND CRANK ASSEMBLY MAINTENANCE .......... 15 6.. 8 3.2 KIT 2 .... GROUND READING................................................. 5 1.................... 2................................................ 11 3...........................0 INSTALLATION OF AUTOMATIC TANK LEVEL GAUGE SYSTEM .....4 W ARNINGS............................................5 SPRING MOTOR CARTRIDGE REPLACEMENT (WITH TANK IN SERVICE) ...........3 ADDITIONAL KITS – INSTALLATION FOR OTHER KITS SUPPLIED BY SHAND & JURS........1 FORWARD ............................................ 18 6... 7 2...................................................1 THE GAUGE: ......................................................................... 13 4..............................................................................................................................................................0 INSTALLATION OF MOUNTING KITS ................. 5 1.....INSTALLATION FOR CONE ROOF TANKS.................................... 12 4.................................... 19 6..................... ROOF ENTRY.......................................................................................2 RECEIVING EQUIPMENT ........................... CAUTIONS AND NOTES ....................................................................................................................................2 INSTALLATION OF A GROUND READING GAUGE HEAD.................3 FACTORS AFFECTING ACCURACY ... 13 5............... 21 6............................ 18 6..............................0 INTRODUCTION: .............. 6 2.....3 CALIBRATION OF LEVEL .................1 KIT 1 ....................................... 8 2...3 MANUAL OVERVIEW : ... 21 Page 3 Instruction Manual Number 92-221-3 Rev........................................... 13 4........ 9 3.................................0 PART LISTS AND EXPLODED VIEWS ..............

Personnel installing or performing maintenance to the gauge must be competent and utilize approved equipment and clothing normally used to work with the process media where the gauge is installed. Maintenance/Commissioning/Testing WARNING: It is dangerous to people to be in the vicinity of the gauge when the cover is open. Calibration of the gauge should be based on the level measurement obtained from a manual dip or tape reading. Selection Verify that the Kit and Model Numbers stamped on the name plates are correct for the installation conditions. 4. Calibration Calibration should only be attempted after complete installation and introduction of liquid into the tank. indoor area.0 8/27/09 . It may relieve tank pressure. Handling of the gauge must be done by personnel trained in all aspects of manual and mechanical handling techniques. Record the model and serial numbers and refer to them when ordering spare parts from the local Shand & Jurs representative or the factory. STORAGE/PROTECTION/SELECTION/SPARE PARTS Storage When Shand & Jurs equipment is to be stored prior to being installed. After the kit and gauge have been secured to the tank. The tank the gauge is installed on must be at atmospheric pressure conditions. 2. Protection Shand & Jurs gauges are delivered with protection as required by customer specifications or the Quality Assurance Manual. The kits are to be installed on the tank prior to trying to install the gauge body. be sure that tank pressure is relieved before attempting maintenance/commissioning/testing with the gauge cover off. storage should be in the original shipping crates with any waterproof lining and/or desiccant remaining in place.0. the float may be installed and connected. The tank must be at atmospheric pressure conditions for inspection and maintenance. therefore. The materials of construction should be compatible with the media in the tank. Spare Parts Shand & Jurs gauges are identified by the model and serial numbers stamped on the nameplate. Installation Mounting All gauges will be shipped with the mounting kit and float separate from the gauge head. Page 4 Instruction Manual Number 92-221-3 Rev. FORWARD The Shand & Jurs Model 92021 Automatic Tank Level Gauge is in conformance with the requirements EC Directive 98/37/EC Machine Safety when installed and maintained in accordance with these instructions and the pertinent Installation Kit Instruction Manual found in section 3. Use manual measurement techniques recommended by the governing body with jurisdiction over your site. 3. dry. 1. 2.Safety Instruction Addendum Safety Instruction Addendum Before installation these instructions must be fully read and understood. ! SAFETY WARNING It is important to take the following precautions before you start work on the mechanical tank gauge. Storage should be off the ground in a clean.

It will give the user a broad understanding of the product and familiarity with the hardware. To replace the tape. however. operate. construction. all variations may not be shown. Only authorized personnel who have been trained to work on this equipment should perform maintenance. the gauge.2 Background of the User: It is assumed that the person using this guide have some general familiarity with the functions and operations of overall system in that the gauge head may be only a component part of a much larger tank gauging system. 1. and maintenance. 2. 1. safety precautions. the person maintaining the equipment should become familiar with other equipment connected to and working in conjunction with the gauge head. operating instructions. If this happens the tape will be wound into the gauge head. It contains a product description.3 Manual Overview: The S&J 92021 manual provides an operational description and the documentation required by the user to properly install. The tape may snap out of the gauge body when the cover is removed. cautions or warnings important to the the 92021. and service. This manual is divided into multiple sections. install. For this reason. and information the user should know to use. in tangles. Ground and roof reading gauges should be calibrated and left to function independent of operator intervention until a periodic verification is made. Typical installations are covered.0 Introduction: This Operating Guide provides the information required by the user to properly install and operate the S&J 92021 Automatic Tank Gauge. This guide provides information on design. Cautions and Notes Throughout this manual. 1. face and hand protection. Prior to installation check the model number of the unit to determine that the gauge that was ordered and that the options provided meet the application requirements. The person maintaining the equipment will find it helpful to have actually operated the equipment before receiving maintenance responsibility. this safe and proper operating of Page 5 symbol will appear to symbolize notes. and maintain the 92021 Mechanical Gauge manufactured by Shand & Jurs.Safety Instruction Addendum Operation The automatic tank gauge is meant to operate without the need of an operator. carefully remove the cover while wearing eye. Section I: Section II: Section III: Section IV: Section V: Section VI: Introduction Accessories and Preparation Installation of Mounting Kits Installation of Gauge Head Parts List and Exploded Views Typical Maintenance Procedures 1.0 8/27/09 . 1.1 The Gauge: The S&J 92021 Gauge has been configured to meet your requirements. Instruction Manual Number 92-221-3 Rev.4 Warnings. WARNING: The perforated tape connected to the float may break.

Damage resulting from misuse will void the warranty. Before attempting to install or operate this equipment. and maintaining the S&J 92021 Automatic Tank Gauge. may indirectly affect operation or produce an unplanned response from the equipment. WARNING: Before attempting to install or otherwise operate this equipment. CAUTIONS: NOTES: 1. Note that only standard versions of the 92021 Gauge are described in this manual. are actions that if not followed. operating. may lead to personal injury or incorrect operation of the equipment. Page 6 Instruction Manual Number 92-221-3 Rev. safety hazard or destruction of the equipment. Failure to follow the guidelines set forth in this manual could result in loss of limb and/or damage to equipment. the user should read and understand the safety notices contained in this manual.5 Using the Manual This manual is primarily a reference to provide the user with guidance in installing. are actions that if not followed.0 8/27/09 . the user should read and be familiar with all portions of this manual as well as the manuals for the other equipment used in the system.Introduction WARNINGS: are actions that if not followed. 2. may lead to personal injury.

Used when horizontal run of tape pipe from tank entry to tank wall exceeds 8 feet.Installation of Automatic Tank Level Gauge System 2. 2.1 Forward The procedures in this manual are written for installations using standard accessories of a Shand & Jurs tank gauging system. Page 7 Liquid Seal Assembly Part Series JC3603 Used to retain tank pressure or isolate the gauge head from tank product.0 Installation of Automatic Tank Level Gauge System 2. Where applicable the additional accessories listed below should be obtained for the reasons stated. Instruction Manual Number 92-221-3 Rev. Intermediate Tape Support JB3580-3 (Normal Service) or JB3580-4 (Severe Service).0 8/27/09 .

Shand & Jurs cannot be responsible for any damage or breakage whatsoever. Plumb tape guide piping. pulleys. Materials of construction in this equipment have been selected as representing the most suitable commercially available material for use in the service intended. and contents as received. couplings.2 Receiving Equipment This shipment is the property of the purchaser when it leaves our plant. Page 8 Instruction Manual Number 92-221-3 Rev.0 8/27/09 . If this shipment is received in damaged condition. they do not constitute a guarantee against corrosion since processes vary from plant to plant and concentration of harmful fluids. E. 2. gasses or solids vary from time to time in a given process. B. guide wire tension. Empirical experience by users should be the final guide and alternate materials based on this are generally available. The transportation company has contracted to deliver this material to you in as good a condition as they receive it from us. etc. Shand & Jurs method of packing these goods has been proven by many years of experience. Pipe is to be of a material not corroded by the stored product. 2. D. Chemical compatibility of the gauge materials to process/product vapors. Condition of inside surface of piping and union connections for tape guide pipe. notify an agent of the transportation company at once. Proper installation of furnished parts (tape/cable. float. Calibration technique and the manual dip (hand gauge) reference. C. and preserve box.Installation of Automatic Tank Level Gauge System Tape guide pipe.). Any claim for damage must be taken up with the transportation company.3 Factors Affecting Accuracy A. unions and any other supporting structures not furnished with the gauging system are furnished by others. However. packing. 2.

Kit 1A . The entry should be in a place where the float will not meet any obstructions during vertical travel and should be well away from tank inlet. Mark position.Ammonia Svc. Find a place where access to the tank may be made.Severe Svc. Drop plumb line through tank nipples to locate the position of the anchor bar on the tank bottom (see Figure 3). the user should read and understand all applicable local regulations and industry standards.0 8/27/09 . Kit 1C Includes: (a) Hex Hd. Prepare cutouts as shown in the next figure for the guide wire spring housing tank nipples. N8090 Steel Fiber Delrin Cast Alum Teflon SS SS Steel Base Steel Steel Steel Steel Steel Steel SS SS SS SS SS Steel 208-09 690-518 890-518 530-511 227-114 579-14 9399-13410 090138 605-1 241-67 660-508 JB3530-1 530-626 JB3486-11 567-511 229-35 805-502 229-337 229-34 117-5 ** ** 090142 514-504 JB3010-21 JA3540-3 3 4 5 6 2 7 8 9 10 1 11 Recommended Spare. (See Sec. E. Roof Entry WARNING: Before attempting to install or otherwise operate this equipment. D. Screw (b) Cover For Kit 1A & 1B For Kit 1C (c) Gasket * (d) Cap Nut (e) Washer (f) Pulley For Kit 1A For Kit 1B & 1C (g) Bearing * (h) Washer (i) Shaft Inspection Frame (Optional) (a) Gasket * Guide Wire Spring Assy (a) Spring (b) Pipe Coupling (c) Tank Nipple (d) Pipe Nipple (1-1/4”NPT X 7) (e) Pipe Cap (1-1/4” NPT) Guide Wire Tape or Tape-Cable Assy Tape Clamp Tape Thimble Float Anchor Bar Material Steel Part Alum. All Alum. N. Place the tank nipples on 6-5/8” centers from the pipe coupling.1 Kit 1 . 2. Weld the inspection frame to the roof before burning out the cutouts. Drop plumb line from tank entry pipe coupling over side of tank to locate center of tape guide pipe.1. Page 9 Instruction Manual Number 92-221-3 Rev. Line o on roof should be 90 to tank roof edge.I.1 Tank Preparation A. F. C. 3. Cut opening and weld in place. Again. Omit any openings for equipment not furnished. location with boiling or near any other cause of turbulence. must have tank height. Place end holes of anchor bar over marks and weld in place. model and serial numbers when ordering spares. make sure they are vertical to the grade before welding in place. 3) JB3435-1 9399-13440 9399-13450 9399-13460 Steel Alum.Installation for Cone Roof Tanks.Normal Svc.Installation of Mounting Kits 3. Item 1 2 3 4 5 6 7 8 9 10 11 * ** Parts List Description Gauge Head 92021 Bracket Pulley Assy . Consult Factory.I.0 INSTALLATION OF MOUNTING KITS 3. Kit1B . the 1-1/2” extra-heavy pipe coupling (furnished by others)* and the inspection frame. B. This should be as close as possible to the 12” minimum distance from the tank wall. Locate a second line 15/16 inch to the left of this line for positioning the pipe brackets. Position the pipe-coupling vertical to grade (not roof) before welding. N. Ground Reading. Part No.

Pipe should be of a material that is compatible with stored products and vapors.1. B. Mount the gage head to tape pipe with union. RF) and hardware are by others. dirt. be careful as they can be easily damaged. The last run of tape pipe should terminate just above last tape bracket and be fitted with half of a pipe union. R. 1-1/2” Tape Guide Pipe is furnished by others. etc to enter the gauge head. F.3 Installing Guide Wires Clamping Nut Stationary Nut Compression Nut A. the tube is pushed upwards thus adding tension to the guide wires (Figure 3 at right). When cable block valve is used. Continue installing the other pulley housing. 3. Continue with installation of first pulley housings.0 8/27/09 . Feed guide wires into tank through the 1-1/4” tank nipples welded on the tank roof and fasten the lower ends of the wires to the anchor bar. Attach other half of pipe union to a pipe nipple (6 inches max) and thread into gauge head opening. Space remaining brackets equally between the top and bottom ones and weld in place. E. Lay the guide wire over the stationary nut (Figure 1 at right) and use the clamping nut to tighten down and secure the guide wire in place (Figure 2 at right). Adjust the compression nut clockwise to insure tension of about 20 lbs.When specified at time of equipment purchase.Installation of Mounting Kits G. Size the length of the horizontal run of the pipe carefully to fit centers of pulley housing between tank entry and vertical run of tape pipe. By compressing the spring. Figure 1 Page 10 Figure 2 Figure 3 Instruction Manual Number 92-221-3 Rev. Remember to select a compatible pipe dope for the pipe threads. For Turbulent Tank Application . U-bolts and couplings until reaching the last pipe bracket at the bottom outside the tank. C.F. flange that will be installed in place of the aforementioned pipe coupling. The cable block valve fits ANSI 150lb. Locate the top bracket within 12 inches of the tank top and weld in place. C.1. Pull guide wire tight and bring the guide wire down through the slot in the guide wire tube. Remove the clamping nut from the guide wire spring assembly. 2. D. When threading the pipe into an aluminum body pulley housing. D. a tape cable assembly and a cable block valve is furnished. mating flanges (ANSI 150 lbs. 3. Thread first section of pipe to be used between the pipe coupling and the pulley housing into the pipe coupling. Attach the pipe nipple to the last support bracket with a U-bolt. Locate and weld in position a second bracket about 20 inches above the expected reading window position. F. piping. G. E. B. Hold the end of the wires at the tank nipple making sure the wires are free of any loops or kinks and not fouled on any structural members. Flange entry must be installed horizontal to grade. Slip the guide tubes (with springs and washers in place) down over the wires until they come to rest on the ends of the tank nipples inside the couplings.2 Tape Guide Pipe Installation A. Brackets must accurately align tape pipe vertically. Do not allow pipe dope.

Temporarily position pulley bracket over end of tape pipe at manhole. F. C. must have tank height. Mark position.0 8/27/09 .1 Tank Preparation o A.Installation for Cone Roof Tanks. Weld top pipe support brackets at 15-1/2” distance shown and 15/16” to left of tank entry centerline. 3. Weld bottom bracket about 20” above expected reading window height. Weld tape pipe to tank wall. Ground Reading. D. Page 11 Instruction Manual Number 92-221-3 Rev. The 135 tape pipe centerline angle should be closely held and directed towards the center of the manhole cover. Shell Entry WARNING: Before attempting to install or otherwise operate this equipment. Kit 2C Includes: (a) Hex Hd. Add a 2-foot length of pipe to the pulley opening. 2. Adjust bracket position so that it is horizontal and perpendicular to the pulley bracket (when the top surface of the pulley bracket is horizontal). Item 1 2 3 Parts List Description Gauge Head 92021 Tank Bracket 45 degree Pulley Assy .I. Use care not to overstress the aluminum body pulley housing. 3) JB3435-1 9399-13470 N.2 Kit 2 . I. N8090 Steel Fiber Delrin Cast Alum Teflon SS SS 208-09 690-518 890-518 530-511 227-114 579-14 9399-13410 090138 605-1 241-67 660-508 JB3505-2 JB3490-1 JB3485-17 117-5 ** ** 090142 514-504 JB3010-21 JA3540-3 Steel SS SS SS SS SS Steel 4 5 6 7 3 2 8 9 10 11 12 1 Recommended Spare. Use this arrangement to accurately locate and maintain the 10-1/2” distance between the tape pipe and the tank wall (clamp stub with U-bolt of first bracket). E. G. (See Sec. Part No. Adjust position of the pulley bracket on the tape pipe so that the tape coming off the front pulley is ½ inch from the vertical surface of the guide wire bracket. N. With top surface of the bracket horizontal.Severe Svc.Normal Svc. Space remaining pipe brackets equally between the top and bottom pipe brackets. Drop plumb line through each cup end of guide wire bracket to locate position of anchor bar at bottom of the tank. H. If length of tape pipe inside tank is more than 10 feet or requires one or more pipe couplings. Tighten bolt then jam nut after being sure the top surface of the pulley bracket is horizontal. Weld the guide wire bracket in place. an internal tank brace furnished by others may be required to compensate for pipe sag. the top surface of the bracket should be 1 inch or more below the surface of the manhole. Place the end holes of the anchor bar over marks and weld to tank floor. Locate shell entry directly in line with manhole as shown above. Screw (b) Cover (c) (d) (e) (f) 4 5 6 7 8 9 10 11 12 * ** Gasket * Cap Nut Washer Pulley (g) Bearing * (h) Washer (i) Shaft Header Assembly Guide Wire Bracket Assembly Guide Wire Spring Assy Guide Wire Tape or Tape-Cable Assy Tape Clamp Tape Thimble Float Anchor Bar Material Steel Part Alum. Add pulley housing to length of tape pipe (furnished by others) used for diagonal tape entry. Kit 2A . Top surface is to be horizontal.Installation of Mounting Kits 3. B. At this position. model and serial numbers when ordering spares. Cut off enough tape pipe to position center of inboard pulley at center of the manhole. position guide wire bracket 1-inch below the bottom of the pulley bracket end up against the side of the manhole. the user should read and understand all applicable local regulations and industry standards. Consult Factory. 9399-13490 Steel Alum.2.I.

D. Mount the gage head to tape pipe with union. By compressing the spring. Pull the guide wire tight and bring it down through the slot in the guide wire tube. When cable block valve is used.3 Additional Kits – Installation for other kits supplied by Shand & Jurs The following instruction sheets are available for the corresponding kits supplied by S&J: Kit 4A1 & 4C1 – IS 92-123 Kit 5A1 & 5C1 – IS 92-124 Kit 6A1 – IS 92-125 Kit 7A1 – IS 92-126 Kit 8A1 & 8C1 – IS 92-127 Kit 9A1 & 9C1 – IS 92-128 Kit 10A1 & 10C1 – IS 92-129 Kit 11A1 & 11C1 – IS 92-130 Kit 12A1 & 12C1 – IS 92-121 and 93-603 (liquid seal) Kit 14A1 & 14C1 – IS 92-132 Page 12 Instruction Manual Number 92-221-3 Rev.0 8/27/09 . Attach other half of pipe union to a pipe nipple (6 inches max) and thread into gauge head opening. E. The last run of tape pipe should terminate just above last tape bracket and be fitted with half of a pipe union. Lay the guide wire over the stationary nut (Figure 1 at right) and use the clamping nut to tighten down and secure the guide wire in place (Figure 2 at right). Insert one end of guide wires through the guide wire brackets near the inboard pulley and lower ends of the wires to the anchor bar. Slip the guide tubes (with springs and washers in place) down over the wires until they come to rest on the bottom of the tubes on the guide wire bracket. dirt. Attach the pipe nipple to the last support bracket with a U-bolt. U-bolts and couplings until reaching the last pipe bracket at the bottom outside the tank.2. Pipe should be of a material that is compatible with stored products and vapors. C.3 Installing Guide Wires A. the tube is pushed upwards thus adding tension to the guide wires (Figure 3 at right). E. Remove stub pipe used in tank preparation and thread first section of pipe to be used into the pulley housing. Adjust the compression nut clockwise to insure tension of about 20 lbs. Remove the clamping nut from the guide wire spring assembly. B.2 Tape Guide Pipe Installation A. mating flanges (ANSI 150 lbs. etc to enter the gauge head.Installation of Mounting Kits 3. D. When threading the pipe into an aluminum body pulley housing. 2. F. Remember to select a compatible pipe dope for the pipe threads. Do not allow pipe dope. Continue installing the other lengths of piping. be careful as they can be easily damaged. 1-1/2” Tape Guide Pipe is furnished by others. Hold the end of the wires at the bracket making sure the wires are free of any loops or kinks and not fouled on any structural members. B. C. G. Stationary Nut Compression Nut Figure 1 Figure 2 Figure 3 3.2. RF) and hardware are by others. Clamping Nut 3.

move the locking pin to the Accutrak cartridge. After making the receiving inspection. C.2 Installation of a Ground Reading Gauge Head (Tank out of service) A.0 8/27/09 . Figure 2 Anchor/Locking pin shown inserted into Accutrak cartridge with the three Phillips head screws are removed. D. B. The float cable is attached to the end of the stainless steel perforated tape by means of a stainless steel swivel/hook. Please refer to diagrams on your specific accessory kit for details on what should be contained. Holding the center spokes of the take-up reel securely. Page 13 Instruction Manual Number 92-221-3 Rev. Remove any packing material installed at the factory prior to shipment. WARNING: Read and obey any safety tags connected to internal components. Remove all bolts from the outside gauge cover of the S&J 92021 (13 of a 5/16” bolt). An installation kit is ordered separately and contains all the necessary parts to install the hardware on a tank. The Accutrak cartridge has been pre-wound at the factory and will have spring tension applied.Installation of Gauge Head 4. Pull all external cable or tape inside the gauge head and attach to tank side piping.1 General Preparation A. repack the Model 92021 in the same manner that it was received. A stainless steel perforated tape is packaged inside the gauge head itself and a spring motor (contained in the Accutrak 90 Negator Motor Cartridge) has been pre-wound two turns. It may include items such as a float. These items are locked in place during shipping with a screw that is inserted through the Accutrak 90 cartridge case (identified as "Anchor/Lock Pin" in Figure 1). guide wire assemblies.0 INSTALLATION OF GAUGE HEAD 4. Figure 3 Cable clamp attached to float WARNING: Exercise extreme caution when attempting this action. All further instructions assume that piping and kit installation has been completed. B. and keep it in the carton to protect it until ready to mount it on the tank. elbows and pulleys. 4. Compare the items received with the items listed on the packing list attached to the box and evaluate the condition of those items upon receipt of the shipment. Figure 1 Anchor/Locking pin shown with Red Tag C. 2.

G. 5-1/2 quarts. Cut the cable to a length equal to the approximate distance between the inboard pulley and the top of the tank. cut the cable so that the cable and clasp cannot enter the valve. CAUTION: Do not allow the float to drop down into the tank. elbows and gauge head) L. Replace and tighten all covers (Tank openings. Make sure to turn the wheel clockwise. Continue feeding the tape and cable to successive pulleys also checking for twists between the pulleys. F. Allow about 6" of extra cable to attach the float. With the float at the top of the tank. Sharp edges may exist. NOTE: Remove any foreign matter that may have fallen inside the gauge head. I. Replace the three Phillips head screws and remove the "Anchor/Lock Pin" screw.Installation of Gauge Head D. NOTE: If oil filling is desired. use a highly refined straight mineral base fluid of low viscosity. remove the three Phillips head screws from the center of the Accutrak 90 cartridge to disengage the tape storage drum from the power spring. wind the loose tape back onto the tape drum. M. Attach the cable to the float with the supplied tape/cable clamp and the float to the guide wires. Ensure the tape is not twisted between the gauge and the (outboard) pulley. 2. The Accutrak cartridge should wind itself during this process to allow tension to be on the tape and cable through the entire range of measurement inside the tank. Slight friction should be present when pulling cable and tape in the next step. Page 14 Instruction Manual Number 92-221-3 Rev. NOTE: If a Tape Block Valve is being used. CAUTION: Hand protection should be worn during handling of the tape. H. Add through tape pipe plug opening and fill only to pipe plug level. Feed the cable and attached stainless steel perforated tape up through the tank side piping to the first elbow and pulley assembly. There should now be tension on the tape and cable attached to the float.Materials of construction of the gauge head are selected to be corrosion resistant to most tank products and oil filling should not be required. This will ensure that the cable and clasp do not run onto the pulley when the float is at its highest position. E. Oil Filling . Slowly lower the float into the tank until it touches the bottom. With the anchor/lock pin in place in the housing to the Accutrak 90 cartridge.0 8/27/09 . Capacity is approx. J. See separate instructions for limit switch and remote transmitter for mounting instructions. K.

0 PART LISTS AND EXPLODED VIEWS Page 15 Instruction Manual Number 92-221-3 Rev.Installation of Gauge Head 5.0 8/27/09 . 2.

#12 Split Lock washer 304SS #12-24 x ¾ SS Pan Head Screw #10-24 x 1/2" Cutting Phillips Head Screw SS Gauge Body Cover Gasket Gauge Body Cover 5/16 – 18 x 1 1/8” Hex Head Screw Zinc Plated #10-24 x 1/2 SS Pan Head Screw #10 SS Washer Retaining Ring – SS Bushing – Aluminum Ball Bearing – SS #6-32 x 1 ½” Socket Head Screw Tape Retainer Spool Teflon Sprocket Wheel and Shaft Assembly (Feet) Sprocket Wheel and Shaft Assembly (Meters) Checker Spindle "O" Ring #008-Viton Checker Spring-SS Checker Knob-Plastic #10-32 x 5/16 Socket Head Set Screw Anchor/Locking Pin Teflon Bearing “O” Ring Viton Instruction Manual Number 92-221-3 Rev. Cartridge Sub-Assembly .SS Cartridge Sub-Assembly .60 Ft.0 8/27/09 . 2.Installation of Gauge Head Gauge Head Exploded View Parts Detail Item # Part Number 15 16 17 18 19 20 21 22 23 24 25 (not sold as spare part) SP371-D 9202-10330 9202-10320 SP375-KG SP322-D SP330-L 9202-14100 9202-12070 SP381-G 9202-14330 9202-14340 SP595-N SP375-PK SP589-GC 9202-10350 (not sold as spare part) SP7-CL SP375-MG SP332-R SP381-G 9202-12770 202-1 SP328-CJ 9202-14070 9202-10600 9202-10610 9202-14190 SP354-W 9202-14270 9202-14300 SP331-GD SP243-ST 9202-10310 SP354-AK 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 Page 16 Description Gauge Body ½” NPT Square Head Plug (Zinc Plated Steel) Teflon Shim (as required) Bushing-Teflon #8-32 x 1/2 Pan Head SS Screw #8 SS Lock washer #8-32-SS Hex Nut Small Tape Drum-Ryton Tape Drum Washer (as required) Retaining Ring .90 Ft.

Installation of Gauge Head 51 54 50 EXPLODED VIEW OF COUNTER HOUSING ASSEMBLY 55 56 52 53 64 57 65 66 67 62 58 59 60 61 63 68 72 71 51 70 73 69 74 Page 17 Instruction Manual Number 92-221-3 Rev. 2.0 8/27/09 .

Push in and turn clockwise to put tension on the take-up real and assure proper tape/cable tension.0 8/27/09 . 2) Metric ( Qty. With the float cranked up to the top of the tank and the tape drum rotated by hand until the hole in the tape drum is over tapped boss in gauge body.2 Tank Cleaning CAUTION: In order to prevent damage to the float and tape during tank cleaning operation. Feet – Outage Millimeters – Innage Millimeters – Outage Item 65 66 67 68 69 70 71 72 73 74 Part # 9206-12570 SP476-B 617-501 SP7-Q SP381-C 9202-10470 9202-10470 9202-13020 9202-10210 9202-10211 9202-11700 9202-10280 9202-11720 9202-10650 9202-11710 9202-13030 SP329-KK Description Adjusting Wheel Assembly ¼ .0 TYPICAL MAINTENANCE PROCEDURES 6. Damage to gauge or float may occur. screw the locking pin into boss. Level readings can be checked for consistency by using the operation checker if gauge head includes this option. 3) Metric Innage Counter Wheel (Qty.16 x 1/2) Bushing – Aluminum Retaining Ring (Feet Only) Counter Wheel Counter Wheel (Qty. It is not predictable.28 Hex Jam Nut Counter Housing Cover Hex. 6. Reverse the procedure to return gauge to service. it is recommended that float be raised to the top of its travel and secured in place. 3) Window Clamp Window – Silk Screened Feet & Inches – Innage to 99 Feet Feet & Inches – Innage to 120 Feet Feet & Inches – Outage Decimal Feet – Innage Decimal Feet – Outage Meters & Millimeters – Innage Meters & Millimeters – Outage Window Gasket Round Head Screw (8 – 32x5/8) Notes: 1. Gauge head bodies and covers are not available as replacement parts. Hd. 2) Feet Innage Counter Wheel (Qty. The Accutrak cartridge will have spring tension applied. Gauges with the optional Hand Crank Assembly allow for raise and lock capability. 2.1 Normal Operation The gauge is automatic in operation and will indicate tank level with the stated accuracy. 1) Pinion Wheel ( Gear) Feet (Qty. Lower float carefully to product surface or floor. CAUTION: Do not allow the float to drop. Page 18 Instruction Manual Number 92-221-3 Rev. Feet – Innage Dec. 2) Feet Outage Counter Wheel (Qty. 6.3) Metric Outage Increments Wheel Inches – Innage Inches – Outage Dec. what the effect of the tank product or its components will have on friction between moving parts. Screw (3/8 . This is shipping position. WARNING: Exercise extreme caution when attempting this action.16 x 1/2) Pinion Retaining Ring (Qty. Those gauges without the option require that the gauge cover be removed.Installation of Gauge Head Item 50 51 52 53 54 55 56 57 58 59 60 61 62 63 Part # See Note 1 SP371-D 9202-14270 9202-14300 SP375-KG SP332-D 9202-10910 9202-12660 See Note 1 202-1 SP9-LC 9202-12770 SP381-F 9202-10460 9202-10480 9202-10460 9202-10480 64 9202-10520 9202-10880 9202-10530 9202-10890 9202-10510 9202-10870 Description Gauge Housing ½” NPT Square Head Plug Checker Spring-SS Checker Knob-Plastic Pan Head Screw (8 – 32 x1/2) Washer (#10) Access Plate Access Plate Gasket Counter Housing Bearing Cap Screw (3/8 . however. and float raised by means of a “crank screw” or previously mentioned locking pin inserted into the Accutrak cartridge power hub and the hub turned clock-wise.

Replace the counter housing access cover and tighten screws. Disconnect the Accutrak Cartridge (25) from the Tape Drum (22) by removing the 3 screws (28). Be sure that there is no tension in the spring. Remove the counter housing access cover (56) by loosening both pan head screws (54). Remove screw (37) and tape retainer (38) to allow for feeding of the tape around the sprocket wheel (39). The black. E. Check the spring motor for damage and replace the entire cartridge. Then remove all tape from the sprocket wheel (39) and tape drum (22). the entire cartridge is replaced with either: 9202-14330 Cartridge Assembly . Hold the notched wheel (65). Now is a good time to inspect all the parts for wear or damage and to verify operation. notched wheel should remain stationary while the increment wheel is turned. ii. A. If the spring is not completely Page 19 Instruction Manual Number 92-221-3 Rev. Remove the loose tape from the tape guide pipe. CAUTION: Hand protection should be worn during handling of tape. The connection of the increment wheel to the notched wheel is a compression fitting that will slip when forced. Install a new tape by fastening to the tape drum and turning tape drum clockwise. Install a stiff wire or long nail through one of the holes in the perforated tape near to the top tape guide pipe entrance to the gauge head to prevent excess movement of the tape when performing this procedure. C. REMOVE OLD CARTRIDGE i.66 feet 9202-14340 Cartridge Assembly . B. B. Unfasten and remove the broken tape from the float. Fish the float up to the top of the guide wires. Removal of the Accutrak cartridge may be necessary (See section on spring motor cartridge replacement). remove from guide wires. C.5 Spring Motor Cartridge Replacement (With Tank in Service) Refer to Exploded View of Gauge Head. at the right of the increments wheel (64). drain any oil by removing the plug (16) located at the bottom of the gauge head and then proceed with removal of the large side cover (30) by removing bolts (31).90 feet A.3 Calibration of Level Refer to the Exploded View of Counter Housing Assembly A.Typical Maintenance Procedures 6. Sharp edges may exist. and lay out on the top of the tank. At the gauge head. G.0 8/27/09 . the spring motor inside the Accutrak Cartridge (25) may recoil too quickly and break as well. If the spring motor breaks.4 Tape Replacement Refer to Exploded View of Gauge Head and Kit Installation Details. D. 2. F. Follow the previously discussed procedure for installation and connection of tape to float. 6. if necessary (See section on spring motor cartridge replacement). It is assumed that the spring is broken. If the tape is found in broken condition. 6. and turn the increments wheel (inch or millimeter) until all counters indicate the correct product level measurement (based on prior hand dipping).

the bearing (36) and the bearing bushing (35) for installation with the new cartridge v. otherwise skip to iv. Remove the #10 Pan Head Screw and #10 Washer (32 & 33). Remove retaining clip (34). Example: Distance from top Wind to 16 feet + 5 feet 21 feet on cartridge scale NOTE: If the spring is at least 10 feet longer than the tank height. Tank Height Liquid Level Distance from top 40 feet −24 feet 16 feet Add 5 feet to the distance from the top of the tank and wind off this much spring as indicated on the 0-90 foot scale on the cartridge. Save this retaining clip.0. lock it by inserting a long screw (1/4″ diameter or smaller) through the hole in the case and larger hole in the power hub as shown in Figure 2 of section 4. vi. then the scale on the cartridge can be used. Prevent the drum from unwinding with one hand while winding with the other hand.67 turns iv. iii. Example: ii. iv. v. B. There are two screw and two washers. See Figure 2 of section 4. Page 20 Instruction Manual Number 92-221-3 Rev. iii. Remove the screwdriver. Divide the distance from the top by 1. proceed to step iii. release the tension in the spring by holding the “Inner Ring” of the spring assembly firmly and removing the Anchor/Locking Pin. then a more accurate method of winding must be used.0 8/27/09 . Save them for installation of the new cartridge.Typical Maintenance Procedures broken and there is tension in the spring.5 ft/turn 10. Wind in the direction as indicated by the arrow on the cartridge. Wind using a small screwdriver by inserting the bit into an open hole on the Accutrak cartridge power hub (inside ring). 2. Remove screw and washer (26 & 27).00 turns 12. WIND NEW CARTRIDGE i. If the spring length is within 10 feet of the height of the tank.67 turns + 2. After the screws are removed. Slowly allow the spring to unwind by rotating the Inner Ring. Set the cartridge on a table or bench. If the spring is not 10 feet longer. Example: Distance from top divided by Total windings 16 feet /1. Save for installation of the new cartridge. WARNING: Exercise extreme caution when attempting this action.5 and add 2. When the spring is wound for the proper length of float travel. Lift the cartridge out of the gauge housing. The Accutrak cartridge may have spring tension applied. This number equals the number of turns by the power hub. Determine the distance from the top of the tank to the liquid surface. insert the Anchor/Locking Pin into the cartridge as shown below before removing the 3 screws. Be careful to save the Bearing and Bearing Bushing.

Install the cover and the gasket. Adjusting Wheel Assembly (65). ii. A. Visually inspect for damage and replace any parts as needed in reverse order. Do no replace the retaining clip (69) until testing operation with the increment wheel. Remove the Jam Nut (66). iv. Insert screws (32) with washers (33). Remove Nut (92). D.6 Counter Wheel Replacement Refer to Exploded View of Counter Housing Assembly in section 5. (91). Install the bushing (35) and retaining clip (34). then parts (93). v. Check for free movement of the tape and gage. C. iii. Install the bearing you saved from steps above. and (88). pinion wheel (70).7 Hand Crank Assembly Maintenance A. 2. shift the cartridge position as much as screws allow until the drum does not rub inside the case. Remove the screw you installed in section B above. and Increment Wheel (64) by turning counterclockwise. vii. 6. INSTALL NEW CARTRIDGE i. iii. vi. 6. Page 21 Instruction Manual Number 92-221-3 Rev.0 8/27/09 . Hold the cartridge case down and install screw and washer (26 & 27)) so that the cartridge is parallel with the top of the gage body. NOTE: Cover gauge head with plastic or other sheeting to prevent wind blown debris from entering the gauge head. (90). B. While turning the drum back and forth. Adjust position or rotation of cartridge to align with 3 holes on tape drum. other counter wheel. Remove cover from gauge head. Remove the Bolts (68) and the cover plate (67) on the counter housing (58). D. Snug. B. Remove the pinion retaining clip (69) then the counter wheel (63). but do not tighten screws at this point. and the last pinion wheel. FINAL CHECKOUT i. The retaining clip should be tight against the bushing. Remove stiff wire or long nail inserted in the steps above.Typical Maintenance Procedures C. Fasten the tape drum to the cartridge with three screws (13). Tighten screws (32). Mount cartridge on the tape drum (22) with the sprocket shaft going through the bearing hole at the base of the cartridge. ii.

Cap Screw 1/4 Loctite MATERIAL Plastic Bronze Stainless Steel Stainless Steel Stainless Steel Bronze Viton Stainless Steel Machined from Aluminum Machined from NI Sht.0 8/27/09 . Test by holding the Drive Yoke (90) with your hand and turning the crank. A solid connection should only occur when the crank handle is turned clockwise and the locking clip (85) is engaged. replace parts (87). Replace O-ring (87) if it is visibly worn. and (93). Stainless Steel Stainless Steel Stainless Steel Aluminum Stainless Steel 20 x 1/2 Stainless Steel Instruction Manual Number 92-221-3 Rev. 87 88 89 86 85 90 84 91 83 92 82 81 96 80 93 95 94 97 & 98 HANDCRANK ASSEMBLY (Part Numbers 9202-13440 and 9202-13441) ITEM 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 PART NO. E. Reassemble as shown in following figure. Hd.17 Drive Yoke Soc.Typical Maintenance Procedures C. (82). 9202-12440 9202-12461 9202-13430 SP111-MM SP111-Y 9202-12481 SP354-GB SP354-V 9202-12530 9202-13390 9202-13391 9202-13420 SP331-DG SP461-F 9202-13410 9202-12540 9202-12830 9202-13400 SP328-GC SP364-C Page 22 DESCRIPTION Ball Handle Handle Shaft Roll Pin 3/16 x 1’ Lg. 8 32 x 5/8 Lg. If the float cannot be raised. Set Scr. Locking Clip “O” Ring "O" Ring Coupling Spring Gauge Cover – see note 1 pg.17 Gauge Cover – see note 1 pg. (90). 2. Hd. Remove Pin (83) and slide Shaft (82) from cover. Roll Pin 5/32 x 1' Lg. D. Elastic Stop Nut ¼-20 Hub Spring Spacer Sleeve Crank Bushing Hol.

2.0 8/27/09 .Typical Maintenance Procedures This Page Intentionally Blank Page 23 Instruction Manual Number 92-221-3 Rev.

Typical Maintenance Procedures This Page Intentionally Blank Page 24 Instruction Manual Number 92-221-3 Rev.0 8/27/09 . 2.