AJAX

AJAX® Engine-Compressor Package Service Manual
Contract# 10754
Engine Compressor
Model Serial Number Model Serial number
DPC-2802LE 85486 23” YK1111MB 14787
13” YK11F 14824
Contents
Section 1 – Supplementary Documentation
Section 2 – Package Drawings
Section 3 – Engine
Section 4 – Fuel System
Section 5 – Cooling System
Section 6 – Cooler
Section 7 – Compressor
Section 8 – Process Gas Equipment
Section 9 – Control Panel and Instrumentation
Section 10 – Lubrication System
Section 11 – IGTB RPM Control
Engine-Compressor Package Service Manual

Section 1 – Supplementary Documentation
Vendor Bulletin No.
Warranty......................................................................... Ajax
Mathematical Conversion Tables ................................... Ajax
Lube Oil & Low Temp Starting
Recommendations .................................................... Ajax ES 1006
Trimming for Sour Gas Applications............................... Ajax ES 25
Installation of Sheave and Flywheel ............................... Ajax ESS-F-961
Flywheel Installation and Ignition Timing........................ Ajax ESS-F-963
Jet Cell Operation and Maintenance............................... Ajax ESS-L-981
Jet Cell System Installation..............................................Ajax ESS-L-983
General PM Schedule .................................................... Ajax TIB 020326
Component Wear Limits................................................. Ajax TIB 020718
% Load vs Engine Coolant Temperature........................ Ajax TIB 030910
Hydraulic Fuel Injection System Purging........................ Ajax TIB 031104
Lubrication Rates ........................................................... Ajax TIB 040910
Installation Design for Permanent Packages.................. Ajax TIB 061115
Engine Operating with Fuel Containing H2S................... Ajax TIB 050610
Torque Tables for Ajax Fasteners....................................Ajax TIB 061212

WARRANTY
Warranties To Original Purchaser (Non-Transferable).
a) "Material and Workmanship Warranty": The Seller warrants

to the Purchaser that the Equipment of Seller's own manufacture to
be supplied hereunder will be complete in all its parts, and, for the
*Warranty Period - The warranty period shall extend for 12 months
from date of start-up, but shall not exceed 18 months from date of
shipment from factory. Warranty Period specified will be free from
defects in material or workmanship caused by the Seller and arising
under normal and proper operating conditions; and that such
Equipment will be delivered free from any lawful security interest or
other lien or encumbrance known to the Seller, except security
interests or other liens or encumbrances arising hereunder. The
obligation of the Seller and the Purchaser's sole and exclusive
remedy hereunder shall be limited at the Seller's option:
1) To replacement or repair of any Equipment or parts thereof
which are returned to the Seller's works within the Warranty
Period, transportation charges prepaid.
2) Should the Equipment or parts thereof be determined by the
Seller to be so defective, however, as to preclude the
remedying of warranty defects by replacement or repair, the
Purchaser's sole and exclusive remedy shall then be a refund
of the purchase price, less a reasonable charge for any
utilization of the Equipment by Purchaser.
3) Nothwithstanding the foregoing, the Seller shall have no
obligation as a result of improper storage, installation,
repairs or modifications not made by the Seller, or as a result
of removal, improper use, or misapplication of the
Equipment after it has been delivered to the Purchaser.
4) Purchaser shall pay freight charges in connection with the
return or replacement of the defective Equipment or parts.
b) "Performance Warranty": The Seller warrants that the
Equipment of its own manufacture, when shipped and/or
installed, will operate within any performance characteristics
which are expressly specified herein as a performance
guarantee. Any performance characteristics indicated herein
which are not expressly stated as guarantees are expected,
"but not guaranteed". When factory testing is conducted for
measuring any performance guarantee of the Equipment
purchased, then certified test results verifying any such
guarantees shall be considered both by the Purchaser and the
Seller as conclusive. The Purchaser may have a
representative present when such factory tests are conducted,
if requested at the time an order is placed. Should Purchaser
desire to conduct a field performance test to verify any
performance guarantee, such test must be conducted by
Purchaser, at his expense, within thirty (30) days from the
date of initial start-up of the Equipment, and in accordance
with the appropriate ASME Power Test Code, except as
otherwise agreed in writing by Seller. Seller shall be entitled
to have a representative or representatives present to witness
such test and Purchaser shall reimburse Seller for the time
and expense of such representatives at the Seller's service
rates then in effect at the time of the test. Purchaser shall
give Seller fifteen (15) days written notice prior to the date
Purchaser intends to commence such test. If the field
performance test is not conducted within the aforesaid period
all performance guarantees shall be deemed to have been
met. In the event any Equipment performance guarantee
which is to be verified by the field performance test is not
successfully demonstrated within thirty (30) days from the
commencement of such test, the obligation of the Seller and
the Purchaser's sole and exclusive remedy hereunder shall be
that set forth in paragraph (a) above.
c) "OSHA" Warranty": The Seller warrants for installations

within the United States that Equipment of its own
manufacture, when shipped, will be in compliance with the
Occupational Safety and Health Act, and any and all
amendments thereto and regulations promulgated thereunder
that may be in effect as of the date of the Seller's quotation
insofar as said law and regulations may pertain to the
physical characteristics of the Equipment "provided
however", the Seller does not warrant such compliance with
respect to the circumstances of use of said Equipment and
"provided further", the Seller makes no warranty with
respect to the noise level of said Equipment, when put into
operation, since such noise levels will be influenced by and
dependent upon the environment into which the Equipment
may be placed. The Seller's obligation and the Purchaser's
sole remedy with respect to this warranty shall be providing
notice of any such non-compliance is given within one year
from the date of delivery of said Equipment to Purchaser, to
repair or replace any part of said Equipment that is proven to
Seller's satisfaction not to have been in compliance with the
Act as amended and regulations thereto in effect as of the
date of quotation or, if it be determined by Seller that the
Equipment or parts thereof cannot be repaired or replaced in
such a manner as to put the Equipment in compliance,
Purchaser's sole and exclusive remedy shall then be a refund
of the purchase price less a reasonable charge for any
utilization of the Equipment by Purchaser. Purchaser shall
pay freight charges in connection with the return or
replacement of any Equipment or parts that are found not to
be in compliance.
Notwithstanding the foregoing, the Seller shall have no
obligation under this warranty as a result of installation,
repairs or modifications not made by the Seller, or as a result
of removal, improper use, improper operation, or mis-
application of the Equipment after it has been delivered to
the Purchaser.
d) "Warranty As To Equipment Not Made By The Seller":
Equipment parts and accessories made by other
manufacturers and supplied hereunder by the Seller are
warranted only to the extent of the original manufacturer's
warranty to the Seller.
e) "EXCEPT AS SET FORTH HEREIN, AND EXCEPT
AS TO TITLE IT IS EXPRESSLY AGREED":
"THAT THERE IS NO IMPLIED WARRANTY OF
MERCHANTABILITY, NOT OTHER WARRANTY,
EXPRESS, IMPLIED, OR STATUTORY, NOR ANY
AFFIRMATION OF FACT, OR PROMISE BY THE
SELLER WITH REFERENCE TO THE EQUIPMENT
OR PARTS THEREOF, OR OTHERWISE, WHICH
EXTENDS BEYOND THE DESCRIPTION OF THE
EQUIPMENT AS SET FORTH HEREIN, AND (2)
THAT THE PURCHASER ACKNOWLEDGES THAT
IT IS PURCHASING THE EQUIPMENT SOLELY ON
THE BASIS OF THE COMMITMENTS OF THE
SELLER EXPRESSLY SET FORTH HEREIN".
DAMAGES. "IN NO EVENT SHALL SELLER BE LIABLE FOR SPECIAL,

CONSEQUENTIAL OR INCIDENTAL DAMAGES, NOR FOR LOSS OF
ANTICIPATED PROFITS NOR FOR LOSS OF USE OF ANY EQUIPMENT,
INSTALLATION SYSTEM, OPERATION OR SERVICE INTO WHICH THE
GOODS OR PARTS MAY BE PUT, OR WITH RESPECT TO WHICH ANY
SERVICES MAY BE PERFORMED BY SELLER". "THIS LIMITATION ON
SELLER'S LIABILITY SHALL APPLY TO ANY LIABILITY FOR
DEFAULT UNDER OR IN CONNECTION WITH THE GOODS, PARTS OF
UNIT SALES OR SERVICESDELIVERED HEREUNDER, WHETHER
BASED ON WARRANTY, FAILURE OF OR DELAY IN DELIVERY OR
OTHERWISE". "ANY ACTION FOR BREACH OF CONTRACT
HEREUNDER MUST BE COMMENCED WITHIN ONE YEAR AFTER THE
CAUSE OF ACTION HAS ACCRUED".
TDI TURBOTWINTM
Engine Air Starters
MATHEMATICAL CONVERSION TABLE

UNITS TO CONVERT INTO MULTIPLY
BY
P
R Bars PSIG 14.5
E Kilograms/Sq. Centimeter PSIG 14.22
S Kilopascals PSIG 0.145
S PSIG Bars 0.069
U PSIG Kilograms/Sq Centimeter (Kg/cm) 0.070
R PSIG Kilopascals (Kpa) 6.895
E
Liters Cubic Inches (in3) 61.023

V Gallons Cubic Inches (in3) 232.56
O Gallons Cubic Feet (ft3) 0.135
3
L Cubic Centimeters Cubic Inches (in ) 0.061
U Cubic Inches Liters (L) 0.0164
M Cubic Inches Gallons (Gal) 0.0043
E Cubic Feet Gallons (Gal) 7.413
Cubic Inches Cubic Centimeters (cm3) 16.39
T Newton Meters Foot Pounds (Ft-lb) 0.7376

O Kilogram Meters Foot Pounds (Ft-lb) 7.233
R Foot Pounds Newton Meters (N-m) 1.356
Q Foot Pounds Kilogram Meters (K-gm) 0.1383
U Kilogram Meters Newton Meters (K-gm) 9.807
E
F Standard Cubic Feet per Minute Cubic Meters/Hr (m/h) 1.70

L Cubic Meters/Hr Standard Cubic Feet per Minute 0.588
O Standard Cubic Feet per Minute (SCFM) 0.0750
W Pounds per Minute (Lb/Min.)
P
O Horsepower Kilowatts (KW) 0.746
W Horsepower Ft-lbsp/Second 550.0
E Kilowatts Horsepower (HP) 1.340
R
AN03-147 9/97
TDI TURBOTWINTM
Engine Air Starters
MATHEMATICAL CONVERSION TABLE

UNITS TO CONVERT INTO MULTIPLY
BY
P
R Bars PSIG 14.5
E Kilograms/Sq. Centimeter PSIG 14.22
S Kilopascals PSIG 0.145
S PSIG Bars 0.069
U PSIG Kilograms/Sq Centimeter (Kg/cm) 0.070
R PSIG Kilopascals (Kpa) 6.895
E
Liters Cubic Inches (in3) 61.023

V Gallons Cubic Inches (in3) 232.56
O Gallons Cubic Feet (ft3) 0.135
3
L Cubic Centimeters Cubic Inches (in ) 0.061
U Cubic Inches Liters (L) 0.0164
M Cubic Inches Gallons (Gal) 0.0043
E Cubic Feet Gallons (Gal) 7.413
Cubic Inches Cubic Centimeters (cm3) 16.39
T Newton Meters Foot Pounds (Ft-lb) 0.7376

O Kilogram Meters Foot Pounds (Ft-lb) 7.233
R Foot Pounds Newton Meters (N-m) 1.356
Q Foot Pounds Kilogram Meters (K-gm) 0.1383
U Kilogram Meters Newton Meters (K-gm) 9.807
E
F Standard Cubic Feet per Minute Cubic Meters/Hr (m/h) 1.70

L Cubic Meters/Hr Standard Cubic Feet per Minute 0.588
O Standard Cubic Feet per Minute (SCFM) 0.0750
W Pounds per Minute (Lb/Min.)
P
O Horsepower Kilowatts (KW) 0.746
W Horsepower Ft-lbsp/Second 550.0
E Kilowatts Horsepower (HP) 1.340
R
AN03-147 9/97

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ESS-F-963
Title: Keyless Flywheel Installation And Timing
Engineering Sales &

Service Bulletin
Ajax-Superior Engines/
Oklahoma City, OK 73129 Compressors
ESS-F-963
Keyless Flywheel Installation and Ignition Timing

This procedure applies to all Ajax models 2200 and 2800 series Ajax engines. It covers the installation of
the keyless ringfeder locking device fitted on flywheels on 2200 and 2800 series engines. The procedure
explains the method used to find top dead center (TDC) and proper ignition timing of the engine.
Installation
1. Stand the flywheel up on its edge, allowing access to both sides of the flywheel.
! Caution
Firmly secure the flywheel to prevent it from falling over.
2. Remove the rust inhibitor paper from the inside of the machined split ring on the ringfeder. Remove
ringfeder (collar, inner ring, and locking screws) from shipping container. Verify that the supplied
locking screw threads, screw head bearing area, and the taper of the inner ring are lubricated. If not,
lubricate with molybdenum disulfide grease, such as Molykote GN paste or equivalent.
3. Place the green ringfeder and split ring assembly on the machined diameter of the flywheel.
4. The bolts to be used on the ringfeder are metric. A 16 mm (FWF2500-1600) hardened flat washer is
required for every bolt. Start each bolt into the ringfeder, but DO NOT TIGHTEN
Figure 1
Flywheel Collar
Hardened
Washer
Inner Ring
Crankshaft
Locking
Screw
5. Use a fine file or emery cloth to remove any burrs from the flywheel and crankshaft, cleaning both
for assembly.
6. Coat the flywheel and crankshaft sparingly with engine oil. The flywheel to crankshaft fit is between
.001”-.003”. Do not over-lubricate.
Note
Step 6 should only be performed during initial engine assembly. Do not lubricate on field units.
7. Carefully place the flywheel on the end of the crankshaft. Do not bump the crank as this will create
a burr that can impede installation. Push the flywheel evenly onto the crankshaft until the face of the
Page 1 of 4 Released: 6/8/99

ESS-F-963
flywheel and the end of the crankshaft are even.
Note
Do not wiggle the flywheel in/out or try to turn the flywheel onto the crankshaft! It will create heat
and possibly gall the surface of the crankshaft.
8. After the flywheel is installed, snug several of the bolts in a criss-cross pattern to lock the flywheel to
the crankshaft.
9. Remove the crosshead side access door from power cylinder one.
10. Set the timing pointer on the ignition bracket, allowing 1/8” clearance from the flywheel. Adjust the
pointer until it is located in the middle of vertical slot on the bracket.
Finding TDC and Timing Degree Marks

11. Place a 4” bar or equivalent between the end of the crosshead and the pack flange. Bar the engine
over clockwise until the bar stops against the packing. Hold the flywheel in this position, keeping
the crosshead against the bar.
12. Mark the flywheel on the outer diameter (O.D.) with an ink marker at the pointer location. This is
“Temporary Mark #1”.
13. Remove the tension on the bar in the crosshead and remove.
14. Rotate the engine clockwise until is has passed TDC far enough to re-insert the bar.
15. Reinsert the bar and rotate the engine counter-clockwise until the bar stops the crosshead against the
packing. Hold the flywheel in this position.
16. Mark the flywheel on the O.D. with an ink marker at the pointer location. This is “Temporary Mark
#2”.
17. Release the tension from the bar and remove. Rotate the engine to allow access to both of the tempo-
rary marks.
18. Measure the distance between the marks. Divide the distance by two and, using an ink marker, cre-
ate a third mark equidistant between the two marks. This will be “Temporary Mark #T”. Mark T
represents the Top Dead Center (TDC) of the crankshaft.
Note
You can verify the position of the TDC mark by measuring the distance between marks #1 and T, then
marks #2 and T. These distances should be equal.
19. It is now necessary to add the ignition timing mark. Verify that the ignition is properly set. All 2200
and 2800 engines use a 48” diameter flywheel. This means that:
3° = 1ÿ” Flywheel O.D. distance
9° = 3¾” Flywheel O.D. distance
11° = 4-5/8” Flywheel O.D. distance
20. Using one of the above distances, create a temporary mark on the flywheel to represent either 3°, 9°
or 11° (depending on model) before TDC or clockwise from the T mark on the flywheel.
21. Rotate the engine so that the timing mark is aligned with the flywheel pointer. This sets the crank-
shaft in the general range of normal ignition timing.
22. Use the nut and stud expanders to lock and hold the crankshaft in position. These should be
installed between the sheave and end cover. See Figure 2. This picture shows the method of locking
the crankshaft used during engine assembly. Alternate methods of locking are acceptable for field
installation.
23. Check that the timing mark is still aligned with the flywheel pointer. As a double check, verify that

ESS-F-963
the scribed line located on the end of the crankshaft is positioned below horizontal. See Figure 3.
24. Loosen the ringfeder bolts to free up the flywheel on the crankshaft.
Figure 2
Figure 3
End of Crankshaft
Power Cylinder Horizontal
Side
DC
#1 T

ESS-F-963
Engineering Sales &

Service Bulletin
Ajax-Superior Engines/
Oklahoma City, OK 73129 Compressors
ESS-F-963
Setting Timing Of the Flywheel

25. Ensure that the ignition pickup coils are in the proper holes:
3° - Top Holes
9° - Two Holes From The Bottom
11° - Bottom Holes
26. Rotate the flywheel on the crankshaft, without moving the crankshaft itself, until the recessed mag-
net is centered over the number 1 pickup coil. This is the “A” pickup coil or the one closest to the
power end.
27. While keeping the magnet aligned, re-tighten the ringfeder to the flywheel. Now place a permanent
timing mark on the flywheel and mark it either 3°, 9°, 11° accordingly.
28. Permanently mark the TDC location and then erase all of the temporary marks made on the fly-
wheel.
29. Remove all crankshaft locking devices and find TDC as in the above procedures to verify that the
TDC position and the ignition timing mark have been correctly located relative to the magnet posi-
tion.
30. When certain that the permanent marks are correct, tighten and torque all flywheel bolts.
31. Match mark the flywheel coincident with the scribe line on the end of the crankshaft using a chisel.
Stamp a “1” next to this mark.
32. Stamp the engine serial numbers on the crankshaft and hub of the flywheel.
33. Chisel mark a line on the OD of the flywheel at TDC. Metal stamp a “0” next to this mark.
34. Chisel mark a line at either the 3°, 9°, or 11° (depending on model) on the OD of the flywheel. Metal
stamp the correct timing value next to this mark.
35. It may be necessary after engine start-up to readjust the timing pointer. The pickup coil should be
centered over the cylinder #1 recessed magnet when the pointer is pointing at the timing mark.
2804 (DPC-800) Engines Only

These engines do not use flywheel magnets and pickup coils. When finished with Step 20 above go
directly to Step 29.The magneto should be adjusted via the slotted holes on the mounting flange until the
cylinder #1 is aligned with the flywheel timing marks.

ESS-L-981
AJAX LOW EMISSIONS ENGINES

ESS-L-981
Date: July 13,1998

Supercedes ESS-L-921
AJAX JET CELL OPERATION AND MAINTENANCE
ABSTRACT
The jet cell concept is required for low emission or emission reduction engines. The high-
energy torch issuing from the pre-chamber allows the main chamber to be operated with a
leaner mixture and consistently ignited, as compared to a conventional spark plug
ignition of a lean mixture.
Also, the jet cell is applied to units to improve combustion stability and improve fuel
consumption when operating at variable speeds and reduced torque. This paper describes
the jet cell operation and general maintenance procedures relating to AJAX Low
Emissions Two-Cycle Engines.
JET CELL OPERATION
The jet cell, or pre-combustion chamber, is a unit which is installed in the cylinder head.
The nozzle end is designed with a specific volume and has a communicating angled exit
orifice. A spark plug for ignition and a fuel admission check valve complete the
necessary operational components.
Pilot fuel headers supply fuel to each admission check valve. The supply to the header is
taken prior to the governor regulated fuel valve, filtered, and the pressure regulated with
an additional regulator.
The ignitor fuel pressure is thus regulated manually according to site conditions.
For one cycle of operation, as the piston comes up on compression, the pressure within
the cylinder is lower than the pilot gas pressure and fuel is admitted into the cell. When
1 Revised 07/98
ESS-L-981
the pressure within the cylinder becomes greater than the fuel pressure, then the pilot
check valves close.
The main fuel valve admits fuel into the cylinder per the designed timing. Ignition occurs
within the jet cell and the rich fuel mixture ignites. The pressure rise caused by this
energy release forces the burning mixture to exit through the nozzle orifice across the top
of the piston in the main combustion chamber, igniting the main combustible charge.
IGNITION TIMING
In standard spark ignited engines, the spark plugs ignite the charge and a progressive
flame front occurs within the combustion chamber. Due to the time required for this
flame propagation, the ignition timing is approximately 9°-12° before top dead center
(BTDC).
With the jet cell, a torch of fire emitting from the exit orifice penetrates into the fuel/air
mixture within the main combustion chamber. The mixture is ignited uniformly by this
higher energy source, which promotes faster burning. For this reason, the ignition timing
is set at 3° BTDC.
For an engine operating at 440 rpm, this sequence of fuel admission, ignition, etc., occurs
7.3 times per second, 440 times per minute, 26,400 times per hour, 663,600 times per day
(24 hrs), and 30 days of operation would equal 19,008,000 times.
MAINTENANCE
The jet cell, when installed into the cylinder head, has a round Armco iron gasket which
acts as a fire seal; a graphoil seal employed as a bottom water seal, and an ‘O’ ring as the
top water seal.
The unit is held in place with a two-bolt flange and torqued to 70 ft-lbs.
If a cell is removed from the head, it is important that the access hole for the cell is clean
and free of any scale build-up. New gaskets and seals should be installed and the unit
properly torqued. A locating dowel is used to assure proper orientation of the exit orifice
of the cell in relation to the main combustion chamber.
SPARK PLUGS
Cooling of the spark plug is accomplished primarily through the spark plug gasket
seating surface and the threads. These areas within the cell have thin metal sections and
are surrounded with engine coolant.
In service, the center and ground electrodes will deteriorate, which increases the spark
plug gap. Erratic firing will occur once the gap increases 0.005”-0.010” from the original
setting and the plugs should be replaced.
2 Revised 07/98
ESS-L-981
On older LE equipment (pre 9/92), where a YK-8209-C jet cell was used, a Champion
RW77N (BM-1022-2) spark plug with an initial gap of 0.015″ to 0.018″ was used. The
main chamber spark plug utilized the Champion W-18 (BM-1022). Current production
models (post 9/92) where a YK-8209-C-1 is utilized, use a Champion W-18 (BM-1022)
spark plug is used with an initial gap of 0.020″. This allows use of the same spark plug
for both the main chamber and igniter. The current production jet cell (YK-8209-C-1)
identified with a ‘3/4’ stamped on the top face.
IMPORTANT: Do not install the W-18 spark plug in the YK-8209-C jet cell. Damage
may occur to igniter and/or spark plug threads as the result of thread depth and thread
reach respectively.
The secondary ignition wiring and associated components should always be in good
condition.
FUEL ADMISSION CHECK VALVES
The primary check valve (P/N YK-8338-A) is most important in the operation of the jet
cell. As noted previously, the number of cyclic operations relates to the unit’s speed, with
fuel being admitted when the cylinder pressure is less than the pilot fuel pressure and
being shut off the cylinder pressure increases. The check valve also withstands the high
pressure within the cell at time of ignition.
Present production check valves use a ceramic ball with tool steel enclosure and seat.
Ajax continues to improve the life and operation of the valves with ongoing research and
development programs.
From the primary check valve, the fuel gas enters the cell through drilled communication
holes. Due to fuel entrapment, incomplete combustion can occur in these passages, which
tends to produce a soot-carbon residue. In some cases, this build-up is not detrimental to
the check valve’s operation, but in other cases it can be severe. If this build-up becomes
heavy, erratic operation of the check valves will occur and they should be removed,
cleaned and tested.
Whenever the spark plugs are replaced, it would be appropriate to remove and clean the
check valves. Some end users have a spare set of check valves which are installed at this
time, and the removed set is cleaned for reinstallation at a later date.
An orifice (P/N K-8050) is installed on the inlet side of the primary check valve to allow
pilot fuel pressures to be comparable to main fuel pressure. The orifice resembles a 1/8″
toe nipple. Ensure this is an orifice by visual inspection, noting a small 0.038″ internal
hole. Clean when servicing the primary check valve.
Connected directly upstream of the orifice is a secondary check valve (P/N BM-21064).
This is utilized only as a backup to the primary check valve.
3 Revised 07/98
ESS-L-981
A jet cell-equipped engine does require some additional maintenance over a standard
combustion engine. This additional maintenance is offset by gains in combustion
stability, lower emissions and improved fuel economy.
4 Revised 07/98
ESS-L-983
LE RETROFIT CONVERSIONS
SUPPLEMENT ASSEMBLY PROCEDURE

ESS-L-983
Date: July 14, 1998

Supercedes ESS-L-923
AJAX LOW EMISSIONS RETROFIT CONVERSIONS
13-1/4″″ & 15″″ BORES
The new AJAX Low Emissions (LE) Engine utilizes a squish design combustion
chamber that includes a jet cell (ignitor cell). The assembly procedure is basically the
same as on a standard engine, with the following additions and changes in gas valve
timing, ignition timing and power piston position.
1. PISTON & HEAD INSTALLATION:
A) The piston used on the LE engine does not incorporate notches or tapped holes in
the crown for installation as compared to the standard combustion engine. It is
recommended that a rod wrench (or strap wrench) be used to install or remove the
power piston.
B) Screw piston into crosshead until approximately three (3) threads are left
showing. Do not tighten rod nut at this time.
C) Install cylinder head (with gasket) and torque to 600 ft-lbs.
D) Using solder, set piston-to-head striking clearance at 0.110″ (± 0.010″). This is

measured at the 6:00 position by inserting solder through the gas injection hole
down towards bottom of head. Roll piston forward (rotate crankshaft in CW
direction) past TDC, thus crushing solder. Using a micrometer or dial calipers,
measure thickness of crushed solder. Adjust piston position accordingly, to
obtain proper striking clearance. Refer to Figure 1.
1 Revised 07/98
ESS-L-983
Figure 1. Measuring Proper Piston-To-Head Distance
E) Once clearance is set, torque rod nut and check clearance again. Piston has a
tendency to turn out slightly when tightening nut.
2. GAS CAM TIMING:
Refer to ESS-T-911 as a basis for fuel injection timing. The following changes must
be made when converting an engine to LE application.
A) The flywheel and gear shield must be removed in order to remove layshaft and
reset cam timing.
B) Cam timing is retarded from the standard 13° ABDC beginning of injection to 37°
ABDC. DO NOT GO BEYOND 37° ABDC! If gears do not line up with cams at
37° ABDC, go back towards BDC (i.e. 35° ABDC). Beginning of injection is 37°
2 Revised 07/98
ESS-L-983
ABDC on all LE engines but the method of setting the timing is different on
DPC-800s & DPC-2804s.
C) On DPC-800s & DPC-2804s, the control box utilizes one (1) cam for two (2)
cylinders. #1 & #3 power cylinders run off the cam closest to the power cylinders.
#2 & #4 cylinders run off the other cam. Refer to Figure 2.
Figure 2. Control Box And Cams
#1 power cylinder gas cam timing is referenced off #3 bank on the control box.
The crankshaft should be rotated in a clockwise direction to 26° ABDC #1 power
cylinder. DO NOT GO BEYOND 26° ABDC! If gears do not line up with cams at
26° ABDC, go back towards BDC (i.e. 24° ABDC). The crankshaft is positioned
at 26° ABDC for setting cam timing on DPC-800s & DPC-2804s only. This is
due to the way the cam is installed on the layshaft. The result will be injection
beginning at 37° ABDC. Refer to FIG 3. The cam can now be set using the
method illustrated in ESS-T-911.
D) Once the preceding is complete, the layshaft gear should be installed and re-
indexed.
3. IGNITION TIMING:
Ignition timing is changed on all LE engines to 3° BTDC. New mag pickup brackets
are furnished for all conversions through the DPC-600 & DPC-2803 to accommodate
the timing change.
3 Revised 07/98
ESS-L-983
On DPC-800 and DPC-2804 engines where the ALTRONIC III is used, the alternator
must be removed and re-indexed to 3° BTDC (refer to the standard DPC-800/DPC-
2804 Operation & Maintenance Manual for procedure).
Figure 3. Alignment Of Crankshaft
4. IGNITOR ASSEMBLY INSTALLATION: Refer to FIG 4
A) Ignitor assembly is indexed with a roll pin that lines up with a slot machined in
the LE power head. This ensures proper direction of ignitor exit orifice. It is very
important that they are lined up properly! Misalignment will result in severe
piston crown damage. It should be noted that when ignitor is torqued into head,
the roll pin will not completely set into slot. This is only an alignment reference.
B) Install gasket (P/N SF-34-65) onto end of ignitor by pressing on or using small
amount of grease to hold gasket in place when installing ignitor into the head.
Insure O-ring is installed on ignitor at this time also.
C) Install water seal (P/N 2-013-129-002) into head.
4 Revised 07/98
ESS-L-983
Figure 4. Ignitor Assembly
D) Install ignitor into head being very careful not to damage water seal. This may
take some hand fitting of seal. Torque down in progressive 5 ft-lb increments to
70 ft-lbs.
5. SPARK PLUGS:
On older LE equipment (pre 9/92), where a YK-8209-C jet cell was used, a
Champion RW77N (BM-1022-2) spark plug with an initial gap of 0.015″ to
0.018″ was used. The main chamber spark plug utilized the Champion W-18
(BM-1022). Current production models (post 9/92), where a YK-8209-C-1 is utilized,
use a Champion W-18 (BM-1022) spark plug with an initial gap of 0.020″. This
allows use of the same spark plug for both the main chamber and igniter. The current
production jet cell (YK-8209-C-1) is identified with a ‘3/4’ stamped on the top face.
IMPORTANT: Do not install the W-18 spark plug in the YK-8209-C jet cell.
Damage may occur to ignitor and/or spark plug threads as the result of thread depth
and thread reach, respectively.
5 Revised 07/98
ESS-L-983
6. GAS INJECTION VALVES:
The gas injection valve used in the LE power end is of the same basic design as the
one used in the standard combustion assembly but the valve housing and plunger
housing are not interchangeable. The gas injection valve assembly on the LE engine
has a longer valve body housing and a shorter plunger housing to accommodate the
profile of the power head.
7. MISCELLANEOUS:
In addition to the preceding requirements, engines that are converted to the LE design
must have:
A) Dry-type, low restriction intake system
B) Ring gear start system on 15″ bore engines
C) 3/8″ hydraulic supply lines on gas injection system
D) Exhaust line adjustment to compensate for length of insertion pipe in muffler
If you have any questions or problems pertaining to an LE retrofit conversion, contact

your local AJAX-SUPERIOR representative.
6 Revised 07/98
Technical Information
Bulletin # 020718 r2
August 24, 2004
Subject: Ajax Component Wear Limits

all 15” Bore x 16” Stroke (Includes DPC-180, -360, -600, -800, & 2800 Series models)
all 13¼” Bore x 16” Stroke (Includes DPC-115, -140, -230, -280, & 2200 Series models)
The following component dimensional specifications and wear limits should be used as a
guide for preventative maintenance programs for Ajax equipment. Problems can be
detected early before failures occur.
These specifications are based on data gathered from a broad range of Ajax installations
covering many decades of operating experience.
Specific unit performance and maintenance requirements may vary based on application
conditions and preventative maintenance practices.
Engine End Data

Item As New Limits Max. Acceptable
Up to 15.013,
15” Cylinder Bore 14.997- 15.001
Max .002 TIR
15” Piston Skirt Diameter 14.968 – 14.970 Down to 14.961
15” Piston-to-Cylinder Clearance .027 - .033 Up to .045
15” Piston Ring 1 & 2 Side Clearance .010 - .0125 Up to .015
15” Piston Ring 3 & 4 Side Clearance .008 - .0105 Up to .013
15” Piston Ring End Gap .115 - .135 Up to .145
Up to 13.263,
13¼” Cylinder Bore 13.247 – 13.251
Max .002 TIR
13¼” Piston Skirt Diameter 13.220 – 13.222 Down to 13.213
13¼” Piston-to-Cylinder Clearance .025 - .031 Up to .045
13¼” Piston Ring 1 & 2 Side Clr. .010 - .0125 Up to .015
13¼” Piston Ring 3 & 4 Side Clr. .008 - .0105 Up to .013
13¼” Piston Ring End Gap .100 - .126 Up to .145
Piston Rod 2.497 – 2.500 Down to 2.495
Crosshead Guide 12.000 – 12.002 Up to 12.004
Crosshead O.D. 11.987 – 11.989 Down to 11.985
Crosshead-To-Guide Clearance .009 - .013 Up to .016
*Note: determine the minimum clearance by passing the thickest feeler gauge
possible over the top of the crosshead to project out the opposite side. Then slide the
gauge along the entire length of the crosshead-to-guide fit.
Engine End Data (continued)
Conn Rod Pin Bushing I.D. 5.5044 – 5.5069 Up to 5.509
Conn Rod Side Clearance .010 - .026 Up to .029
Down to 5.4985
Crosshead Pin O.D. 5.4995 – 5.5000
Max .001 TIR
Crosshead-to-Pin Clearance .0044 - .0074 Up to .0085
Up to 7.507
Conn Rod Bearing Bore 7.503 – 7.505
Max .001 TIR
Down to 7.4975
Crank Pin O.D. 7.499 – 7.500
Max .0015 TIR
Crank Pin-to-Bearing I.D. Clearance .0044 - .006 Up to .0075
Main Brg. Journal O.D. 8.374 – 8.375 Down to 8.3725
Up to 8.3831
Main Bearing I.D. 8.3796 – 8.3816
Max .002 TIR
Main Journal-to-Bearing I.D. .0046 - .0076 Up to .0091
Main Bearing Thrust,
r2> DPC-600, DPC-800, DPC-2803, DPC-2804 only
.010 - .020 Up to .022
Layshaft Bearing Bore 1.502 - 1.503 Up to 1.504
Layshaft O.D. 1.498 - 1.500 Down to 1.497
Layshaft O.D.-to-Bearing Bore
.002 - .005 Up to .007
Clearance
Center Main Bearing I.D. on Twins 7.754 - 7.756 Up to 7.757
Crankshaft Journal on Twins 7.749 - 7.750 Down to 7.748
Center Main-to-Journal Clearance on
.004 - .007 Up to .0084
Twins
Compressor End Data

Cylinder Bore ** **
Piston Rings & Riders ** **
Piston-to-Cylinder Clearance ** **
** contact the Technical Support department at Ajax
Piston Rod, 2½" 2.497 – 2.500 2.495
Piston Rod, 2¼ " 2.249 – 2.250 2.2455
Crosshead Guide 11.999 - 12.001 Up to 12.008
Crosshead O.D. 11.984 - 11.986 Down to 11.982
Crosshead-To-Guide Clr.* .011 - .015 Up to .018
*Note: determine the minimum clearance by passing the thickest feeler gauge
possible over the top of the crosshead to project out the opposite side. Then slide the
gauge along the entire length of the crosshead-to-guide fit.
Connecting Rod Pin Bushing I.D. 4.5035 - 4.5062 Up to 4.507
Crosshead Pin O.D. 4.4995 - 4.500 Down to 5.4985
Pin Bushing-to-Pin Clearance .0044 - .006 Up to .0066
Connecting Rod Bearing I.D. 7.503 - 7.505 Up to 7.506
Crank Pin O.D. 7.499 - 7.500 Down to 7.498
Crank Pin-to-Rod Bearing Clearance .0042 - .0066 Up to .008
Bulletin # 031104
November 4, 2003
Subject: Hydraulic Fuel Injection System
a) Potential Fire Hazard
b) Purging Procedure
c) Recommended System Modifications
A potential fire hazard exists on Ajax engines with hydraulic fuel injection:
1) An incorrect purging procedure can allow hydraulic fluid to

contact a hot exhaust pipe and ignite. Use the following procedure:
Hydraulic System Purging Procedure:
1. Shut the engine off.

2. Pressurize the hydraulic reservoir to 15-20 psig.
3. Open the flow control valve (at control box) for the gas injection valve line to be purged.
4. Connect a 10”-12” length of clear plastic 3/8” hose to the bleed valve.
5. Slowly open the bleed valve while directing purged fluid and bubbles into a clean container for reclamation.
6. After the fluid runs without bubbles, close the bleed valve.
7. Close the flow control valve at the control box.
8. Check the reservoir’s fluid level. Be certain to depressurize the reservoir before replenishing the fluid.
Note
Use Ajax® hydraulic fluid p/n YAE-2150-2.
Do not use other fluids.
2) A damaged purge valve assembly can allow hydraulic fluid to leak and contact a hot
exhaust pipe and ignite .
As seen in Figure 1, the bleed valve is assembled to the cap of the injection valve by use of a
pipe nipple and pipe tee. These assembled parts can be bumped and damaged when servicing
adjacent components such as cylinder heads. The pipe nipple can also be damaged if the gas
injection valve assembly is mishandled during servicing.
Traditional bleed valve location for

purging of the hydraulic injection system.
Figure 1
As seen in Figure 2, relocation of the bleed valve to the topmost part of the gas injection valve
minimizes damage potential, and permits more efficient purging of the hydraulic system.
Relocated bleed valve Bend tubing to 45º for

for improved purging optimum fluid flow and
of the hydraulic vibration resistance
injection system.
Clear plastic 3/8” hose

temporarily connected
Figure 2 for purging the system.
Convert to the current design by replacing the injection valve’s cap with the current design.
A parts kit for the conversion is available, or individual pieces can be specified. See the
appropriate table below for a kit P/N or the individual P/Ns.
See Figure 2 for a typical installation of the current design.
“Top Purge Conversion Kit”

(one per Gas Injection Valve)
p/n: SPEC 7456-S p/n: SPEC 7456-SS

(steel valve & fittings) (ss valve & fittings)
Item Description P/N Qty Item Description P/N Qty
1 Valve Cap A-2565-F-4 1 1 Valve Cap A-2565-F-4 1
2 Bleed Valve BM-10936 1 2 Bleed Valve BM-16580-2 1
3 3/8 Tube x ¼ NPT BM-11573-S-6-4 1 3 3/8 Tube x ¼ NPT BM-11573-SS-6-4 1
Reducer, ¼ NPT(F) Reducer, ¼ NPT(F)
4 BM-21147-S-4-2 1 4 BM-21147-SS-4-2 1
x 1/2 NPT(M) x 1/2 NPT(M)
5 ¼ Tube Nut & Ferrules BM-21163-S-4 1 5 ¼ Tube Nut & Ferrules BM-21163-SS-4 1
6 3/8 Tube Nut & Ferrules BM-21163-S-6 1 6 3/8 Tube Nut & Ferrules BM-21163-SS-6 1
7 ¼ Tubing, 316SS BM-21071-2-035 4’ 7 ¼ Tubing, 316SS BM-21071-2-035 4’
8 3/8 Tubing, 316SS BM-21071-3-035 4’ 8 3/8 Tubing, 316SS BM-21071-3-035 4’
Bulletin # 040910
September 10, 2004
Subject: Lubrication Rates for DPC-2200 and DPC-2800 series engine-compressors
Use of divider valve designs provides a simple, reliable and predictable approach to engine cylinder and compressor
cylinder lubrication. Simplicity is enhanced by use of a lubrication monitor that senses divider valve operation, and
displays pints/day of lube oil consumption based on RPM and a divider valve assembly’s displacement volume.
The following rates for engine cylinders are based on the use of dry gas, and lube oil per Ajax engineering standard
ES-1006. HP listings are at standard conditions of 100ºF and <1500’ elevation.
Load Lube Rate Load Lube Rate

RPM RPM
Condition Pints/Day Condition Pints/Day
DPC-2201 & LE DPC-2803

74 HP 440 2.9* 317 HP 440 12.7 *
76 HP 300 2.6 324 HP 300 10.8
111 HP 440 3.7 475 HP 440 15.8
101 HP 300 3.4 432 HP 300 14.4
148 HP 440 4.9 634 HP 440 21.1
DPC-2202 & LE DPC-2803LE

148 HP 440 5.9 * 300 HP 440 12 *
151 HP 300 5 307 HP 300 10.2
222 HP 440 7.4 450 HP 440 15
202 HP 300 6.7 409 HP 300 13.6
296 HP 440 9.9 600 HP 440 20
DPC-2801 & LE DPC-2804
96 HP 440 3.8 * 422 HP 440 16.9 *

98 HP 300 3.3 432 HP 300 14.4
144 HP 440 4.8 634 HP 440 21.1
131 HP 300 4.3 576 HP 300 19.1
192 HP 440 6.4 845 HP 440 28.2
DPC-2802 & LE DPC-2804LE
192 HP 440 7.7 * 400 HP 440 16.0 *

196 HP 300 6.5 409 HP 300 13.6
288 HP 440 9.6 600 HP 440 20.0
262 HP 300 8.7 545 HP 300 18.1
384 HP 440 12.8 800 HP 440 26.7
* This rate is for initial break in running. It is calculated at 1 pint/25 HP.
Engine lubrication rates for normal operations are based on 1 pint/30 HP.
The following rates for compressor cylinders are based on the use of clean and dry gas, and lube oil per Ajax
engineering standard ES-1006. Rates listed are based on MWP and maximum bore size and include the rod packing’s
requirements. Refer to the O & M manual for other conditions.
NOTE: to attain the total lube rate for a compressor unit, add the lube rates for the individual cylinders.
Cylinder MWP Bore Total Lube Rate- Pints/Day

Model (PSIG) (Inches) @ 440 RPM - @ 300 RPM
YKCBA 1500 7.25 2.4 1.8
YKCD 1800 5.00-5.75 2.2 1.7
YKDC 1350 6.50-8.00 2.4 1.8
YK11EA 900 9.00-10.50 2.7 1.9
YK11F 600 11.00-13.00 2.9 2.1
YK11G 400 14.00 3.0 2.1

400 15.00 3.2 2.2
YK11HA 400 16.00-17.00 3.5 2.4
YK11J 275 18.00 3.6 2.5
YK11K 250 20.00 3.9 2.7
YK11MA 200 22.00-23.00 4.3 3.0
YK11R 100 28.00 5.0 3.4
3000 3.00-3.50 2.3 1.9

YK11S
3000 4.00-4.75 2.5 2.0
3000 5.00-5.75 2.6 2.1
YK11T 5500 3.00-3.50 3.1 2.7

5500 4.00-4.50 3.3 2.8
Individual cylinder and rod packing assembly lubrication rates are based on the following formula:
(0.0000314 x Cylinder Bore x Stroke x RPM) + (0.000333 x Discharge Pressure) + 0.75
Example: YK11G, 14” bore, 11” stroke, @ 440 RPM, 400 psig
(0.0000314 x 14 x 11 x 440) = 2.13
(0.000333 x 400) = 0.13
0.75 = 0.75
3.00 pints/day
The lube monitor’s rate display is calculated by using the divider valve assembly’s cycle signal, and a
BLOCK TOTAL of the assembly. The assembly’s BLOCK TOTAL is determined by adding the “sizing number”
for each element within the assembly. Refer to the following table for the sizing number for a particular SMX
element:
DropSa Element Sizing Number
SMX-08 5
SMX-12 8
SMX-16 10
SMX-25 15
SMX-35 20
SMX-40 25
SMX-50 30
Assure that the correct values are used for the engine’s divider valve assembly, and the compressor cylinder’s divider
valve assembly. (Metering element designation (the SMX number) is stamped on each element’s nameplate.)
Installation Design for Permanent Ajax Compressor Packages
When designing the engine-compressor installation, several factors should be taken into
consideration which can affect the overall performance of the installation:
• An adequate foundation must be provided to assure a stationary mounting base for the engine-
compressor skid and any accessory equipment not mounted on the skid. If the unit is installed
inside a building or adjacent to other machinery, sufficient space must be allowed around the
unit to facilitate maintenance and service work (refer to the unit’s foundation drawing).
• Avoid arrangements that allow hot air from the muffler or cooler to flow to the air inlet of the
cooler or air cleaner.
• It is recommended that the engine-compressor skid and accessories be placed on grouting on
the foundation to ensure full, even bearing support under the equipment. Grouting is poured
after the equipment has been properly set and aligned on the foundation. For a grouted instal-
lation, the foundation top surface should have a rough surface (not trowelled) to ensure an
optimal grout-to-cement bond.
• Air cleaners may be located outside the building to avoid heat generated by the unit; however,
direction of prevailing winds should be considered in their location.
• Installation of units inside buildings should be designed to allow for the passage of hot air
from the coolers to the outside through adequate natural ventilation or through ducting to the
outside of the building. Unitized vertical discharge coolers may frequently be installed outside
the building to ease the disposal of heated air.
• The exhaust system must be properly designed for the operating conditions of the engine-
compressor, both for proper scavenging of the power cylinders, and for correct dissipation of
exhaust heat.
• The instrument panel should be placed in a location convenient for the operator.
NOTICE: The size and construction of the foundation must be selected to suit the soil
conditions at the unit location.
In designing the foundation, the static and dynamic loads must both be considered. The
unbalanced forces and couples of each engine-compressor unit are available, on request, from the
service branch or factory. In well compacted, high load capacity soils, (6 tons/ft2 minimum) the
minimum dimensions shown on the appropriate foundation drawing supplied should be adequate
for a reinforced concrete foundation (refer to the unit’s foundation drawing).
! "#
The foundation design must include anchor bolts to secure the engine-compressor unit. Anchor
bolts must be located to achieve precise alignment with the skid’s anchor bolt holes (refer to the
unit foundation drawing). Use sufficiently long anchor bolts to ensure deep placement and
adequate length above the foundation (account for full thread engagement of nuts and space
required for grouting).
Preferred practice is to set anchor bolts while pouring concrete for the foundation. A common
practice is to use canister-style anchor bolts to afford position adjustment capability. Here, the
anchor bolt is centered inside a piece of 2” to 2-1/2” pipe and positioned so the top of the pipe is
flush with the top of the completed foundation. The open pipe end should be blocked to keep
foundation concrete out. This approach is illustrated in Figure 1.
% & '
If the foundation has already been poured, then anchor bolts may be set by first drilling holes in
the foundation and then placing and grouting the anchor bolts in. Sulphuring, a means to dissolve
concrete, may also be used to create anchor bolt holes.
In soils having a low load support capacity, a wider and longer foundation or one which angles out
at the bottom should be used to distribute the load over a larger area on the bottom face of the
foundation.
NOTICE: In general, it is poor practice to economize on the amount of concrete used on the
engine compressor unit foundation.
If the soil load bearing capacity is questionable, it is highly recommended that a soil analysis be
made prior to designing or pouring the foundation. If unsuitable soil is encountered, the
foundation design must be changed to accommodate the soil.
$
Allow foundation concrete to cure for at least 28 days before installing an engine-compressor
package. Using ASTM guidelines, a concrete physical properties test may be performed to ensure
that sufficient curing has occurred. Any concrete-related problems that may exist, such as low
tensile or compressive strength, may be detected at this time. If the concrete is ready for engine-
compressor installation and grouting, then proceed with foundation surface preparation.
In order to achieve optimal grout-to-concrete bonding, prepare surfaces for grouting by chipping
away all laitance, oil-soaked concrete, and damaged concrete until 50% aggregate is exposed (the
foundation contractor may have already prepared the foundation in this manner). A chipping
hammer or 15-pound chipping gun (with chisel point) may be used for chipping.
NOTICE: Avoid heavy chipping guns as they may create micro fractures within the foundation.
Rebar wickets or dowels may be used to provide additional mechanical locks between grout and
concrete. These may be set by drilling into the foundation and inserting the wickets or dowels.
Locate the wickets/dowels away from foundation anchor bolts. Exposed length above the
foundation surface should be limited to ≈60% of the grout thickness (1-1/2” maximum for 2-1/2”
grout thickness).
Determine whether or not grout expansion joints are required. Foam strips or other suitable
(compressible, temporary) material may be used. Strips may be secured to the foundation with
glue; apply wax to exposed surfaces to allow easy removal after the grout has cured. If a crane is
to be used to place the engine-compressor unit, then expansion joints may be installed in advance.
If jacks and rollers are used, then expansion joints should be added prior to lowering the unit.
Set leveling planes in level position on the foundation under the leveling screw locations.
Clean all residual paint, oil, grease, and dirt from foundation surfaces that will come into contact
with grout. For final cleaning, use the grout manufacturer’s recommended solvent using clean
solution and clean cloth for the last wash. Lacquer thinner may be substituted if necessary;
however, mineral spirits cannot be used for this purpose.
If cement-based grout is to be used then pre-soak the foundation with water to help ensure that
foundation concrete does not draw water away from the grout after placement.
If epoxy resin grout is to be used, then use compressed air to blow away all dust and debris and
dry all moist foundation surfaces.
NOTICE: Grout may adhere to levelling screws, tools, forms or other items which have not
been protected with paste type wax.
The end result is a properly prepared foundation ready for setting the engine-compressor package.
( % ) * % +
! "#
It is recommended that the skid bottom in contact with grout be free from all paint, grease, primer,
or other material that could inhibit grout bonding. A light film of rust is usually acceptable. Use
evaporative solvent to wipe down all skid surfaces to be bonded to grout.
The engine-compressor skid is normally set directly upon the foundation block. Where overhead
space and/or crane capacity permit, the unit may be lifted using brackets or lifting lugs (provided)
and placed over the foundation anchor bolts. Lifting cables must be provided with spreaders so
that the lifting cables will remain parallel to the vertical center-line of the unit.
If overhead lifting capacity is not available, then jacks and rollers (cribbing) may be used to move
the unit into place over the foundation anchor bolts.
Lower the engine-compressor unit to its final elevation. Allow 2” nominal clearance between the
foundation and skid (1-3/4” minimum, 2-1/2” maximum). This clearance is recommended to
allow sufficient room for placing grout to all necessary locations beneath the skid. Use leveling
screws to make final skid elevation adjustments such that all mounting pads are at the prescribed
elevation.
Make certain that the unit is set

level, accurately aligned with the
cooler, aligned with any other off-
skid accessories, and adequately
supported so that all bearing
surfaces on the bottom of the skid
have full contact to avoid
deflections in the bed or skid
Perform web deflection measurements on the engine to check crankshaft alignment. Use these
measurements to fine-tune the engine-compressor elevation using the leveling screws. For long-
term engine performance it is essential that web deflections are held within specification (see
Ajax-Superior Engineering Standard ES-4025: Crankshaft Web Deflections for Three- and Four-
Cylinder Ajax Engines).
Install belts on cooler drive and check alignment. Accurate alignment is essential to ensure
acceptable drive component service life and to eliminate detrimental loads and vibrations.
The drive alignment is checked by drawing a string taut between adjacent faces of the two
sheaves (pulleys), lined up to intersect the two hubs. When the drive is properly aligned, the string
will barely touch the face of each sheave at the points where the string crosses the sheave rims
(see Figure 2 below).
% , % - ( ) % .
Primary Sheave Critical Alignment Point
Secondary Sheave
Line
Bring Line toward the Critical

Alignment Point to establish
Line Attachment
Secondary Sheave alignment
% $& / % (
After properly positioning the engine-compressor unit, then finish up by taping off or paste-
waxing all leveling screw threads so screws can be removed after the grout has cured.
Grout should have the following characteristics:
• A consistency that allows for proper placement

• High bonding strength
• High dimensional stability
• Strength to transmit static and dynamic forces from unit to foundation
Grout may be either of the conventional (cement based) type or of the epoxy resin type.
Each type has advantages and disadvantages:
Working Time: Check the grout specifications. Working time may vary from as little as 15-20
minutes to over 1 hour. Select a product that will allow adequate mixing, handling, and placing
time.
Working Temperature: Check the grout specifications. Manufacturers often recommend that
foundation, equipment, and grout materials attain equilibrium temperature on the order of 70°F
before mixing and pouring. If possible, avoid grouting at temperatures below 50°F, although
grouts for use at such temperatures are available. Note, however, that temperature can affect grout
working time.
Flowability: Most grout manufacturers will claim that their products are “flowable,” but this is a
relative term. Grout viscosity should not be too low (runny, not stackable) or too high (not
pourable). Grout flowability may be increased by reducing the amount of aggregate used. Consult
with the grout manufacturer’s technical representative if questions arise here.
*
! "#
Compressive Strength and Curing Time: Epoxy-resin grouts, although more costly, provide
greater compressive strength and cure much more quickly than do cement-based grouts.
Long-Term Performance: Properly mixed, installed, and cured cement-based grouts have very
good long-term dimensional stability but may degrade structurally (cracking) under continual,
excessive vibration input. Epoxy-resin grouts have better long-term structural integrity but, being
viscoelastic materials, are subject to creep that is heightened by elevated temperatures.
Tables 1 and 2 provide examples of cement-based grout and epoxy resin grout respectively.
0 &, - * 1 2
* ' / %
% 1 2 1 2
Unisorb V-1® Non-Shrink Grout 11,800 28
Five Star® Products’ High Strength Grout 10,000 - 14,000 28
Philadelphia Resins Chockfast® ITWPRC 100 Non-Shrink 8,400 28
0 $& , , 3 * 1 2
* ' / %
% 1 2 1 2
L&M Construction Chemicals’ Epogrout 758 13,200 7
Tristar Masterflow® 648CP 15,900 3
Ceilcote® 848 Grout 8,000 3-10
Epoxy resin type grouting materials

may present certain health hazards.
The grout manufacturer’s handling
instructions should be strictly
followed.
Affirm that the selected grout will meet the installation load requirement, the working
temperature condition, and the working time requirement. Grouts such as those listed in Tables 1
and 2 have sufficient compressive load strength to support typical AJAX engine-compressor and
cooler packages.
*
Table 3 provides compressive load estimates for 2801-, 2802-, 2803-, and 2804-based units. Skid
footprint is the skid base area that will be in direct contact with the grout. The cooler load is
computed separate from the engine-compressor load for 2803- and 2804-based units.
NOTICE: The estimates in Tables 1,2, and 3 are for reference purposes only!
Be aware that total package weight is dependent on the number and size of compressor cylinders,
and the number of compression stages and associated pressure vessels. If needed, grout
manufacturer representatives can help in the grout selection process.
0 +& * / % 3 5 , 1
2
! " 6 9 9 8*
7 % 1 0 82 ) /
6 * % ;1 2
$2
:1
2801 31,000 26.3 8.6
2802 57,300-67,300 43.3 9.2-10.8
2803 70,000 35.2 13.8
2804 85,000 66.4 8.9
†: Minimum footprint comprised of primary longitudinal skid members only.
‡: Compressive Strength (Pressure) = Unit Weight / Skid Footprint Area.
All grout should be mixed according to manufacturer’s instructions and recommendations.
All longitudinal skid members must be grouted. Major load-bearing lateral skid members should
also be grouted. Grout the skid base using procedures suitable to the application or unit involved.
The final grout level should be approximately up to the skid flange thickness. Care must be taken
to provide adequate forms to retain grout. Remove any excess grout before it has been completely
set.
After grout has set and cured sufficiently to carry the weight of the unit, relieve the load on all
levelling screws.
NOTICE: This is essential to insure that the unit is being supported only by the grout, not by
the screws.
Properly tighten foundation bolts after grout has sufficiently cured, and then recheck alignment.
Remove temporary expansion joint materials and fill expansion joints with joint compound.
* % 4
Table 1: Torque Table for Critical Ajax Fasteners
! & "'( %
"# "$
$ %
) %
Frame and Crankshaft:
End covers/bearing supports Bolts 1 150
Front end bearing support Bolts 1&2 25
Center main bearing Bolts 2 95
Center main bearing cap Bolts 2 250 - 265
Crankshaft counterweight Stud nuts 1 520 - 600
Flywheel ringfeder Bolts All 185
Drive shaft ringfeder Bolts All 185
Main bearing cap Studs 3&4 250
Main bearing cap Stud nuts 3&4 360
Tie bars to frame Bolts 3&4 260
Top Center for crosshead guide Bolts 3 100
Power cylinder to frame Bolts All 490
Connecting rod caps Bolts All, P & C 650 - 700
Power cylinder side cover plate Allen Bolts All 38
Cylinder Head:
Head to cylinder Studs 15 Bore 220 -250

* +,
! & "'( %
"# "$
$ %
) %
Head to cylinder Stud nuts 15 Bore 600
Head to cylinder Studs 13-1/4 Bore 8-1/8 height
Head to cylinder Stud nuts 13-1/4 Bore 490
Precambrian hold down flange Bolts All LE 70
Pilot fuel check valve clamp Bolts All LE 15
Spark plugs Plugs All 60
Indicator cock Valve All 70
Control Box and Layshaft 1
Control box to frame Stud nuts 1 95
Control box to frame Stud nuts 2,3, & 4 160
Support bracket on crank end of Bolts All 45

layshaft
Cover on crank side of control Bolts All 10 -12

box
Caps for hydraulic power Bolts All 11

plungers
Cover on top of control box Bolts All 25
Gears in control box Set Screws All 25
Cams in control box Set Screws All 25
Ajax governor drive gear Nut All 0.003 - 0.006

clearance
Woodward gov. drive gear Nut All 7 - 15 (line up with

pin)
Crosshead and Piston Rod:

! & "'( %
"# "$
$ %
) %
Compressor guide to frame Stud nuts All, C 280 - 300
Rod packing ass’y to x-head Bolts All 38

guide
Piston rod to crosshead Nut All, P & C 3200
Crosshead set screws Set screws All 55
Crosshead jam nuts Nuts All 50
Note #1: Key to “Type of Unit” Abbreviations
1 = 2201 & 2801

2 = 2202 & 2802
3 = 2803
4 = 2804
C = Compressor
P = Power Side
Note #2: Torques are based on the use of Lubriplate
Table 2: General Torque Table for Fasteners
) 2 & "'( & "'( %

. / %3 3
$ ' 45 45
)0 1
#8 32 2 2.5
#8 36 2 2.5
#10 24 3 3.7
#10 32 3 3.7
1/4” 20 5 6
28 6 7.5
-
* +,
) 2 & "'( & "'( %

. / %3 3
$ ' 45 45
)0 1
5/16” 18 10 12
24 11 13
3/8” 16 17 20
24 18 21
7/16” 14 28 34
20 30 36
1/2” 13 43 53
20 50 60
9/16” 12 62 75
18 71 85
5/8” 11 85 103
18 100 120
3/4” 10 155 190

16 190 225
7/8” 9 250 310

14 280 340
1” 8 340 415
12 385 460
14 400 475
1-1/8” 7 450 550

8 475 575
12 525 625
1-1/4” 7 660 795

8 690 830
12 760 895
1-3/8” 6 870 1020

8 940 1090
12 1000 1150
1-1/2” 6 1150 1370

8 1220 1440
12 1310 1530
1-5/8” 6 1430 1690

8 1510 1770
12 1610 1870
6
) 2 & "'( & "'( %

. / %3 3
$ ' 45 45
)0 1
1-3/4” 8 1920 2260

10 1990 2330
12 2050 2400
• Torque values are for Grade 5 fasteners.

• Values are Based on the use of Lubriplate.
• For torques less than 10 lb-ft, a lb-in torque wrench should be used to improve accuracy (mul-
tiply the torques in this table by 12 to get lb-in).
7
Section 2 – Package Drawings
Vendor Bulletin No.
General Arrangement..........................................Ajax 02-00-T05E-397
P&ID....................................................................Ajax 02-00-T00A-307
Foundation(unit)..................................................Ajax 02-00-T050-363
Foundation(cooler)..............................................Ajax 02-00-T050-362

Section 3 – Engine
Operation and Maintenance Manual
– Integral Engine-Compressors .......................... Ajax
Frame and Engine Crossheads ..................... 0102-000
Crankshaft and Flywheel................................ 0202-000
Power Connecting Rod .................................. 0300-000
15” Power Cylinder......................................... 0500-200
Fuel Distribution System ................................ 0802-002-01
Gas Injection Valve................................................... YAE-5100
Ignitor......................................................................... YK-8209-C-2
Control Box and Layshaft ............................... 0902-000
Air Intake Manifold...........................................GD-0043
Cooling System .............................................. 1102-200
Divider Block Lubrication System................... 1202-000-03
Integrated Governor Throttle Body................. 1302-000-04
Lubricator Drive Assembly ......................................... YAE-5581
Alternator Drive Assembly .......................................... YAE-1561-E
Compressor Crossheads and Guides ............ 1402-000
Compressor Connecting Rod ......................... 1512-000
Shielded Ignition System................................ 1802-000-06
Altronic III Service Manual................................... Altronic AIII SM 12-96
Altronic III Installation .......................................... Altronic AIII II 04-92
Ignition Coil, 591-010-S....................................... Altronic 591-010-S

Frame with Counterweights and Solid Pin on Throw # 1 Crosshead
Assembly Drawing 0102-000
Ref # Desscription P/N Qty Ref # Desscription P/N Qty
1 Bed Compressor K-6000-J 1 ea 28 Gasket A-2253-B 2 ea
2 Nameplate BM-10003-M-1 1 ea 29 Gasket Flat Rd A-2235-A 2 ea
3 Screw Drive BM-1386-A 8 ea 30 Gasket K-6241 2 ea
4 Support Bearing K-6015-C 1 ea 31 Bolt Hex Head BM-11900-C-0420-06 8 ea
5 Support Bearing YAE-5549-3 1 ea 32 Bolt Hex Head BM-11900-C-0813-08 10 ea
* Support Bearing A-3320 1 ea 33 Bolt Hex Head BM-11900-0813-10 41 ea
* Cap Bearing A-3321-1 1 ea 34 Bolt Hex Head K-7021-28 6 ea
* Nut Castle BM-11916-1614 4 ea 35 Bolt Hex Head K-7021-B-9 8 ea
* Bolt P-5455-2 4 ea 36 Bolt Hex Head BM-11900-1409-18 12 ea
6 Support Bearing A-2581-F-1 1 ea 37 Stud K-8095-0813-16 16 ea
7 Washer Plain A-573 6 ea 38 Nut Plain Hex BM-11904-0813 18 ea
8 Packing Engine Rod YAE-5014-A 2 ea 39 Bearing Journal A-3310-A 1 ea
C Scraper A-3649 1 ea 40 Shim Laminated A-3326-D 2 ea
D Ring Set BM-1328-L-1 1 ea 41 Shim Solid A-3326-D-1 2 ea
E Plate A-3666 1 ea 42 Pin Cotter BM-11925-05-07 4 ea
F Cup A-3667 1 ea 43 Crosshead Power Rod A-1220-K 2 ea
G Adapter A-3665-A 1 ea 44 Solid Pin Crosshead A-1222-D 1 ea
H Cup A-3668-A 1 ea * CounterweightCrosshead K-6343-L-1 2 ea
K Bolt K-7021-D-5 3 ea * Bolt Hex Head BM-11900-0813-18 8 ea
L Wire XAISI 1010 WR 15GA 2 ft * Washer Plain BM-11918-10-N 8 ea
M Bolt BM-11900-C-0616-20 3 ea
9 Slinger A-1264-A-1 2 ea NOTE: components are not shown; see SK-9059-R for the counterweighting
10 Ring Retaining Q-6316-A 1 ea components used on throw # 1.
11 Plug Pipe BM-11953-06 4 ea 45 Plate A-4629 2 ea
12 Plug Pipe BM-11958-08 2 ea 46 Screw Set BM-11921-1210-32-CP 2 ea
13 Plug Pipe BM-11953-04 4 ea 47 Screw Set BM-11921-1210-20-DP 2 ea
14 Cover Rect A-1944-A-1 1 ea 48 Screw Set BM-11921-1210-20-CP 2 ea
15 Bolt Hex Head BM-11900-0813-08 8 ea 49 Nut Jam BM-11910-A-1210 6 ea
16 Cover Square K-6013-F 2 ea 50 Flange Orifice K-8010-B 2 ea
17 Breather BM-776-F 2 ea 51 Gasket Flat Rd K-8011-A 2 ea
18 Support Bearing K-6018-B 1 ea 52 Plug Pipe BM-11953-02 1 ea
19 Shield A-2579-E 1 ea 53 Bolt Hex Head BM-11900-1409-16 8 ea
20 Gasket Flat Rect A-4522 1 ea 55 Wire XAISI 1010 WR 15GA 14 ft
21 Gasket Flat Rd A-4521-A 1 ea 56 Bracket K-7257-K 1 ea
22 Gasket Flat Rect A-2233 1 ea 57 Bolt Hex Head BM-11900-1409-22 4 ea
23 Baffle K-6243 2 ea 58 Pin Dowel T-278-A 2 ea
24 Washer Plain A-4675 8 ea 59 Stud Double End 913-942-013 2 ea
26 Gasket Flat Rd A-2227-A 2 ea 60 Decal Hyd System BM-21164 1 ea
Frame with Counterweights and Solid Pin on Throw #1 Crosshead
Assembly Drawing 0102-000 020205
Power Connecting Rod
Assembly # 0300-000
Ref # Description P/N Qty Ref # Description P/N Qty

1 Conn Rod Power C600-3-1A 2 ea
B Bearing A-2894-E-2 1 ea
C Pin BM-16475-6-8 1 ea
D Wire XAISI 1010 WR 15GA 3 ft
E Dip A-2933 2 ea
F Bushing A-1223-3 1 ea
G Screw BM-11090 1 ea
H Screw K-6650 2 ea
J Pin BM-11548-24-64 2 ea
Power Connecting Rod

022002
Assembly # 0300-000
15" Power Cylinder, LE Cylinmder Head, Piston-Rod, and Mixing Valve
Assembly # 0500-200

1 Cylinder, 15" Power K-7201-E 2 ea
3 Stud K-8093-1608-32 8 ea
4 Valve Indicator BM-16556 2 ea
A Gasket A-3794 1 ea
6 Head, LE Power A-4502-N 2 ea
7 Gasket Head A-4513-C-1 2 ea
9 Screw Twelve Pt K-8142 16 ea
10 Washer Finished BM-11808 28 ea
11 Plug Pipe BM-11953-04 2 ea
13 Lockwasher Split SF-115-2-036 28 ea
14 Stud Tap End 1-04F-001-108-106 28 ea
15 Nut Plain Hex 1-08F-005-108 28 ea
17 Nut BM-11904-1608 8 ea
18 Gasket, Cyl-to-Frame A-474-B 2 ea
19 Piston/Rod Engine YAE-7516-B-2 2 ea
* Piston A-4506-A 1 ea
* Rod XTGSDI0208-041062 1 ea
20 Ring Piston A-4711-A 8 ea
21 Nut Piston Rod A-1278-B 2 ea
22 Gasket, Cyl-to-Exh Pipe A-4514 2 ea
23 Capscrew Hex Head BM-11900-1409-16 24 ea
24 Valve Mixing YAE-7510-B-1 2 ea
A Valve Plate A-2693-F 10 ea
B Stop A-4512 2 ea
C Stop A-4512-1 2 ea
D Spring M-1485 20 ea
E Bolt BM-11900-C-0420-08 10 ea
F Seat A-4527-2 1 ea
G Pin 01RP121600 20 ea
15" Power Cylinder, LE Cylinder Head, Piston-Rod, and Mixing Valve

Assembly # 0500-200 010307
DPC-2802 Divider Block with Proximity Switch Lubrication System
Assembly # 1202-000-03

1 Lubricator (ref 5.33:1 ratio) BM-21087-C-2 1 ea 23 Tubing Stainless BM-21071-1-3-035 3 ft
A Pump, " BM-21136-1 1 ea 24 Connector Tubing BM-11610-S-6-4 1 ea
B Pump, ¼" BM-21137-1 1 ea 25 Union Tubing BM-11623-S-6-6 1 ea
C Rupture Disc 1750 psi BM-21138-17 1 ea 26 Elbow Tubing BM-11573-S-6-4 1 ea
D Rupture Disc 2950 psi BM-21138-29 1 ea 27 Gasket Flat Oval A-2117 1 ea
E Check Valve Assembly BM-21171 1 ea 28 Capscrew Hex Head BM-11900-0616-10 2 ea
2 Bracket K-8016-A 1 ea 29 Trough A-2115 1 ea
3 Capscrew BM-11900-0616-10 2 ea 30 Clamp Tubing T-112 2 ea
4 Capscrew BM-11900-0616-18 2 ea 31 Clamp Tubing T-110-A 2 ea
5 Bracket K-8016-B 1 ea 32 Screw Machine BM-11929-2520-04 6 ea
6 Bolt Hex Head BM-11900-0813-16 2 ea 33 Gasket A-3175 1 ea
7 Capscrew Hex Head BM-11901-0820-06 2 ea 34 Clamp Tubing 2516 0402 3 ea
8 Washer Plain BM-11918-10-N 6 ea 35 Clamp Tubing 2516 0403 3 ea
9 Nut Plain Hex BM-11904-0813 2 ea 36 Clamp Tubing 2516 0404 2 ea
10 Tubing Stainless BM-21071-2-035 40 ft 37 Nut Hex BM--11468-0420 12 ea
11 Bracket Angle K-7193-17-A 1 ea 42 Capscrew Hex Head BM-11900-0420-20 1 ea
12 Capscrew Hex Head BM-11900-0813-08 4 ea 43 Lockwasher Split BM-11782-A-06 2 ea
13 Valve Divider BM-11083-W-2 1 ea
E Filter Assembly BM-21135 1 ea
F Filter Element 10 Micron BM-21135-A 1 ea
G Switch Proximity BM-21133 1 ea
H Valve Check BM-21171-1 6 ea
J Cycle Indicator BM-21134 1 ea
14 Bolt Hex Head BM-11900-0420-16 2 ea
15 Nut Plain Hex BM-11904-0420 5 ea
16 Lockwasher Split BM-11782-A-04 5 ea
17 Connector Tubing BM-11610-S-4-2 6 ea
18 Elbow Tubing BM-11573-S-4-4 1 ea
19 Valve Check BM-10885-F-1 6 ea
20 Elbow Tubing BM-11573-S-4-2 2 ea
21 Capscrew Hex Head BM-11900-0813-08 3 ea
22 Union Tubing BM-11623-S-4-4 1 ea
DPC-2802 Divider Block with Proximity Switch Lubrication System

Assembly # 1202-000-03 032807
Integrated Governor Throttle Body (Mechanical Assembly)
1302-000-04

1 IGTB Governor, 30mm, 24VDC BM-21152-30 1 ea 40 Magnetic Pick Up, -18 x 3" 2049 1291 1 ea
2* Cable & J-box Assembly YAE-5583 1 ea 41* Mag P/U Cable Assembly 3850 0033 1 ea
3 O-ring BM-21146 2 ea 42 Mag P/U Bracket 8025 9400 1 ea
4 Outlet Flange K-8256-A 1 ea 43 O-ring, Alternator Flange BM-16348-F-236 1 ea
5 Inlet Flange K-8256-C 1 ea 44 Plate A-1944-A-2 1 ea
6 SHCS #10-24 x 5 UNC BM-11473-0324-40 4 ea 45 Gasket Flat Oval A-2233 1 ea
7 Lock Washer, #10 BM-11782-A-03 4 ea 46 Trough A-2115 1 ea
8 Support Bracket K-8256-B 1 ea 47 Gasket Flat Oval A-2117 1 ea
9 HHCS, -11 UNC x 3¼ BM-11900-1011-26 2 ea 48 Stud K-8095-0813-16 2 ea
10 Flat Washer, " BM-11918-12-N 2 ea 49 Nut Plain Hex BM-11904-0813 2 ea
11 PCC Fuel Filter Bracket K-7889-1 1 ea 50 Bolt Hex Head BM-11900-0616-10 2 ea
12 Lock Washer, " BM-11782-A-06 2 ea 51 Elbow Tube Compn BM-11573-S-6-4 2 ea
13 HHCS, -16 UNC x 1 BM-11900-0616-08 8 ea 52 Bolt Hex head BM-11900-0813-10 5 ea
14 Needle Valve 2549 0057 2 ea 53 Tubing Welded BM-21071-3-035 1 3 ea
15 Gauge, 0-30 PSIG 2015 3312 2 ea 54 Union Tube Compn BM-11623-S-6-6 1 ea
16 Hex Head Plug, ¼" NPT BM-11950-02 1 ea
17 Male Tubing Elbow, ¼" BM-11573-S-4-4 1 ea
18 Flexible Hose, 1" K-8263-A-24 1 ea
19 Flexible Hose, 1½" K-8262-A-30 1 ea
20 Pipe Nipple, 1½" x 4"L BM-11932-12-09 1 ea
21 Street Elbow, 45º, 1" NPT BM-11969-08 1 ea
24 Alternator Drive Assy, 5.33:1 YAE-1561-E 1 ea
25 Drive Assembly Gasket K-6258-C 1 ea
26 Drive Gear, 5.33:1 System A-4658-A 1 ea
27 Set Screw BM-11095-A 1 ea
28 Stud, -16 UNC x 2¼"L K-8095-0616-18 4 ea Note: refer to Manual's section 11 for additional
29 Flat Washer, " BM-11918-08-W 8 ea information about the IGTB system.
30 Lock Washer, " BM-11782-A-06 6 ea
31 Hex Nut, -16 UNC BM-11904-0616 4 ea *shipped separately
32 V1 Alternator, 24VDC BM-21156 1 ea
34 HHCS, -16 UNC x 1¼"L BM-11900-0616-10 2 ea
37* Battery Pack BM-21158 1 ea
38 Lubricator Drive Assy, 5.33:1 YAE-5581 1 ea

1302-000-04 091205
Section 4 – Fuel / Start System
Vendor Bulletin No.
Fuel Filter Drawing .............................................. Ajax TP 00-22-T05A-002
Instrument Gas Pressure Regulator, 67CFR-225........... Fisher Form 5469
Differential Pressure Gauge, 120-AA-00-00-30 .............. Mid-West IM 120/05
Drain Trap, 22-LD ........................................................... Armstrong LD-39
Level Controller, L1200NDVO, O & M ............................ Murphy 00-02-0175
Dump Valve, DVU-150, O & M........................................ Murphy 00-02-0483
Fuel / Start Gas Piping Drawing.......................... Ajax TP 02-22-T010-331
Starter Relief Valve...............................................Ajax 00-22-T010-307
Starter / Relief Valve Vent Header....................... Ajax 02-48-T010-388
Regulator, Main Fuel, Type 627, O&M ........................... Fisher 5252
Fuel Shutdown Valve, M5081-C-LS................................ Murphy M-7980
Mercer Relief Valve 8100 Series O & M.......................... Mercer
Mercer Relief Valve 9100 Series O & M.......................... Mercer
Regulator, PCC Fuel Pressure, Type 64
Operation and Maintenance........................................ Fisher 1245
Shutoff Valve, PCC Fuel, Type 119
Operation and Maintenance........................................ Fisher 5204
Starter Motor, BM-11679-Q-1, 90 PSIG, IOM ................ TDI T1-702
Starter Motor Service Manual ......................................... TDI T1-701
Performance Curve, T121-B, Natural Gas...................... TDI AN00-639 8/00

Flange Fastener Tightening Torques
The vessel’s closing flange Thread Size Torque, Lbs-ft
gasket p/n is 3050 0160. 3/4”-10 190
Notes:
1. The threads and nut faces must be
lubricated to attain the correct clamping
force. Use only crankcase oil or Lubriplate.
At 12-14 psid, replace
the filter element. 2. Use a criss-cross star pattern to tighten
Set the instrument gas the bolts in sequence.
Replacement element p/n
is 6321 9734.
pressure regulator at 3. The torque should be applied in a minimum
30-50 psig. of three increments.
The element’s retaining
cap should be tightened
to 5-10 lbs-ft only.
Warning
All repair and resetting of
safety relief valves should be
performed by a National Board
certified valve repair shop
Fuel Inlet
holding a “VR”stamp.
Fuel Outlet
Front View
Connect to the Fuel Filter Assembly
Rear View
Manual Drain Valve
liquid drain system TP 00-22-T05A-002 r2
Fuel Filter Assembly
TP 00-22-T05A-002 r2

1 Ball Valve, ½" NPT 2549 2094 1 36 Tubing, 316SS, ¼" x 0.035 Wall 5551 3504 18"
2 Bushing, ½" x ¼" NPT 2527 0402 2 37 Tubing, 316SS, ¼" x 0.035 Wall 5551 3504 16"
3 Bushing, ¾" x ½" NPT 2527 0604 1 38 Tubing, 316SS, ¾" x 0.049 Wall 5551 4912 9"
4 Bushing, ¾" x ¼" NPT 2527 0602 1 39 Tubing, 316SS, 1" x 0.049 Wall 5551 4916 47"
5 Bushing, 2" x 1" NPT 2527 2010 1
6 Differential Pressure Gauge, 0-30 psid 2015 0116 1
7 Drain Trap, 22-LD 2051 0102 1
8 Male Tubing Elbow, ½" Tube x ½" NPT 2507 4204 2
9 Male Tubing Elbow, ¼"Tube x ¼" NPT 2507 4202 6
10 Male Tubing Elbow, ¼"Tube x " NPT 2507 4201 2
11 Male Tubing Elbow, ¾"Tube x ¾" NPT 2507 4606 1
12 Pressure Regulator, Instrument Gas 2040 0063 1
13 Gauge Glass Valve Set 2015 3169 1
14 Level Controller, L1200NDVO 2005 9124 1
15 Male Connector, ½" Tube x ½" NPT 2507 1404 2
16 Male Connector, ¼" Tube x ¼" NPT 2507 1202 2
17 Male Connector, ¾" Tube x ¾" NPT 2507 1606 1
18 Male Connector, 1" Tube x 1" NPT 2507 1808 2
19 Relief Valve, 1" x 1" 155 psig 63ME2M2FVAC0155 1
20 Dump Valve, DVU 150 2003 6222 1
21 Needle Valve, ¼" 2549 0028 1
22 Pipe Nipple, Close, Sch 80, ½" NPT 2539 4404 1
23 Pipe Nipple, Close, Sch 80, ¼" NPT 2539 4200 1
24 Pipe Nipple, Close, ½" NPT x 3 LG 2539 4414 1
25 Pipe Plug, Hex Head, 2" NPT 2541 6020 1
26 Pressure Gauge, 0-60 psig 2015 0220 1
27 Red Line Gauge Glass 2015 0158 1
28 Tee Tube, ½" 2545 4004 1
29 Tee Tube, ½" 2507 6504 1
30 Tubing, 316SS, ½" x 0.035 Wall 5551 3508 11"
31 Tubing, 316SS, ½" x 0.035 Wall 5551 3508 8"
32 Tubing, 316SS, ½" x 0.035 Wall 5551 3508 25"
33 Tubing, 316SS, ¼" x 0.035 Wall 5551 3504 32" Filter Element 6321 9734 1
34 Tubing, 316SS, ¼" x 0.035 Wall 5551 3504 46" Flange Gasket 3050 0160 1
35 Tubing, 316SS, ¼" x 0.035 Wall 5551 3504 20"
Fuel Filter Assembly

TP 00-22-T05A-002 r2 120804
Instruction Manual
Form 5469 67C Series
May 2006
67C Series Instrument Supply Regulators
TYPE 67CF FILTER REGULATOR TYPE 67C OR67CR REGULATOR

WITH OPTIONAL GAUGE
Figure t Typical 6 7C Series Regulators
Introduction The Types 67C and 67CS are the standard instrument
supply regulatorswithout a filter or internal relief.
Scope of Manual The Types 67CF and 67CFS are equipped with a
filter for removing particles from the supply gas.
This manual provides instructions and parts lists for
67C Series instrument supply regulators. Instructions The Types 67CR and 67CSR have an internal
and parts lists for other equipment mentioned in this relief valve with a soft seat for reliable shutoff with no
instruction manual, as well as for other 67 Series discernible leakage.
regulators, are found in separate manuals. The Types 67CFR and 67CFSR have a filter and
internal relief valve with a soft seat for reliable shutoff
with no discernible leakage.
Product Descriptions
The 67C Series direct-operated regulators are Specifications
typically used to provide constantly controlled,
reduced pressures to pneumatic and electropneumatic Some general 67C Series ratings and other
controllers and other instruments. They are suitable specifications are given on page 2. A label on the
for most air or gas applications. Other applications spring case gives the control spring range for a given
include providing reduced pressures to air chucks, air regulator as it comes from the factory.
jets, and spray guns.
EMERSONL
Process Management
BULLETIN NO. IM120/05
Mid-West
(Supersedes IM120/03)
®
Instrument
®
Model 120 Series “Filter Minder”
Installation and Operating Instructions
INSPECTION The precise piston/bore fit allows minimal leakage

from high to low sides. This leakage is only 5 to 15
Before installation check the nameplate on each SCFH air at ambient conditions and a pressure
instrument against the receiving paperwork and the differential of 100 PSID.
intended application for correct part number,
materials of construction, working pressure, dial INSTALLATION
range, etc. If equipped with switches, check electrical ®
Model 120 Series "Filter Minder" is calibrated and
rating, type of enclosure, etc. Inspect for shipping tested prior to shipment and is ready for immediate
damage and, if damaged, report it immediately. installation. Use of the following installation
NOTE - Before attempting repairs contact your procedures should eliminate potential damage and
local Mid-West Representative or our factor y. provide optimum trouble-free operation.
Failure to do so will void any warranty.
1. CONNECTIONS
PRODUCT DESCRIPTION 1/4” FNPT are provided as standard but check
®
paperwork for connections ordered. There are two
The Model 120 Series "Filter Minder" is a rugged, connections on the housing identified as “hi” and “lo”
medium-range differential pressure instrument for high pressure and low pressure (Fig. 2). Be sure
available as a switch, a gauge, or both. See "Part these get plumbed to the proper connections on your
Numbering System". (Fig. 4) for available options. system. Improper connection will not damage the
Differential pressure is sensed by the movement of a instrument, but it will not function properly. Flexible
floating piston magnet against a calibrated spring. The tubing is recommended to minimize the effect of any
magnetically coupled gauge pointer outside the vibration that may exist.
pressure housing follows the movement of the piston 2. INSTRUMENT LOCATION
magnet and indicates differential pressure on the dial On liquid service the instrument should be mounted
scale. below the process connections to facilitate self-
When equipped with switches, a contact is made or bleeding. On gas service it should be located above
broken by the magnetic field of the piston magnet. the process connections to promote self-draining. If
See Bulletin ELECIM120/latest for gauges with the process contains particulates, a “pigtail” loop or
switches. drop leg (manometer “U-tube” configuration) in the
tubing will minimize the possibility of it migrating into
The unit provides full over-range protection to the the instrument.
rated working pressure of the housing in either
direction.
3. PANEL MOUNTING TROUBLE SHOOTING
Gauges with 2-1/2” dials can only be mounted 1. Gaug e does not indicate differential.
through the rear of the panel. Make the proper panel A. Check for proper hook up, high to “hi” and low
cutout as indicated in (Fig.1). Remove the (4) bezel to “lo”.
screws. Insert the gauge front through the rear of the
B. Make certain block valves are open and, if using
panel and reinstall the bezel screws through the front
a 3-valve manifold, that the equalizer (balance)
of the panel and into the gauge bezel. Tighten the
valve is closed.
screws securely, alternating in a diagonal pattern.
C. If A & B check out correctly, loosen or
Gauges with 3-1/2" dial should be mounted from the disconnect the high pressure line to determine
front of the panel. Contact factory for mounting if there is pressure to the instrument.
information and dimensional data. D. If there is pressure to the instrument, check to
determine that there is differential across the
Gauges with 4-1/2" dial should be mounted from the unit being monitored. If so, contact the factory
front of the panel. Make the cutout as indicated in (Fig. for assistance and/or an “RGA” (return goods
1). Insert the (4) panel mounting studs, finger tight, into authorization) number to return the instrument
the metal inserts located in the rear of the bezel. Insert for repair or replacement.
the gauge through the panel, aligning the panel
mounting studs with the holes in the panel. Install the (4)
#8-32 nuts onto the studs and tighten securely.
4. PIPE MOUNTING
An optional pipe mounting kit is available for mounting
the gauge to a 2” vertical or horizontal pipe (Fig. 3).
Model 120 2-1/2 Inch Dial (Std.)
Model 120 4-1/2 Inch Dial (Opt'l)
(Fig. 1)
Supplementar y 120 Dimensional/Mounting Data
(Fig. 2)
(Fig. 3)
NOTES: 1. Drawings show standard gaug e nominal dimensions. (not to scale)

2. Dimensions shown in parentheses are in millimeters.
3. Manufacturer reserves the right to chang e specifications without prior notice .
STANDARD MODEL SPECIFICATIONS
120-AA-00-OO
6000 P.S.I.G. Working Pressure Aluminum Body, Stainless Steel Piston, Ceramic Magnets, Buna N Seals,
2-1/2" Engineering Plastic Case with Shatter-Resistant Lens. 1/4" FNPT Back Connections.
Accuracy +3-2-3% Full Scale (Ascending).
PART NUMBERING SYSTEM 1 2 0 – – – –
➅ OPTIONS (Up to four options)

O. None (Standard)
➀ BASIC MODEL NUMBER A.
B.
Reversed High/Low Process Connections
DIN2353 12-S (12mm) Steel Tube Fittings (2)
C. Mounting Holes in Gauge Body for Field Mounting of Electrical Configurations Options A & B
➁ MATERIAL
A. Aluminum Body, S.S. Piston (Standard)
D.
F.
Mounting Holes in Gauge Body for Field Mounting of Electrical Configurations Options L & M
Pipe Mounting Kit (Carbon Steel) (Not available w/C, D, E or F Electrical Switch Options)
L. Liquid Fill (Not available w/follower pointer) (Not available with 3-1/2" dial)
M. Monel Body (See 120 ABM) (5000 P.S.I.G. working pressure)
M. Maximum Indicator Follower Pointer
N. Aluminum Bronze Body (See 120 ABM) (5000 P.S.I.G. working pressure)
T. Oxygen Cleaning
S. 316 S.S. Body & S.S. Piston (Standard)
U. S.S. Tag Mounted w/S.S. Wire
Z. SPECIAL (Uncoded Options)
V. S.S. Tag Mounted w/S.S. Screws
W. Wall Mounting Kit
➂ DIAL TYPE
A. 2-1/2” Round Uni-Directional Engrd. Plastic Housing Assy. (Standard)
X. Individual Gauge Packaging
Z. Special (Uncoded Options)
B. 2-1/2” Round Bi-Directional Engrd. Plastic Housing Assy.
C. 4-1/2” Round Uni-Directional Engrd. Plastic Housing Assy.
D. 4-1/2” Round Bi-Directional Engrd. Plastic Housing Assy.
E. 3-1/2” Round Uni-Directional Anod. Aluminum Housing Assy.
F. 3-1/2” Round Bi-Directional Anod. Aluminum Housing Assy.
G. 4-1/2” Round Uni-Directional Anod. Aluminum Housing Assy.
– (Up to three options)

H. 4-1/2” Round Bi-Directional Anod. Aluminum Housing Assy.
T. Non-Indicating Differential Pressure Switch Only (Select Appropriate Electrical Option) ➆ ELECTRICAL CONFIGURATIONS
(NOTE: All options marked, except E, F, J & K)
O. None
A. One (1) Switch in STD. Enclosure with Grommet Wire Seal
B. Two (2) Switches in STD. Enclosures with Grommet Wire Seal
C. One (1) Switch in STD. Enclosure with 1/4” FNPT Electrical Connection NEMA 4X
➃ SEALS
0. Buna N (Standard)
D.
E.
Two (2) Switches in STD. Enclosures with 1/4” FNPT Electrical Connection NEMA 4X
One (1) Switch in General Purpose Enclosure, C.S.A. & U.L. Listed, Division II Locations (1) (3)
1. Viton® F. Two (2) Switches in General Purpose Enclosure, C.S.A. & U.L. Listed, Division II Locations (1) (3)
2. Neoprene G. One (1) Switch & Gauge in NEMA 4X Plastic Enclosure (Not Available With End Connections)
4. Teflon® H. Two (2) Switches & Gauge in NEMA 4X Plastic Enclosure (Not Available With End Connections)
J. One (1) Switch in Explosion Proof Enclosure with Glass Window Cover and C.S.A. & U.L. Listing (2)
➆➇
5. Ethylene Propylene
6. Perfluoroelastomer K. Two (2) Switches in Explosion Proof Enclosure with Glass Window Cover and C.S.A. & U.L. Listing (2)
9. Special (Uncoded Options) L. One (1) Switch in STD. Enclosure with Plug-In Connector (DIN 43650/IP65-PG11)
*Viton® is a Registered Trademark of DuPont Dow Elastomers. M. Two (2) Switches in STD. Enclosure with Plug-In Connector (DIN 43650/IP65-PG11)
**Teflon® is a Registered Trademark of DuPont. Z. Special (Uncoded Options)
(1)
Complete Assembly Rated Class I, Div. II, Groups A, B, C, & D; Class II, Div. II, Groups F and G.
(2)
Complete Assembly Rated Class I, Div. I, Groups C & D; Class II, Div. I, Groups E, F, & G.
(3)
5000 PSIG Working Pressure.
➄ CONNECTIONS
(NOTE: Models 120M and 120N available only with end connections)
0.
2.
1/4" FNPT Back Connections (Standard)
1/4" FNPT End Connections
➇ ELECTRICAL SPECIFICATIONS (For Resistive Loads)
A. S.P.D.T., 3W, 0.25 Amp., 125 VAC/VDC (Standard) (Switch adjustable range of 10-90%)
6. 7/16" - 20 Str. Thd. O-Ring Port (Back Connections) E. S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC (Normally Open) (Switch adjustable range of 25-95%)
7. 1/2" FNPT Stainless Steel Adaptors F. S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC (Normally Closed)
8. 1/2" FNPT Monel Adaptors (Switch adjustable range of 25-95%)
9. Special (Uncoded Options) G. S.P.S.T., 60W, 3.0 Amp., 240 VAC/VDC One (1) Normally Open, One (1) Normally Closed (4)
H. S.P.D.T., 60W, 1.0 Amp., 240 VAC/VDC (Switch adjustable range of 25-100%)
(4)
Available with Electrical Configurations B, D, F, H, K and M only.
NOTE: NOT ALL OPTIONS AVAILABLE IN COMBINATION WITH OTHER OPTIONS.
NOTE: FACTORY PRESET SWITCHES AT NO CHARGE (SPECIFY SETTING)
NOTE: THE USE OF DIAPHRAGM SEALS IS NOT RECOMMENDED FOR MODEL 120 SERIES GAUGE.
ATTEMPTS TO INSTALL SUCH SEALS ON THIS GAUGE WILL VOID THE WARRANTY. (Fig. 4)
Manufacturer reserves the right to change specifications without prior notice.

PROOF PRESSURE: 12,000 PSI for models 120-A and 120-S.
10,000 PSI for models 120-M and 120-N.
TEMPERATURE LIMITS: -40°F(-40°C) to +200°F (+93°C) - These limits are based on the entire instrument being saturated to
these temperatures. System (process) temperatures may exceed these limitations with proper installation. Contact our customer
service representative for details.
STANDARDS: All Model 120 Series differential pressure gauges either conform to and/or are designed to the requirements of the
following standards:
ASME B1.20.1 NACE MR0175
ASME B40.100 NEMA Std. No. 250
CSA-C22.2 No. 14.25 and 30 SAE J514
EN-61010-1 UL Std. No. 50,508 and 1203
R E P R E S E N T E D B Y:
Mid-West
Instrument
®
6500 Dobry Dr. ■ Sterling Heights, MI 48314 U.S.A.

(586) 254-6500 ■ FAX (586) 254-6509
E-mail: sales@midwestinstrument.com
Website: www.midwestinstrument.com
Printed in U.S.A.
hms-
A Free Floating Guided Lever Drain Traps
For Loads to 9,500 lblhr(4.309 kglhr) ...Pressures to 570 psig (39 bar)
Armstrong's stainless steel, free-floating guided lever drain The hemispherical valve, seat and leverage of the 11-LD,
traps use the same bodies, caps, lever mechanisms, valves 22-LD and 13-LD stainless steel traps are identical in design,
and seats of Armstrong inverted bucket steam taps that materials and workmanship to those for saturated steam
have been proven in years of service. Elliptical floats and service up to 570 psig (39 bar) with the exception of the
high leverage make it possible to open large orifices to addition of a guidepost to assure a positive, leaktight valve
provide adequate capacity for drain tap size and weight. closing under all conditions.
List of Materials For a fully detailed certified drawing, refel to list below:
11-LD CD #I066
I I I
I b L D and 22-LD CD #I086
I NO. I
Model Valve&
Seat I Leverage
Svstern
loa at Body & Cap Gasket I
11~LD Sealed
22.~0 Stainless Steel Stainless Steel. -
13-LD 304L
For intomatianon special materials, consull the Armstrang Application
Figure LO-34.
No. 11-LD. 22-LD and 13-LD stainless steel guided lever
liquid drain trap with sealed, tamperproof construction.
Physical Data
NOD: Vessel aes pn press~remay exceeo lloatcollapre pressure n some carer

Pce rile 01 vent conne?on s sme as mar 01 P ?I anc a l e : c0nPe:I 01s
",T115mm1o.net "ha sde caqnecnoi
All dimensions and weights are appmximafe. Use ceriffledprlnf lor exact dlmenrlons. Deslgn and malerlals are SubIect to change without notice.
Armstrong Steam and Condensate Group. 816 Maple St.. P.O.Box 408. Three Rivers. MI 49093 -USA Phone: (269) 273-1415 Fax: (269)278-6555
LO-39 w.armrtrong-intl.com
00-02-0175
Installation for L1100, L1200, L1200N Series Revised 03-06
Section 15
Liquid Level Switches and DVU150, DVU175,

and DVU2105/2115/2120 Series Dump Valves.
Please read the following instructions before installing. A visual inspection for damage during shipping is recommended before mounting.
GENERAL INFORMATION
Description **
Series L1100 and L1200 Liquid Level Switches are float activated to
WARNING operate an electrical SPDT snap switch (optional DPDT on some models) for alarm
or shutdown of an engine or electric motor. They screw directly into the wall of the
vessel. Series L1200 can also be used with a weld collar or external float chamber.
Series L1200N is a float-activated, pneumatic-vent level device used to operate dump
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT valves or similar devices. This model screws directly into the vessel or can be
✔ Disconnect all electrical power to the machine. mounted via an external float chamber. It cannot be used with weld collar 15050375.
✔ Make sure the machine cannot operate during installation. Model variations include a dump valve operator with or without a filter/pressure
regulator and indicating pressure gauge.
✔ Follow all safety warnings of the machine manufacturer.
NOTE: All stainless steel versions of L1100, L1200, L1200N, L1200NDVO, and
✔ Read and follow all installation instructions. L1200NDVOR series carry Canadian Registration Number OF1476.2.
✔ OBSERVE all pressure and electrical ratings and require- Series DVU150, DVU175, DVU2105/2115/2120 Dump Valves receive a
ments for the devices and the operating environment. pneumatic input signal to cause an orifice to open or close allowing liquid
✔ BE SURE all pressure HAS BEEN REMOVED from the condensate to be drained from a pressure vessel. A pop up button indicates valve
vessel before opening any pressure connections. open/closed. Stainless steel versions available.
Specifications L1100 L1111 L1200 L1200N L1200NDVO L1200NDVOR

Body
• Standard: Electroless Nickel plated steel ✗A ✗A ✗B ✗B ✗B ✗B
• Optional: 316 Stainless Steel† ✗A ✗A ✗B ✗B ✗B ✗B
Pressure Rating
• 15 psi (103 kPa) [1.03 bar] Polyethylene Float
• 1500 psi (10.3 MPa) [103.42 bar] Stainless Float ✗ ✗ ✗ ✗ ✗ ✗
• 2000 psi (13.8 MPa) [138 bar] BUOYGLAS™ Float ✗ ✗ ✗ ✗ ✗ ✗
Temperature Rating
• Standard: -20/175°F (-29/79°C)
• Standard: -20/300°F (-29/149°C) ✗ ✗ ✗ ✗ ✗ ✗
• Optional: -20/400°F (-29/204°C)* ✗ ✗ ✗ ✗ ✗
Specific Gravity
• Standard: 0.5 with BUOYGLAS™ float ✗ ✗ ✗ ✗ ✗ ✗
• Optional: 0.65 with 304 Stainless Steel† ✗ ✗ ✗ ✗ ✗
• Standard 0.73 Polyethylene Float
Electrical
• Standard SPDT: 5 A @ 125/480 VAC (see p. 3 for full ratings) ✗ ✗ ✗
• Optional DPDT: 10 A @ 250 VAC (see p. 3 for full ratings) ✗ ✗ ✗
Wire: 18 AWG x 36 in. (1.0 mm2 x 914 mm) ✗ ✗ ✗
O-Rings: Viton ✗ ✗ ✗ ✗ ✗ ✗
Valve: Two-way snap-action vent type
• 1/8 in. (3 mm) orifice w/Viton “A” seat
• 1/8 NPT inlet; 1/4 NPT vent ✗ ✗ ✗
• 30-70 psi (207-483 kPa) [2.07-4.83 bar] operating pressure
Dump Valve Operator: Operates Murphy DV Series
dump valves or similar. 1/8 NPT inlet, outlet & vent. ✗ ✗
Pressure Regulator/Filter and Murphy 20BPG:
0-75 psi (0-517 kPa) [0-5.17 bar] pressure gauge. ✗
Maximum input 300 psi (2.07 MPa) [20.68 bar].
1/8 NPT in/out.
Operation:
H=For high level, L=For low level H L H H H H
A =1-1/2 NPT B =2 NPT †Meets NACE standard MR-01-75 for direct exposure to H S service. *Not available with DPDT snap-switch.
2
**Products covered by this literature comply with EMC Council directive 89/336/EEC regarding electromagnetic compatibility.
Installation 00-02-0175 page 1 of 6
DIMENSIONS
L1200N, L1200NDVO and L1200NDVOR with

L1100 and L1200 Dump Valve Operator, Pressure
Regulator and Gage
11 in. Pressure
(279 mm) Regulator
3-1/2 in. with 20BPG
(89 mm) Pressure Gage New Dump Valve
Operator Assembly
p/n 15010216
2-3/16 in. See 1/8 NPT

(56 mm) Note 2
Old Round Dump Valve
Operator Assembly
p/n 15000940
1/2 NPT See Float travel between Operate
1/8 NPT
Note 1 and Reset= 0.25 in. (6 mm).
INLET
Switch operates on Rising Level 3-5/8 in. (92 mm) 5 in. (127 mm.) minimum
3-5/8 in. w/ float at horizontal centerline clearance is required for
Note 1: (92 mm) 3/4 Hex float movement.
±0.25 in. (6 mm). (See Note)
L1100: 1-1/2 NPT
L1200: 2 NPT
Note 2: 1-9/16 (40 mm) 2-3/16 in.
SF option: (56 mm) 1-9/16 in.
L1100: 1-1/2 (38 mm) (40 mm)
L1200: 1-3/4 (44 mm) SF option=
1-3/4 in.
1/4 NPT 2" 11-1/2 NPT (44 mm)
3-1/2 in. (89 mm)
VENT SF= 3-3/4 in. (95 mm)
11 in. (279 mm) SF option= 11-1/4 in. (286 mm)
Note: For use only with Old Round Dump Valve Operator Assembly (15000940).
L1111
11-5/16 in.
(287 mm)
3-53/64 in.
(97 mm)
DVU150, DVU175, DVU2105/2115/2120
Series Dump Valves
2-3/16 in.
(56 mm)
See
Note A
Pressure Manual Valve
Inlet Port Operator
1/2 NPT 1-1/2 NPT Float travel between Operate 1/8 in.-27 NPT
and Reset= 0.25 in. (6 mm).
Switch operates on Rising Level
3-5/8 in. w/ float at horizontal centerline
(92 mm) ±0.25 in. (6 mm).
Note: 1-9/16 (40 mm)
Vent
B
Weep Hole Valve Open/Closed
Union Indicator Button
Electrical installation to be done by
qualified person according to the NEC.
F Drain
Connection C
E D
Plug Seal G (dimension shown
for reference only)
Model A B C D E F G
DVU2120 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2115 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2105 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU175 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 3/4”-14 NPT 1.03
DVU150 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 1/2”-14 NPT 1.03
NOTE: Dimensions are in inches and (millimeters)

REPLACING AND INSTALLING THE DVOA ASSEMBLY
When replacing/installing the old style DVO assembly with the new style (DVOA), tubing and fitting modifications are required. We suggest
removing the L1200NDVO/DVOR from the vessel. Relieve pressure from the vessel or use block valves before removing the L1200NDVO/DVOR.
Replacing and Installing the DVOA

Assembly For Models L1200NDVO &
NOTE: Clean, dry instrument quality gas should be used.
L1200NDVOR Use of filters will improve service life and reliability.
Tools Needed: Strap or pipe wrench; 3/4” Hex wrench; 9/16” hex
wrench; needle nose pliers; tubing cutters and benders and the
appropriate tools for the fittings.
1. Block off and bleed the instrument gas pressure supply to the Outlet
Old DVO
L1200NDVO. (opposite side)
2. Remove the tubing between the L1200NDVO and the
separator dump valve, and remove the supply gas tubing Inlet
(regulator [-R] if used).
3. Remove the L1200NDVO from the vessel (optional).
4. If the L1200N was removed from the vessel, mount it in a
suitable vise on a work bench (if possible).
5. Using the proper tools, disconnect the Inlet, Outlet and Exhaust
Valve
Exhaust fittings from the existing DVO (see fig. 1). You will Figure 1
re-connect these to the new DVOA in a later step. Bushing
NOTE: The following steps must be done with the DVO in the
upright position (on top of the L1200N).
6. Remove the L1200N cover (this will aid with the alignment
of the new DVOA Valve Bushing). The use of a strap
wrench or a pipe wrench may be needed.
7. Insert the new Valve Bushing through the new DVOA (see Figure 2
fig. 2). The markings on top of the DVOA must be facing New DVOA
up. This will be needed in step 9.
8. With a 3/4” hex wrench loosen the existing DVO, valve
stem, and static seal (see fig. 3). Once the assembly is
loosened, VERY CAREFULLY use needle nose pliers to
hold the Valve Seat Assembly in place. Remove the existing
DVO making sure the Valve Seat Assembly inside the
L1200NDVO is aligned and straight (see fig. 4). Figure 3
CAUTION: MAKE SURE the Valve Seat Assembly inside
the L1200N remains in place after removing the DVO. Valve Seat
Assembly
9. Holding the Seat Assembly up with the needle nose pliers
inside the L1200NDVO body, place the tip of the new Outlet
DVOA valve bushing through the spring and into the hole in
the center of the valve seat, and tighten the valve bushing.
The Valve Seat Assembly should be able to move freely up Inlet Figure 4
and down after the bushing has been tighten. The DVO red Exhaust
button must face away from the vessel.
10.With the new DVOA aligned over the hex on the L1200NDVO
body, tighten the Valve Bushing using the 9/16” hex wrench.
You may need to hold the DVOA while tightening the Valve
Bushing to keep it from rotating (see fig. 5). New DVOA
11.If the L1200N is in the vise, operate the float and inspect for Figure 5
smooth and proper operation of the Valve Seat Assembly.
12.Replace the L1200NDVO cover (see fig. 6).
13.Using the appropriate tools re-install the Inlet, the Outlet and L1200N
the Exhaust fittings to the new DVOA (see fig. 5). Cover
14 If the L1200N was removed from the vessel re-install it at this
time.
15.Modify existing or install new tubing to connect the Inlet, the
Outlet and Exhaust fittings. Figure 6
PRESSURE VESSEL INSTALLATION: L1100, L1200, and L1200N
Direct Installation into the Wall of the positioned away from the tank wall.
Pressure Vessel 2. A tee is typically installed at the bottom of the lower 1 inch
1. Determine that the float travel is not pipe riser to allow draining of the float
obstructed by the coupling in chamber for servicing or replacement.
the vessel wall, internal Tank
Wall NOTE: A typical installation Float
baffles, etc. with Blocking and Bleed valves is Chamber
Do NOT use more than shown at right. Tank
Block
one arm extension P/N Valves
3. Install the L1200 or
15050395.
L1200N
2. BE SURE that the float Explosion proof Level
Level conduit seal in the 2 NPT connection Switch
and extension are tight Switch where required. of Tee
and that the lock washer is the float chamber.
in place. Bleed
BE SURE float travel Valve
3. Before installing the level is not restricted and that the Explosion proof
switch a suitable pipe thread sealant float is tight onto conduit seal
is recommended. Screw the unit directly into the threaded where required.
the float shaft.
connection in the wall of the pressure vessel. 4. To complete installation and
4. Be sure that the electrical connection is positioned at the wiring, follow the instructions for
bottom. For L1200N the 1/8 NPT pneumatic connection mounting directly into wall of the vessel and for wiring.
should be on top (the 1/4 NPT vent connection should be on
the bottom). See “Pneumatic models” section for further Pneumatic Models
instructions for the L1200N. 1. All pneumatic models
5. Make the electrical wiring connections according to operate on the vent Filter/Regulator
appropriate wiring diagrams for the alarm or shutdown principle. The Tank
New Dump Valve
system to be used. The electrical connection is 1/2-14 NPT. pneumatic signal Pneumatic Operator Assembly
p/n 15010216
Electrical wiring and conduit should be installed by qualified source MUST BE Signal
personnel according to the NEC. CLEAN AND DRY.
6. BE SURE all electrical connections are insulated and the The input pneumatic MURPHYGAGE®
cover is fully installed before reconnecting electrical power. signal must be
7. BE SURE all pressure connections are tight before regulated between 30
pressurizing the system. and 70 psi (207-483 L1200N
kPa) [2.07-4.83 bar].
Installation with a Weld If produced gas is used as the
Collar Tank Wall
signal source, it should be taken
1. The weld collar, P/N after gas passes through the final scrubber.
15050375, must be welded Weld Collar A suitable filter must be positioned before the L1200NDVO
into the wall of the to prevent liquids and/or particulates from entering the dump
pressure vessel according valve operator.
to code standards and NOTE: Check filter periodically for wear and tear and
good welding practices. elements that hamper the flow of the pneumatic signal.
L1200 2. All pressure connections must be tight and maintained tight
2. Follow above instructions
for installation directly into so as not to leak air/gas.
the wall of the pressure Explosion proof 3. Valve seat adjustment can be made if air/gas begins to leak.
conduit seal
vessel. where required. Care should be taken when adjusting as only slight movement
3. NOTE: Weld collar 15050375 can is necessary to stop the leakage; excessive force will bind the
be used ONLY with model L1200. It cannot be used with
L1200N.
Installation Using External L1200N
Hex Socket Set Screw
Float Chamber 15051098 • loosen for adjustment
• tighten after adjustment
CAUTION: USE “NON SPARKING TOOLING”.
Hex Adjustment Nut
• turn left until air Trip Cam (float down)
1. Install the float chamber 15051098 on the outside wall of the seepage stops • should be in
pressure vessel using 1 NPT piping. Position the 2 NPT • Caution: only slight this position
adjustment is needed—too • non-adjustable
threaded connection at the height where you want the level much will lock up mechanism
switch to operate. The 2 NPT threaded connection must be
TYPICAL INSTALLATION ON GAS COMPRESSORS
Basic Operation
As condensate rises in the scrubber, the float on
Typical/Scrubber/Separators
the L1200NDVOR rises and trips its pneumatic
valve. The valve opens allowing pressure to enter VESSEL
the dump valve pilot chamber. Once the pressure Minimum control
Rising Level Shutdown
enters the pilot chamber it forces the diaphragm L1200 (with snap-switch) pressure 30 psi
(207 kPa) [2.07 bar]
and valve stem forward thus opening the valve seat Air Supply Maximum
300 psi (2.07 MPa)
(valve open/closed indicator button pops out) and [20.70 bar]
releasing condensate through the valve stem and Explosion proof
conduit seal required
out the drain. As the condensate level drops, the for Class I. Div 1, not
Filter/Regulator
required for intrinsically
L1200NDVOR pneumatic valve closes to shut off safe or non-incendive L1200NDVOR
with MURPHYGAGE®
circuits like FWM TTD.
the pressure to the dump valve causing it to close. Dump Valve
Electrical Rising Operator
If for any reason the condensate continues to rise Level Minimum control pressure
Conduit 30 psi (207 kPa) [2.07 bar]
Trips Union
beyond normal dump levels, model L1200 DVO
operates the alarm and/or shuts down
the equipment.
The L1200NDVOR Filter/Regulator and the DVU Series Dump Valve
MURPHYGAGE® help keep the control pressure Union

clean and dry. They also allow the operator to
adjust pressure to recommended levels. Condensate Line (Out)
Manual Drain Valve
ELECTRICAL INFORMATION REPLACEMENT PARTS
DPDT (Snap Switch) Order by part number designation.

SPDT (Snap Switch)
Green Grd. Connection L1100/L1200*
Black N.O.
Green Grd. Connection Red N.C.
White COM. 15000893: BUOYGLAS™ float
Black N.O.
White COM. Blue N.C. 15000894: Stainless Steel float for L1200
Red N.C. Yellow COM.
Orange N.C. 15000937: Stainless Steel float for L1100
Switch Rating: 5 A @ 125-250- 480 VAC
15000124: SPDT snap switch assembly
1/2 A @ 125 VDC Switch Rating: 10 A @ 125-250 VAC 15010213: L1100 counter balance assembly
1/4 A @ 250 VDC 1/2 A @ 125 VDC 15010214: L1200 counter balance assembly
2A @ 6-30 VDC Resistive 1/4 A @ 250 VDC
1A @ 6-30 VDC Inductive 10 A @ 6-24 VDC L1200N
Inductive/Resistive
15050420: Cam spring return
15050421: Cam
15000893: BUOYGLAS™ float
15000894: Stainless Steel float for L1200N
15050453: Valve stem
15010189: Counter balance assembly
L1200NDVO and L1200NDVOR
55050621: Regulator only
05706499: 20BPG-D-75 Pressure MURPHYGAGE®
0-75 psi (517 kPa) [5.17 bar]
15010216: DVOA assembly (New rectangular style)
15000940: DVO assembly (Old round style)
*To maintain hazardous location listings, all other repairs must be made by the factory.

ACCESSORIES
Order by part number designation.
55050617: DVU150/DVU175 Adapter Bushing 15050375: Weld Collar
Material: 2-1/2 Hex bar stock C.R.S 2 NPT
2-1/16 in
(52 mm) 2-1/2 in
(64 mm)
1-1/16 in 2-7/8 in
(27 mm) (73 mm)
3-5/8 in.
1 NPT (92 mm)
4-1/2 in
(114 mm)
Operating Pressure: 2000 psi (13.8 MPa) [138 bar].
2 NPT
Operating Temperature: 400°F (204°C).
15051098: External Float Chamber

3 in.
1-11.5 NPT (2 places) (76 mm)
2-11.5 NPT
10.5 in. 3 in.

(266 mm) (76 mm)
1/2-20 UNF-2B
(4 places)
7.55 in. 3.5 in.

(192 mm) (89 mm) 7.01 in.
(179 mm)
Material: Cast Steel, WCB
15000892: Float Shaft Extension

10-32 UNF
10-32 UNF
3/8 in
(10 mm)
1-3/8 in
(35 mm)
Warranty
A limited warranty on materials and workmanship is given with this FW Murphy product.
A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
MURPHY, the Murphy logo are registered and/or common law trademarks of Murphy Industries, Inc. This document,
including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved.
www.fwmurphy.com (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are the property of
918.317.4100 Email: sales@fwmurphy.com their respective owners and are used for identification purposes only.

00-02-0483
Installation and Operation Manual for Revised 03-06
Section 15
DVU Series Dump Valves

Models: DVU150, DVU175, DVU2105, DVU2115 and DVU2120
Please read the following information before installing. A visual inspection of this product for damage during shipping is recommended
before mounting. It is your responsibility to have a qualified person install this unit and make sure it conforms to local codes.
GENERAL INFORMATION
Fig. 2 Dimensions (all models)
WARNING Pressure
Inlet Port
A
Manual Valve
Operator
1/8 in.-27 NPT
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

✔ Disconnect all electrical power to the machine.
✔ Make sure the machine cannot operate during installation. Vent
B
✔ Follow all safety warnings of the machine manufacturer. Weep Hole Valve Open/Closed
✔ Read and follow all installation instructions.
Description
The DVU Series models are pneumatically controlled dump valves. F Drain
The valves open and close automatically by pneumatic control from a Connection C
Murphy L1200NDVOR or similar level controller and dump valve opera-
E D
tor. Diaphragm actuated, the DVU series dump valves operate at 30–70 psi
(207–483 kPa) [2.07–4.83 bar] and up to 2000 psi (13.8 MPa) [138 bar] Plug Seal G (dimension shown
for reference only)
vessel pressure (depending on the model).
A key benefit of this design is a hex union that provides the ability
to replace the seat without removing the valve from piping.
Model A B C D E F G
DVU2120 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2115 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2105 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
Fig. 1 Control Pressure vs. Working Pressure DVU175 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 3/4”-14 NPT 1.03
DVU150 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 1/2”-14 NPT 1.03
Minimum Actuation Pressure NOTE: Dimensions are in inches and (millimeters)

70
DVU2115 DVU2120
Control Pressure (PSIG)
60
50 Specifications
40
DVU2105 DVU150/175 Operating Temperature: -30 to 250°F (-34.4 to +121°C)
30 Valve Operating Pressure: Refer to chart, Fig 1.
20
Maximum Process Pressure:
10 DVU2120: 2000 psi (13.8 MPa) [138 bar].
0 500 1000 1500 2000 DVU2115: 1500 psi (10.3 MPa) [103 bar].
Vessel Pressure (PSIG) DVU2105: 500 psi (3.44 MPa) [34 bar].
DVU150 and DVU175: 1800 psi (12.4 MPa) [124 bar].
Flow Characteristics: See chart, page 4 (DVU150/175 models only).
Body Material: Electroless Nickel Plated 12L14 Carbon Steel
Model Inlet Outlet Trim Size
Internal Wetted Parts: Plug Seal: 90 Durometer Urethane.
DVU2120 2 NPT 1 NPT 0.436 in. (11 mm) Other: 303 stainless steel; Electroless Nickel Plated 12L14 Carbon Steel
DVU2115 2 NPT 1 NPT 0.576 in. (15 mm) Shipping Weights: DVU150 and DVU175: 9 lbs. (4 kg.).
DVU2105 2 NPT 1 NPT 0.859 in. (22 mm) Shipping Weights: DVU2105, DVU2115 and DVU2120: 14 lbs. (6.4 kg.).
DVU175 1 NPT 3/4 NPT 0.359 in. (9 mm) Shipping Dimensions: 7-1/2 x 7-1/2 x 10-3/4 in. (191 x 191 x 274 mm.).
DVU150 1 NPT 1/2 NPT 0.359 in. (9 mm)

Fig. 3 The Murphy Gas Compressor Scrubber Level System (SLS)

Scrubber/Separators
The system provides for liq-
uid control in gas scrubber High Level Shutdown Switch
Basic Operation applications, by dumping liq- Stainless steel float actuated level switches to alarm
As condensate rises in the scrubber, the float uids to drain and protecting and/or shutdown the equipment.
on the L1200NDVOR rises and trips its pneu- compressors with a high liq- L1200: 2” NPT pipe connection; Rated 2000 psi
matic valve. The valve opens allowing pres- uid level switch. Wetted metal (13.7MPa) [137bar]; Class I, Division 1. SPDT
snap-switch standard. DPDT Optional.
sure to enter the dump valve pilot chamber. parts are made to survive
All Stainless Steel available.
Once the pressure enters the pilot chamber it constant use in corrosive
environments.
forces the diaphragm and valve stem forward
See Bulletin: SLS-04005B for
thus opening the valve seat (valve open/closed more details.
indicator button pops out) and releasing con-
Filter/Regulator &
densate through the valve stem and out the Control
MURPHYGAGE®
drain. As the condensate level drops, the Panel
L1200NDVOR pneumatic valve closes to shut
“Instrument
off the pressure to the dump valve causing it to Quality Air/Gas
close. Supply”
If for any reason the condensate continues to
rise beyond normal dump levels, model L1200
operates the alarm and/or shuts down the
Pneumatic Level Control
equipment. Float actuated level snap-acting switch
The L1200NDVOR Filter/Regulator and the controls pneumatic pressure to open
and close dump valve.
Pneumatic Dump
MURPHYGAGE® help keep the control pres- Valves See DVU-01069B
sure clean and dry. They also allow the opera- L1200NDVOR: Dump Valve Operator,
for more details.
pressure regulator, and pressure indi-
tor to adjust pressure to recommended levels. Two piece union design with manual valve operator
cating MURPHYGAGE.® allows soft plug and hard seat to be replaced with-
NOTE: Always use clean, dry, out disassembling outlet piping or scrubber pipe
instrument quality gas. connection. Diaphragm actuated valves operate on
30-70 psi (207-483 kPa; 2-5 bar).
DUMP VALVE INSTALLATION
DVU Series Installation

Upper Assembly
(removable)
CAUTION: ALWAYS USE “NON-SPARKING TOOLS”
Pneumatic
WHEN GAS IS KNOWN TO BE PRESENT. Input Signal
Valve
Union
The following describes the “Direct Mounting” method to the Fig. 4
tank wall. Typical
1. Install the valve so the drain connection is on the bottom. Use Dump Valve Maintenance
Bolt
pipe thread sealant on all the connections. Installation
2. Be sure the unit is screwed tight and does not leak. Valve Indicator
3. Install the piping for the pneumatic input signal into the
Vessel Wall
1/8 NPT threaded connection of the pressure inlet port (on Weep Hole
top of the diaphragm housing of the DVU).
6. Install a union between the DVU drain connection and the Drain
condensate out line. Use pipe thread sealant on all the con- Connection
nections.
Union
Condensate Out
2-Way (Manual Drain)

Shutoff Valve

REPAIR PROCEDURE
CAUTION: THE INSTALLATION AND REPAIR PROCEDURES SHOULD 6. Using a back-up wrench on the plug, remove the stem nut on the shaft
ONLY BE PERFORMED BY TRAINED, QUALIFIED, AND EXPERIENCED under the plug. Once the stem nut is broken loose, the 9/16” head main-
PERSONNEL. THE TRAINING, QUALIFICATION AND EXPERIENCE
tenance bolt and top assembly will keep the stem from turning. The plug
turns freely on the stem once loose. The plug and seat can now be
REQUIRED IS FOR WORK AROUND PRESSURE VESSELS, NATURAL GAS, POSSI- removed. All soft seals should be replaced. Refer to kit part numbers
BLY SOUR GAS, OR ANY SUBSTANCE TO BE FOUND IN THE VESSEL. EXTREME under service parts on page 4.
CARE MUST BE TAKEN TO INSURE ANY RESIDUAL OR FULL PRESSURE IS
RELIEVED FROM ALL PARTS OF THE SYSTEM TO BE SERVICED. Replacing the Diaphragm
6A. If the diaphragm is to be replaced, all preceding steps have to be
Suggested Tools (Sizes listed are wrench openings. done. Additionally, do the following:
Adjustable crescent wrenches, socket and/or end wrench, pipe wrenches, 6B. Loosen the 9/16” head maintenance bolt, allowing the diaphragm
flat edge screwdriver with 1/4” blade width, can also be used .) spring to relax, and the stem to retract. Make alignment marks on
Model Valve Body Union Nut Plug Seal Hex Stem Nut the top and bottom halves of the diaphragm assembly for align-
DVU2120 3” 3” 7/8” 1/2” ment during re-assembly.
DVU2115 3” 3” 1” 1/2” 6C. Remove the 8, 7/16" bolts/nuts holding the diaphragm housing
DVU2105 3” 3” 1-1/4” 1/2” together.
DVU150/DVU175 2-1/4” 2-1/4” 3/4” 3/8” 6D. Using a straight edge screwdriver, gently separate the 2 halves of
the diaphragm housing, and remove the top, or outside portion.
Replacing the Plug and Seat 6E. Lift the diaphragm and support plates far enough for the 1-1/8" hex
1. Close the pressure block valves (suction & discharge valves) on the inlet or 1” round nut on the bottom of the diaphragm assembly to be
and outlet of the skid. Lock them closed if possible. accessible to a wrench and not have the spring interfere. If it is
2. Open the blowdown valve to remove pressure from the unit. Lock the desired to replace the packing, pull the stem all the way out. The
blowdown valve open if possible. packing can be easily removed using a small screwdriver to pry the
3. After taking all possible precautions to insure there is no pressure in the packing out. The new packing can be simply pressed in, making
vessel. (If the condensate line is pressurized, it must also be blocked and sure the orientation of the packing installed is the same as the ori-
locked.) Open the manual drain valve so it bleeds into the vessel so it entation of the packing removed. The packing is wider toward the
can also be bled down. Disconnect the pneumatic input signal connection plug end. You will have to use the seat to hold the packing in place
after insuring it also has been de-pressurized. when re-inserting the stem.
4. Using a back-up wrench on the valve body, with a quick "breaking" 6F. With the 1-1/8" hex or 1” round nut held by a wrench, use a
action loosen the union nut on the valve. There is a "weep" hole in the wrench to loosen and remove the 1/2" nut on top of the diaphragm.
nut. If at any time while loosening and taking off the nut pressure is The diaphragm can now be removed and replaced.
escaping through the "weep" hole, immediately stop loosening the nut. 6G. With the new diaphragm in place and the 1/2" nut tightened, place
Retighten the nut and check the preceding procedures to ensure the pres- the assembly, diaphragm down on a clean, smooth sturdy surface.
sure is bled off the vessel. Never remove the assembly if pressure is 6H. Have the seat, plug, washers and stem nut handy (if any of these
coming through the weep hole. See Figure 4 on page 2.
parts are to be replaced, use the old parts for this procedure). Press
5. With the upper assembly removed from the vessel the plug and/or seat can
down evenly and smoothly on the bottom of the diaphragm assem-
be replaced. Loosen the 9/16” jam nut on the maintenance bolt on top of
bly to cause stem to come up. Place the seat and plug in place.
the diaphragm cover. Spin the nut up against the head of the bolt. Tighten
the bolt to extend the shaft and plug. DO NOT OVERTIGHTEN. Then push the bottom of the diaphragm assembly down far enough
to install the washers and stem nut on the stem. Tighten the stem
nut enough to hold against the diaphragm spring.
Fig. 5 Stem O-Ring Seals 6J. Align the diaphragm holes to the bolt holes (bottom half of the
Plug Seat Stem Packing Against Outlet housing). Install the upper diaphragm housing using the alignment
Washer(s)* marks from step 6B. Install the 8, 7/16" bolts and nuts. Tighten the
bolts evenly going from one bolt then 180° around to the next bolt,
then either 120°or 240° around to the next bolt and so forth until
all 8 bolts are evenly tight.
Stem O-Ring 6K. Using the 9/16” head maintenance bolt, tighten, pushing the stem
Nut Crush Washer Seal Seat butts into here out until the 9/16"bolt stops – DO NOT OVERTIGHTEN.
*Number of washers varies depending on the model from 1 to 3. 6L. Remove the stem nut holding the plug. (If old parts were used, pre-
pare to install the new parts now.)
Seal Washer Maintenance 7. Install the seat and plug. Place the O-ring on the stem, followed by the
Fig. 6 Bolt Diaphragm
Pressure Inlet washer and stem nut.
Housing 8. Tighten the stem nut. Loosen the 9/16” head maintenance bolt by at least one
Diaphragm 1/2" Nut
turn past the point where it is no longer in contact with the stem. Tighten the
9/16" jam nut holding the 9/16” head maintenance bolt.
9. Replace the crush washer and the O-ring hidden by the union nut.
NOTE: If pressure or fluid comes out the weep hole of the union nut,
either the O-ring under the union nut is leaking, or the packing could be
Backup leaking through the internal weep hole above that O-ring.
1-1/8" or Diaphragm 10. The assembly is ready to be re-installed. Check for relative position of
Plate Spring
1" round nut Stem Assembly the pneumatic input signal connections before tightening the union nut.

PRESSURE VS. FLOW CHART
Fig. 7 Pressure vs. Flow for DVU150 and DVU175 models only
250
250
200
200
150
150
Pressure (psid)
100
100
50
50
0
0 5 10 15 20 25 30 35 40 45
Flow (gpm)
SERVICE PARTS
Part No. Description Typical Diaphragm Repair Kit includes:

DVU2120 Diaphragm; Diaphragm Washer (upper), Diaphragm Nut, Diaphragm Plate
55-00-0237 Seal Kit (includes plug) (1 or 2 pcs.), Packing, “O” Ring, Stem, Seal Washer for Maintenance Bolt.
55-00-0236 Diaphragm Kit
The DVU Series Valve is included in the
DVU2115 following Scrubber Levels Systems.
55-00-0241 Seal Kit (includes plug)
55-00-0240 Diaphragm Kit (Includes L1200, L1200NDVOR, and DVU valve)
SLS2120: Includes DVU2120 valve
DVU2105
55-00-0245 Seal Kit (includes plug) SLS2115: Includes DVU2115 valve
55-00-0244 Diaphragm Kit SLS2105: Includes DVU2105 valve
DVU175 SLS175: Includes DVU175 valve
DVU150 -LR: Less Regulator option
55-00-0230 Seal Kit (includes plug) Warranty
55-00-0231 Diaphragm Kit A limited warranty on materials and workmanship is given with this FW
Typical Seal Kit includes: Nut, Washer (1 to 3), “O” Ring, Plug and Murphy product. A copy of the warranty may be viewed or printed by going
Seal, Seat, Crush Washer. to www.fwmurphy.com/support/warranty.htm

Warning
All repair and resetting of safety relief valves should
be performed by a National Board certified valve
repair shop holding a “VR”stamp.
See engine assemblies for details
Service the PCC fuel filter every 800 hours.
Tubing Fitting, Item 43, Starter motor Ajax p/n BM-11679-Q-1.

with 0.030" orifice supplies Maximum inlet pressure = 90 psig.
positive head pressure to Pinion-to-ring gear backlash = 0.020” to 0.030”
hydraulic system.
1 ” travel (ref.)
Starter Pinion
Ring Gear
Flywheel
Adjust 0.06” minimum
main fuel pressure regulator
to 15 psig (typically). ” minimum
engagement
(Ajax p/n 2040 6430)
(Fisher Type 627)
Adjust PCC fuel shut off relay valve

(item 57) to actuate at 5 psig.
Starter Motor Gas Supply (Fisher Type 119) ! "#
" # !$
Maximum pressure = 90 psig Adjust PCC fuel (LE) 2802LE Starter/Fuel Gas Piping
Approximate maximum flow rate = 2028 scfm pressure regulator (item 58)
(values based on typical natural gas properties) to 13-14 psig (typically). TP 02-22-T010-331-90
(Fisher 64 Series)
2802LE Starter/Fuel Gas Piping
TP 02-22-T010-331-90

1 Tubing ¼" x 0.035 Wall 5551 3504 55" 36 Pipe 2", Sch 80 4053 0205 11"
2 Tubing ¼" x 0.035 Wall 5551 3504 73" 37 Pipe 2", Sch 80 4053 0205 15"
3 Angle, 2" x 2" x ¼" x 28" Lg. 7004 2020 1 38 Pipe 2", Sch 80 4053 0205 23"
4 Ball Valve, ½"NPT, 2000# 2549 2004 1 39 Pipe 2", Sch 80 4053 0205 58"
5 Ball Valve, 1"NPT 2549 2006 1 40 Plug, Hex Head, 2"NPT, 3000# 2541 6020 2
6 Ball Valve, 2" Spring 2549 2012 1 41 Fuel Shutdown Valve, 2"NPT 2090 2521 1
7 Bushing, ½"NPT x ¼"NPT, 3000# 2527 0402 1 42 Street Elbow, 1½"NPT, 3000# 2535 8014 1
8 Bushing, ¾"NPT x ½"NPT, 3000# 2527 0604 2 43 ¼" Male Tubing Conn. w/0.030" Orifice 2507 1325 1
9 Bushing, 1½"NPT x 1" NPT, 3000# 2527 1410 1 44 Tee, ½"NPT, 2000# 2545 4004 1
10 Bushing, 1"NPT x ½"NPT, 3000# 2527 1004 1 45 Tee, ¼"NPT, 2000# 2545 4002 1
11 Bushing, 1"NPT x ¼"NPT, 3000# 2527 1002 1 46 Tee, 1"NPT, 2000# 2545 4010 3
12 Bushing, 2"NPT x 1"NPT, 3000# 2527 2010 3 47 Tee, 2"NPT, 2000# 2545 4020 2
13 Elbow, 1"NPT, 2000# 2535 3010 1 48 Tee Reducing Union, ½" x ¼" 2507 6205 1
14 Elbow, 1"NPT, 3000# 2535 4010 1 49 Tubing ½" x 0.035 Wall 5551 3508 15"
15 Elbow, 2"NPT, 2000# 2535 3020 2 50 Tubing ½" x 0.049 Wall 5551 4908 48"
16 Elbow, Male Tubing, ½" Tube x ½"NPT 2507 4204 3 51 Tubing 1" x 0.049 Wall 5551 4916 14"
17 Elbow, Male Tubing, ¼" Tube x ¼" NPT 2507 4202 2 52 U-Bolt, 1" 1590 0100 1
18 Flat Bar, ½"NPT x 2" x 6" L 7040 0420 1 53 U-Bolt, 2" 1590 0103 3
19 Gauge, 0-30 psig 2015 3312 2 54 Union, 1"NPT 3000# 2547 5010 1
20 Male Connector, ½" Tube x ½" NPT 2507 1404 1 55 Union, 2"NPT 3000# 2547 5020 2
21 Male Connector, ¼"Tube x ¼"NPT 2507 1202 1 56 Unitstrut, 3" L 7020 2558 2
22 Male Connector, 1" Tube x 1" NPT 2507 1808 2 57 Valve, PCC Fuel Shut Off Relay BM-16089-K 1
23 Mercer Relief Valve, 1" In x 1" Out 63ME2M2FVA0080 1 58 Regulator, PCC Fuel Pressure 2-04V-034-003 1
24 Needle Valve, ¼", 6000# 2549 0057 2
25 Close Nipple, ¼"NPT, Sch 80 2539 4200 1
26 Close Nipple, 2"NPT, Sch 80 2539 4909 1
27 Nipple, ½"NPT x 2" L, Sch 80 2539 4408 1
28 Nipple, ½"NPT x 3"L, Sch 80 2539 4414 2
29 Nipple, 1"NPT x 2½L, Sch 80 2539 4610 4
30 Nipple, 1"NPT x 6"L, Sch 80 2539 4626 2
31 Nipple, 1"NPT x 8"L, Sch 80 2539 4628 1
32 Nipple, 2"NPT x 8"L, Sch 80 2539 4928 1
33 Pipe 1", Sch 40 4053 0102 13"
34 Pipe 1", Sch 40 4053 0102 12"
35 Pipe 2", Sch 80 4053 0205 27"
2802LE Starter/Fuel Gas Piping

TP 02-22-T010-331-90
M-7980N
Revised 11-02
M2582, M5081, and M5180 Series Section 55
(00-02-0206)
Electromechanical and Pneumatic, Fuel Gas Shut-

off Valves Installation and Operation Instructions
Please read the following instructions before installing. A visual inspection of this product for damage during shipping is
recommended before mounting. It is your responsibility to have a qualified person install the unit and make sure installation
conforms with NEC and local codes.
GENERAL INFORMATION
WARNING
✔ Make sure the machine cannot operate during installation.
Model M5081
Approved*
M2582 and M5081Series M5081FS

Tripping Power From Engine Ignition System or Battery Normally Energized Circuit
(Models available for magneto, CD ignition or 12/24 V battery) The M5081FS is manually opened, electrically latched open and tripped
These fuel shut-off valves are semi-automatic devices for shutdown of by interrupting the coil power circuit.
natural gas fueled engines. The standard valve opens by manual
operation of the reset handle. A latch in the upper body of the valve will Magnetic Switch Adapter
set and hold the valve open. At this point no electric power is used. As ignition systems wear from usage, their power output becomes less
The electromagnetic coil is de-energized, the snap-switch(es) is SET. and less. Ignition may not have the capacity to reliably trip the Fuel
Valve. Therefore, the use of a Magnetic Switch Adapter for CD
If a SWICHGAGE® contact closes, a circuit is completed from power ignition systems is recommended. The Magnetic Switch Adapter is a
through the snap-switch and coil. Now energized, the electromagnet device that stores energy from the CD ignition to trip the Fuel Valve.
trips the latch, (latch can be tripped manually), the valve closes, and the Three models are available:
snap-switch resets. Power switches from the coil circuit to your choice 65700053 (was 65020126): For use with negative ground ignitions
of an open line, an electrical ground, or an alarm. After tripping, the up to 240 VDC.
vent seal opens, and on the M50 models, the open/close indicator (green
button) retracts to indicate that the valve is closed. 65700054 (was 65020127): For use with positive ground ignitions
up to 450 VDC.
Valve body is sandcast aluminum. Optional cast steel for M5081 models.
65700055 (was 65020155): For use with negative ground ignitions
M2582-P and M5180-P up to 450 VDC.
MURPHY-NUMATIC™ Pneumatic Version for Pressure
100 ohm, 2 watt Resistor
The M2582-P and M5180 pneumatically controlled valves can operate For Capacitor Discharge Ignitions that are specified to be grounded when
from pressure, and are designed to open and close automatically or semi- the valve closes, and a Magnetic Switch Adapter is in use. The resistor
automatically (the supply can be air, oil or gas). must be connected in the system to prevent damage to the snap-switches
NOTE: If using oil as a pressure source, use a lightweight oil. in the fuel shut-off valve (see typical wiring diagrams).
These valves will open on rising control pressure and close on
Diode Package
decreasing control pressure. M2582-P and M5180-P automatically open
The Murphy diode package (65010065) is designed to allow the fuel shut-
at 2 psi (14 kPa) [0.14 bar] and fully open at 3 psi (21 kPa) [0.21 bar].
off valve to be used with dual Magneto Ignition systems.
All models include a built-in lever to aid in opening the valve manually.
The M2582-P can be manually opened against inlet pressure of 80 psi
(552 kPa) [5.52 bar]. The M5180-P valve can be opened against inlet NOTE: All aluminum versions of the M5081 Series Fuel Valve carry
pressure of 100 psi (689 kPa) [6.89 bar]. Canadian Registartion Number OC1476.2.
* M5081 model is CSA approved for Class I, Division 1, Groups C and D.
Standard models include an escape vent for gas trapped forward in the
See Specifications on page 12.
line after shut-off.
Installation M-7980N page 1 of 12

FLOW CHARACTERISTICS VALVE CUT-OUT
Understanding the Basic Operation

of the Fuel Shut-off Valve
M2582 Series The valve below is shown in the run (open) position.
10.0
Pressure is equalized, seat (B) is open, allowing
the fuel to flow. When valve is in the tripped position
]
]
g.)
bar]
]
[254.0]
bar
bar
bar
.28 k
(closed), seat closes (C).
.38
.69
0.34
.07
9.0
g.)
[228.6]
) [1
) [0
) [2
z. (0
The vent (D) opens to relieve trapped downstream fuel
a) [
11 k
Inches water column (∆p) drop across valve.
kPa
kPa
kPa
8.0
10 o
4 kP
[203.2]
. (0. to vent to a non-hazardous area.
Millimeters water column in brackets [ ].
38
07
(69
ig (3
g (1
g (2
4 oz
7.0
sig
[177.8]
psi
psi
5 ps
10 p
20
30
6.0
[152.4] TYPICAL MODEL (M5081) SHOWN
5.0
Terminal Block is
[127.0]
4.0
[101.6] within this case.
3.0
F
[76.2]
2.0
[50.8]
1.0
[25.4]
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000
[7.08] [14.16] [21.24] [28.32] [35.40] [42.48] [4956] [56.64] [63.72] [70.80] [77.88] [84.96]
E
Standard cubic feet per hour. Cubic meters per hour in brackets [ ].
G
B
C
A
M5081 and D
M5180 Series Vent to relieve trapped fuel
outside the hazardous area. H Pipe Plug (remove to
install vent tube).
Inches water column (∆p) drop across valve.
Millimeters water column in brackets [ ].
g.)
1k
(.1
A. Main Stem
z.
3.0
4o
.)
[76.2]
kg
B. Pressure Disc/seal (in run/open)

28
. (.
oz
C. Pressure Disc/seal (in trip/closed)

10
2.0
ar]
[50.8]
a ) [.6
9b D. Vent Seal Gland
k P
(69 bar] E. Reset Knob (latches valve open)
sig [1.38
10 p 38 kPa)
1.0
20 p
sig (
1
2.07
bar] F. Manual Trip Knob (not available for M5081FS)
Pa) [
[25.4]
0 7 k
30 ps
ig (2 G. Indicator Button (out with valve open)
H. Pipe Plug
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
[14.16] [28.32] [42.48] [56.64] [70.80] [84.96] [99.12] [113.28] [127.44] [141.60]
Standard cubic feet per hour. Cubic meters per hour in brackets [ ].
NOTE: If the vent-after-tripping feature is not used,
remove O-ring (D), to avoid condensation accumulation
that can hamper trip action.
Be sure to replace Pipe Plug (H) and to clean vent
periodically.

DIMENSIONS
CAUTION: THE ARROW ON THE SIDE OF THE FUEL VALVE MUST POINT TO THE CORRECT DIRECTION OF THE
FLOW, FROM FUEL SOURCE TO THE ENGINE. APPLY PIPE DOPE ONLY TO FUEL PIPE, NOT TO THE FUEL VALVE.
M2582 M2582-P
1/4 in. (6 mm) tube connection; control
1/2 NPT Conduit pressure 3 psi (21 kPa) [0.21 bar] minimum,
Reset Knob Connection Latch Arm (see NOTE) 75 psi (517 kPa) [5.17 bar] maximum.
Manual Trip
Knob
1 NPT Breather/Vent
(2 places) 1/16 in. (2 mm)
1 NPT
(2 places)
6-9/16 in.
7-5/16 in. 1/4 NPT (167 mm)
1/4 NPT (186 mm) Vent and
Vent and Plug Plug
3-3/32 in.
3-3/32 in. (79 mm)
(79 mm) 5-1/2 in. (140 mm)
5-1/2 in. (140 mm)
NOTE: Thumb operated opening latch (2.5 psi [17 kPa]
[0.17 bar] required to release cocking latch)
M5180-P
Latch Arm (see NOTE 2)
Breather Vent 10-7/16 in. (265 mm) 6-1/8 in.

(see NOTE 1) (156 mm)
1/4 in. (6 mm)
connection;
2 NPT control pressure
(2 places) 3 psi (21 kPa)
[0.21 bar] minimum,
80 psi (552 kPa)
[5.52 bar] maximum
(see NOTE 1) 4-3/8 in.
(111 mm)
Vent and Plug
1/2 NPT
9-3/8 in. (238 mm) 4-1/4 in.

(108 mm)
NOTE 1: Control pressure connection fitting and breather vent fitting can be swapped to convert to vacuum control.
NOTE 2: Thumb operated opening latch (2.5 psi [17 kPa] [0.17 bar] required to release cocking latch).
Magnetic Switch Adapters

65700053 (was 65020126); 65700054 (was 65020127); 65700055 (was 65020155)
2-5/16 in. (59 mm)
3/8 in.
1-15/32 in. (10 mm) 2-5/8 in. (67 mm)
(37 mm)
1-23/32 in.
Panel Mount screws (44 mm)
10-24 N.C. x 31/32 in.
5/16 in. (8 mm) long (25 mm)
2-7/16 in.
(62 mm)
15/32 in. GND ALT1 ALT2 SW
(12 mm)
Terminal screws
8-32 N.C. x
1/4 in. (6 mm) long
DIMENSIONS continued
CAUTION: THE ARROW ON THE SIDE OF THE FUEL VALVE MUST POINT TO THE CORRECT DIRECTION OF THE
FLOW, FROM FUEL SOURCE TO THE ENGINE. APPLY PIPE DOPE ONLY TO FUEL PIPE, NOT TO THE FUEL VALVE.
M5081 and M5081FS
Manual Trip Knob 1/2 NPT Conduit

(M5081 only) Reset Knob Connection (2 plcs.)
1-3/8 in. (35 mm)
Inlet
Breather
10-5/16 in.
(262 mm)
3-7/16 in.
Indicator (87 mm)
Button
4-1/16 in.
2 NPT (103 mm)
Vent and Plug (2 places)
1/2 NPT
3 in. (76 mm)
9-3/8 in. (238 mm) 7-3/4 in. (197 mm)
M5081-3 Steel Flanged Option
45°
3-5/8 in.
(92 mm) dia.
3/4 in. (19 mm) dia.

(4 places) each end
2 in. (51 mm) dia. 2 places equally spaced on a
150# RF (raised face) pipe flange 15/32 in. (121 mm) b.c.
(bolt circle)
14-25/64 to 14-29/64 in.
(366/367 mm)

INSTALLATION
WARNING: STOP THE ENGINE AND DISCONNECT ALL ELECTRICAL POWER BEFORE BEGINNING INSTALLATION. BEGIN THE
INSTALLATION BY SECURING AREA OF ANY HAZARDOUS CONDITIONS. SHUTOFF THE FUEL GAS SUPPLY. FOR HAZARDOUS
APPLICATIONS REFER TO NATIONAL ELECTRICAL CODE SPECIFICATIONS.
Connecting the Fuel Shut-off Valve

Figure 1
1. Before connecting the unit, apply pipe dope to plumbing male threads
Physical Location and Plumbing (typical)
that will be inserted into the valve. Do not apply pipe dope to the valve.
2. Make sure that the arrow on the side of the valve indicates the correct
Fuel Shut-off Valve
direction of the flow.
3. Fuel shut-off valves can be installed in all three planes. However, Master Regulator Bypass Fuel
mounting the valve horizontally (with vent pointing down) is (High pressure) Regulator Filter Carburetor
recommended. Do not install valve with top down. (Refer to Figure 1.)
4. Hold valve in position, (use a tool on valve wrench flats) and tighten
plumbing into inlet and outlet ends. (Refer to dimensions on pages 3-4.)
Wrench Flats
CAUTION: DO NOT TWIST THE VALVE BODY HOUSING. Remove plug and attach vent line.
FUEL FLOW Route to non-hazardous area.
5. To mount flanged models, follow the appropriate installation codes
and ordinances for the application. (For dimensions see page 4.)
6. A vent line (to allow gas trapped forward between fuel valve and the
carburetor to escape) should be attached to the vent connection at the
bottom of the valve housing. Remove the plug and install the line. Figure 2
(Refer to Figure 1.) Pull the lever up, and press the latch
down into ridge with thumb.
Connecting Pneumatic Models
M2582-P and M5180-P
1. Repeat the steps above (1 thru 5), and observe the necessary cautions. Level Arm (Handle)
2. A lever/arm (handle) and a cocking latch are provided to allow manual
opening of the valve. The thumb-operated latch can be locked in place
to hold the lever/arm latched. The cocking latch will be released when Control Pressure
Connection
pilot pressure reaches 2.5 psi (17 kPa) [0.17 bar]). M2582-P and
M5180-P automatically open at 2 psi (14 kPa) [0.14 bar], and fully Thumb-operated
Cocking Latch
open at 3 psi (21 kPa) [0.21 bar]. See Specifications, page 12 for Breather
maximum control pressure. Vent
CAUTION: BE SURE PNEUMATIC SOURCE

RELEASES THE MECHANICAL LATCH WHEN RUNNING.
3. If vacuum control is desired, swap the Control Pressure connection

fitting and the Breather Vent fitting on your M5180-P model (see Fig. 2).

WIRING INFORMATION
WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NON-HAZARDOUS.
MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS. HARD CONDUIT
WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
M2582 Internal Wiring Internal Wiring

Wiring shown in normal mode of operation (seat open). The 20 AWG for M2582
(0.75 mm2) wire is color coded to the coil:
For CD ignitions: White and Orange Optional
White Resistor
For Magneto ignitions: White and Green (Note)
For Battery: White and Blue Black
Conduit Installation NOTE:

Install a 1/2 NPT conduit from the M2582 conduit connection to the For grounding the ignition (CD models only) Red
through the fuel valve snap-switch, use a
power source. See M2582 Dimensions (page 3) for location. Magnetic Switch Adapter (see Magnetic Ground
For wiring the M2582 fuel valve to Solid-State TATTLETALE® Switch Adapter, below) and install a 100
annunciators, refer to pages 9, 10, and 11. ohm; 2 watt resistor (included on page 11).
M5081 Internal Wiring

M5081 Internal
Wiring shown in normal mode of operation (seat open). The 18 AWG
Wiring Disconnect
(1.0 mm2) wire is color coded to the coil: Valve Switches
Coil Ignition 1 Ignition 2
For CD Ignitions: White and Orange
For Magneto Ignitions: White and Green
For Battery: White and Blue
Conduit Installation
Install a 1/2 NPT conduit from the M5081 conduit connection to the
power source. Refer to Dimensions (on page 4) for location.
For typical wiring of the M5081 models refer to pages 7 and 8. Ground
For wiring the M5081 fuel valves to Solid-State TATTLETALE ®

10 9 8 7 6 5 4 3 2 1
annunciators, refer to pages 9, 10, and 11.
Jumper Jumper
M2582-C-LS Wiring M5081-C-LS Wiring
Optional
White Resistor
White (See Note)
FV– FV–
NOTE: For grounding the ignition (CD models only) through the fuel
Orange Orange valve snap-switches, use a Magnetic Switch Adapter, see Magnetic
FV+ (IGN) FV+ (IGN) Switch Adapter, below and the “TO CLOSE THE FUEL VALVE and
GROUND THE IGNITION” attachment, and install a 100 ohm; 2
watt resistor (included with your attachment).
M5081FS Internal Wiring Magnetic Switch Adapters for Use with

For typical Wiring refer to page 8. Capacitor Discharge Ignitions
For wiring the M5081FS to MARK IV 12/24 refer to page 10. Connect the Magnetic Switch Adapter between the fuel Valve
terminal 1 and the CD Ignition. See wiring diagrams (pages 7 and 11).
Valve
Coil
Ground Switch 2 (Note) Switch 1
65700053 (was 65020126): For use with
negative ground ignitions up to 240 VDC. +
65700054 (was 65020127): For use with
positive ground ignitions up to 450 VDC.
IN4007
65700055 (was 65020155): For use with ALT ALT
10 9 8 7 6 5 4 3 2 1 GND 1 2 SW
negative ground ignitions up to 450 VDC.
Negative ground
Magnetic Switch Adapter shown
NOTE: Wiring shown in normal mode of operation (seat open). The 18 AWG (1.0 mm2)
wire is red color for both options: 12 VDC and 24 VDC.

TYPICAL WIRING for M5081-C (CD IGNITION MODELS)
M5081-C
CD Ignition Models Magnetic
Switch
GND ALT1 ALT2 SW Adapter
Terminal Block
10 9 8 7 6 5 4 3 2 1
CD ignition Additional
CD ignition
Ground Jumpers
100 ohm, 2 watt

Start-run Resistor (Notes 3 and 4)
timer
MS2100 MS2100
6 1 2 3 4 5 6 1 2 3 4 5
To additional
TATTLETALE®
NOTE 1: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITION (Single CD Ignition Systems) Remove the factory-installed jumper on terminals 6-5.
Do NOT ground terminal 6.
NOTE 2: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITIONS (Dual CD Ignition Systems) Remove the jumper on terminals 6-5.
Connect second ignition to Magnetic Switch Adapter terminal ALT2.
NOTE 3: To CLOSE FUEL VALVE and GROUND THE IGNITION (Single CD Ignition Systems) Remove the jumper on terminals 6-5.
Connect a 100 ohm, 2 watt resistor between valve terminals 1-2. Ground terminal 6.
NOTE 4: To CLOSE FUEL VALVE and GROUND THE IGNITION (Dual CD Ignition Systems) Remove the jumper on terminals 6-5. Connect a 100 ohm,
2 watt resistor between valve terminals 1-2. Ground terminal 6. Connect second ignition to Magnetic Switch Adapter terminal ALT2.
TYPICAL WIRING for M5081-B (BATTERY IGNITION MODELS)
M5081-B
Battery Models + --
DC Power
Terminal Block source
10 9 8 7 6 5 4 3 2 1
Ground
Jumpers
* *forIN4005 Diode
flyback protection
MS2110 MS2110
Start-run
timer
6 1 2 3 4 5 6 1 2 3 4 5
To additional
TATTLETALE®
TYPICAL WIRING for M5081-A (MAGNETO IGNITION MODELS)
M5081-A
Magneto Ignition Models
Terminal Block
10 9 8 7 6 5 4 3 2 1
Magneto
Ground
65010065 Additional
Diode Package
(See Notes 2/4) Jumpers Magneto
MS2120 MS2120
Start-run
timer
6 1 2 3 4 5 6 1 2 3 4 5
To additional
TATTLETALE®
NOTE 1: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITION (Single Magneto Systems) Remove the factory-installed jumper on terminals 6-5.
Do NOT ground terminal 5.
NOTE 2: To CLOSE FUEL VALVE–NOT GROUNDING THE IGNITIONS (Dual Magneto Systems) Remove the factory-installed jumpers on terminals 6-5 and 9-8.
Add 65010065 diode package as shown. Do NOT ground terminals.
NOTE 3: To CLOSE FUEL VALVE and GROUND THE IGNITION (Single Magneto Systems) The factory-installed jumpers (6-5 and 9-8) must be in place.
Add ground wire to terminal 5.
NOTE 4: To CLOSE FUEL VALVE and GROUND THE IGNITION (Dual Magneto Systems) Remove the jumper on terminals 9-8.
Add 65010065 diode package as shown. Add ground wire to terminal 5.
TYPICAL WIRING for M5081FS (NORMALLY ENERGIZED MODELS)
M5081FS
12 or 24 VDC Models
Terminal Block
10 9 8 7 6 5 4 3 2 1
+ --
Ground Ground * DC Power
source
MS2110 MS2110
6 1 2 3 4 5 6 1 2 3 4 5
* forIN4005 Diode
flyback protection
* *
Start-run timer

TYPICAL WIRING to SOLID-STATE TATTLETALE® Annunciators
WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NON-HAZARDOUS.
MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS. HARD
CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
M2582-C to LCDT-PS-CD (R)-P (positive ground) M5081-C to LCDT-PS-CD (R)-P (positive ground)
LCDT-PS-CD (R)-P LCDT-PS-CD (R)-P

M5081 Terminal block Terminal block
M2582 Fuel Valve + –
IGN 1 + –
White 10 9 8 7 6 5 4 3 2 1 IGN 1
GND
GND
Black FV(+)
FV Relay
FV(-)
Contacts
Red jumper jumper FV(-) *
NO
C
Relay NO
Contacts C
NC
NC
Ground
* FV(-) FET output rated: 0.5 A @ 250 VDC max.
Relay contacts rated: 3 A, 30 VDC, 4 A, 125/250 VAC
M2582-C to LCDT-PS-CD-N (negative ground) M5081-C to LCDT-PS-CD-N (negative ground)
LCDT-PS-CD-N LCDT-PS-CD-N
+ M5081 Terminal block Terminal block
–
M2582 Fuel Valve
IGN 1 – +
White 10 9 8 7 6 5 4 3 2 1 IGN 1
FV(+)
FV(+)
Black FV(-) * Relay
FV(-) *
GND
jumper jumper GND
Contacts
Red
NO
C
Relay NO
Contacts C
NC
NC
Ground * FV(-) FET output rated: 0.5 A @ 250 VDC max.

* Relay contacts rated: 3 A, 30 VDC, 4 A, 125/250 VAC
M2582-C to MARK IV-N (negative ground) M5081-C to MARK IV-N (negative ground)
M2582 Fuel Valve M5081 Terminal block

+ –
White
10 9 8 7 6 5 4 3 2 1
Black
Red jumper jumper

IGN 1
F/V+
GRD
F/V-
IGN 1
F/V+
GRD
F/V-
Ground MARK IV-N *

terminal block
MARK IV-N * MARK IV has FET outputs rated: 0.5 A @ 250 VDC max.
terminal block

TYPICAL WIRING to SOLID-STATE TATTLETALE® Annunciators
WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NON-
HAZARDOUS. MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS.
HARD CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
M5081FS to MARK IV-12/24 M5081-B to MARK IV-12/24
M5081FS Terminal Block M5081-B

K1 and K2:
MARK IV-12/24 1 External
terminal block 10 9 8 7 6 5 4 3 2 1 – –
10 9 8 7 6 5 4 3 2 1 Relay(s)
K1 *
+
K2 *
+
12/24V *
SD jumper jumper
* K2 K1
F/V
GRD
F/V
S/D
GRD
+
12/24V
--
DC Power
source -- +
DC Power
* forIN4005 Diode
flyback protection
IN4005 Diode
* for flyback protection source
MARK IV-12/24 1
1 MARK IV has FET outputs rated: 0.5 A @ 250 VDC max. terminal block
1 MARK IV has FET outputs rated: 0.5 A @ 250 VDC max.
Remove shunt jumper E2 for ignition ground time delay.
M5081FS to MARK III-12/24 M5081-C to MARK III-N

†† Alarm Relay
*– + Power –
M5081FS Terminal Block K1 Supply
1 + -- M5081 Terminal block
MARK III-12/24 12/24 VDC
10 9 8 7 6 5 4 3 2 1 terminal block Power source
10 9 8 7 6 5 4 3 2 1
Ignition
12/24 IGN 90-250 Vdc
* S/D +FV
jumper jumper
-FV
FV
ALM
ALM
GRD
GRD
* IN4005 Diode for flyback protection 2
Auxiliary Relay * IN4005 Diode for flyback protection
MARK III has FET outputs rated: † MARK III-N
1
0.5 A @ 250 V max.
*– + 2
† MARK III has FET outputs rated: terminal block
K1 0.5 A @ 250 V max.
Auxiliary or
2 Auxiliary Relays must be
*– Shutdown Relay †† Alarm Relay must be
hermetically-sealed, third party + hermetically-sealed, third party
certified for use in Class I, K2 certified for use in Class I,
Division 2, Gps. C & D areas. Division 2, Gps. C & D areas.
M5081-C to TTDJ-IGN-(T) M2582-C to TTDJ-IGN-(T)
M5081 Terminal block

M2582 Fuel Valve
10 9 8 7 6 5 4 3 2 1 – +
IGN White
NA IGN
GRD NA
Black
FV+ GRD
jumper jumper FV- FV+
ALR FV-
NA
NA
Red ALR
NA
NA

TYPICAL WIRING to SOLID-STATE TATTLETALE® Annunciators continued
WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF” AND THE AREA MADE NON-
HAZARDOUS. MAKE SURE THE VOLTAGE AND CURRENT REQUIREMENTS ARE WITHIN THE FUEL SHUT-OFF VALVE RATINGS.
HARD CONDUIT WITH APPROVED SEALS IS REQUIRED BY THE NEC FOR HAZARDOUS AREA INSTALLATIONS.
(A) M5081-B to TTDJ-DC-(T) (B) M2582-B to TTDJ-DC-(T)

To 12 or 24 VDC
M5081 Terminal block To 12 or 24 VDC power supply
power supply
M2582 Fuel Valve
10 9 8 7 6 5 4 3 2 1 SD
White
10-32VDC
GRD
SD Black K2 K1 NA
*
10-32VDC 1 FV
jumper jumper GRD
ALR
K2 K1 NA
1
Red MPU
FV
GRD
ALR
MPU
GRD
1 K1 and K2 are hermetically Sealed

auxiliary relays, third party certified for 1 K1 and K2 are hermetically Sealed
use in Class I, Div. 2, Gps. C & D areas.
auxiliary relays, third party certified for
* 1N4005 diode for flyback protection. use in Class I, Div. 2, Gps. C & D areas.
TTDJ-DC-(T) to Relays
Connections Shown for Use with M5081FS to TTDJ-DC-(T)
Diagrams (A), (B), (C), and (D) on this page.
To 12 or 24 VDC
M5081FS Terminal Block power supply
1
IGNITION RELAY + –
K1
10 9 8 7 6 5 4 3 2 1 SD
*
10-32VDC
12-24 VDC GRD
NA
Power supply 1
FV
*
SD
+ – ALR
K2 10-32VDC
MPU
GRD GRD
* NA
FV
ALR
1 K1 and K2 are hermetically Sealed MPU
GRD
auxiliary relays, third party certified for
use in Class I, Div. 2, Gps. C & D areas. * 1N4005 diode for flyback protection.
* 1N4005 diode for flyback protection.
(C) M2582-C w/Magnetic (D) M5081-C w/Magnetic

Switch Adaptor to CD Ignition Switch Adaptor to CD Ignition
Magnetic Magnetic
Switch Switch
Adapter Adapter
GND ALT1 ALT2 SW GND ALT1 ALT2 SW
M5081 Terminal block
M2582 Fuel Valve +

10 9 8 7 6 5 4 3 2 1
White K2 – +
Black 1 –
jumper jumper K2
Red 1
1 K2 is hermetically sealed auxiliary relay, third party 1 K2 is hermetically sealed auxiliary relay, third party
certified for use in Class I, Div. 2, Gps. C & D areas. certified for use in Class I, Div. 2, Gps. C & D areas.

SPECIFICATIONS
Valve Body: Sandcast aluminum, painted red (corrosion resistance); Coil Rating: Intermittent duty; coil type must match power source;
Optional cast steel available for M5081 and M5081FS models only. • CD ignition coil resistance: 72 Ω
Valve Seat: Buna-N CD ignition primary voltage: 1.38 to 3.8 A
• M5081FS: Energized to Run (continuous-duty coil) coil resistance:
Maximum Valve Inlet Pressure: 12 V model: 33 Ω;
• M2582/M2582-P: 80 psi (552 kPa) [5.52 bar] 24 V model: 136 Ω
• M5081/M5081FS/ M5180-P: 100 psi (689 kPa) [6.89] • Magneto ignition coil resistance: 0.5 Ω
Maximum Control Pressure (Pneumatic Models): Magneto primary voltage: 1 to 5 A
• M2582-P: 75 psi (517 kPa) [5.17 bar] • Battery coil resistance : 7 Ω
• M5180-P: 80 psi (552 kPa) [5.52 bar] 12 or 24 VDC: 1.2 to 2.4 A
Snap-switch: M2582: One SPDT, 5 A @ 480 VAC Laboratory Approval: CSA listed for Class I, Groups C and D
M5081, and M5081FS: Two SPDT, 5 A @ 480 VAC Hazardous Locations. 5 amps maximum; intermittent duty; models
Wiring: M2582: Wire leads; M5081, and M5081FS: Terminal blocks M5081 and M5081-CD engine ignition powered, and model M5081-B, 12
NOTE: All aluminum versions of the M5081 Series Fuel Valve carry or 24 VAC or VDC; switch contacts rated 5 A @ 480 VAC maximum.
Canadian Registartion Number OC1476.2. Maximum pressure 100 psi (689 kPa) [6.89 bar].
SERVICE PARTS M2582 M5081 M5081FS M2582-P M5180-P

Coil Assembly
Battery 55000128 55000126 ------------ ------------ ------------
CD Ignition 55000129 55000127 ------------ ------------ ------------
Magneto Ignition 55000094 55000080 ------------ ------------ ------------
M5081FS Coil Assembly
12 VDC ------------ ------------ 55000158 ------------ ------------
24 VDC ------------ ------------ 55000159 ------------ ------------
Latch Block Assembly
Latch block assembly 55000095 55000074 ------------ ------------ ------------
Latch block switch and coil assembly ------------ ------------ ------------ ------------ ------------
Latch block switch and mounting bracket assembly ------------ 55000118 55000196 ------------ ------------
Handle and Latch Kit
Handle and latch kit ------------ 55000102 55000102 5500148 55000154
Handle kit 55000096 ------------ ------------ ------------ ------------
Manual DIsconnect Assembly 55000097 55000137 --------------- --------------- ---------------
Snap Switch Assembly 55000098 55000072 55000160 --------------- ---------------
Close/Open Indicator Assembly ------------ 55000138 55000138 --------------- ---------------
Stem and Seat Kit 55000093 55000075 55000135 55000147 55000135
Top Works Complete Valve Less Body and Vent 55000146 55000131 55000161 55000150 55000155
Vent Bushing Assembly 55000143 55000132 55000132 55000143 55000132
Diaphragm Assembly ------------ ------------ ------------ 55000184 55000153
Pilot Diaphragm ------------ ------------ ------------ 00007908 55050420

Diode Package for Dual Magneto Ignitions ------------ 65010065 ------------ ------------ ------------
Magnetic Switch Adapter for CD Ignitions
Single/Dual ign. – negative ground up to 240 VDC 65700053 65700053 ------------ ------------ ------------
Single/Dual ign. – positive ground up to 450 VDC 65700054 65700054 ------------ ------------ ------------
Single/Dual ign. – negative ground up to 450 VDC 65700055 65700055 ------------ ------------ ------------
Warranty
A two year limited warranty on materials and workmanship is provided with this Murphy product.
Details are available on request and are packed with each unit.
CONTROL SYSTEMS & SERVICES DIVISION FRANK W. MURPHY, LTD. MACQUARRIE CORPORATION
P.O. Box 1819; Rosenberg, Texas 77471; USA Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. 1620 Hume Highway
(281) 342-0297 fax (281) 341-6006 +44 1722 410055 fax +44 1722 410088 Campbellfield, Vic 3061; Australia
FWMurphy e-mail sales@fwmurphy.com e-mail sales@fwmurphy.co.uk +61 3 9358-5555 fax +61 3 9358-5558
P.O. Box 470248 MURPHY DE MEXICO, S.A. DE C.V. www.fwmurphy.co.uk e-mail murphy@macquarrie.com.au
Tulsa, Oklahoma 74147 USA Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje
MURPHY SWITCH OF CALIFORNIA
(918) 317-4100 San Luis Potosí, S.L.P.; México 78384 41343 12th Street West
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In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.
Printed in U.S.A. 0966106
Type 119
Fisher Controls Instruction Manual
Type 119 Control Valve
June 1990 Form 5204
Introduction
Scope of Manual
This instruction manual provides installation, spring adjust-
ment, maintenance, and parts information for the Type 119
control valve.
Description
The Type 119 control valve (figure 1) is used for on-off or
throttling control of noncorrosive or mildly corrosive liquids
and gases. It is designed to meet the low-pressure liquid
and gas application requirements in many varied industries.
As loading pressure is applied to the Type 119 control valve

diaphragm, the disk holder is pulled off the orifice. As load-
ing pressure is reduced, the opposing spring force moves
the disk holder toward the closed position, resulting in W3735-1
spring-close action should a loss of supply pressure occur.
Figure 1. Type 119 Control Valve
Specifications the service conditions do not exceed the lim-

its shown in table 1. The leak-off and spring
Table 1 lists specifications for the Type 119 control valve. case vents must be kept open. To avoid dan-
Some of the specifications for a given control valve as it ger of fire or explosion from venting of flam-
originally comes from the factory are stamped on a name- mable or otherwise hazardous fluid into a
plate (figure 2) located on the spring case flange. closed or poorly vented location, pipe the
vents to a well-ventilated location, away
from any buildings or windows so as not to
create a further hazard.
1. Before installing the valve, be sure the valve body and

Installation associated equipment are free of damage and foreign ma-
terial.
WARNING 2. The control valve can be installed in any position, but

the normal orientation is with the actuator portion vertical
D100261X012
above the body. If installing the control valve at an outside

To avoid personal injury or property damage location, point the spring case and bonnet vents in the
caused by controlled process fluid or burst- downward direction to protect them from moisture or foreign
ing of pressure-retaining parts, be certain materials.
eFisher Controls International, Inc. 1982, 1990; All Rights Reserved

R
Type 119
Table 1. Specifications
Maximum Inlet Pressure(1) Material Temperature Capabilities(1)

150 psig (10.3 bar) With Nitrile Elastomers: -20 to 170_F (-29 to 77_C)
With Fluoroelastomers: 0 to 250_F (-18 to 121_C)
Note: Not for use with hot water or ammonia.
Spring Ranges
See table 2 Flow Direction
Up through the seat ring
Maximum Control Pressure to Diaphragm
Spring Case Vent and Bonnet Leak-Off Connection
150 psig (10.3 bar)
1/4-inch NPT female
Maximum Pressure Drop(1) Approximate Weight

150 psi (10.3 bar) for all port diameters 6 lb (2.7 kg)
1. The pressure and temperature limitations in this manual, and any applicable code
limitation, should not be exceeded.
Table 2. Spring Selection

SPRING RANGE SPRING
SPRING PART
COLOR
Psig Bar NUMBER
CODE
3-15 0.2-1.0 1D8923 27022 Red
5-20 0.3-1.4 1D7515 27022 Cadmium
5-35 0.3-2.4 1D6659 27022 Blue
30-60 2.1-4.1 1D7455 27142 Green
1E5427-F
Material Orifice
Code Seat Disk Material
AI/N
SST/N
Aluminum/Nitrile
Stainless steel/Nitrile
Spring Adjustment
SST/V Stainless steel/Fluoroelastomer
The control valve spring has been selected to meet the
pressure condition requirements of the application as spe-
cified on the order. This pressure condition is stamped on
Figure 2. Type 119 Nameplate the actuator nameplate.
The spring has a fixed pressure span over which loading

pressure will stroke the valve. Adjustment of the spring
compression shifts the span so that more or less loading
3. Install the valve using accepted piping practices. Make pressure is required to start travel. Since the span does not
sure that the valve is oriented so that flow through the body change, there will be a corresponding increase or decrease
will match the flow direction arrow on the body. in the pressure requirements at the end of the valve stroke.
4. If continuous operation is required during maintenance

and inspection, install a three-valve bypass around the con- If the control valve has been disassembled or pressure
trol valve. conditions have changed, the spring may need adjustment
to make the valve travel coincide with the diaphragm pres-
5. Connect the control pressure line to the 1/4-inch NPT sure range. Make the adjustment in the following manner.
connection in the valve body bonnet marked PILOT. Key numbers refer to figure 3.
2
Type 119
1. Loosen the locknut (key 13) on the spring case. 7/8-inch socket wrench, and replace it with a new seat ring
of the proper size.
2. Turn the adjusting screw (key 12) clockwise to
compress the spring (key 16) or counterclockwise to 4. Remove the bonnet O-ring (key 11), and inspect it for
decrease spring compression. Increased spring compres- wear and damage.
sion results in increased loading pressure necessary to
start travel. Decreased spring compression results in less 5. Unscrew and remove the spring case cap screws (key
loading pressure required to start travel. 14). Remove the spring case, upper spring seat, and spring
(keys 2, 17 and 16). Do not lose the nameplate (key 20)
when removing the spring case.
3. After adjustment, tighten the locknut. Note that the
spring can be identified by the color code. Depending on 6. Pull the hair pin clip (key 6) from the stem and remove
how much conditions are changed, it may be necessary to the disk holder assembly (key 4).
install a new spring, using appropriate steps in the Mainte-
nance section. After changing the spring, adjust the valve 7. Pull the diaphragm/stem assembly (key 5) out of the
using the above steps in this section, and indicate the new bonnet (key 9), and inspect for damage or deterioration. If
spring range on the nameplate. necessary, replace the entire diaphragm assembly.
8. Without removing the O-rings and bushing spacers

(keys 8 and 7) inspect their inside diameter surfaces for
damage or deterioration.
Maintenance
Note
Valve parts are subject to normal wear and must be
inspected and replaced as necessary. Inspection and The following step should be performed
maintenance depends on the severity of the service only when there is an indication of O-ring or
conditions. bushing spacer failure.
9. Remove the internal retaining rings, stem wipers, O-

rings, and bushing spacers (keys 10, 19, 8 and 7). Inspect
WARNING these parts for wear or deterioration, and replace if neces-
sary.
To avoid personal injury or property damage
caused by sudden release of pressure or
uncontrolled process fluid, isolate the Assembly
control valve from the pressure system, and This procedure assumes that the control valve has been
release all pressure from the valve body and completely disassembled. If the control valve has been only
actuator before performing maintenance partially disassembled, start these instructions at the ap-
operations. propriate step.
The following describes the procedure for complete 1. If the orifice (key 3) was removed during disassembly,
disassembly and assembly of the actuator-valve body lubricate the threads with Never-Seez(1) lubricant (key 21)
combination. When inspection or repairs are required, or equivalent, and screw it into the valve body using a thin-
disassemble only those parts necessary to accomplish the wall 7/8-inch socket wrench.
job. Key numbers refer to figure 3.
2. Lubricate the bushing spacers, O-rings, stem wipers,
and internal retaining rings (keys 7, 8, 19 and 10) with Dow
Corning(2) No. 111 silicon-base lubricant (key 22) or equiva-
Disassembly lent, and install as shown in figure 3.
1. Isolate the control valve from all pressure, and release
3. Carefully slide the diaphragm assembly (key 5) into and
pressure from the valve body and actuator. Loosen the lock-
through the O-rings and bushing cavity. Turn the diaphragm
nut (key 13), and remove all spring compression from the
assembly to line up the diaphragm holes with the bonnet
control valve by turning the adjusting screw (key 12) out of
holes.
the spring case.
4. Slide the disk holder assembly (key 4) all the way into
2. Remove the two bonnet cap screws (key 15, not shown) the stem. Connect the disk holder assembly with the hair pin
that secure the bonnet to the body, and lift the spring case, clip (key 6).
bonnet, and trim assembly from the body.
5. Coat the bonnet O-ring (key 11) with Dow Corning No.
3. Examine the seating edge of the orifice (key 3). If it is 111 lubricant (key 22) or equivalent. Install the O-ring in the
nicked or rough, unscrew it from the body with a thinwall recessed notch in the bonnet (key 9).
1. Trademark of Never-Seez Corp.

2. Trademark of Tretolite Div. of Petrolite Corp. 3
R
Type 119
6. Mount the bonnet (key 9) on the valve body (key 1), in- Key Description Part Number
sert two cap screws (key 15, not shown), and tighten to 7 Part Kits
foot-pounds (9 newton-meters). Kits include keys 4, 5, 6, 8, 10, 11, and 19.
For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4
7. Put the spring (key 16) on the diaphragm assembly (key (6.4 mm), 5/16 (7.9 mm), & 3/8 (9.5
5), and place the upper spring seat (key 17) in the end of the mm) inch orifices w/aluminum
disk holder nitrile diaphragm, and
spring. nitrile disk & O-rings R119X 000A12
For 1/2 (12.7 mm) & 9/16 (14.3 mm) inch
8. Lubricate the point and threads of the adjusting screw orifices w/aluminum disk
(key 12) with Never Seez lubricant (key 21) or equivalent. holder, nitrile diaphragm and nitrile
disk & O-rings R119X 000A22
For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4
9. Position the spring case (key 2) and nameplate (key 20)
(6.4 mm), 5/16 (7.9 mm), & 3/8 (9.5
on the diaphragm assembly (key 5). Insert the cap screws mm) inch orifices w/stainless
(key 14). steel disk holder, nitrile diaphragm
and nitrile disk & O-rings R119X 00SN12
10. Tighten all cap screws until finger tight. Then, following For 1/2 (12.7 mm) & 9/16 (14.3 mm) inch
a crisscross pattern, tighten each cap screw. orifices w/stainless steel disk
holder, nitrile diaphragm and nitrile
disk & O-rings R119X 00SN22
11. Connect the control piping to the control connection in For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4
the bonnet. (6.4 mm), 5/16 (7.9 mm), & 3/8 (9.5
mm) inch orifices w/stainless
12. Adjust the spring by following the procedures in the steel disk holder and fluoroelastomer
Spring Adjustment section, and remark the nameplate if diaphragm, disk, & O-rings and
stainless steel disk holder R119X 00SV12
necessary.
For 1/2 (12.7 mm) & 9/16 (14.3 mm) inch
orifices w/stainless steel disk
holder and fluoroelastomer diaphragm,
disk & O-rings R119X 00SV22
NACE Construction
Parts Ordering For 1/8 (3.2 mm), 3/16 (4.8 mm), 1/4 (6.4 mm),
5/16 (7.9 mm), and 3/8 (9.5 mm) inch orifices
When contacting your Fisher sales office or sales represen- w/aluminum disk holder, fluoroelastomer
tative for technical assistance or ordering replacement diaphragm, disk and O-rings R119X N0SV32
parts, include the type number and all other pertinent in- For 1/2 (12.7 mm) and 9/16 (14.3 mm) inch
formation stamped on the nameplate attached to the spring orifices w/aluminum disk holder,
case. fluoroelastomer diaphragm,
disk and O-rings R119X N0SV42
When ordering replacement parts, also be sure to include 1 Valve Body

the 11-character part number for each part required from the Cast iron
following parts list. 3/4-inch 1E9871 19012
1-inch 1E9873 19012
1-1/4-inch 1E9875 19012
Steel
3/4-inch 1E9871 X0012
1-inch 1E9873 X0012
Parts List 2 Spring Case
Aluminum 2P9015 08012
Key Description Part Number 3* Orifice
Aluminum
1/8-inch (3.2 mm) diameter 1A9367 09012
Note 3/16-inch (4.8 mm) diameter 009912 09012
1/4-inch (6.4 mm) diameter 0B0420 09012
In this parts list, parts marked NACE are intended for cor- 5/16-inch (7.9 mm) diameter 0B0421 09012
rosion-resistant service as detailed in the National 3/8-inch (9.5 mm) diameter 0B0422 09012
Association of Corrosion Engineers (NACE) standard
9/16-inch (14.3 mm) diameter 1E9852 09022
MR-01-75. Stainless steel
3/16-inch (4.8 mm) diameter 009912 35032
9/16-inch (14.3 mm) diameter 1C4252 35032
*Recommended spare parts

4
Type 119
Key Description Part Number Key Description Part Number
4* Disk Holder Assembly(1) 8* O-Ring(1) (2 req’d)

Aluminum/nitrile Nitrile 18A7019 X012
1/2 and 9/16-inch 1C4248 000B2 Fluoroelastomer (high-temperature,
Stainless steel/nitrile corrosion) 18A7019 X022
1/8 (3.2 mm), 3/16 (4.8 mm), 1/4 (6.4 mm), Nace MR-01-75, fluoroelastomer 18A7019 X022
5/16 (7.9 mm) & 3/8 (9.5 mm) inch 9 Bonnet, aluminum 48A7025 X012
orifices 1A8328 000A2 10 Internal Retaining Ring(1) (2 req’d)
1/2 (12.7 mm) & 9/16 (14.3 mm) inch Nitrile & fluoroelastomer 18A7020 X022
orifices 1C4248 000A2 Nace MR-01-75, fluoroelastomer 18A7020 X032
Stainless steel/fluoroelastomer
1/8 (3.2 mm), 3/16 (4.8 mm), 1/4 (6.4 mm) 11* Bonnet O-Ring(1)
5/16 (7.9 mm) & 3/8 (9.5 mm) inch Nitrile 1K5949 06562
orifices 1A8328 000M2 Fluoroelastomer (high-temperature,
1/2 (12.7 mm) & 9/16 (14.3 mm) inch corrosion) & Nace MR-01-75 13A5559 X012
orifices 1C4248 X0052 12 Adjusting Screw, zinc plated steel 1D9954 48702
Nace MR-01-75, aluminum/fluoroelastomer 13 Locknut, zinc plated steel 1A3537 24122
1/8 (3.2 mm), 3/16 (4.8 mm), 1/4 (6.4 mm) 14 Cap Screw, zinc plated steel (8 req’d) 1A3917 24052
5/16 (7.9 mm) & 3/8 (9.5 mm) inch
orifices 1A8328 X0122 15 Cap Screw, zinc plated steel (2 req’d)
1/2 (12.7 mm) & 9/16 (14.3 mm) inch (not shown) 1B7877 24052
orifices 1C4248 X0182 16 Actuator Spring, zinc plated steel See table 2
5* Diaphragm/Stem Assembly(1) 17 Upper Spring Seat, zinc plated steel 1D6671 25072
Aluminum/nitrile 17A8080 X032 18 Type Y602-12 Vent (not shown) 27A5516 X012
Stainless steel/nitrile 17A8080 X022 19 Stem Wiper(1), TFE (2 req’d) 18A7024 X012
Stainless steel/fluoroelastomer 17A8080 X012 20 Nameplate, aluminum 1E5427 11992
Nace MR-01-75, Aluminum/fluoroelastomer 19A0348 X022
6 Hair Pin Clip(1) 21 Never-Seez Lubricant, 1 gal (3.81 L) can
All except NACE 19A0347 X012 (not furnished with valve) 1M5239 06992
NACE MR-01-75 19A0347 X022 22 Dow Corning 111 Lubricant, 10 lb (4.53 kg) can
7 Bushing Spacer, Delrin 500(2) (2 req’d) 18A7021 X012 (not furnished with valve) 1M5283 06992
23 Vent Screen, stainless steel (not shown) 0L0783 43062
24 Nace Tag 19A6034 X012
25 Tag Wire 1U7581 X0022
*Recommended spare part.

1. Included in repair kit.
2. Trademark of DuPont Co.
5
R
Type 119
V APPLY LUB/SEALANT
37A8078-C
Figure 3.Type 119 Control Valve
While this information is presented in good faith and believed to be accurate, or any other matter with respect to the products, nor as a recommendation to
Fisher Controls does not guarantee satisfactory results from reliance upon such use any product or process in conflict with any patent. Fisher Controls reserves
information. Nothing contained herein is to be construed as a warranty or guar- the right, without notice, to alter or improve the designs or specifications of the
antee, express or implied, regarding the performance, merchantability, fitness products described herein.
For information, contact Fisher Controls:

R
Fisher Controls Marshalltown, Iowa 50158 USA Sao Paulo 05424 Brazil
Cernay 68700 France Singapore 2158
6
Printed in U.S.A.
Publication T1-702, Rev. 1
Dated: January 22, 2001
INSTALLATION AND OPERATING

MANUAL
MODELS: T100-B, T100-D, T100-F, T100-P
TURBOTWIN Engine Air Starters
AN 95-414 From Tech Development Inc

6800 Poe Ave. ·Dayton OH 45414
Tel: (937) 898-9600 ·Fax: (937) 898-8431
TDI TURBOTWIN
FROM TECH DEVELOPMENT INC
TABLE OF CONTENTS
SECTION SUBJECT PAGE

1.0 GENERAL INFORMATION 2
1.1 DESCRIPTION 2
1.2 PRODUCT IDENTIFICATION 2
1.3 PERFORMANCE 3
2.0 ORIENTATION OF THE STARTER 3

2.1 GENERAL 3
3.0 INSTALLING THE STARTER 3

3.1 SUPPLY LINE INSTALLATION 3
3.2 NLET PRESSURE PORT 4
3.3 EXHAUST PIPING 4
3.4 NATURAL GAS INSTALLATION 4
3.5 PIPING SYSTEM 4
3.6 BACKLASH 5
4.0 STARTER OPERATION 5

4.1 BASIC OPERATION 6
4.2 AUTOMATED START PANEL 6
5.0 PREVENTIVE MAINTENANCE 6
6.0 TROUBLE SHOOTING GUIDE 7
7.0 TURBOTWIN WARRANTY 8
LIST OF FIGURES
1. TURBOTWIN PART NUMBER LISTING

2. MODEL T112B/T121B INSTALLATION DRAWING
3. MODEL T106F/T112F INSTALLATION DRAWING
4. MODEL T112D/T121D INSTALLATION DRAWING (STD MESH)
5. MODEL T112D/T121D INSTALLATION DRAWING
Publication T1-702, Rev 1

Issued January 22, 2001 1
TDI TURBOTWIN
1.0 GENERAL INFORMATION This aerodynamic speed control helps protect the
TURBOTWIN starter from damage caused by starter motor
This manual provides instructions for the installation and over speed.
operation of the TDI T100 TURBOTWIN Starters (Series:
B,D,F,P). If there are questions not answered in this The T100 TURBOTWINS employ a 7.5:1 or 9:1 ratio
manual, please contact your TDI TURBOTWIN distributor or planetary gearbox. This low gear ratio allows the turbine
dealer for assistance. motor to spin at low speeds for long bearing life. At a
typical 3000 rpm pinion speed, the turbine is cruising at a
The T100 TURBOTWIN models are turbine driven starters low 22500 rpm (7.5:1 ratio). Reliability and part commonality
with an inertially engaged starter drive. Depending on the are designed into all TURBOTWINS.
starter model and engine installation, the TURBOTWIN
starters have applications ranging from 1200 CID (20 Liters) A simple and reliable inertia drive delivers the torque to the
on diesel engines and up to 15000 CID (250 Liters) on gas pinion. The pinion is thrown out to engage the engine's ring
engines. The TURBOTWIN models are suited to operate gear by the turbine motor's acceleration. Lighter weight
within a wide range of inlet pressures and ambient rotating parts used in the TURBOTWIN provide low inertia
temperatures. The engine size and parasitic loading will and even "softer" engagement. In the event of over-
determine the exact minimum pressure that will assure pressure, the friction clutch used in every TURBOTWIN
reliable starting. protects ring gear teeth from static torque overloads. In
addition, an inertia engaged starter eliminates the need for
The T100 TURBOTWIN starters are designed for operation complex pre-engagement control plumbing...and is easier to
with compressed air or natural gas; materials used are install and maintain than pre-engaged type starters.
compatible with “sour” natural gas and marine environments.
Small amounts of foreign matter or liquid in the air stream Compressed air or natural gas is used to power T100
will not adversely affect TURBOTWIN starters. As with all TURBOTWIN air starters through the inlet port. The air or
other TDI starters, no lubrication is required in the air supply. gas is expanded through the first nozzle or stators. The high
velocity gas impinges on the first stage rotor to yield torque
Please review the rest of this manual before installing the to the gearbox. The gas is further expanded through the
T100 TURBOTWIN series air starter. second stage stators, which impart additional torque to the
second stage rotor.
WARNINGS, CAUTIONS AND NOTES
1.2 PRODUCT IDENTIFICATION
Certain types of information are highlighted in this manual
for your attention: The starter nameplate which is attached to the turbine
housing contains the following information: model number,
WARNING - used where injury to personnel or serial number, part number, direction of rotation and the
damage to the equipment is likely. maximum rated operating pressure.
CAUTION - used where there is the possibility of The directions of rotation are either right hand or left hand
damage to the equipment. rotation as shown in Figure 1. Right Hand rotation is defined
as clockwise rotation as viewed from the pinion end of the
NOTE - used to point out special interest starter, and Left Hand rotation is counter clockwise rotation
information. viewed from the pinion end of the starter.
NOTE The maximum operating pressure is also stamped on the

Throughout this manual, the term “air” is used to designate nameplate. This pressure is measured at the check port on
the starter drive medium. Unless other wise stated, air “ the starter inlet with the starter in operation.
means either compressed air or natural gas.
CAUTION
1.1 DESCRIPTION Exceeding the maximum pressure shown on the nameplate
may result in drive failure, damage to the starter, or damage
All models feature three basic subassemblies: a unique two to the engine.
stage turbine motor section, a planetary gearbox section and
an inertia drive assembly. The housing proof pressure is 600 psig and is also shown
The two stage motor section features greater stall torque on the nameplate. This means the turbine housing will not
than a single stage turbine plus aerodynamic speed control. burst when subjected to a static pressure of 600 psig.
Page 2 Publication T1-702, Rev 1

Issued January 22, 2001
TDI TURBOTWIN
WARNING
If a fuel (pulse) lubricator has previously been installed in the
system, disconnect and plug the line to eliminate spraying
diesel fuel on the engine.
The starter should be installed with the inlet in a position

between horizontal and straight down. Any condensation will
be restricted to the air lines and not in the starter.
WARNING
Do not operate this starter unless it is properly connected to
an engine.
3.1 SUPPLY LINE INSTALLATION
WARNING
Be sure to either bleed the pressurized air reservoir and/or
Figure 1. Direction of Rotation viewed from Pinion End. safety the system such as closing all valves prior to installing
starter supply line.
1.3 PERFORMANCE
The T100 TURBOTWIN series air starters come standard
Graphs of the performance curves feature pinion torque with a 2" NPT female pipe thread for the inlet connection
versus pinion speed (rpm) at constant drive air pressures port. The supply line consists of the line from the air source,
and shaft horsepower versus pinion speed at constant drive
a pressure regulator (when necessary), a manual or relay
air pressures. Pinion speed is shown on the horizontal axis.
valve, and the connection to the starter inlet. Hard piping
The pinion torque is shown along the left edge vertical axis.
may be used, but a section of flexible tubing should be
The shaft horsepower is shown along the right edge vertical
installed at the starter to prevent leaks due to engine
axis. Air consumption rates are given for the various drive
vibration.
pressure lines. These performance curves feature air as the
drive gas and have open exhaust (standard exhaust guard)
Care must be taken to ensure that all inlet supply line piping
which have no back pressure.
is no less than 1.5" and all components used are capable of
passing the required air flow.
2.0 ORIENTATION OF THE STARTER
NOTE
2.1 GENERAL Valves with a Cv of 40 or higher are recommended.
If the factory orientation of the starter’s pinion housing
If the supply line must be longer than 20 feet, the inlet supply
assembly in relation to the inlet port does not fit your engine
line piping should be increased to 2" in diameter to ensure
installation, these components can easily be re-oriented.
proper performance by your TURBOTWIN.
All TURBOTWINS have the capability to rotate the inlet port
Because turbine starters such as the T100 TURBOTWIN
relative to the drive opening for the optimum inlet port
series are sensitive to flow restrictions, care must be taken
location. The number of different positions is 6 to 12
to use uniform hose or tubing and fittings for connection of
depending on model.
the supply line. Tees, elbows and line length must be kept
to a minimum. TDI recommends that hose or flex couplings
3.0 INSTALLING THE STARTER are installed to eliminate possible leakage caused by strain
on the supply line.
A turbine air starter does not require lubrication in the supply
air. Therefore, if a vane type starter motor is being replaced, Normally, an air strainer is not required. However, in dirty
TDI recommends that all lubrication devices and lines environments use of a #40 mesh Y-strainer is
removed to minimize flow restrictions. recommended. The T100 TURBOTWIN series is highly
tolerant of dirt in the air line, however, starter life can be
increased with the use of an air strainer.

TDI TURBOTWIN
A pressure regulator is required when the air supply installed at the pressure check port and electrical lines
pressure is great enough to exceed the starter operating routed to a digital display at the operator's station.
pressure (at the inlet port) and/or the maximum torque.
This pressure port is invaluable in diagnosing air starter
A manual ball valve may be used to admit drive air/gas to and/or installation problems.
the starter. The manual valve should be located in a safe
position away from the engine. 3.3 EXHAUST PIPING
A preferred valve is pilot-operated, which can be The turbine exhaust may be plumbed away from the starter
pneumatically or electrically actuated. The valve should be area. All starters using natural gas must be piped according
located close to or even on the starter inlet for best to industry codes and local regulations.
performance. Pneumatic or electrical control lines may be
routed virtually anywhere for the customer's preferred The performance of a turbine starter will be decreased
operating station. This type of valve actuates from a fully because of back pressure when smaller than recommended
closed to a fully open position very rapidly. TDI offers a exhaust piping is installed. If back pressure hampers starter
variety of relay valves such as P/N RLVA-25683-001-2-01, performance, compensation can be made by increasing the
which is a 1-1/2" port, pneumatically actuated valve. supply pressure. Consult your TDI distributor for advice.
The supply line should be dry-fitted for proper alignment Exhaust piping should be routed downward to help prevent
/location prior to final assembly. All pipe threaded joints any accumulation of condensation in the starter motor.
should be sealed with Loctite Pipe Thread Sealant (TDI P/N
9-94085) or equivalent for leak tight joints prior to final If the overhung section of the starter is not otherwise
assembly. Be sure to tighten all joints to proper torque after supported, TDI recommends supporting the exhaust piping
final assembly. with a suitable bracket(s).
CAUTION Exhaust piping should be routed downward to help prevent

In cold weather climates, care should be taken while any accumulation of condensate in the starter motor.
designing your installation to prevent condensation from
developing in the starter system. In systems with a regulator 3.4 NATURAL GAS INSTALLATION
valve or relay valve, there is the possibility of freeze-ups.
The installation of the starter using natural gas is similar to
A tee connection with a quick disconnect can be added to the air installation except all fittings, piping, valves and
the inlet. This will allow an external air source to be used to regulators must be compatible with natural gas.
accomplish a “blow start” if the system freezes. Once the
engine has been started, the other system components may Proper control of natural gas is a major consideration when
be thawed. used in the starter system. All starters using natural gas
must pipe the exhaust according to industry codes and local
CAUTION regulations.
On new installations, it is strongly recommended to blow out
the supply line with air to remove possible dirt and welding There is a natural gas vent port in the turbine housing that is
slag prior to final connection to the TURBOTWIN starter. Be plugged for compressed air use. This vent is used to remove
sure to secure the free end of the supply line prior to blowing any natural gas that could leak past the primary turbine shaft
out the line. seal. Remove this 3/8"NPT plug and install a line to carry
gas away from the starter area.
3.2 INLET PRESSURE PORT
WARNING
A 1/4" NPT port is located on the air inlet. This port may be Do not connect the turbine housing vent line to the turbine
used to check the supply pressure at the starter when the exhaust line. Exhaust gas can pressurize the housing.
starter is operating. Remove the 1/4" NPT pipe plug and
save for later use. Install a 1/4" minimum size tubing to the 3.5 PIPING SYSTEM
port. Route the tubing away from the starter to a safe
location away from the engine. Install a pressure gauge on Only type approved metallic hose assemblies are approved
the tubing. This pressure monitoring line/gauge may be in permanently pressurized compressed air lines of starters.
permanently installed. Use Loctite Pipe Thread Sealant or Non-metallic hose assemblies are allowed only in case the
equivalent. Alternately, a pressure transducer may be piping system will be emptied after the starting procedure.

TDI TURBOTWIN
Pipe unions must be type approved by GL. Downstream of mounting bolts. Torque the three 5/8" screws to 100 lb-ft.
the pressure regulator a pressure relief valve is to be
provided. 4.0 STARTER OPERATION
3.6 BACKLASH Prior to operation, check that all connections are tight and
free from leaks. Check the 1/4" NPT pipe plug or a pressure
Backlash is the "free play" between the mesh of two gears. gauge/transducer that may be connected to the pressure
Figure 15 shows the backlash between two gears. port on the starter inlet.
Maintaining the proper gear backlash setting allows the
gears to mesh smoothly. Proper backlash and alignment WARNING
allows smooth engagement/disengagement of the pinion Do not operate the TDI TURBOTWIN starter with air pressure
gear and loads the tooth face surfaces evenly producing greater than the pressure rating on the nameplate. This
longer gear life. The correct backlash setting for 6/8 pressure is measured at the starter inlet while the starter is
diametral pitch gearing used on larger engines is as follows: running.
Minimum backlash .015 inch
The maximum operating pressure limit is the inlet pressure
Maximum backlash .025 inch
measured at the starter’s inlet pressure check port. In order
to check the starter, a 1/4"NPT pipe tap connection is
To check the backlash, the pinion will need to be rolled out
provided in the inlet housing to attach a pressure
onto the end of the drive prior to starter installation. This can
gauge/transducer). The maximum pressure assumes an
be accomplished by using a hex drive wrench to rotate the
open exhaust (standard turbine exhaust guard). The
turbine end of the starter while holding the pinion from
standard exhaust guard causes no back pressure.
rotating. The pinion will simply walk to the end of the shaft.
An access hole to reach the turbine screw is provided in the
The static non-flowing supply pressure will always be higher
turbine exhaust guard. The starter must then be installed on
than the operating (dynamic) pressure. The maximum
the engine. Checking backlash can be accomplished using
pressure limit (proof pressure) that the TDI TURBOTWIN
a dial indicator or a simple blade-type feeler gauge. Because
starter housings may be subjected to is 600 PSIG (42 BAR).
ring gears are not usually perfectly round, it is necessary to
System pressure that exceeds the maximum operating limit
must use a pressure reducing device to ensure that the
operating pressure limit to the TDI TURBOTWIN starter is
maintained.
System static pressure that exceeds the 600 PSIG (42 BAR)
limit must, in addition to pressure reducer devices
incorporate a pressure relief valve set below 600 PSIG (42
BAR) in the supply air line.
NOTE
For maximum life of the starter pinion and for the protection
of the engine ring gear, limit the operating pressure to that
necessary to start the engine at its most difficult starting
Figure 2. Checking Backlash conditions.
check backlash at several (six or more) points around the All appropriate local pressure codes and pressure limitations
circumference of the ring gear. Average the highs and lows on other system components must be adhered to and
to allow a setting that is in the range cited above. supersede the guidelines given in this manual.
Setting the correct backlash may involve "shimming" and/or Consult your TDI distributor if you have exhaust plumbing
moving the starter bracket(s). An adjustable starter bracket that creates back pressure and reduces starter
design will simplify this procedure. Always re-check the performance. You may be able to increase the supply
backlash after a ring gear replacement. pressure to restore the lost power.
Follow the engine manufacturer’s instructions for starting the
Liberally grease the starter’s drive teeth with chassis lube engine.
and then mount the TURBOTWIN starter on the engine.
Tighten all mounting hardware as appropriate. Make sure to
use Loctite Threadlocker #290 or equivalent on the starter 4.1 BASIC OPERATION
TDI TURBOTWIN
speed.
The basic operation of the starter is as follows:
The automated start panel should monitor engine speed to
Pressurized air or natural is admitted to the starter by determine air on and air off. Do not simply use time as a
opening of the manual or relay valve. The air expands control parameter. Avoiding excessive operation of the
through the turbine, which produces shaft rotation and starter after the engine is firing will maximize the starter life.
torque. The acceleration of the drive assembly causes the
pinion to advance and engage the ring gear of the engine. 5.0 PREVENTIVE MAINTENANCE
The starter motor torque causes the engine to accelerate. The TDI TURBOTWIN starters provide distinct advantages
This acceleration causes the pinion to be disengaged from of size and efficiency as compared to electric motor, vane-
the ring gear. The fuel and ignition systems now fire the type or other turbine-type starters. It is important to properly
engine. Closing the relay valve stops the starter. install the starter to receive full benefit of these advantages.
Repair technicians or service organizations without turbine
The operator may decrease starter life by the continual starter experience should not attempt to repair this machine
operation of the starter after the engine has started. Upon a until they receive factory approved training from TDI, or its
successful engine start, turn the air off to the starter representatives.
immediately. Minimizing the time the starter is operating
unloaded (i.e. the engine is running) will maximize starter Proper operation and repair of your TDI TURBOTWIN
life. If a start is aborted, a restart may be attempted after the starter will assure continued reliable and superior
engine and the starter has come to rest. performance for many years.
CAUTION 5.1 Every Six (6) Months

Do not engage the starter while the engine is running.
Perform the following procedures at six(6) months intervals
The drive air pressure is the primary starter control if the normal cranking cycle is 0 - 10 seconds.
parameter. It is important, especially on new installations, to
measure this pressure during several engine starts. The 5.1.1 Check the amount and condition of grease in the
secondary parameter is the starter pinion speed. This speed planetary gearbox. If gearbox requires re-greasing, only use
is usually measured by knowledge of the engine starting TDI grease. Approximately one (1) pint of grease is needed
speed and the starter cranking ratio. The cranking ratio is to repack the gearbox.
the number of ring gear teeth divided by the number of
pinion teeth. The starter pinion speed is then found by 5.1.2 Check the turbine bearing and carrier output bearings
multiplying the engine speed by the cranking ratio. The for freedom of rotation without excessive play between
pinion speed is usually 2000-3500 rpm at typical engine races. If bearings are damaged, replace them with genuine
starting speed. TDI parts. Refer to TDI Service Manual for part numbers.
4.2 AUTOMATED START PANEL 5.1.3 Place a small amount of chassis lube on the starter’s
pinion teeth.
The starter drive pressure measured at the starter inlet must
be set. As noted above, for maximum life of the starter 5.2 Every Three (3) Months
pinion and for the protection of the engine ring gear, limit the
operating pressure to that necessary to start the engine at its Follow the six (6) month procedures if there is severe starter
most difficult starting conditions. loading or extended duration crank cycles. Also perform
these procedures every three (3) months when starter is
The speed control parameter will then need to be set. used for motoring the engine for maintenance or valve
Engine starting speed along with the cranking ratio number adjustments.
can be used to determine starter pinion speed. The pinion
speed is usually 2000-3500 rpm for a typical engine starting Motoring Crank Cycle: 10 -60 seconds
speed. Once the start sequence has begun, the air is
admitted to the starter. The starter begins to accelerate the Extended Crank Cycle: 60 seconds or longer
engine. Once the firing speed of the engine is reached, the
automated start panel may deliver fuel to the engine. The starter, use only genuine TDI replacement parts. The
engine will begin to accelerate under its own power. The component part numbers are found in the Illustrated Parts
starter should be dropped out of the sequence at a rpm Breakdown.
higher than the firing speed, but less than the engine idle
TDI TURBOTWIN
6.0 TROUBLESHOOTING CHART
TROUBLE PROBABLE CAUSE SOLUTION

1. Starter does not A. Relay valve not fully open. A. Repair or replace relay valve.
run; small air flow from
exhaust. B. Nozzle blockage. B. Remove blockage or obstruction from nozzles.
2. Starter does not A. Broken turbine rotor. A. Replace all damaged parts.
run; normal air flow
from exhaust. B. Broken gear train. B. Repair or replace geartrain.
C. Damaged starter drive. C. Repair or replace starter drive.
3. Reduced Starter A. Inlet air pressure too low. A. Increase air pressure in 10 PSIG (0.6 BAR)
output power. increments; DO NOT EXCEED OPERATING LIMIT.
B. Inlet supply piping too small. B. Supply piping must be a minimum of 1.5" diameter.
C. Pressure regulator orifice too C. Increase orifice size or replace pressure regulator
small.
D. Inlet supply line valve (ball, D. Install larger valve.
gate, relay, plug) too small.
E. In line lubricator installed in E. Remove lubricator.
supply line.
F. Y-Strainer in supply line F. Clean strainer.
clogged.
G. Excessive back pressure; G. Clean exhaust piping or increase size to at least the
exhaust restricted. minimum diameter recommended.
H. Damaged turbine nozzle. H. Replace turbine nozzle.
I. Broken started drive. I. Repair or replace starter drive.
J. Wrong rotation starter. J. Replace with starter or proper rotation.
K. Wrong size starter. K. Check the Application Guide for the correct starter.
4. Engine cranks too A. Inlet air pressure too high. A. Decrease air pressure in 10 PSIG (0.6 BAR)
quickly. increments.
OR
If there is a manual shut-off valve in the supply line,
partially close it.
OR
Install a restriction orifice in the inlet supply line.
B. Wrong size starter. B. Check the Application Guide for the correct starter.

TDI TURBOTWIN
7.0 WARRANTY
TDI TURBOTWIN ENGINE STARTER WARRANTY

Tech Development Inc. (TDI) warrants to the original user of the TDI TurboTwin™ Model T30 Series air starters to be free from
defects in material and workmanship for a period of one year from date of purchase by such user. The warranty period shall
begin on the actual delivery date to the original user or twelve (12) months from the date of shipment from TDI, whichever
comes first. The conditions of this warranty are: a) TDI is notified within this period by return of such product to TDI or its
authorized distributor or dealer, transportation prepaid by user; b) such product has been installed according to TDI’s
specifications; c) such product has not been misused, abused or improperly maintained by user; d) the defect is not the result
of normal wear and tear; and e) such starter product has not been repaired with parts not manufactured or authorized by TDI,
and TDI installation and repair procedures as outlined in the appropriate manual were properly followed.
Tech Development Inc. shall, at its option, either repair or replace, without charge, any such starter product found by TDI’s
examination to be defective, or by mutual agreement, refund the user’s purchase price in exchange for such starter product.
Repairs or replacements are warranted for the remainder of the original warranty period.
Tech Development Inc. makes no other warranty, and IMPLIED WARRANTIES INCLUDING ANY WARRANTY OR
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED.
This warranty constitutes the entire obligation of Tech Development Inc. relating to the sale and use of such product, and
TDI’s maximum liability is limited to the purchase price of such product at the date of purchase. In no event shall TDI be
liable for incidental, indirect, consequential or special damages of any nature arising from the sale or use of such engine
starter product.

TDI TURBOTWIN

TDI TURBOTWIN

TDI TURBOTWIN

TDI TURBOTWIN

TDI TURBOTWIN

TDI TURBOTWIN
T112-B / T112-D Performance Curve
TORQUE 12 Nozzles, Compressed Air, 7.5:1 RATIO POWER
Nm LB.FT HP KW
476 350 100 74.6
Inlet Pressure SCFM Nm3/h
150 psig Maximum Torque 150 psig 1360 2312
408 300
Transmitted by Drive 120 psig 1090 1853
90 psig 860 1462 80 59.6
120 psig
60 psig 610 1037
340 250
90 psig 60 44.8
272 200
204 150
60 psig 40 29.8
136 100
20 14.9
68 50
0 0 0
0 5 10 15 20 25 30 35 40 45 50 55
T121-B / T121-D Performance Curve

TORQUE POWER
21 Nozzles, Compressed Air, 7.5:1 RATIO
Nm LB.FT HP KW
476 350 100 74.6
90 psig 90 psig 1560 2652
408 300 Maximum Torque
60 psig 1070 2140
Transmitted by Drive
30 psig 620 1054 80 59.6
340 250
60
ps
ig
60 44.8
272 200
204 150
40 29.8
30
psi
g
136 100
20 14.9
68 50
0 0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500

TDI TURBOTWIN
TORQUE
T106-F Performance Curve POWER
Nm LB. FT 6 Nozzles, Compressed Air, 7.5:1 RATIO HP KW
238 175 50 37.2
150 psig Inlet Pressure SCFM Nm3/h
150 psig 680 1156
204 150 Maximum Torque 120 psig 550 935
Transmitted by Drive 90 psig 430 731 40 29.8
12
0p 60 psig 310 527
sig
170 125
90 30 22.4
136 100 ps ig
102 75
60 20 14.9
p sig
68 50
10 7.5
34 25
0 0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
TORQUE
T112-F Performance Curve POWER
Nm LB.FT 12 Nozzles, Compressed Air, 7.5:1 RATIO HP KW
238 175
90 psig
Maximum Torque Inlet Pressure SCFM Nm3/h
Transmitted by Drive 90 psig 860 1462
204 150 60 psig 610 1037 45 33.5
30 psig 370 629
60
ps
170 125 ig
136 100 30 22.4
102 75 30
ps i
g
68 50 15 11.2
34 25
0 0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500

TDI TURBOTWIN
POWER
TORQUE
Nm LB.FT
T109-P Performance Curve HP KW
9 Nozzles, Compressed Air, 9.0:1 RATIO
476 350 80 59.6
408 300 150 psig 1050 1785
15 120 psig 850 1445
0 DRIVE TORQUE LIMIT 90 psig 670 1139
ps 60 psig 460 782 60 44.8
340 250
12 ig
0p
sig
272 200
90
psi 40 29.8
g
204 150
136 100
20 14.9
60 p
s ig
68 50
0 0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500

Publication T1-701, Edition 1
Dated: December 1998
SERVICE MANUAL
T100 Series (T112B/T121B,

T112D/T121D, T106F/T112F, T109P/T115P)
TURBOTWIN ENGINE AIR STARTERS
From Tech Development Inc

6800 Poe Ave. ·Dayton OH 45414
Tel: (937) 898-9600 ·Fax: (937) 898-8431
TDI TURBOTWINÔ
FROM TECH DEVELOPMENT, INC.
TABLE OF CONTENTS LIST OF ILLUSTRATIONS

Section Subject Page Figure Title Page
1.0 Introduction……………………………. 1 23 Pressing Bearing onto Shaft………….. 18

2.0 Description of Basic Groups…………. 4 24 Installing Shaft into Gearbox Hsg…….. 18
3.0 Disassembly………………………… … 8 25 Tightening Retainer Nut……………….. 19
4.0 Cleaning and Inspection…………… … 12 26 Woodruff Key Installation……………… 19
5.0 Assembly………………………………. 15 27 Tightening Retainer Nut (T106F)…….. 20
6.0 Parts List……………………………. … 21 28 Drive Hsg. Installation (T106F)………. 20
7.0 Accessories……………………………. 30 29 Illustrated Parts Breakdown (B)……… 25
30 Illustrated Parts Breakdown (P)……… 26
LIST OF TABLES 31 Illustrated Parts Breakdown (D)……… 27
32 Illustrated Parts Breakdown (D)……… 28
33 Illustrated Parts Breakdown (F)……… 29
Table No. Title Page
1 T100 Series Service Tool Kits……….. 8

2 Cleaning Materials & Compounds.. … 12
3 Parts Inspection Check Req………. … 13
4 Parts Wear Limits………………….. … 14
5 Materials for Assembly……………….. 15
LIST OF ILLUSTRATIONS
Figure Title Page
1 TDI Turbotwin Nameplate……………. 2

2 T30 Series Part Number Coding…….. 3
3 Turbine Housing Assembly…………… 4
4 Gearbox Housing Assembly (B/P)…… 5
5 Gearbox Housing Assembly (F)……… 5
6 Gearbox Housing Assembly (D/Std) … 6
7 Gearbox Housing Assembly (D/Lg). … 6
8 Bendix Drive Assembly………………. 7
9 Bendix Drive Removal………………… 8
10 Bendix Drive Removal (F)……………. 9
11 Gearbox Retainer Nut Removal……… 9
12 Pressing Out Carrier Shaft……………. 10
13 Turbine Rotor Removal………………... 10
14 Turbine Shaft Removal….…………….. 11
15 Nozzle 2 Removal……………………… 11
16 Gear Teeth Wear Allowance………….. 14
17 Pressing Front Turbine Bearing………. 15
18 Pressing Spacer onto Bearing…………15
19 Installation of Turbine Shaft……………16
20 Installing the Aft Seal into Nozzle 1…...16
21 Pressing Aft Bearing onto Shaft……… 17
22 Planet Gear Carrier Shaft Assembly…. 17
Publication T1-701
Issued Dec 11, 1998
Page: i
TDI TURBOTWINÔ
SECTION 1.0 INTRODUCTION CAUTION - used where there is the possibility

of damage to equipment.
NOTE - use to point out special interest
1.1 GENERAL INFORMATION information.
This manual provides information for servicing,
disassembly, and reassembly of the TDI Turbotwin
1.3 DESCRIPTION OF OPERATION
T100 series air starters. If there are questions not
answered by this manual, please contact your local TDI The Turbotwin T100 series starters are powered by a
distributor or dealer for assistance. Illustrations and pair of axial flow turbines coupled to a simple planetary
exploded views are provided to aid in disassembly and gear reduction set. The T100 series starters
reassembly. incorporate an inertia bendix drive coupled to the starter
gearbox drive train to provide a means of disengaging
The TDI Turbotwin T100 series of engine starters are the pinion from the engine’s ring gear.
specially designed for starting today’s automated, low-
emission engines. The Turbotwin uses aerodynamic The high horsepower of the turbine air motor combined
speed control, eliminating the need for a mechanical with the planetary gear speed reducer results in a very
automatic trip valve (ATV) to control starter motor efficient and compact unit. The Turbotwin T100 series
speed. starters can be used over a wide range of drive
pressures from 30 psig (2 BAR) to 150 psig (10 BAR)
The Turbotwin T100 series air starters are suited to and are suitable for operation on either air or natural
operate within a wide range of inlet pressures and gas.
ambient temperatures. These starters are designed for
operation with either compressed air or natural gas. The Turbotwin T106F & T112F weighs approximately
47 pounds (21 KG) and each is capable of delivering
The robust turbine motor design in the Turbotwin T100 over 44 HP (33 kW) of cranking power at their
series starters has no rubbing parts, and is therefore maximum pressure of either 150 psig (10 BAR) or 90
tolerant of hard and liquid contamination in the supply psig (6 BAR) respectively.
gas with almost no adverse affects. The motor is well
adapted to running on “sour” natural gas. The Turbotwin T112B & T121B weighs approximately
55 pounds (25 KG) and each is capable of delivering
As with all TDI air starter products, there are no rubbing over 80 HP (60 kW) of cranking power at their
parts so there is no lubrication required. This maximum pressure of either 150 psig (10 BAR) or 90
eliminates failures due to lubricator problems, the psig (6 BAR) respectively.
expense of installing and maintaining the system, and
the messy and hazardous oil film around the starter The Turbotwin T112D &T121D weighs approximately
exhaust. The starter is factory grease packed for the 70 pounds (32 KG) and each is capable of delivering
life of the starter so it requires no maintenance. over 80 HP (60 kW) of cranking power at their
maximum pressure of either 150 psig (10 BAR) or 90
psig (6 BAR) respectively.
NOTE
Throughout this manual, the term “air” is used to donate The Turbotwin T109P & T115P weighs approximately
the starter drive medium. Unless otherwise stated, “air” 59 pounds (27 KG) and is capable of delivering over 60
means compressed air or natural gas. HP (41 kW) of cranking power at their maximum
pressure of either 150 psig (10 BAR) or 90 psig (6
Please review the rest of this manual before attempting BAR) respectively.
to provide service to the TDI Turbotwin T100 series
starters.
1.4 INSTALLATION AND SERVICE
1.2 WARNINGS, CAUTIONS, & NOTES It is important to properly install and operate the TDI
Turbotwin T100 series starters to receive the full
Throughout this manual, certain types of information will benefits of the turbine drive advantages. It must be
be highlighted for your attention: installed in accordance with the instructions provided by
Tech Development, Inc. (TDI).
WARNING - used where injury to personnel or damage
to equipment is likely.
Publication T1-701 Page 1

Issued Dec 11, 1998
TDI TURBOTWINÔ
FROM TECH DEVELOPMENT INC.
WARNING NOTE
Failure to properly install the starter or failure to operate You should always have the starter’s Part Number,
it according to instructions provided byTDI may result in Serial Number, Operating Pressure, and Direction of
damage to the starter or engine, or cause personal Rotation information before calling your TDI distributor
injury. DO NOT OPERATE THIS STARTER UNLESS or dealer.
IT IS PROPERLY ATTACHED TO AN ENGINE.
Repair technicians or service organizations without TDI TURBOSTARTä

turbine starter experience should not attempt to repair ENGINE AIR STARTERS
this starter until they receive factory approved training FROM TECH DEVELOPMENT, INC.
from TDI, or its representatives. Proper operation and BARBER-COLEMAN - a Siebe Company
repair of your TDI Turbotwin will assure continuous 6800 POE AVE., DAYTON, OH 45414
reliability and superior performance for many years. MODEL NO. SERIAL NO.
T112-B 9609-124
1.5 NAMEPLATE INFORMATION
PART NUMBER
T112-60001-B1R
The nameplate, located on the turbine housing,
provides important information regarding the
construction of your T100 series starters, refer to Figure CW (RH) CCW (LH)
1. The part number coding explanation, refer to Figure X AIR or NAT. GAS
USAGE
2, can help you when talking to your distributor.
MAX PRESS. 150 PSIG
MAESURED AT INLET WHILE OPERATING
PROOF PRESSURE OF HOUSING IS 600 PSIG
WARNING:DO NOT OPERATE UNLOADED OR WITHOUT
TURBINE GUARD OR EXHAUST FITTING
U.S PATENT 4509896
Figure 1. TDI Turbotwin Nameplate
Page 2 Publication T1-701

Issued Dec 11, 1998
TDI TURBOTWINÔ
Figure 2. Part Number Coding

Issued Dec 11, 1998
TDI TURBOTWINÔ
SECTION 2.0 DESCRIPTION OF 2.2 TURBINE HOUSING ASSEMBLY

BASIC GROUPS
The Turbine housing assembly, refer to figure 3,
2.1 GENERAL consists of a stage one (15) and a stage two (6) turbine
wheel mounted on sungear shaft (33) . The front
The TDI Turbotwin T100 Series air starters are bearing (10) is secured by a retainer plate (32). The aft
lightweight, compact units driven by a dual stage turbine bearing is preloaded by wavy spring (12).
type air motor. The starter is composed of three basic
assembly groups: Turbine Housing Assembly; Gearbox The ring gear (29) is heat shrunk into the front of the
Housing Assembly; and Bendix Drive Assembly. turbine housing (26) and secured by a setscrew (25).
Figure 3. Turbine Housing Assembly

Issued Dec 11, 1998
TDI TURBOTWINÔ
The carrier shaft is mounted on two ball bearings (41) in

2.3 GEARBOX HOUSING ASSEMBLY
the gearbox housing (58). The retainer nut (48)
secures the carrier shaft in the gearbox housing. The
The gearbox housing assembly, refer to figures 4,
front bearing (41) is secured by a retainer plate (46).
consist of a planet gear carrier and output shaft (35),
The back bearing is preloaded by use of a spring
three planet gears (37), needle bearings (38), spacers
washer (42).
(36), and bearing pins (39).
Figure 4. Gearbox Housing Assembly (T112B/T121B/T109P/T115P)
Figure 5. Gearbox/Bendix Assembly (T106F/T112F)

Issued Dec 11, 1998
TDI TURBOTWINÔ
Figure 6. Gearbox Assembly (T112D/T121D STD MESH)
Figure 7. Gearbox Assembly (T112D/T121D LONG MESH)

Issued Dec 11, 1998
TDI TURBOTWINÔ
2.4 BENDIX DRIVE ASSEMBLY The other end of the drive unit is mounted into a needle
bearing (54), which is installed in the nose of the drive
The Bendix drive assembly, refer to figure 8, consists of housing.
an inertial engagement drive or “bendix” (57) and drive
housing (61). The bendix is mounted to the output
shaft with two keys and a retaining set screw (53).
Figure 8. Bendix Drive Assembly (T112B, T121B, T112D, T121D, T109P, T115P)

Issued Dec 11, 1998
TDI TURBOTWINÔ
SECTION 3.0 DISASSEMBLY

Remove the needle bearing (62), if necessary, by
3.1 GENERAL simply tapping out the “welch” plug from the front of the
drive housing and press bearing out.
Always mark adjacent parts on the starter housing;
Nozzle 2/ Containment Ring (13), Turbine Housing (26), 3.3 DRIVE HOUSING
Gearbox Housing (58), and Bendix Drive Housing (61) (T112D/T121D)
so these parts can be located in the same relative
position when the starter is reassembled. 3.3.1 Removal of Drive Housing
Do not disassemble the starter any further than Remove the six screws (22). Mark position of bendix
necessary to replace a worn or damaged part pinion opening relative to gearbox housing for reference
during reassembly. Pull drive housing (49) from
Always have a complete set of seals and o-rings on gearbox housing (44). If drive housing is too tight, tap it
hand before starting any overall of a Turbotwin T100 with a mallet to loosen.
series starter. Never use old seals or o-rings.
3.3.2 Removal of Bendix Drive
The tools listed in Table 1 are suggested for use by
technicians servicing the Turbotwin T100 series In loaded spring area of drive (57) remove retaining ring
starters. The best results can be expected when these (51) from set screw (53) slot.
tools are used, however the use of other tools are
acceptable. Remove set screw using a flat head screwdriver, Figure
9, and pull the bendix assembly from the starter carrier
TOOL DESCRIPTION TDI/PN shaft.
Spanner wrench 52-20134
Spanner wrench 52-21345 Remove spring (52). This spring fits loosely between
Shaft Removal Tool 2-26945 the bendix assembly and carrier shaft. Remove the
Stage 2 Rotor Puller Tool 52-20076 needle bearing (62), if necessary, by simply tapping out
Carrier Shaft Holding Tool 52-20202 the “welch” plug from the front of the drive housing and
Tool, Bearing Pressing 52-20143 press bearing out.
Tool, Bearing/Seal 2-26943
Table 1. T100 Series Service Tools
3.2 DRIVE HOUSING

(T112B,T121B,T109P,T115P)
3.2.1 Removal of Drive Housing
Mark position of bendix pinion opening relative to

gearbox housing for reference during reassembly.
Remove the six bolts (60) and lock nuts (59). Pull drive
housing (61) from gearbox housing (58). If drive
housing is too tight, tap it with a mallet to loosen.
In loaded spring area of drive (57) remove retaining ring

(51) from set screw (53) slot.
Remove set screw using a flat head screwdriver, Figure

9 and pull the bendix assembly from the starter carrier
shaft. Remove spring (52). This spring fits loosely Figure 9. Bendix Drive Removal
between the bendix assembly and carrier shaft.

Issued Dec 11, 1998
TDI TURBOTWINÔ
3.4 DRIVE/GEARBOX HOUSING Remove bearing (65) from shaft by pressing shaft
while supporting inner race of bearing. Remove
(T106F/T112F)
bearing retainer plate (64).
3.4.1 Removal of Drive Housing
3.4.3 Planet Gear Disassembly
Mark position of bendix pinion opening relative to
Remove snap ring (34) from planet shaft (39) using
turbine housing (26) for reference during reassembly.
snap ring pliers and push shaft through holes in
Per Figure 10, remove the six screws (27). Pull drive
assembly.
housing (69) from turbine housing. If drive housing is
too tight, tap it with a mallet to loosen.
Slide the planet gear (37) out from the carrier shaft and
remove the two nylon spacer (36). Unless the needle
roller bearings 38) are damaged, do not remove. If
removal is necessary, simply press bearing out.
Figure 10. Bendix Drive Removal (T106F/T112F)

Figure 11. Gearbox Retainer Nut Removal
Remove four screws (31). Pull carrier shaft assembly
(63) from drive housing (69). The bendix (68) will 3.5 GEARBOX HOUSING
remain in the drive housing. With snap ring tool, (T112B/T121B,T112D/T121D,T109P/T115P)
remove snap ring (66) and bendix drive (68)from drive
housing. * The drive housing removal procedure should be
performed before performing this procedure.
If it is necessary to remove needle bearing (70) from
drive housing, simply press bearing out. 3.5.1 Removal of Gearbox Housing
Mount the carrier shaft assembly on the TDI holding Remove the six screws (27) and lift the gearbox
tool P/N 52-20202 placing the three holes on the assembly from the turbine assembly. If the gearbox
gearbox over the dow pins. Refer to Figure11. assembly is too tight, tap it with a mallet to loosen).
Place TDI tool P/N 52-21345 (Spanner Wrench) over 3.5.2 Gearbox Disassembly
shaft and into slots of retainer nut (67). Hold down
carrier shaft and remove nut. Mount the gearbox on the TDI holding tool P/N 52-
20202 placing the three holes on the gearbox over the
dow pins. Refer to Figure 11.

Issued Dec 11, 1998
TDI TURBOTWINÔ
Remove woodruff keys (40) from shaft by tapping them Slide the planet gear (37) out from the carrier shaft and
with a chisel and hammer remove the two nylon spacer (36). Unless the needle
roller bearings 38) are damaged, do not remove. If
With screwdriver remove tang of lockwasher (47) from removal is necessary, simply press bearing out.
slot of retainer nut (48).
3.6 TURBINE HOUSING
Place TDI tool P/N 52-20134 (Spanner Wrench) over
shaft and into slots of retainer nut. Hold gearbox down
3.6.1 Stage 2 Rotor Removal
and remove nut.
Remove the six screws (27) that connect the gearbox
In most cases the gearbox housing (58, D-44) can be
assembly to the turbine housing and separate the two
removed from the carrier shaft (35) by holding shaft
assemblies. Remove the four screws (18) and the
down and pulling directly up on housing. If this is not
clamping plate (32).
the case, press carrier shaft from housing per Figure
12.
Turn the turbine to the (exhaust) end up and remove
the six screws (1), screen support ring (2), and the
screen (3). For the T109P, remove six screws (74) and
Exhaust Cover Housing (75).
Hold the stage 2 rotor (6) and remove the turbine screw
(4) and washer (5).
Install the rotor puller tool P/N 52-20076 and remove

the stage 2 rotor per Figure 13.
Remove the woodruff key (7) using a hammer and

chisel.
Figure 12. Pressing Out Carrier Shaft
The aft bearing (41), spring washer (42), and bearing

spacer (43) will come out with the shaft. Remove aft
bearing (41) from shaft by pressing shaft while
supporting bearing.
If the aft bearing (41) is retained in the gearbox

housing when the carrier shaft is removed, apply
pressure through housing to the bearing to remove it. It
will be necessary to elevate the housing with a brace to
remove the bearing completely.
Remove the six screws (18) and retainer plate (46).

The front bearing may then be removed by lightly
tapping.
3.5.3 Planet Gear Disassembly
Remove snap ring (34) from planet shaft (39) and push Figure 13. Turbine Rotor Removal
shaft through holes in assembly.
Page 10 Publication T1-
701
Issued Dec 11, 1998
TDI TURBOTWINÔ
3.6 Turbine Shaft Removal Separate the stage 2 nozzle assembly (13) from the
turbine assembly (26) by firmly holding the turbine
Using the shaft removal tool P/N 2-26945 per figure 14, assembly, while tapping nozzle 2 with a mallet. If
press on the turbine shaft (33) while supporting the nozzle 2 is too tight, it can be removed by installing two
turbine housing. threaded screws into nozzle 2 and using them as jacks
to separate nozzle 2 from the turbine assembly. Refer
Press the shaft assembly (33) through the aft bearing to Figure 15.
(10) and continue pressing until the shaft assembly is
completely out of the housing (26). Rotate the stage 1 rotor if necessary to allow the jacks
to travel through the large holes in the rotor. The jacks
Remove the woodruff key (16), seal spacer (8), bearing will damage the stage 1 rotor if pressure is applied to
spacer (30), and bearing (10) from the shaft. The them while removing nozzle 2.
bearing can be removed from the shaft by pressing the
shaft through the bearing. Note that if T100 is the The stage 1 rotor (15) may now be removed.
original design (SN: 9501-239 to9611-191), the bearing
will be pressed inside a spacer. Remove the four screws (18) and nozzle 1 (19) from
the turbine assembly. It may be necessary to tap the
screws with a hammer and chisel to loosen.
On the stage 2 nozzle (13), remove the seal spacer (8)

from the forward side of the nozzle. Place the stage 2
nozzle on the exhaust end. Press through the lip seal
nd
onto the bearing until it, including the 2 lip seal and
seal spacer disengages from the nozzle. Turn the
nozzle over and press on the lip seal to remove.
Figure 14. Turbine Shaft Removal
Figure 15. Nozzle 2 Removal

Issued Dec 11, 1998
TDI TURBOTWINÔ
SECTION 4.0 CLEANING and Clean aluminum parts using the solutions per Table 2;
soak for 5 minutes. Remove parts, rinse in hot water,
INSPECTION
and dry thoroughly.
4.1 CLEANING Clean corroded steel parts with a commercially

approved stripper.
Degrease all metal parts, except bearings, using a
commercially approved solvent. Refer to Table 2. Clean corroded aluminum parts by cleaning as stated
above and then immerse the parts in chromic-nitric-
NOTE phosphoric acid pickle solution per Table 2. Rinse in
Never wash bendix assembly or bearings in cleaning hot water and dry thoroughly.
solvents. It is recommended that the bearings be
replaced with new parts.
MATERIAL or COMPOUND MANUFACTURER

Degreasing Solvent (Trichloroethylene) (O-T-634) Commercially Available
Acetone Commercially Available
Aluminum Cleaning Solution Diversey Corp., 212 W. Monroe, Chicago, IL 60606
Dissolve 5 oz of Diversey 808 per gallon of water at
155°- 165°F.
Steel Cleaner - Rust & Corrosion Oakite Products Corp., 50 Valley Rd., Berkeley
Heights, NJ 07992
Mix 3-5 lb. of Oakite rust Stripper per gallon of water;
use at 160°- 180°F.
Chromic-Nitric-Phosphoric Acid Pickle Solution Mix 8lb. of chromic acid, 1.9 gal. of phosphoric acid,
1.5 gal. of nitric acid with enough water to make a total
of 10 gal. of solution.
WARNING Follow all instructions provided with the MSDS sheets on the materials and compounds listed
above.
Table 2. Cleaning Materials and Compounds
4.2 INSPECTION
Check all bearing bores for wear and scoring. Bearing
Use Table 3 as a guide to check for acceptable bores shall be free of scoring lines, not to exceed
condition of the parts listed. 0.005² width and 0.005² depth.
Check all threaded parts for galled, crossed stripped, or Check gear teeth and turbine housing ring gear for
broken threads. wear. In general, visually check for spalling, fretting,
surface flaking, chipping, splitting, and corrosion. If
Check all parts for cracks, corrosion, distortion, scoring, wear is apparent, check the gear teeth dimensions in
or general damage. accordance with Table 4. Nicks and dents that cannot
be felt with a .020 inch radius scribe are acceptable.

701
Issued Dec 11, 1998
TDI TURBOTWINÔ
Part Check For Requirements

Description (Defective Parts Must Be Replaced)
Bendix Worn, loose, or missing parts Defective unit to be replaced. Use figure 5
as a guideline for acceptable pinion wear.
Drive Housing Cracks and breakage Cracks are not acceptable
Planet Gear Cracked, chipped, or galled Wear must not exceed limits per table 4.
teeth. Wear must not exceed
limits per Table 4. There shall be no evidence of excessive
wear.
Carrier Shaft Cracks, scoring or raised Deformation of metal smearing in planet
metal in planet shaft holes and pin holes & keyways not acceptable.
keyways. Integrity of knurl Scoring on bearing diameter not to
connection. exceed .005² depth.
Wear must not exceed limits per Table 4.
Planet Pins Wear grooves or flat spots Wear grooves in flat spots not permitted.
Wear must not exceed limits per Table 4.
Washers Wear created grooves Wear must not exceed limits per Table 4.
Gearbox Housing Cracks and Breakage Cracks and breakage not acceptable.
Sungear / Turbine Cracks, scoring, wear created
Shaft grooves, chipped or broken
gear- teeth, galling or scoring
on bearing surface of shaft.
Raised metal on the keyway. Wear must not exceed limits per Table 4.
Spacers Parallelism of end surfaces Ends must be parallel within 0.0005².
Turbine Housing Cracks and breakage Cracks and breakage are not acceptable.
Minor surface damage is permitted if
function is not impaired.
Ring Gear Cracks, wear, chipped, or

broken gear teeth. Wear must not exceed limits per Table 4.
Seal Assembly Wear grooves or scratched Wear is not permitted.
surfaces on carbon ring.
Seal Spacer Wear Grooves No wear permitted.
Needle Bearings Freedom of needle rollers Replace bearings
Ball bearings Freedom of rotation without Replace bearings
excessive play between races
Containment Corrosion, erosion, cracks Cracks and breakage are not acceptable.
Ring/ Nozzle and broken nozzle edges. Minor surface damage is permitted if
function is not impaired.
Turbine Rotors Corrosion, erosion, cracks Minor tip rub is permitted if function is not
and broken edges. impaired.
Tip wear; bore and key way Wear is not permitted.

wear
Table 3. Parts Inspection Check Requirements

Issued Dec 11, 1998
TDI TURBOTWINÔ
PART DESCRIPTION LIMIT, Inches

Ring gear / Turbine Housing
Internal measurement
between two .084² diameter 5.0890 max.
pins.
Sun Gear / Turbine Shaft
Bearing diameter 0.6690 min
External measurement over
two .096 diameter pins.
7.5:1 0.952 min
9:1 0.808 min
11.4:1 0.670 min
Planet Gear
External measurement over
two .0864² diameter pins.
7.5:1 2.3067 min
9:1 2.3699 min
11.4:1 2.4359 min
Carrier Shaft
Bearing Diameter 1.1800 min
Planet Pin Bore 0.8750 max
Planet Pins
Bearing Diameter 0.873 min
Thrust Washer
Thickness .055 min
Table 4. Parts Wear Limits
Figure 16. Gear Teeth Wear Allowances

701
Issued Dec 11, 1998
TDI TURBOTWINÔ
SECTION 5.0 ASSEMBLY
5.1 GENERAL
The tools listed in Table 1 are suggested for use by
technicians servicing the T100 Series starters. The
best results can be expected when the proper tools are
used, however, use of other tools is acceptable.
CAUTION
Replace all screws , O-rings, lip seals, and bearings
when the T100 Series starter is reassembled. These
parts are included in the overhaul kits shown in
Section 6.0
NOTE
Always press the inner race of a ball bearing when
installing a bearing on a shaft. Always press the outer Figure 17. Pressing Front Turbine Bearing
race of a ball bearing when installing into a housing.
Refer to Section 6.0, for a list of kits and components,

which are available to aid in rebuilding T100 Series
starters.
Lubricate all O-rings with petroleum jelly or Parker-O-

Ring Lube before assembly. Refer to Table 5 for a list
of materials to be use during assembly.
MATERIALS SOURCE
Petroleum Jelly Commercially Available
Parker-O-Ring Lube Commercially Available
Loctite RC290 Commercially Available
Grease, gearbox TDI P/N 9-94121-001
Table 5. Materials for Assembly
CAUTION
The screws that secure the Containment Ring/ Stage 2
Nozzle must have a drop of Loctite RC290 applied to
the threads before being used.
Figure 18. Pressing Spacer onto Bearing
5.2 TURBINE HOUSING T100 is the original design (SN: 9501-239 to 9611-191),
press the spacer (31) onto the outer race of the bearing
5.2.1 Turbine Shaft Installation (10) per Figure 18 by supporting the bearing outer race,
and then press the bearing/spacer (10, 31) onto the
Press the bearing (10) onto the shaft (33) until seated. shaft.
Support the shaft and press on the inner race only with
press tool P/N 2-26943 per Figure 17. Note that if Press the bearing/shaft assembly, keyway end first, into
bearing housing of the turbine housing. Use press tool
P/N 2-26943 if required per Figure 19. Do not press on
the end of the shaft because the load could damage the
balls of the bearing.
Issued Dec 11, 1998
TDI TURBOTWINÔ
Install bearing retainer plate (32) and secure with four Install nozzle 1 onto the turbine housing (26). Orient
screws (18). Torque screws to 30 in-lbs. the nozzles facing the air inlet (23). Install four screws
(18) to secure the nozzle. Do not tighten the screws at
this time.
5.2.3 Rotor 1 Installation
Install the woodruff key (large key) (16) for stage 1 rotor
into the shaft (33).
Install the stage 1 rotor (15), while supporting sun gear

end of shaft, onto the turbine shaft by aligning the slot in
the rotor with the woodruff key and hand press the rotor
until firmly seated. Use press tool P/N 2-26943 if
required.
Visually inspect that the key was not pushed out

during assembly. Note that the direction of rotation
was oriented properly. This turbine rotor can be
installed backwards.
Temporarily install Nozzle 2 on the turbine housing.

Tighten the four screws that secure nozzle 1 (18) to 30
in-lb. The four screws can be accessed via the holes in
nozzle 2 and the first stage turbine rotor. Remove
Figure 19. Installation of Turbine Shaft
Nozzle 2 when the four screws are tight.
Place turbine housing front surface (sungear end) on
5.2.3 Nozzle 2 Installation
flat surface. Install long bearing space (30) over shaft.
Press the lip seal (9) into the forward side of nozzle 2
Install the seal spacer (8) onto the shaft. Note the small
with seal lip facing up. Use press tool P/N 2-26943.
end of the spacer faces the long bearing spacer.
Install the O-ring (11) into the bearing bore of nozzle 2
Install the O-ring (21) into the aft face of the turbine
(13). DO NOT LUBRICATE THIS O-RING.
housing (26).
5.2.2 Nozzle 1 Installation Install O-ring (14) onto the outer diameter of nozzle 2.
Install nozzle 2 (13) onto the turbine housing (26). The

Press the aft seal (17) into nozzle 1 (19) using press
three flats of nozzle 2 are always oriented opposite the
tool P/N 2-26943 per Figure 20 with the lips facing up.
turbine housing air inlet (SN 9505-213 to 9611-191).
Install the seal spacer (8) onto the shaft with the small
end facing the aft bearing (10).
Install the wavy spring washer (12) into the bearing bore
of the stage 2 nozzle.
Support the sun gear end of the shaft. Press the aft
bearing (10) onto the shaft by pressing onto the inner
and outer race simultaneously. Use press tool per
Figure 21. Press until bearing is seated.
Figure 20. Installing the aft seal into Nozzle 1

701
Issued Dec 11, 1998
TDI TURBOTWINÔ
5.2.5 Air Inlet Installation
Place the O-ring (24) into the groove on the air inlet
(23).
Install the 2² NPT air inlet flange (23) and secure with
six screws (22). Tighten the six screws to 170 in-lb.
Mark the number of stage 1 nozzles (usually 6, 12,or

21) onto the O.D. of the unit for identification of the unit
prior to name plate installation.
5.3 GEARBOX HOUSING

(T112B/T121B, T112D/T121D, T109P/T115P)
5.3.1 Planetary Gear Carrier Reassembly
If disassembled, press needle bearing (38) into planet

gears (37). The planet gears are not identified by part
number, therefore, dimensionally check if correct gears
are being used. Use table 4 for over the wire
measurements.
With a thrust washer (36) on each side of gear, slide

gear into carrier shaft slots (35), and align with pin
holes.
Lightly slide plant shafts into aligned holes, making sure

snap ring groove on end of pins goes in first per Figure
Figure 21. Pressing Aft Bearing onto Shaft 22.
Install the seal spacer (8) with the small end facing the
aft bearing (10).
Press the lip seal (9) into the stage 2 nozzle using press
tool P/N 2-26943 with lip seal facing up.
Install the stage 2 woodruff key (7) into the shaft (33).
5.2.4 Stage 2 Rotor Installation
Install the stage 2 rotor (6) onto the shaft. Use press
tool P/N 2-26943 if required. Visually inspect that the
key was not pushed out during assembly. Note that the
direction of rotation was oriented properly. This turbine
can be installed backwards.
Install the rotor washer (5) and secure with screws (4).
Tighten screw to 100 in-lb.
Figure 22. Planet Gear Carrier Shaft Assembly
Install the exhaust screen (3) and back plate (2).
Secure with six screws (1). Tighten the screws to 80 in-
lb.

Issued Dec 11, 1998
TDI TURBOTWINÔ
NOTE
Make sure that anti-rotation pins on shafts are properly
located in retaining slots of carrier shaft (35).
Install snap ring (34) with a snap ring tool.
5.3.2 Gearbox Reassembly
Press the bearing (41) into the forward side of the

gearbox housing (58, D-44). Pressing force should be
on the outer race only.
Install retainer plate (46) and secure with six screws

(18).
Press rear bearing (41) onto carrier shaft (35) using TDI
Tool P/N 52-20143 per Figure 23. Pressing force
should be on the inner race of bearing.
Install spring washer (42) and bearing spacer (43) onto

shaft and locate against bearing.
Figure 23. Pressing Rear Bearing onto Carrier Shaft
Position carrier shaft assembly (35,41,42,43) into
bearing bore of the gearbox housing (58). Lift up on
housing and slide shaft down. If shaft will not slide into
bearing bore, press housing per Figure 24 until bearing
is seated (41).
Place gearbox assembly on TDI Tool P/N 2-20202 per

Figure 25. Install lockwasher (47) and then retainer nut
(48). Torque to 600-800 in-lb. Tang lockwasher into
retainer nut slot.
Place O-ring (14) onto outer diameter of gearbox

assembly.
Thoroughly grease planet gears, ring gear and sun

gear using the grease specified in Table 5 and pack the
center of the gears with grease.
5.3.3 Gearbox to Turbine Housing Assembly
Rotate carrier shaft (35) slightly, and at the same time,

align gearbox into the front of turbine housing (26).
Install six screws and torque 90-120 in-lbs.
Figure 24. Installing Carrier Shaft into Gearbox

Housing

701
Issued Dec 11, 1998
TDI TURBOTWINÔ
5.5. DRIVE/GEARBOX HOUSING

(T106F/T112F)
5.5.1 Planetary Gear Carrier Reassembly
If disassembled, press needle bearing (38) into planet

gears (37). The planet gears are not identified by part
number, therefore, dimensionally check if correct gears
are being used. Use table 4 for over the wire
measurements.
With a thrust washer (36) on each side of gear, slide

gear into carrier shaft slots (63), and align with pin
holes.
Lightly slide plant shafts (39) into aligned holes, making

sure snap ring groove on end of pins goes in first.
NOTE
Make sure anti-rotation pins on shafts are properly
located in the retaining slots of the carrier shafts (63).
Figure 25. Tightening Retainer Nut
5.5.2 Planetary Carrier Bearing Installation
5.4 DRIVE HOUSING
(T112B/T121B, T112D/T121D, T109P/T115P) Install bearing retainer plate (64) over carrier shaft (63)
5.4.1 Bendix Drive Installation Press bearing (65) onto shaft making sure pressing
force is on inner race of bearing only.
Install two woodruff keys (40). Ensure keys are
properly installed per Figure 26. Place carrier shaft assembly onto TDI Tool P/N 52-
20202, see Figure 27. Thread retainer nut (67) onto
Position bendix assembly (57) on shaft with retainer set shaft (63). Hold carrier assembly down and torque nut
screw (53) removed. Install spring ( 52) between to 600-800 lb.-in. with spanner wrench, TDI Tool P/N
bendix cavity and end of output shaft. Slide bendix over 52-21345.
shaft until set screw hole aligns with set screw hole in
shaft.
Install set screw and tighten firmly. Slip retainer (51)

ring into set screw slot.
5.4.2 Bendix Drive Housing Installation
If disassembled, press needle bearing (62, P-80) into

drive housing (61) until flush with bottom surface.
Mount drive housing over bendix drive, and align holes

for desired bendix opening orientation with starter inlet
connection. Torque bolts and nuts to 90-120 in-lbs.
Figure 26. Woodruff Key Installation

Issued Dec 11, 1998
TDI TURBOTWINÔ
Figure 28. Gearbox/Drive Housing Installation

(T106F/T112F)
Figure 27. Tightening Retainer Nut (T106F, T112F)
5.5.3 Bendix Drive Installation
Install bendix drive (68) into drive housing (69), aligning

bendix shaft into front needle bearing (70).
With snap ring tool, install snap ring (66)into drive
housing (69).
Align carrier shaft assembly (63) into bendix drive and

push assembly until seated against snap ring (66) per
Figure 28.
Install six screws (27) and torque 90 to 120 lb.-in.

701
Issued Dec 11, 1998
TDI TURBOTWINÔ
SECTION 6.0 PARTS LIST
The components illustrated and/or described

in this section are for the Turbotwin T100 series
air starters. When rebuilding a T100 series
starter, it is recommended to purchase, and
completely install the appropriate service kit(s).
Key No. Description Part Number

B D F P
1 Screw (6) 11F- 25020-072 ü ü ü
2 Screen Support Ring 2-20831
3 Screen 2-26148
4 Screw 19F- 25028-012 ü ü ü ü
5 Washer 9-93047
6 Rotor 2 2-26604
7 Woodruff Key 9-90211-006
8 Seal Spacer (3) 9-93083-001 ü ü ü ü
9 Seal, Lip (2) 2-26719 ü ü ü ü
10 Bearing (2) 9-91224 ü ü ü ü
11 O-ring (2) 9-90001-027 ü ü ü ü
12 Wave Spring Washer 9-90439 ü ü ü ü
13i Nozzle 2/Containment Ring 2-27333-00R

R.H.
13ii Nozzle 2/Containment Ring 2-27333-00L

L.H.
14 O-ring 9-90001-050 ü ü ü ü
15 Rotor 1 2-26603
16 Woodruff Key 9-90211-009
17 Lip Seal 2-22376 ü ü ü ü
18 Screw (14) 14F-19024-008 ü ü ü ü
19i Nozzle 1, R.H. 21 Noz 2-26718-21R
19ii Nozzle 1, L.H. 21 Noz 2-26718-21L
19iii Nozzle 1, R.H. 12 Noz 2-26718-12R
19iv Nozzle 1, L.H. 12 Noz 2-26718-12L

Issued Dec 11, 1998
TDI TURBOTWINÔ
Key Number Description Part Number B D F P
19v Nozzle 1, R.H. 6 Noz 2-26718-06R
19vi Nozzle 1, L.H. 6 Noz 2-26718-06L
20 Pipe Plug 9-93556-004
21 O-ring 9-90001-034 ü ü ü ü
22 Screw (6) or (12 for 14F-31218-016

ü ü ü ü
T112D/T121D std)
23 Inlet Flange 1-18967
24 O-ring 9-90001-037 ü ü ü ü
25 Set Screw (See Note 1) 52F-50013-016
26 Turbine Housing (See Note 2-27045

1)
27 Screw (6) 14F-25020-016 ü ü ü
28 Pipe Plug 9-93501-004
29 Ring Gear (See Note 1) 1-18780
30 Bearing Spacer 9-93091-001
31 Screw (4) 14F-25020-008 ü
32 Clamping Plate 2-26750
33 Turbine Shaft 2-26554
34 Retainer Ring (3) 9-92001-001
35 Planet Gear Carrier Shaft 2P-20156-006
36 Washer (6) 9-93004
37 Planet Gear (3) 1-19441
38 Needle Roller Bearing (3) 9-91004-001 ü ü ü ü
39 Planet Shaft (3) 2P-20182
40 Woodruff Key (2) 9-90211-019
41 Bearing (2) 9-91351 ü

701
Issued Dec 11, 1998
TDI TURBOTWINÔ
Key Description Part Number B D F P
42 Wave Spring Washer 9-90402-025
43 Bearing Spacer 9-93007
44 Gearbox Housing 2-22226
45 Screw (6) 14F-25020-028 ü
46 Retainer Plate 1-18817
47 Lockwasher 9-93061-007
48 Retainer Nut 9-92127-007
49 Drive Housing 2-22301
50i Inertia Drive Assembly, R.H. 2-22795
50ii Inertia Drive Assembly, L.H. 2-22796
51 Retaining Ring Included with item 50 or 57
52 Spring Included with item 50 or 57
53 Set Screw Included with item 50 or 57
54 Needle Bearing 9-91393
55 Adapter Plate 2-22794
56 Screw 14F-31218-020 ü
58 Gearbox Housing 1-18810
59 Lock Nut (6) 9-92107-015 ü ü
60 Screw (6) 11F-31218-024 ü
62 Needle Bearing 9-91005 ü ü
63 Carrier Shaft 3P-20858-006
64 Retainer Plate 2-20855
65 Bearing 9-91356 ü

Issued Dec 11, 1998
TDI TURBOTWINÔ
Key Description Part Number B D F P
66 Snap Ring 9-92001-006
67 Lock Nut 9-92105-008
70 Needle Bearing 9-91380 ü
71 Washer, Flat 9-93018-011
72 Nut, Hex 9-92108-003
73 Cover, Plate 2-20192
74 Screw (6) 11F-25020-072 ü
75 Housing, Exhaust Cover 2-27069
76 Spring, Compression 9-90408-016
77 Post 2-27223
79 Screw (12) 11F-31218-024 ü

80 Needle Bearing 9-91423 ü
Model Overhaul Kit for S/N’s before: 9611-191 Overhaul Kit for S/N’s after: 9611-192
B T10B-27618 T10B-27634
D T10D-27619 T10D-27635
F T10F-27617 T10F-27633
P T10P-27620 T10P-27636

701
Issued Dec 11, 1998
TDI TURBOTWINÔ
Figure 29. Illustrated Parts Breakdown (T112B/T121B)

Issued Dec 11, 1998
TDI TURBOTWINÔ
Figure 30. Illustrated Parts Breakdown (T109P/T115P)

701
Issued Dec 11, 1998
TDI TURBOTWINÔ
Figure 31. Illustrated Parts Breakdown (T112D/T121D, Standard Mesh)

Issued Dec 11, 1998
TDI TURBOTWINÔ
Figure 32. Illustrated Parts Breakdown (T112D/T121D, Long Mesh)

701
Issued Dec 11, 1998
TDI TURBOTWINÔ
Figure 33. Illustrated Parts Breakdown (T106F/T112F)

Issued Dec 11, 1998
TDI TURBOTWINÔ
SECTION 7.0 ACCESSORIES
SIZE PART NUMBER SIZE PART NUMBER
RELAY VALVES GAUGES

1½" STAINLESS STEEL (AMOT) 52-93505 REAR CENTER MOUNT 52-21982
2" STAINLESS STEEL (AMOT) 52-93505-100 U-CLAMP REAR CENTER 52-21982-100
MOUNT
1½" 316 SST MANUALLY 52-93508-300 BOTTOM MOUNT 52-21982-200
OPERATED
2" 316 SST MANUALLY 52-93508-400
OPERATED
1¼" NPT; BUNA N RLVA-25683-001-1 EXHAUST
1½" NPT; BUNA N RLVA-25683-001-1-01 3" ELBOW KIT T100-27015
1¼" NPT; VITON RLVA-25683-001-2 ECP KIT T100-27068
1½" NPT; VITON RLVA-25683-001-2-01 MUFFLER KIT (21 NOZ) T100-27074
12VDC; 1¼"; BUNA N RLVA-25683-012-1 MUFFLER KIT (6/12 NOZ) T100-27075
12VDC; 1½"; BUNA N RLVA-25683-012-1-01 3" NPT ADAPTER KIT - T100-27651
FEMALE
12VDC; 1¼"; VITON RLVA-25683-012-2 4" NPT ADAPTER KIT - T100-27652
FEMALE
12VDC; 1½"; VITON RLVA-25683-012-2-01 4" STRAIGHT PIPE KIT T100-27791
24VDC; 1¼"; BUNA N RLVA-25683-024-1 3" ELBOW KIT T100-27900
24VDC; 1½"; BUNA N RLVA-25683-024-1-01 EXHAUST ELBOW W/ 3" PIPE T100-28182-001
WELD FLANGE
24VDC; 1¼"; VITON RLVA-25683-024-2 EXHAUST ELBOW W/OUT T100-28182-002
WELD FLANGE
24VDC; 1½"; VITON RLVA-25683-024-2-01
110VDC; 1½"; VITON RLVA-25683-110-2-01 CONTROL & SOLENOID VALVES
120VAC; 1½"; VITON RLVA-25683-120-2-01 1/8" NPT STR CONROL VALVE 52-93504
1/4", 24 VDC, CONDUIT 52-21981
PRESSURE REGULATORS 1/4", 12 VDC, GROMMET 52-21981-002
2" GAS 300 52-93552 1/4", 120 VAC, CONDUIT 52-93506-100
2" GAS 125 52-93553 1/4", 120 VAC, GROMMET 52-93506-200
1½" AIR; MAX 1200 SCFM 52-20724-100 1/4", 24 VDC, CONDUIT 52-93506-300
2" AIR; MAX 1600 SCFM 52-20724-200 1/4", 24 VDC, GROMMET 52-93506-400
1/4" 72 VDC 52-93506-500
Y-STRAINERS
1½" CARBON STEEL BODY, #40 52-93549-100
MESH, SST SCREEN
2" CARBON STEEL BODY, #40 52-93549-200
MESH, SST SCREEN
1½" CAST IRON BODY, #40 52-93550-100
MESH, SST SCREEN
2" CAST IRON BODY, #40 MESH, 52-93550-200
SST SCREEN

701
Issued Dec 11, 1998
Model: T I 21-B, T I 21-D Performance Curve
TORQUE POWER
N~ ~b.ft 21 Nozzles, Natural Gas, 7.5:l Ratio HP KW
I
Inlet Pressure SCFM Nm31h -
90 psig 2028 3448

-
- 90 psig 1391 2365

806 1370 Y~
0 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000 5,500 6,000 6,500
Output Speed, rpm
Section 5 – Cooling System
Vendor Bulletin No.
Coolant System Drawing................................................ Ajax TP 02-04-T010-307
Compressor Cylinder Coolant System ........................... Ajax 02-04-T020-300
Water Pump and Mounting............................................. Ajax TP 02-04-T03A-001
F1 820 AM Pump, Illustrated Parts List (8” Impeller) ............... Ajax
Pump Maintenance Bulletin........................................................ Peerless 4845749
Pump Lubrication Guide ............................................................. Peerless 4852918
Thermostatic Control Valve Bulletin ........................................... FPE
Butterfly Valve, 2”, O&M Bulletin ................................................ DEMCO TC 1512

Note
The pump’s bearings must be lubricated.
Inject grease once per month as follows:
3.0 ounces in the inboard bearing
4.7 ounces in the outboard bearing
Belt Tensioning Procedure

1. Loosen the 4 bolts clamping the
pump’s frame to item 7.
2. Assure correct alignment of the
pump sheave to the engine sheave
for minimum wear.
3. Tighten the 4 bolts clamping the
pump’s frame to item 7.
DO NOT OVERTIGHTEN the belt.

It will cause premature bearing wear or
failure.
4. Check the tension after the first 24

Pump drive belt is not shown.
hours of initial operation, and
Belt p/n is 1020 2131.
retension if necessary. Tighten the
belt by turning the two adjusting
screws (item 5) an equal amount of
CW turns.
Coolant Pump & Mounting

Assembly
TP 02-04-T03A-001
Coolant Pump & Mounting Assembly
TP 02-04-T03A-001
Item Description P/N Qty
1 Belt, 5V 1020 2131 1
2 Sheave, 2 Groove 5V x 5½" SDS 4536 2550 1
3 Pump, Peerless 5027 2825 1
4 Bushing, SDS 1 " Dia., ¼" x 1¾" Key 5240 0611 1
5 Set Screw, ½" x 6" C.P. 6833 1209 2
6 Angle 2 x 2 x ¼ x 7½ Lg. 7004 2020 2
7 Pump Mounting Bracket 802-0403-01002 1
8 Pump Retaining Bracket 802-0403-01003 2
Note:
Some items illustrated are

not used in all assemblies.
Refer to the BOM for items

used for the specific Ajax
assembly.
Peerless Pump Model F1-820AM for Ajax DPC-2802 Series

Peerless F1-820AM Pump for Ajax P/N 5027 2825
Item Description Material P/N

1 Casing Cast Iron order by S/N
2 Impeller, Trimmed to 8" Diameter Bronze V1735B-449
6 Shaft Steel 2681134-492
7 Casing Ring Bronze 284006-186
13 not used, see #65 & #81
14 Shaft Sleeve Bronze 2691519-199092
16 Inboard Bearing Steel Assembly 1100750-000
17 not used, see #65 & #81
17B not used, see #65 & #82
17C not used, see #65 & #83
17D not used, see #65 & #84
18 Outboard Bearing Steel Assembly 266935-000
19 Bearing Frame Cast Iron order by S/N
22 Bearing Lock Nut Steel 2681602-056
24A Impeller Washer Steel 2698080-079
26 Impeller Cap Screw Nylon/18-8 Stainless Steel 2698078-641
32 Impeller Key Steel V2343A-064
40 Deflector Rubber 2675921-118
46 Coupling Key Steel V2377A5
49 Outboard Bearing Grease Retainer Rubber/Steel Assembly 2681122-000
51 Inboard, Bearing Grease Retainer Rubber/Steel Assembly 2681123-000
65 Mechanical Seal Seat Ni-Resist 268716501-000
71 Adapter Cast Iron order by S/N
73A Casing Gasket Fiber V1774A-122
80 Mechanical Seal Rotary Steel (Metal & Spring) 268716501-000
119 Shaft Sleeve "O" Ring Viton 2691534-199
Page 1 of 12
Installation, Operation and Maintenance Manual
DEMCO®
Resilient Seated
Butterfly
Valve
DEMCO Resilient Seated Butterfly Valve Publication

TC1512
Page 2 of 12
Publication TC1512 Published May 2000
DEMCO® is a trademark of Cooper Cameron Corporation

©Cooper Cameron Corporation, Cooper Cameron Valves Division, 2000.
All rights reserved.
Publication DEMCO Resilient Seated Butterfly Valve

TC1512 Installation, Operation and Maintenance Manual
Page 3 of 12
Table of Contents
Bill of Materials ................................................ 4

Scope .............................................................. 6
Nameplate Information .................................... 6
Storage .............................................................. 6
Installation ........................................................ 7
Disc to Pipe Clearance ................................ 8
Flange Bolts ................................................ 8
Procedure .................................................... 9
Operation .......................................................... 9
Trouble Shooting ............................................ 10

TC1512
Page 4 of 12
Bill of Materials
Figure 1 - Demco 2" thru 12" Resilient Seated Butterfly Valve
Demco 2" thru 12" Parts List
ITEM REQ'D DESCRIPTION
1. 1 Body
2. 1 Seat
3. 1 Disc
4. 1 Upper Stem
6. 1 Lower Stem
7. 2 Spring Pin
14. 1 Retainer
22. 1 Top O-Ring
23. * Stem O-Ring
24. 2 Bearing
* 4 Req'd for throttling valves only.

Page 5 of 12
Figure 2 - Demco 14" thru 36" Resilient Seated Butterfly Valve
Demco 14" thru 36" Parts List
ITEM REQ'D DESCRIPTION
1. 1 Body
2. 1 Seat
3. 1 Disc
4. 1 Upper Stem
6. 1 Lower Stem
7. 2 Spring Pin
14. 1 Retainer**
23. * Stem O-Ring
24. 2 Upper bearing
25. 1 Lower bearing
* 4 Req'd for throttling valves only.

** 24" 36" Spacer

TC1512
Page 6 of 12
Scope
Demco resilient seated butterfly valves are an pressure and are capable of throttling service.
economical alternative to ball, gate or plug valves They are easily adapted to automatic actuators.
in many applications. They are light weight The Demco butterfly valve is available in flangeless
quarter turn devices with few parts. They are wafer design or single flange tapped lug configu-
designed for bubble tight sealing up to rated ration.
Nameplate Information
4 3 2 1
Figure 3 - Demco Resilient Seated Butterfly Valve Nameplate.

5 6
ITEM STAMP
1 Product ID Number
2 Product Description
3 Body Material
4 Disc Material
5 Seat Material
6 Stem Material
Storage
Demco butterfly valves are shipped in the partial
open position to minimize permanent deforma-
tion of the resilient seat. The disc edge is
contained within the flange faces of the valve to
prevent damage to the sealing area (Figure 4).
Caution: Valves with fail open or closed

actuators are shipped with the disc in the
fail position, and extra care should be
given to prevent damage to the disc
edges.
Valves should be stored in a clean dry area away
from extremes of heat. The resilient seat sur-
faces should be protected from sunlight and
physical abuse.
Figure 4

Page 7 of 12
Installation
Direction -
Demco butterfly valves are bi-directional and will
operate in any position. Normally the valve is
installed with the upper stem pointing upward
(Figure 5). Elevated valves with gear operators and
chainwheels should be installed with the upper
stem pointing down (Figure 6) so the open-closed
indicator is visible from the ground and the chain
does not drag on the pipe.
End-of-Line Service -
Demco tapped lug butterfly valves are suitable for
liquid service end-of-line applications with down-
Figure 5
stream piping removed (Figure 7). Only weld neck
or socket weld flanges can be used for this service.
Since the upstream pressure is excluded between
the flange and the seat face by the exclusive
Demco flange seal, there is no effective force to
slide the seat downstream.
Caution: The valve must not be opened or

closed with the downstream piping re-
moved as the seat might be shifted break-
ing the flange seal and allowing pressure
to slide the seat downstream.
Gaskets
Flange gaskets are not required nor recommended
for use with positive shut-off Demco butterfly
valves. An integral flange seal is molded into the
edge of the rubber seat eliminating the need for
flange gaskets.
Throttling Valves, only, utilize an o-ring stem

seal that must be assisted with flange gaskets for a Figure 6
proper seal.
Flanges -
Steel Class 150 ANSI (or MSS SP-44) weld neck, slip-
on, threaded and socket weld as well as stub end
type C flanges are suitable for use with 2 thru 24
Demco butterfly valves. 30 and 36 Demco
butterfly valves fit between ANSI 125 flanges (or
MSS SP-44).
Other flange types may be applicable also, but
should be thoroughly checked to assure proper seal
makeup. Plastic flanges are subject to damage at
installation by over-tightening the bolting and
may deflect or cup resulting in flange leaks.
Figure 7

TC1512
Page 8 of 12
Disc to Pipe Clearance -

Before beginning installation, disc/pipe clearance
should be checked to avoid the possibility of
scraping the disc edge on the pipe ID and damag-
ing the sealing surface. Minimum pipe ID require-
ments are given in Table 1.
Valve Disc Swing Opens into:

Size Clearance Std Pipe Sch 40 Sch 80
2" 1.467" x x x
2-1/2" 2.144" x x x
3" 2.743" x x x
4" 3.601" x x x
5" 4.582" x x x
6" 5.624 x x x
8" 7.428" x x x
10" 9.382" x x x
PIPE I.D.
12" 11.35" x x x
DISC 14" 12.86" x x
CHORD 16" 14.72" x x
18" 16.61" x x
20" 18.53" x x
24" 22.57" x x
30" 28.67" x
36" 34.70" x
Figure 8 Table 1 - Disc Clearance
WAFER BODY
Flange Bolts -
Recommended bolt and stud lengths for installa-
STUDS & HEX NUTS
tion in ANSI flanges are provided in Table 2.

MSS flanges require longer bolts.
Valve Bolt Wafer Body Lug Body

Size Size Stud Screw Screw
Qty Length Length Qty. Length
"A"(in.) "B"(in.) "B"(in.)
2" 5/8"-11 4 5" 8 1-1/2"
2-1/2" 5/8"-11 4 5-1/2" 8 1-1/2" Figure 9
3" 5/8"-11 4 5-1/2" 8 1-1/2"
4" 5/8"-11 8 5-3/4" 16 1-3/4"
5" 3/4"-10 8 6-1/2" 16 1-3/4"
6" 3/4"-10 8 6-1/2" 16 2"
8" 3/4"-10 8 7" 16 2-1/4"
10" 7/8"-9 12 7-1/2" 24 2-1/4"
12" 7/8"-9 12 8-1/4" 24 2-1/2"
14" 1"-8 12 8-1/4" 24 2-1/2"
16" 1"-8 16 10" 32 3-1/4"
18" 1-1/8"-7 16 10-1/2" 32 3-1/2"
20" 1-1/8"-7 20 11-3/4" 40 4"
24" 1-1/4"-7 20 12-1/2" 40 4"
30" 1-1/4"-7 24 (8) 13-1/2" (4") 56 4"
36" 1-1/2"-6 28 (16) 16" (4") 64 4"
Table 2 - Flange Bolt Size B
Figure 10

Flanges -
Page 9 of 12
Procedure wafer body is equal to the inside of the bolt

The following procedure applies to new installa- circle of the flanges, so the valves are self-
tion between standard ANSI pipe flanges. When centering.) Install the remaining flange bolts.
replacing a valve from an existing installation, 3. Lug bodies have tapped holes coinciding with
clean flange faces and check for excessive corro- those in the flanges. They should be posi-
sion or other damage to the sealing face of the tioned between the flanges and the capscrews
flange. inserted through the flange holes into the
threaded lug holes.
1. Remove the valve from any packaging mate- 4. Tighten all bolts or capscrews in a crossover or
rial. Close the valve disc so that it is contained star pattern to assure even sealing. Tighten
within the flange faces. It is not necessary to sufficiently to assure metal-to-metal contact
fully close the valve; the disc must be con- between the flange face and the metal butter-
tained within the confines of the valve body fly valve body. No further tightening is re-
so it will slip between the mating flanges quired.
without contact with the flanges. 5. Carefully check disc clearance by placing the
2. When installing wafer valves, install the lower valve in the full open position. Any binding or
flange bolts without tightening. Position the scraping should be investigated and corrections
valve between the flanges, within the pocket made.
formed by the flange bolts. (The OD of the
Operation open (Figure 11). When perpendicular to the pipe,

the valve is closed (Figure 12).
Demco butterfly valves should never be operated
without a handle or other means of controlling Worm gear operated
the disc. Worn gear operators are recommended for valves
larger than 6 inches. Clockwise rotation of the
Caution: Failure to restrain the disc under handwheel closes the butterfly valve. Counter-
flow conditions can result in the disc clockwise rotation opens the valve. Gear operators
slamming closed and possible damaged or are always mounted with the input shaft perpen-
broken parts. dicular to the pipe axis for handwheel clearance.
Each operator has an arrow on the top of the gear,
2 thru 12 Demco butterfly valves have flats on
which indicates the OPEN CLOSED position of
the upper stem. 14 and larger valves have a
the valve (Figure 13).
single square key. Stem flats or the square key
indicate valve position. When they are in line
Automated valves
with the flow stream, the valve is open. When
Butterfly valves with their quarter turn operation
perpendicular, the valve is closed.
are easily adapted to automatic actuators for
remote operation. To prevent water hammer,
Manually operated
actuators should close the valve slower than 6 to 8
Demco butterfly valves operate from fully open to
seconds, open-to-close. Rapid closure causes water
fully closed by a 90° turn of the handle. The
hammer which can break or otherwise damage
handle is marked with a flow arrow. When this
valve parts.
arrow is in line with the pipe axis, the valve is
Figure 11 - Figure 12 - Figure 13 -

Valve shown open Valve shown closed Valve with gear operator

TC1512
Page 10 of 12
Troubleshooting
Trouble Probable Cause Remedy
The seat and/or disc is worn or Replace worn parts.*

damaged.
The valve will not seal Foreign matter is present between seat Operate several times to wipe clean.
properly. and disc.
Operator stops are not set properly. Adjust stops to proper setting.
Build up of solids or roughness is on Operate several times to wipe clean or disassemble

The valve is hard to edge of disc. valve and clean disc edge.*
operate.
Operator is not installed properly. Reistall operator in proper alignment with valve
stem.
The valve will not open. Disc hits on side of pipe. Check for proper pipe clearance.
Seat is damaged or worn. Replace Seat.*
The valve is leaking Disc is bent. Replace disc, stems and seat as required.*
around stem.
Correct flange seal leak to prevent fluid
Flange seal is leaking. from migrating behind seat and out stem.
Handle or actuator does not provide Restrain disc with handle or actuator.
The valve closes with line proper restraint.
flow.
Line flow too great. Choose larger valve or slow down flow.
Flange seal surface on seat is damaged. Replace seat.*
Flange leaks. Flange surfaces are damaged or

Clean, repair or replace flanges.
corroded.
Flange bore is too large. Replace with proper flanges.
Clockwise rotation of
Gear operator has been rotated 90o on
Gear Operator handwheel
valve top. Rotate gear operator 90o on valve top to put input
opens valve. Open-Shut
Hand-wheel shaft aligns with pipe shaft perpendicular with pipe axis.
indicators do not coincide
(should be perpendicular).
wth valve disc position.
Automatic actuator slams Speed control valves missing or not Install and/or adjust speed control valves.
valve shut or open. adjusted.
Hard, soft or cracked Replace elastomer seat with compatible material

Heat or chemical damage to seat.
seat damage is present. and/or correct offending fluid conditions.
*Contact your CCV representative for repair manual

Page 11 of 12
NOTES

TC1512
Headquarters
Cooper Cameron Valves

16500 South Main Street, Missouri City, TX 77489-1300
Phone: 281-499-8511, 800-323-9160, Fax: 281-499-6965
Manufacturing
Cooper Cameron Valves

Demco Products
P.O. Box 94700
Oklahoma City, OK 73143
Phone: 405-631-1321, Fax: 405-631-0420
http://www.ccvalve.com
DEMCO® is a trademark of Cooper Cameron Corporation

c Cooper Cameron Corporation, Cooper Cameron Valves Division, Printed in USA / 5-00 / TC1512
Section 6 – Cooler
Vendor Bulletin No.
E72-9 Cooler Drawing ..................................................ACE 07366-C
Cooler Spec Sheet .........................................................ACE 7249PW
Cooler Spare Parts List ..................................................ACE E72-9
Cooler Start Up Procedures.................................................ACE
Cooler Operation and Maintenance Instructions .................ACE
Bearing Lubrication Schedule
Fan O&M Bulletin................................................................Crowley

8 7 6 5 4 3 2 1
6"
n7/8"
3"
SECTION A-A
6"
D D
(4 PLACES)
3"
1 1/2" 1 1/2"
84 1/4"
82"
74 1/4"
125 1/2" 59"
SEE CL BELOW 42 7/8"
29"
19 7/8" 67" 19 7/8" 5 1/2" LOUVER
2 3 1" NPT
1
1" NPT
C C
ADD 2" LOUVERS OPEN

ACCESS
DOOR
(N.S.)
91"
85"
74 3/4"
NC
56 3/4"
56 1/4"
36 7/16"
24 5/16"
A A
78"
76"
B B
END ELEVATION
SIDE ELEVATION
RPM= 636
HP= 12.5 PER FAN
BLADE ANGLE= 32
UNIT: 0736601 − 02
SEE CL BELOW - THESE DIMENSION (S) ARE SYMETRICAL TAG: CT. 10753 − 54
ABOUT THE CENTER OF COOLER. JOB: 07366
DESIGN DESIGN
FLAG SERVICE CL LOUVERS NOZZLES IN NC
NOTES PRESSURE TEMPERATURE
NOZZLES OUT OTHER NOZZLE
AIR COOLED EXCHANGERS, LLC
1 EJW 112.75 N/A 150 PSI 350 Deg F/−20 Deg F (1)2−150RF (1)2−150RF N/A 18.375
1. WEIGHT: 7239 POUNDS
SCALE: 1:1 (FIT TO PLOT) DRAWN BY: AID
2 IC 113.75 AUTO 215 PSI 350 Deg F/−20 Deg F (1)6−150RF (1)6−150RF N/A 18.875 ACE MODEL E72−9
2. FINISH: ACE std prep. w/ one coat QL-5505 primer DATE: 10/18/2007 CHECKED BY: DHB
A (1)6−300RF A
3 AC 113.75 AUTO 350 PSI 350 Deg F/−20 Deg F (1)6−300RF N/A 18.875
3. FAN DRIVEN BY V-BELT DRIVE BY (1) 15 HP 1500 RPM 380/3/50 TEFC ELECTRIC MOTOR CUSTOMER: CAMERON COMPRESSION P.O: 4501415535
4. ASME CODE ON IC,AC, BY DATE DESCRIPTION CK’D DRAWING NUMBER REV
REV−1 DB 10/25/07 SHOW MISSING NOZZLE DHB 07366 2
−C
REV 2 KG 11−08−07 MOVE NOZ ON EJW PER SALES KG
8 7 6 5 4 3 2 1
AIR COOLED EXCHANGERS, INC.
P.O. BOX 577 - BROKEN ARROW, OKLAHOMA 74013
Ph (918) 251-7477
Fax (918) 258-1833
E-MAIL: MAILHUB@ACE-COOLERS.COM
COOLER PERFORMANCE SPECIFICATION

CUSTOMER CAMERON COMPRESSION PROPOSAL NUMBER 7249PW
REFERENCE QT. 07126 - Purneftagas DATE 10/12/2007
MODEL E72-9 PAGE 1
PERFORMANCE OF ONE UNIT
SERVICE EJW IC AC
FLOW 121.5GPM 3.01MMSCFD 3.01MMSCFD
FLUID 50%GLY .947 .947
TEMPERATURE IN, F 165.0 162.8 191.0
TEMPERATURE OUT, F 150.0 130.0 120.0
INLET PRESSURE, PSIG 41.9 80.0
PRESSURE DROP, PSI 5.4 1.9 2.3
DUTY, BTU/HOUR 801200 148245 326450
CORRECTED MTD 34.1 33.7 35.4
BARE TUBE RATE 207.4 56.8 61.7
FOULING 0.00050 0.00200 0.00200
BARE SURFACE, SQ. FT. 113 77 149
TOTAL SURFACE SQ. FT. 2710 1848 3572
CONSTRUCTION
NO. SECTIONS 1 1 1
NO. TUBES/SECTION 66 45 87
LENGTH 9.0 9.0 9.0
NO. ROWS 4 6 6
NO. PASSES 3 1 2
COUNTERFLOW
TUBE O.D. AND BWG .75X16BWG .75X16BWG .75X16BWG
TUBE MATERIAL SA214(WLD) SA214(WLD) SA214(WLD)
DESIGN PRESSURE, PSI 150 215 350
DESIGN TEMPERATURE, F 350/-20 350/-20 350/-20
NOZZLES-INLET 2-150RF 6-150RF 6-300RF
NOZZLES-OUTLET 2-150RF 6-150RF 6-300RF
HEADER TYPE RECT TUBE BOX W/PLUGS BOX W/PLUGS
HEADER MATERIAL STEEL SA-516-70 SA-516-70
ASME CODE STAMP YES YES
GROOVED TUBE SHEET YES
CORROSION ALLOWANCE
PLUGS, TYPE TAPER TAPER TAPER
PLUGS, MATERIAL STEEL SA-105 SA-105
TURBULATORS
ACCELERATORS
LOUVERS AUTO AUTO
STRESS RELIEVE NO NO NO
NDE 100% X-RAY 100% X-RAY
ADDITIONAL CODES
CANADIAN REGISTRATION
ADDITIONAL COUPLINGS 1 1
BYPASS NOZZLE
FINS ALUMINUM ALUMINUM ALUMINUM
AIR DATA
INLET AIR, F 100.0 ELEVATION, FT. 1500
OUTLET AIR, F 131.1 TOTAL SCFM 37861
MECHANICALEQUIPMENT
NO FANS 1 HP/FAN 12.5 RPM 637 DIA 72
FAN CROWLEY 9WL FAN MATERIAL ALUM NUMBER OF BLADES 5 PITCH 32 DEGREES
V-BELT DRIVE BY (1) 15 HP 1500 RPM 380/3/50 TEFC ELECTRIC MOTOR
DRAFT TYPE FORCED
EST SHIPPING WEIGHT 7239 WIDTH 6.9 LENGTH 10.4 HEIGHT 7.1
ACCESSORIES
FINISH ACE std prep. w/ one coat QL-5505 primer
Parts List Air Cooled Exchangers, LLC
1201 S. 9th Street
Broken Arrow, Oklahoma 74012
Phone: 918-251-7477
Fax: 918-251-7482
Customer: CAMERON COMPRESSION
ACE Serial Number(s): 0
Cooler Model: E72-9
Fan Make & Model 1 6 Dia. 5 Blades 32 deg. Pitch at 5/6 RAD Fan RPM: 636
CROWLEY 72/5-10/32/PAG/9WL/SK/1.4375/AR LEFT HAND Bore with STD Keyway PRICE EACH $2,006.00
Fan Shaft ## 1.4375 Dia. 34.9 Long with 4.25 in Keyway Fan end 6 in Keyway other end
### ## PRICE EACH $295.00
Idler Shaft 0 Dia. 0 Long with Keyway one end PRICE EACH $0.00
Fan Bearing 2 1.4375 in REXNORD MODEL ZA-2107 PRICE EACH $249.00
Idler Bearing 0 0 PRICE EACH $0.00
Electric Motor ### 15 HP 1500 RPM 380 Volt 3 Phase 50 Cycle
TEFC Enclosure 254T Frame Size WITH SlideBase 0
0 PRICE EACH $1,149.00
Motor Sheave 1 0 O.D. 2-5V5.2Type 0 Groove 0 Bore PRICE EACH $0.00
Fan Sheave 1 0 O.D. 2-5V11 Type 0 Groove 0 Bore PRICE EACH $0.00
V-Belts 0 5VX780 PRICE EACH $0.00
0 0 0 PRICE EACH
0 0 0 PRICE EACH
LOUVER FOR IC 0 108 IN X 16.75 IN ALUMINUM AUTO WITH JOHNSON 3153-5 AIR MOTOR AND KIMRAY T12 T.C. PRICE EACH $0.00
LOUVER FOR AC 0 108 IN X 30.75 IN ALUMINUM AUTO WITH JOHNSON 3153-5 AIR MOTOR AND KIMRAY T12 T.C. PRICE EACH $0.00
0 0 0 PRICE EACH $0.00
0
0
0
0
FAN, SHAFT, BEARINGS & V-BELTS ARE RECOMMENDED SPARE PARTS.

ALL PRICES SUBJECT TO CHANGE WITHOUT NOTICE.
ALL INQUIRiES AND ORDERS MUST BE ACCOMPANIED BY COOLER SERIAL NUMBER.
AIR COOLED HEAT EXCHANGER
SUGGESTED START UP PROCEDURE
Before any start up procedure is begun, a thorough inspection of the Air Cooled
Exchanger should be made.
1.) Be sure all bolted connections are properly tightened.
2.) After tube bundle and piping hydrotest, remove hydrotest connections.
Be sure tube bundle is properly drained, and if required, dried. Connect
process piping and any auxiliary connections.
3.) Inspect all process connection, as well as, vent drain, temperature and
pressure, or any other auxiliary connections to be sure they are plugged
or connected properly.
4.) Check mechanical equipment before starting process through the tube
bundle(s).
a.) Thoroughly check the plenum and fan drive area to be sure all
tools and construction materials are removed.
b.) Rotate the fan by hand and check fan tip clearance and alignment
of belts and sheaves.
c.) Check belt tension.
d.) Check all fan drive bolts to be sure they are properly tightened.
This includes bearing bolts, fan and sheave bushing bolts, set
screws, motor bolts and fan blades attachment bolts.
e.) If air operated auto-variable pitch fans are used, check for proper
pitch with the air off. Fans may go to either minimum or maximum
pitch at air failure. Check specifications for requirements. If fan
pitch is not satisfactory, set pitch per manufacturer's instructions
(see Operation and Maintenance Instructions). If fan pitch is
satisfactory, cycle fan through it's range, using plant air and an air
regulator.
Page 1
f.) If air operated louvers are provided, it is advisable to disconnect
the air motor linkage and cycle the louvers by hand to assure
there is no binding or obstruction of the louvers blades. If binding
occurs, check to be sure louver frames are square. Attaching
bolts may have to be loosened and frames shifted to ease binding.
If louvers operate smoothly, reconnect air motor. Cycle the air
motor, using plant air and an air regulator.
g.) If manually adjusted pitch fans are provided, check fan pitch and
re-pitch per manufacturer's instructions if required.
h.) If manual operated louvers are provided, check for binding of the
blades, as in instruction (f). Operate louvers to be sure there is no
linkage obstruction or binding.
i.) Remove condensate drain plugs, if provided, in electric motors

and other electrical components to drain any condensation that
might have occurred during storage. If space heaters are
furnished in electric motors, louver actuators, controls, etc.,
activate the space heaters and allow approximately 24 hours
before starting equipment.
j.) After all the applicable steps previously stated are completed, the
mechanical equipment may be cycled.
k.) Be sure all personnel and equipment are away from the fan and
fan drive area. For safety reasons, equipment guards should be
installed. Activate the drive motor and let it reach speed. Check
for vibration and excessive noise. If vibration or excessive noise
occurs, immediately shut motor down, and check for loose
connections or insufficient clearance between moving parts. If the
system is running smoothly, replace any guards removed and
move to the next drive and repeat above steps.
5.) Start the process through the tube bundle(s). Open the inlet valves
slowly and let the process "Warm" the bundles slowly. This will allow the
components of the tube bundle to expand at the same rate and lessen the
thermal shock.
Page 2
OPERATING AND MAINTENANCE INSTRUCTIONS FOR ACE COOLERS
IMPORTANT
Before start up, check set screws and bolts in the fan assembly and set screws in
locking collars of all bearings and sheaves. These items should be checked
again several days after start up.
FAN & DRIVE
Although the fan and drive are inspected before shipment, clearance between
the fan blades and the fan ring and guard, and alignment of the fan shaft should
be checked to assure that rough handling during shipment has not loosened
bearing mounting bolts or caused misalignment.
V-belt drives should be adjusted until tight enough to prevent excessive belt
slippage. The belt is generally tight enough when it can be twisted one-quarter of
a turn with the thumb and fore-finger.
LUBRICATION
Bearings should be greased in accordance with normal maintenance practice.

Over-lubrication is the most common cause of bearing failure. In general, about
one cubic inch of grease in each bearing every 2 to 3 months is adequate. The
operating temperature of the bearing may indicate how much lubrication is
required.
Normal temperature may range from “cool to warm to touch” up to a point “too
hot to touch for more than a few seconds” depending on bearing size and speed,
and surrounding conditions. Unusually high temperature accompanied by
excessive leakage of grease indicates too much grease. High temperature with
no grease showing at the seals, particularly if the bearing seems noisy, usually
indicates too little grease. Normal temperature and slight showing of grease at
the seals indicates proper lubrication.
Page 1
TUBE CLEANING
Operating conditions sometimes cause an accumulation of dirt on the outside fin

surface. This can be removed by directing compressed air, or a greaseless
solvent followed by a water spray through the fins in a direction opposite the
normal air flow. The inside of the tubes will require periodic inspection and
cleaning as necessary. Removal of access plugs allows visual inspection, and if
necessary, the use of mechanical tube cleaners.
PLUG LEAKS
Should tapered plugs develop leaks, additional tightening is normally all that is
required. Thread dope may be used if tightening alone is not sufficient. If
shoulder type plugs develop leaks, the gaskets should be replaced. Tapered
plugs that are removed for the tube inspection or cleaning should be replaced in
the same hole.
TUBE LEAKS
Tube leaks can be of two types: (1) leaks in the tubewall itself (usually corrosion)
and (2) leaks in the tube to tubesheet joint. In the first case, it is usually most
practical to plug both ends of the tube with the resulting loss in heat transfer
surface. When so many tubes have been plugged that performance is affected,
retubing will be necessary. If leaks develop in the tube to tubesheet joints, re-
rolling of the tube will be required. Care must be used in selection of the proper
tube expander for the size and BWG of the tube being used. As with all rolled
tube joints, over-rolling must be avoided.
GENERAL
If it is ever necessary to contact our plant for service or replacement parts, it is

essential that our serial number or other identifying data be obtained from the
metal nameplate attached to the cooler. This is the only way to positively identify
the correct parts that may be required.
Page 2
Multi-Wing Z Series Fans
Blade Pitch Angle Setting Instructions
Before You Begin:
To maintain balance of fan:

• Mark the hub castings across a joint, so the fan hub can be reassembled in the same orientation.
• Mark the location of any balancing weight. Balancing weight will be on the outer bolt circle, in the
form of washers, and/or longer bolts, or an additional balancing nut.
• Number the blades and blade sockets, so that they are replaced into their original position.
If possible, note the location of the pitch setting pin in the blade socket when disassembling the fan, and
whether pin is located in the Hub or Retainer half of the fan (see step 7 for detailed definition).
Step 1 – Determine Blade Type: “1Z”, “2Z”, “4Z”, “5Z”, or “6Z”
If the blade has a sickle shape, then look for 1Z or 2Z molded on the blade.
If the blade is wider at the tip than at the base near the hub, then you have a 6Z.
Otherwise, look for 4Z or 5Z markings on blade which are in one of two places:
Look on cone section at base of blade (visible when fan is assembled), or
Look inside the bottom of the socket (blade must be removed from hub).
Alternatively, measure the width of the blade at the widest portion at base of blade:
4Z blade is approximately 4-1/2 inches, 5Z blade is approximately 5-1/4 inches.
Step 2 – Determine Rotation Code: “L” or “R”
R rotation rotates clockwise facing air discharge, L rotation is counterclockwise facing air discharge.
The 1Z and 2Z blade profiles have an arrow showing rotation molded into the blade on inlet side.
The 6Z is universal and can be used as an R or L rotation, depending on how pitch angle is set.
For 4Z and 5Z blades, the rotation code is molded into the blade, either on the cone section at base of
blade, or inside bottom of the socket.
Examples of rotation for 4Z blades as viewed from end of socket are below, and 5Z is similar.
R, or clockwise L, or counterclockwise
P.O. Box 425, 15030 Berkshire Industrial Parkway, Burton, Ohio 44021
Phone 440-834-9400 Fax 440-834-0449 www.mw-america.com
44 Multi-Wing America - Z Series Pitch Setting Instructions - Page 2 of 4
Step 3 – Determine Boss location code: “A” or “B”
The boss is the center section of the hub through which the fan is mounted to the shaft, and typically
contains either setscrews or a center-tapered hole where the bushing inserts.
Select boss location A or B:

A is the boss on air inlet, including A, AR, and AS configurations.
B is the boss on air discharge, including B, BR, and BS.
See examples in drawing below.
For flange mounted (engine) fans, use boss location A for blower fans, and boss location B for suction
fans.
Step 4 – Find Blade Pitch Angle: 20, 25, 27.5, 30, 32.5, 35, 37.5, 40, 45, or 50
The blade pitch angle can be found several ways:
First, by knowledge of the Multi-Wing fan part number.

The pitch angle precedes the blade material code in the part number. For example, the pitch angle is
30 degrees in this part number: 36/9-9/30/PPG/5ZR/ SH 1-3/8 /AS
Second, by careful disassembly with this method:
• Disassemble fan on flat surface, and note in which groove the pin is
located. See number code in picture to the right.
• Using pictures in step 7 on next page, determine if the pin was in the
hub (HUB) or retainer side (RET) of fan.
• Using table in step 6 below, find the possible blade pitch.
• Using table in step 5 below, select your blade angle based on whether
your pin was in the HUB or RET.
Third, by calling a sales engineer at Multi-Wing America for assistance in selecting a blade pitch angle
for your application.
Step 5 – Determine Hub/Retainer Code: “HUB” or “RET”
Find “HUB” or “RET” in chart below:
Rota- Boss Blade Pitch Angle

Type tion Pos. 20° 25° 27.5° 30° 32.5° 35° 37.5° 40° 45° 50°
1Z,2Z,4Z R or L A RET RET - RET RET HUB HUB HUB HUB -
1Z,2Z,4Z R or L B HUB HUB - HUB HUB RET RET RET RET -
5Z R or L A - RET - RET RET RET HUB HUB HUB HUB
5Z R or L B - HUB - HUB HUB HUB RET RET RET RET
6Z R A RET RET HUB RET HUB RET - - - -
6Z R B HUB HUB RET HUB RET HUB - - - -
6Z L A HUB HUB RET HUB RET HUB - - - -
6Z L B RET RET HUB RET HUB RET - - - -
Step 6 – Determine Groove Number: 1 or 2 or 3 or 4
Find the groove number in chart below:
Rota- Blade Pitch Angle

Type tion 20° 25° 27.5° 30° 32.5° 35° 37.5° 40° 45° 50°
1Z,2Z,4Z R 4 3 - 2 1 4 3 2 1 -
1Z,2Z,4Z L 1 2 - 3 4 1 2 3 4 -
5Z R - 4 - 3 2 1 4 3 2 1
5Z L - 1 - 2 3 4 1 2 3 4
6Z R 1 2 1 3 2 4 - - - -
6Z L 1 2 4 3 3 4 - - - -
Step 7 – Final Assembly
Definition of HUB and RET for purposes of these instructions:
For 2-piece hubset like below:
Top half is the HUB, and bottom half is the RET or retainer ring.
Step 7 – Final Assembly continued
For 3-piece hubset as below:
Top two pieces together are considered the HUB, and bottom piece is considered the RET or retainer ring.
Using the HUB or RET code found in Step 5:
If code is HUB, place the hub down on work surface first (one or two pieces, depending on above).
If code is RET, place one retainer ring only down on the work surface first.
A weighted coffee can could be used to elevate the fan from the work surface.
Using the Groove Number found in Step 6:
Using picture to right, place the locking pin in the groove number that you
found in Step 6 above.
Finally, Insert Blades:
• Place the blade over the pin in the hub/retainer blade socket, so that the
pin also fits into the appropriate pitch angle groove in the blade. See
example picture to the right.
For 6Z fans, use the pitch angle groove in the blade marked with your
rotation (R or L) and pitch angle. Example: L35 is “L” rotation and 35-
degree pitch angle.
• Repeat for all blades.
• Assemble hubset together, aligning the match marks you made.
• Replace any balancing weight to its original position.
• To finish, tighten the bolts in a cross pattern to 5 to 6 foot-pounds of torque.
Phone 440-834-9400 Fax 440-834-0449 www.mw-america.com Z pitch setting Rev 1
1/25/05
INSTRUCTIONS FOR BLADE PITCH ADJUSTMENT
FOR THE LARGE SERIES MULTI-WING W BLADES
1) NOTE ORIGINAL POSITION OF RETAINING PLATES, CENTER BOSS AND ALL HARDWARE
INCLUDING ADDITIONAL HARDWARE USED FOR BALANCING
2) REMOVE ALL THE BOLTS AND NUTS.
3) DETERMINE BLADE ROTATION – ON THE CONCAVE SIDE OF THE BLADE IS A BLADE

MARKING SHOWING 6WR, 6WL, 7WL, 7WR, OR 9WR. THE “L” AND “R” DENOTE THE ROTATION
OF THE BLADE.
4) REPLACE THE PITCH INSERT IN THE BLADE ROOT WITH AN INSERT OF THE DESIRED PITCH.
PITCH IS DETERMINED BY COUNTING DIAL MARKS ON THE INSERT FROM THE SIDE OF
APPROPRIATE BLADE ROTATION FOUND IN STEP 3. EACH LARGE MARK REPRESENTS 5
DEGREES. THE ENDS OF THE INSERT ARE 20 AND 50 DEGREES ACCORDINGLY.
5) REPLACE BLADES TO THEIR ORIGINAL LOCATION.
6) REPLACE ALL NUTS, BOLTS, AND WASHERS ON THE FAN HUB.
7) REPLACE RETAINING PLATES AND CENTER BOSS TO ORIGINAL LOCATION.
7) TIGHTEN NUTS AND BOLTS TO:

14 FOOT POUNDS OF TORQUE
(REV. 9/7/05)
Multi-Wing America P.O. Box 425 Ph. 440 834 9400

A Crowley Company 15030 Berkshire Industrial Pk. Fax 440 834 0449
Burton, Ohio 44021 Toll free 800 311 8465
info@multi-wing.net
www.multi-wing.net ISO 9001 QEC-15013
SAI Global
FANs 268.1, 1628.3
Product Bulletin D-3153
Issue Date 0596
D-3153 Pneumatic Actuator
The D-3153 Pneumatic Actuator is a multipurpose

positioning device used primarily for operating
ventilating dampers in response to the output signals
of a pneumatic controller or electro-pneumatic
transducer.
The D-3153 can be used with dampers up to a

maximum area of 16 square feet for proportional
volume control and 25 square feet for two position
actuation provided that the torque requirements are
compatible with the specific application.
The D-3153 is UL component recognized for use on

UL classified 555/555S smoke and combination
fire/smoke dampers which have been tested and
approved to a degradation temperature of 250°F
(121°C).
Figure 1: D-3153
Features and Benefits

❑ All-aluminum Housing Lightweight, non-combustible
❑ Telescoping Linkage Fast, flexible installation
❑ Long Life and Reliable Over a million now in service
❑ 2-way Swivel Head Ensures full power delivery
❑ Agency Recognized UL Recognized component for fire and smoke

applications to 250°F (121°C)
© 1996 Johnson Controls, Inc. 1

Code No. LIT-2681054P
A pplication I nstallation
When used with proportional control, the damper size Two standard mounting packages are available with
is limited to 16 square feet maximum. As a 2-position the D-3153 pneumatic piston actuator. The models
control, damper size is limited to 25 square feet. with universal mounting bracket assemblies provide all
Three nominal spring ranges are available: of the parts and instructions required for applying the
3-7 psi (D-3153-7), 5-10 psi (D-3153-3 and -6), actuator to Johnson Controls D-1300 damper
and 8-13 psi (D-3153-1, 2, 4, 5, and 18). The control applications: duct (wall) mounting or frame mounting--
air pressure for normal HVAC operation is 0-20 psig. either normally open or normally closed.
The minimum control pressure for safety damper The auxiliary mounting bracket assembly facilitates
functions is 20 psig with the maximum pressure of applying the D-3153 actuator to allied equipment
30 psig. When used for both proportional and safety manufacturer’s products, and non-Johnson Controls
applications, a separate air signal should be provided installations for actuator conversions. These
to override normal HVAC operation and cause safety assemblies are furnished with a crank arm linkage and
damper functions. pedestal style bracket. Two positions are provided on
The D-3153 incorporates several internal and external the pivot post for attaching the actuator to the
features that add functional flexibility. A 2-way swivel mounting bracket so that force can be more directly
connection on the actuator cylinder head provides applied to linkage points that are neither perpendicular
non-binding movement. All actuators have a nor parallel to the actuator mounting plane.
telescoping piston rod for easy linkage of the damper A stop screw kit is available for special applications to
for attachment points up to 8-3/4 inches (222 mm) limit the power stroke of the actuator when required.
away from the face of the actuator. A swivel ball joint A 4 foot (122 cm) linkage rod is also available for
and slotted crank arm connector are furnished on all special applications to reach extended linkage when
actuators for optional methods of linkage to the damper. required.
The UL component recognized D-3153 actuator with Where precision sequential operation is desired, or
universal and auxiliary mounting brackets are additional positioning power is necessary, a D-9502
specifically designed for use with Johnson Controls positioner should be used. Up to four more D-3153
safety dampers up to 250°F (121°C). actuators may be slaved from one pilot for coupled
dampers. A D-9502 kit is also available to enable
2-stage actuator control for providing minimum outdoor
O peration
Air pressure from a pneumatic controller is applied to
air during occupation (refer to D-9502 literature).
Refer to the appropriate D-3153 Installation Bulletin for
the diaphragm of the actuator, which moves the piston more details.
against the forces of the internal spring and the load.
The external load force shifts the operating range from
the nominal spring range. The piston will move to a
position where the applied force and the spring plus
R epair Information
Field repairs must not be made. For a replacement
external forces are in equilibrium. However, with a
D-3153 body, contact the nearest Johnson Controls
pilot positioner added, the piston will move to a position
representative.
proportional to the control signal regardless of the load.
Table 1: Force Values at 20 psig (140 kPa) Supply

Spring Range psig Stroke Force lb (Newton) Torque Output for
(kPa) 90° Rotation
8 to 13 Power 105 (467) 158 in·lb (18 N·m)
(56 to 91) Return 120 (534) 180 in·lb (20 N·m)
5 to 10 Power 150 (667) 225 in·lb (25 N·m)
(35 to 70) Return 75 (334) 113 in·lb (13 N·m)
3 to 7 Power 195 (867) 293 in·lb (33 N·m)
(21 to 49) Return 45 (200) 68 in·lb (8 N·m)
2 D-3153 Pneumatic Actuator Product Bulletin

D imensions
P isto n R o d E xten sion S et S crew
S wiv e l B a ll Jo int
M axim u m T ele sco p ing
6-1/2 (1 65 )
Crankarm 2 -1 /4
(5 7)
5-1 /4 (1 3 3) 7 -2 3/3 2 (19 6 )
1 1-5 /8 (2 9 5)
Figure 2: D-3153, inches (mm)
D -9502
8-7 /8 P ositioner
(2 2 5)
6- 9/1 6
(167 )
6-9/32 (16 0) 15-7/16 (39 2 )
Figure 3: D-3153 with Universal Mounting Bracket, inches (mm)
7 -7 /8 D -95 0 2 P o sitio ne r
(20 0 )
P ositio n B
3 -2 5/3 2 (96 )
5-9/1 6
(1 41 )
P iv o t P o st
4 (1 0 2) A u xilia ry M o un ting B ra cket
P ositio n A
1 1-5/8 (2 95 )
2-15 /16 (7 5 )
Figure 4: D-3153 with Auxiliary Mounting Bracket, inches (mm)
Table 2: Ordering Information

Nominal Spring Range With Universal With Auxiliary Body Only
Mounting Bracket Mounting Bracket
8-13 D-3153-2 D-3153-5 D-3153-6003

8-13 w/D-9502 D-3153-1 D-3153-4 -
0-3 and 9-13 w/2-stage Pilot - D-3153-18 -
5-10 D-3153-3 D-3153-6 D-3153-6002
3-7 - D-3153-7 D-3153-6001
D-3153 Pneumatic Actuator Product Bulletin 3

Table 3: Accessories
Description Shipping Weight Code Number
lb (Kg)
Rubber Boot Kit 0.2 (0.09) D-3073-100
Ball Joint weather resistant 0.3 (0.11) D-3073-604
Blade Arm Kit 1.0 (0.45) D-9999-100
Crank Arm 1/2 inch adjustable to 2-3/4 inch radius 0.5 (0.23) D-3153-101
Linkage Rod 4 ft. (122 cm) 2.0 (0.91) D-3153-102
Linkage Rod replacement 1.0 (0.45) D-3153-103
Stop Screw Kit, 1/4 - 24 x 3 inches 0.5 (0.23) D-3153-104
Proportional Pilot Positioner Kit 2.0 (0.91) D-9502-8
Ball Joint 0.5 (0.23) D-9999-104
Pivot Post, 5 per kit 0.5 (0.23) D-3153-110
E-rings for Pivot Post, 10 per kit 0.5 (0.23) D-3153-111
Mounting Nuts for Pivot Post, 10 per kit 0.5 (0.23) D-3153-112
Universal Mounting Bracket 3.5 (1.13) D-3153-105
Auxiliary Mounting Bracket 1.0 (0.45) D-3153-106
2-stage Positioner Kit 2.0 (0.91) D-9502-9
Note: Positioner kit includes: positioner, mounting plate, spring, and mounting hardware.
Specifications
Product D-3153 Pneumatic Actuators
Stroke 3 inches (76 mm)
Control Air Pressure 0-20 psig for HVAC
20 psig (137 kPa) minimum for safety damper functions
30 psig (205 kPa) maximum w/o pilot
Air Connections 1/8 inch NPT straight barbed fitting for 5/32 or 1/4 inch O.D. polytubing (furnished)
compression fitting for 1/4 inch O.D. copper tubing (optional)
Ambient Operating Conditions -20 to 150°F (-29 to 66°C)
Effective Diaphragm Area 15 inch2 (97 cm2)
Materials Body - Die-cast Aluminum, Diaphragm - Synthetic elastomer
Dimensions (H x W x D) See Figures 2 through 4.
Shipping Weight, lb (Kg) D-3153-1 11.5 (5.2) D-3153-3 10.0 (4.5) D-3153-5 8.5 (3.9) D-3153-7 8.5 (3.9)
D-3153-2 10.0 (4.5) D-3153-4 10.5 (4.8) D-3153-6 8.5 (3.9) D-3153-18 10.5 (4.8)
Agency Listing UL Recognized component to 250°F (121°C) with compression fitting for copper tubing
File No. R15581
D-3153-42 and D-3153-43 ULC Listed
For application at conditions beyond these specifications, consult the local Johnson Controls office. Johnson Controls, Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
Controls Group
507 E. Michigan Street
P.O. Box 423
Milwaukee, WI 53201 Printed in U.S.A.
4 D-3153 Pneumatic Actuator Product Bulletin

Section 7 – Compressor
Vendor Bulletin No.
Performance Request Form ........................................... Ajax
Performance Runs ......................................................... Ajax
Illustrated Parts List, 23” Cylinder .................................. Ajax MB-0000
Illustrated Parts List, 13” Cylinder .................................. Ajax F-0000
Rod Packing Manual .................................................................... C.L.Cook TBP 97U

NOTICE:
Cameron – Ajax ® furnishes compressor design performance to assist

you in compressor operation. If operating conditions change beyond
the ranges shown, new performance conditions can be obtained by
supplying your Cooper Compression Sales Representative with the
information on the accompanying form.
Alternately, our sizing software, eAjax ™, is available for your use without
charge. It is Windows® based, and user-friendly. If you have access to the
World Wide Web, go to www.aciservicesinc.com/ajax to download a
current version of the software.
WARNING!
Improper setting of variable volume pockets, fixed volume pockets,

valve unloaders, improperly de-activated ends, or other unloading
devices can result in dangerous operation and possible damage and/or
injury to equipment or personnel. Operating this unit without
clearance and unloading information can result in failure due to
overloading, excessive rod loads or high temperature.
Fill out and return to: Cameron Compression Systems- Ajax
Application Engineering
2101 Southeast 18th Street
Oklahoma City, OK 73129-8351
Or Fax: 405-672-8103
Package Contract Number:
Engine Model & S/N:
Compressor Cylinder Model & S/N:
Site Elevation (Feet):
Max. Ambient Temperature (Deg. F):
Suction Gas Temperature (Deg. F):
Gas Specific Gravity:
Gas “N” Value:
Design Suction Pressure (PSIG):
Anticipated Suction Pressure Range (PSIG):
Design Discharge Pressure (PSIG):
Alternate Discharge Pressure (PSIG):
In addition to the above data a complete gas analysis should be supplied.
Return address for performance:
_______________________
Cameron Compression Systems, Ajax Division eAjax Performance Software
DATE: Friday, June 01, 2007 Version = 02.05.02

TIME: 11:17:57 AM
QUOTE:
MODEL: DPC-2802LE 2-Throws
CYLINDER ON THROW #1: YK11MA [23] (HE equipped with a manual VVP.) {Poppet Valves}
CYLINDER ON THROW #2: YK11F [13] (HE equipped with a manual VVP.) {Poppet Valves}
ARRANGEMENT: Two Double Acting Cylinders, One Cylinder per Stage.
Elevation (m): 199.9 Barometric Pressure (Bars): 0.989

Ambient Temperature (°C): 37.8 Gas to be Compressed: User Entered Gas Analysis
Gas Gravity: 1.3370 Ratio of Specific Heats: 1.1440
Gas Compress. Used: Redlich-Kwong Rated Speed (RPM): 440
KW Available for Compression: 287.8 Non-lube Factor: 1.00
Standard Conditions: Base Pressure of 1.0101 Bars and Base Temperature of 15.56°C.
Suction and Discharge Pressures are considered measured at the skid edge.
Run ID#-->> 1
============================================================================================
Stage : Throw: 1 : 1 2 : 2
Speed (RPM): 440 440
Active HEs : CEs: 1 : 1 1 : 1
* Cyl. Bore Diameter (mm):0.05/84.20 0.03/30.20
Stroke (mm): 279.40 279.40
Max Gas RL-Cmpress (Kg): 7216 4170
Max Gas RL-Tension (Kg): 7124 3851
Max Net RL-Cmpress (Kg): 4695 4241
Max Net RL-Tension (Kg): 4236 3412
Min Rod Reversal (°): Passed Passed
Rod Diameter (mm): 63.50 63.50
* HE Fixed Clearance (%): 10.80 12.60
* HE Set Clearance (%): 10.80 12.60
* HE's VVP Setting (mm): 0.00 0.00
* CE Clearance (%): 10.80 11.60
* FC Clearance (%): 10.80 12.11
Z-Suction: 0.9860 0.9695
Z-Discharge: 0.9693 0.9484
Minimum HE VE Suct. (%): 76.0 83.3
Minimum CE VE Suct. (%): 76.0 84.4
Suction Press. (bar): 0.1 2.6
Discharge Press. (bar): 2.7 7.0
Suction Temp. (°C): 10.0 54.4
Discharge Temp. (°C): 56.3 89.8
Cooler Temp. (°C): 54.4 48.9
Compression Ratio: 3.33 2.26
Load Per Stage (KW): 142.9 110.5
Load Per Unit (KW): 253.4 253.4
Per Unit Flow (KW/MMscmd): 3214.06 3215.05
Flow (MMscmd): 0.08 0.08
User Notes: Run#1 Run#1
Cooler (bar): 1.06=6% 2.31=11%
VVP Throw#1 (mm): 0.00
VVP Throw#2 (mm): 0.00
============================================================================================
PERFORMANCE PREDICTIONS ASSUME STEADY-STATE PRESSURES FREE OF THE EFFECTS OF PULSATION.
Underlined items indicate corresponding Run ID# details a non-valid operating condition!
Flow tolerances measured at suction (psig) flanges: ±3%:Ps>50/R>2.5, ±6%:Ps<20, else ±4%.
Page 1 of 1
23" YK11MB Compressor Cylinder
Assembly MB-0000

1 Body Compr Cyl K-6955-B-1 1 ea 22 Gasket Flat BM-17047-30 12 ea
2 Head Compr Rear K-6957-A-1 1 ea 23 Stud K-8093-1409-32 72 ea
3 Piston/Rod Compressor YK11M-2302-3 1 ea 25 Stud K-8098-2 14 ea
* Piston Half K-6966 1 ea 26 Stud K-8093-A-1808-42 32 ea
* Piston Half K-6966-1 1 ea 27 Screw Set BM-16485-1 6 ea
* Stud K-6967 6 ea 28 Nut Plain Hex 06HN1400PC 72 ea
* Nut Self Lock BM-16428-E-1011 12 ea 29 Nut BM-19067-A-1409 14 ea
4 Ring Compr Seg BM-17042-14 2 ea 31 Nut Plain Hex BM-19067-1808 32 ea
5 Rider Ring BM-17011-B-34 2 ea 33 Connector Tube Compn BM-11610-SS-4-2 4 ea
6 Seal O Ring BM-16348-F-393 2 ea 34 Valve Check BM-11580 3 ea
7 Rod Compr Pstn K-6598-L 1 ea 35 Elbow Tube Compn BM-16310-A 2 ea
8 Collar Thrust K-7074-C 2 ea 36 Tubing Stainless 04TU070240 1 ea
9 Nut Self Lock K-4799-F 1 ea 38 Plug Pipe BM-11950-04 5 ea
10 Packing Compr Rod BM-16154-H 1 ea 39 Nut Piston Rod A-1278-B 1 ea
A Packing Ring Set BM-16012-D 5 ea 42 Bushing Pipe Redn BM-11942-02-01-S 1 ea
B Gasket Wire BM-16689-7 1 ea 43 Nameplate BM-10003-N-1 1 ea
11 Cover Compr Vlv 7-065636-001 12 ea 45 Tack Metal 907-004-001 4 ea
12 Cage Valve K-6937-B 12 ea 48 Bushing Pipe Redn BM-11942-04-02-S 1 ea
13 Valve Poppet Suct VPP971-026 6 ea 49 Valve Needle BM-17025-N 2 ea
SA Seat SPP9710&01 1 ea 50 Connector Tube Compn BM-11610-SS-6-4 2 ea
SB Guard GPP9710&01 1 ea 51 Tubing Stainless 06TU040240 2 ea
SC Poppet VPX-118&01 28 ea 52 Tee Pipe Thded BM-11961-02 1 ea
SD Spring Wire VXPS-005&01 28 ea 53 Nipple Pipe BM-11934-02-05 1 ea
SE Screw 1-02F-017-016-012 2 ea 61 Stud K-8094-1409-35 4 ea
SF Pin 1-10F-001-008-003 2 ea 62 Nut BM-19067-A-1409 4 ea
SG Spring Belleville VPX-065&1 2 ea 63 Gasket Flat Rd K-6293-B 1 ea
14 Valve Poppet Dis VPP971-027 6 ea 75 Guide K-6455-A 1 ea
DA Seat SPP9711&01 1 ea 76 Fitting Grease BM-10046 1 ea
DB Guard GPP9711&01 1 ea 77 Screw Drive BM-1386-A 2 ea
DC Poppet VPX-118&01 28 ea 78 Bar K-6456-1 1 ea
DD Spring Wire VXPS-005&01 28 ea 79 Handwheel K-6960 1 ea
DE Screw 1-02F-017-016-014 2 ea 80 Key Square K-6457-A 1 ea
DF Pin 1-10F-001-008-003 2 ea 81 Nut Plain Hex BM-11917-2408 1 ea
DG Spring Belleville VPX-065&1 2 ea 82 Screw Socket Hd BM-11473-1608-28 10 ea
21 Gasket Wire BM-15777-G-6 16 ea 83 Seal BM-16741-A 1 ea
23"YK11MB Compressor Cylinder

010407
Assembly MB-0000
23" YK11MB Compressor Cylinder
Assembly MB-0000

84 Plate Aluminum BM-16417-A 1 ea
85 Head Compressor K-6956 1 ea
86 Piston/Rod Adj Clear YK11M-2307 1 ea
* Piston Compressor K-7134 1 ea
* Rod Compr Piston K-6426-C 1 ea
87 Ring Compn BM-16247-278 2 ea
88 Seal O Ring BM-16348-F-278 2 ea
89 Adapter K-6698 1 ea
90 Stud K-8093-2007-44 8 ea
91 Nut 06HN2000PC 8 ea
92 Gasket Flat Rd BM-19016-Z 1 ea
Not shown: cylinder-to-guide gasket

p/n: K-6293-B
23"YK11MB Compressor Cylinder

010407
Assembly MB-0000
13" YK11F Compressor Cylinder with Poppet Valves
Assembly # F-0000

1 Body, 13" Cylinder K-6791-D 1 ea 32 Stud Clr Plug Flange K-8093-1011-26 16 ea
2 Head Crank End K-6957-C-1 1 ea 33 Nut Plain Hex 06HN1000PC 16 ea
3 Piston Compressor YK11F-1302-2 1 ea 34 Gasket, Water Jacket K-6769 2 ea
4 Collar Piston K-7074 2 ea 35 Cover, Water Jacket K-6768 2 ea
5 Ring Piston BM-17042-3 2 ea 36 Capscrew Hex Head BM-11900-0813-07 20 ea
6 Rider Ring Piston BM-17011-B-54 1 ea 37 Plug Pipe BM-11950-01 1 ea
7 Plug Clearance K-6348-V-3 2 ea 38 Valve Discharge VHP771-003 4 ea
8 Cage Valve K-7783-B 8 ea DA Seat SHP7711&2 1 ea
9 Rod Piston K-6598-E 1 ea DB Guard GHP7711&1 1 ea
10 Nut Self Locking K-4799-F 1 ea DC Poppet VPX-119&01 19 ea
11 Packing Rod BM-16154-K 1 ea DD Spring VPS-017&6 19 ea
A Packing Ring BM-16011-K 5 ea DF Pin CSA-152-1-008-003 2 ea
B Gasket Wire BM-16689-7 1 ea DE Screw 1-02F-015-024-013 2 ea
12 O Ring Head-to-Cyl BM-16348-F-383 2 ea 39 Set Screw Valve Cage BM-16485-2 4 ea
13 Connector Tubing BM-11610-SS-4-2 4 ea 41 Stud, Packing Case-to-Head K-8094-1409-35 4 ea
14 Tubing Stainless 04TU040240 1 ft 42 Nut Piston Rod A-1278-B 1 ea
15 Gasket Valve-to-Body BM-17047-14 8 ea 43 Nut BM-19067-A-1409 4 ea
16 Valve Suction VHP771-004 4 ea 45 Tack Metal 907-004-001 8 ea
SA Seat SHP7710&1 1 ea 52 Plug Pipe BM-11958-10 2 ea
SB Guard GHP7710&7 1 ea 53 Valve Check BM-11580 2 ea
SC Poppet VPX-119&01 19 ea 54 Elbow Tubing BM-16310-A 1 ea
SD Spring VPS-017&6 19 ea 55 Gasket, JW In/Out Cover K-7844 4 ea
SF Pin CSA-152-1-008-003 2 ea 56 Cover, JW In/Out K-7845 4 ea
SE Screw 1-02F-015-024-012 2 ea 57 Capscrew Hex Head BM-11900-0813-10 24 ea
18 Gasket, Valve Cap-to-Body BM-15777-G-9 8 ea 58 Bushing Pipe BM-11942-02-01-S 1 ea
19 Valve Cap K-6790-A 8 ea 59 Nameplate Identification BM-10003-N 1 ea
20 Stud Valve Cap K-8093-1409-33 32 ea 60 Nameplate Danger 914-175-001 1 ea
21 Nut Plain Hex 06HN1400PC 32 ea 61 Stud, CE Head-to-Guide K-8098-2 14 ea
26 Stud Cyl-to-Head K-8093-2007-44 16 ea 62 Nut BM-19067-A-1409 14 ea
27 Nut 06HN2000PC 16 ea 63 Valve Needle BM-17025-N 2 ea
28 O Ring Cyl-to-Head BM-16348-F-224 8 ea 64 Connector Tubing BM-11610-SS-6-4 2 ea
29 Gasket, Clr Plug-to-Body BM-19016-F 2 ea 65 Tubing Stainless 06TU040240 2 ft
30 Plug Pipe BM-11950-04 3 ea 66 Tee Pipe BM-11961-02 1 ea
31 Flange, Clearance Plug K-6433-D-6 2 ea 67 Nipple Pipe BM-11934-02-05 1 ea
13" YK11F Compressor Cylinder with Poppet Valves 021804
Asssembly # F-0000
13" YK11F Compressor Cylinder with Poppet Valves
Assembly # F-0000

68 Bushing Pipe Redn BM-11942-04-02-S 1 ea
not shown Gasket, Cylinder-to-Guide K-6293-B 1 ea
75 Guide VVP K-6455-1 1 ea
76 Fitting, VVP Grease BM-10046 1 ea
77 Screw Drive BM-1386-A 2 ea
78 Bar Locking K-6456-1 1 ea
79 Handwheel VVP K-6429-B 1 ea
80 Key Square K-6457 1 ea
82 Screw Socket Hd BM-11473-1608-28 10 ea
83 Seal VVP Sten BM-16741-A 1 ea
84 Scale VVP BM-16417 1 ea
85 Head Cylinder K-6689 1 ea
86 Piston/Rod VVP YKPC-1307 1 ea
* Piston Compressor K-7133 1 ea
* Rod Piston CompressorK-6426-B 1 ea
87 Ring VVP Piston BM-16247-275 2 ea
88 O Ring VVP Piston BM-16348-F-275 2 ea
89 Adapter, VVP Guide-to-Head K-6677 1 ea
90 Stud, Adaptor-to-Head K-8093-1807-42 8 ea
92 Gasket, Adaptor-to-Head BM-19016-Y 1 ea
13" YK11F Compressor Cylinder with Poppet Valves 021804
Asssembly # F-0000
Section 8 – Process Gas Equipment
Vendor Bulletin No.
Process Control Tubing Schematic ................................ Ajax 02-18-T020-353
Murphy L1200N DVO Liquid Level Controller

Installation and Operation Manual........................................... Murphy 00-02-0175
Dump Valve Assembly ................................................... Ajax TP 00-06-T01A-001
Murphy DVU-175 Dump Valve O & M........................................ Murphy
Vent Header Piping......................................................... Ajax 02-48-T010-388
Relief Valves and Fittings.................................................Ajax 02-17-T020-393
Mercer Relief Valve, 9100, O & M................................................Mercer
Blowcase Piping...............................................................Ajax 00-06-T010-320
Norriseal 3023 Control Valve, O & M...........................................Norriseal OM 704004M
Blowdown Piping..............................................................Ajax 02-47-T010-324
Morin Actuator O & M...................................................................Morin OMI 0802
Bypass Piping ................................................................ Ajax 02-50-T010-356
Ball Valve, WKM, 310F O & M.....................................................Ajax
Gauge Glass Assembly...................................................Ajax 00-06-T02A-001
Liquid Level Gauge Glass, Model RA-16.....................................Inferno F1-4
Gauge Valves, Model 15A............................................................Inferno M031196
Gauge Valves...............................................................................Inferno A031231 & A031226
Auto Blowdown ESD Schematic......................................Ajax 00-18-T020-351
Norriseal Piston Check Valve.......................................................Norriseal 707000M

00-02-0175
Section 15

GENERAL INFORMATION
Description **

Body
Pressure Rating
Temperature Rating
• Standard: -20/175°F (-29/79°C)
• Standard: -20/300°F (-29/149°C) ✗ ✗ ✗ ✗ ✗ ✗
• Optional: -20/400°F (-29/204°C)* ✗ ✗ ✗ ✗ ✗
Specific Gravity
Electrical
1/8 NPT in/out.
Operation:
2
DIMENSIONS

Regulator and Gage
11 in. Pressure
(279 mm) Regulator
Operator Assembly
p/n 15010216
2-3/16 in. See 1/8 NPT

(56 mm) Note 2
Operator Assembly
p/n 15000940
1/8 NPT
INLET
±0.25 in. (6 mm). (See Note)
L1100: 1-1/2 NPT
L1200: 2 NPT
Note 2: 1-9/16 (40 mm) 2-3/16 in.
L1100: 1-1/2 (38 mm) (40 mm)
L1200: 1-3/4 (44 mm) SF option=
1-3/4 in.
1/4 NPT 2" 11-1/2 NPT (44 mm)
3-1/2 in. (89 mm)
VENT SF= 3-3/4 in. (95 mm)
L1111
11-5/16 in.
(287 mm)
3-53/64 in.
(97 mm)
DVU150, DVU175, DVU2105/2115/2120
Series Dump Valves
2-3/16 in.
(56 mm)
See
Note A
Inlet Port Operator
(92 mm) ±0.25 in. (6 mm).
Note: 1-9/16 (40 mm)
Vent
B
F Drain
Connection C
E D
for reference only)
Model A B C D E F G
DVU2120 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2115 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2105 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU175 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 3/4”-14 NPT 1.03
DVU150 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 1/2”-14 NPT 1.03


Old DVO
Valve
Assembly
time.
Block
15050395.
L1200N
in place. Bleed
the float shaft.
New Dump Valve
p/n 15010216
kPa) [2.07-4.83 bar].
Collar Tank Wall
conduit seal
L1200N.
Hex Adjustment Nut
Basic Operation
(207 kPa) [2.07 bar]
300 psi (2.07 MPa)
Filter/Regulator
with MURPHYGAGE®
Trips Union
the equipment.

Manual Drain Valve

SPDT (Snap Switch)
Black N.O.
Black N.O.
Inductive/Resistive
15050421: Cam
0-75 psi (517 kPa) [5.17 bar]

ACCESSORIES
2-1/16 in
(52 mm) 2-1/2 in
(64 mm)
1-1/16 in 2-7/8 in
(27 mm) (73 mm)
3-5/8 in.
1 NPT (92 mm)
4-1/2 in
(114 mm)
2 NPT

3 in.
1-11.5 NPT (2 places) (76 mm)
2-11.5 NPT
10.5 in. 3 in.

(266 mm) (76 mm)
1/2-20 UNF-2B
(4 places)
7.55 in. 3.5 in.

(192 mm) (89 mm) 7.01 in.
(179 mm)

10-32 UNF
10-32 UNF
3/8 in
(10 mm)
1-3/8 in
(35 mm)
Warranty

Set the control signal
pressure at 45 psig.
NOTE
If pressure or fluid comes out the weep
hole of the union nut, either the o-ring
under the union nut is leaking, or the
packing could be leaking through the
internal weep hole above that o-ring.
Dump valve operating temperature is -30ºF to 250ºF.

Dump valve maximum process pressure is 1800 psi.
Refer to the manufacturer’s bulletin for details.
Murphy DVU175
Dump Valve Assembly
TP 00-06-T01A-001 Rev 2
Murphy DVU175 Dump Valve Assembly
TP 00-06-T01A-001 Rev 2

1 Dump Valve, Murphy 1" NPT x ¾" NPT 2003 6225 1
2 Male Connector, ¾" Tube x ¾" NPT 2507 1606 2
3 Bushing, 1" x ¾" NPT, 3000# 2527 1006 1
4 Pipe Nipple, 1" NPT x 2"L, Sch 160 2539 8608 2
5 Pipe Tee, 1" NPT, 2000# 2545 4010 1
6 Ball Valve, 1" NPT, 2000# 2549 2107 1
7 Tubing, ¾" x 0.049 Wall 5551 4912 19"
00-02-0483
Installation and Operation Manual for Revised 03-06
Section 15
DVU Series Dump Valves

Models: DVU150, DVU175, DVU2105, DVU2115 and DVU2120
Please read the following information before installing. A visual inspection of this product for damage during shipping is recommended
before mounting. It is your responsibility to have a qualified person install this unit and make sure it conforms to local codes.
GENERAL INFORMATION
Fig. 2 Dimensions (all models)
WARNING Pressure
Inlet Port
A
Manual Valve
Operator
1/8 in.-27 NPT

✔ Make sure the machine cannot operate during installation. Vent
B
✔ Follow all safety warnings of the machine manufacturer. Weep Hole Valve Open/Closed
Description
The DVU Series models are pneumatically controlled dump valves. F Drain
The valves open and close automatically by pneumatic control from a Connection C
Murphy L1200NDVOR or similar level controller and dump valve opera-
E D
tor. Diaphragm actuated, the DVU series dump valves operate at 30–70 psi
(207–483 kPa) [2.07–4.83 bar] and up to 2000 psi (13.8 MPa) [138 bar] Plug Seal G (dimension shown
for reference only)
vessel pressure (depending on the model).
A key benefit of this design is a hex union that provides the ability
to replace the seat without removing the valve from piping.
Model A B C D E F G
DVU2120 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2115 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2105 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
Fig. 1 Control Pressure vs. Working Pressure DVU175 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 3/4”-14 NPT 1.03
DVU150 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 1/2”-14 NPT 1.03
Minimum Actuation Pressure NOTE: Dimensions are in inches and (millimeters)

70
DVU2115 DVU2120
Control Pressure (PSIG)
60
50 Specifications
40
DVU2105 DVU150/175 Operating Temperature: -30 to 250°F (-34.4 to +121°C)
30 Valve Operating Pressure: Refer to chart, Fig 1.
20
Maximum Process Pressure:
10 DVU2120: 2000 psi (13.8 MPa) [138 bar].
0 500 1000 1500 2000 DVU2115: 1500 psi (10.3 MPa) [103 bar].
Vessel Pressure (PSIG) DVU2105: 500 psi (3.44 MPa) [34 bar].
DVU150 and DVU175: 1800 psi (12.4 MPa) [124 bar].
Flow Characteristics: See chart, page 4 (DVU150/175 models only).
Body Material: Electroless Nickel Plated 12L14 Carbon Steel
Model Inlet Outlet Trim Size
Internal Wetted Parts: Plug Seal: 90 Durometer Urethane.
DVU2120 2 NPT 1 NPT 0.436 in. (11 mm) Other: 303 stainless steel; Electroless Nickel Plated 12L14 Carbon Steel
DVU2115 2 NPT 1 NPT 0.576 in. (15 mm) Shipping Weights: DVU150 and DVU175: 9 lbs. (4 kg.).
DVU2105 2 NPT 1 NPT 0.859 in. (22 mm) Shipping Weights: DVU2105, DVU2115 and DVU2120: 14 lbs. (6.4 kg.).
DVU175 1 NPT 3/4 NPT 0.359 in. (9 mm) Shipping Dimensions: 7-1/2 x 7-1/2 x 10-3/4 in. (191 x 191 x 274 mm.).
DVU150 1 NPT 1/2 NPT 0.359 in. (9 mm)

Fig. 3 The Murphy Gas Compressor Scrubber Level System (SLS)

Scrubber/Separators
The system provides for liq-
uid control in gas scrubber High Level Shutdown Switch
Basic Operation applications, by dumping liq- Stainless steel float actuated level switches to alarm
As condensate rises in the scrubber, the float uids to drain and protecting and/or shutdown the equipment.
on the L1200NDVOR rises and trips its pneu- compressors with a high liq- L1200: 2” NPT pipe connection; Rated 2000 psi
matic valve. The valve opens allowing pres- uid level switch. Wetted metal (13.7MPa) [137bar]; Class I, Division 1. SPDT
snap-switch standard. DPDT Optional.
sure to enter the dump valve pilot chamber. parts are made to survive
All Stainless Steel available.
Once the pressure enters the pilot chamber it constant use in corrosive
environments.
forces the diaphragm and valve stem forward
See Bulletin: SLS-04005B for
thus opening the valve seat (valve open/closed more details.
indicator button pops out) and releasing con-
Filter/Regulator &
densate through the valve stem and out the Control
MURPHYGAGE®
drain. As the condensate level drops, the Panel
L1200NDVOR pneumatic valve closes to shut
“Instrument
off the pressure to the dump valve causing it to Quality Air/Gas
close. Supply”
If for any reason the condensate continues to
rise beyond normal dump levels, model L1200
operates the alarm and/or shuts down the
Pneumatic Level Control
equipment. Float actuated level snap-acting switch
The L1200NDVOR Filter/Regulator and the controls pneumatic pressure to open
and close dump valve.
Pneumatic Dump
MURPHYGAGE® help keep the control pres- Valves See DVU-01069B
sure clean and dry. They also allow the opera- L1200NDVOR: Dump Valve Operator,
for more details.
pressure regulator, and pressure indi-
tor to adjust pressure to recommended levels. Two piece union design with manual valve operator
cating MURPHYGAGE.® allows soft plug and hard seat to be replaced with-
NOTE: Always use clean, dry, out disassembling outlet piping or scrubber pipe
instrument quality gas. connection. Diaphragm actuated valves operate on
30-70 psi (207-483 kPa; 2-5 bar).
DUMP VALVE INSTALLATION
DVU Series Installation

Upper Assembly
(removable)
CAUTION: ALWAYS USE “NON-SPARKING TOOLS”
Pneumatic
WHEN GAS IS KNOWN TO BE PRESENT. Input Signal
Valve
Union
The following describes the “Direct Mounting” method to the Fig. 4
tank wall. Typical
1. Install the valve so the drain connection is on the bottom. Use Dump Valve Maintenance
Bolt
pipe thread sealant on all the connections. Installation
2. Be sure the unit is screwed tight and does not leak. Valve Indicator
3. Install the piping for the pneumatic input signal into the
Vessel Wall
1/8 NPT threaded connection of the pressure inlet port (on Weep Hole
top of the diaphragm housing of the DVU).
6. Install a union between the DVU drain connection and the Drain
condensate out line. Use pipe thread sealant on all the con- Connection
nections.
Union
Condensate Out
2-Way (Manual Drain)

Shutoff Valve

REPAIR PROCEDURE
CAUTION: THE INSTALLATION AND REPAIR PROCEDURES SHOULD 6. Using a back-up wrench on the plug, remove the stem nut on the shaft
ONLY BE PERFORMED BY TRAINED, QUALIFIED, AND EXPERIENCED under the plug. Once the stem nut is broken loose, the 9/16” head main-
PERSONNEL. THE TRAINING, QUALIFICATION AND EXPERIENCE
tenance bolt and top assembly will keep the stem from turning. The plug
turns freely on the stem once loose. The plug and seat can now be
REQUIRED IS FOR WORK AROUND PRESSURE VESSELS, NATURAL GAS, POSSI- removed. All soft seals should be replaced. Refer to kit part numbers
BLY SOUR GAS, OR ANY SUBSTANCE TO BE FOUND IN THE VESSEL. EXTREME under service parts on page 4.
CARE MUST BE TAKEN TO INSURE ANY RESIDUAL OR FULL PRESSURE IS
RELIEVED FROM ALL PARTS OF THE SYSTEM TO BE SERVICED. Replacing the Diaphragm
6A. If the diaphragm is to be replaced, all preceding steps have to be
Suggested Tools (Sizes listed are wrench openings. done. Additionally, do the following:
Adjustable crescent wrenches, socket and/or end wrench, pipe wrenches, 6B. Loosen the 9/16” head maintenance bolt, allowing the diaphragm
flat edge screwdriver with 1/4” blade width, can also be used .) spring to relax, and the stem to retract. Make alignment marks on
Model Valve Body Union Nut Plug Seal Hex Stem Nut the top and bottom halves of the diaphragm assembly for align-
DVU2120 3” 3” 7/8” 1/2” ment during re-assembly.
DVU2115 3” 3” 1” 1/2” 6C. Remove the 8, 7/16" bolts/nuts holding the diaphragm housing
DVU2105 3” 3” 1-1/4” 1/2” together.
DVU150/DVU175 2-1/4” 2-1/4” 3/4” 3/8” 6D. Using a straight edge screwdriver, gently separate the 2 halves of
the diaphragm housing, and remove the top, or outside portion.
Replacing the Plug and Seat 6E. Lift the diaphragm and support plates far enough for the 1-1/8" hex
1. Close the pressure block valves (suction & discharge valves) on the inlet or 1” round nut on the bottom of the diaphragm assembly to be
and outlet of the skid. Lock them closed if possible. accessible to a wrench and not have the spring interfere. If it is
2. Open the blowdown valve to remove pressure from the unit. Lock the desired to replace the packing, pull the stem all the way out. The
blowdown valve open if possible. packing can be easily removed using a small screwdriver to pry the
3. After taking all possible precautions to insure there is no pressure in the packing out. The new packing can be simply pressed in, making
vessel. (If the condensate line is pressurized, it must also be blocked and sure the orientation of the packing installed is the same as the ori-
locked.) Open the manual drain valve so it bleeds into the vessel so it entation of the packing removed. The packing is wider toward the
can also be bled down. Disconnect the pneumatic input signal connection plug end. You will have to use the seat to hold the packing in place
after insuring it also has been de-pressurized. when re-inserting the stem.
4. Using a back-up wrench on the valve body, with a quick "breaking" 6F. With the 1-1/8" hex or 1” round nut held by a wrench, use a
action loosen the union nut on the valve. There is a "weep" hole in the wrench to loosen and remove the 1/2" nut on top of the diaphragm.
nut. If at any time while loosening and taking off the nut pressure is The diaphragm can now be removed and replaced.
escaping through the "weep" hole, immediately stop loosening the nut. 6G. With the new diaphragm in place and the 1/2" nut tightened, place
Retighten the nut and check the preceding procedures to ensure the pres- the assembly, diaphragm down on a clean, smooth sturdy surface.
sure is bled off the vessel. Never remove the assembly if pressure is 6H. Have the seat, plug, washers and stem nut handy (if any of these
coming through the weep hole. See Figure 4 on page 2.
parts are to be replaced, use the old parts for this procedure). Press
5. With the upper assembly removed from the vessel the plug and/or seat can
down evenly and smoothly on the bottom of the diaphragm assem-
be replaced. Loosen the 9/16” jam nut on the maintenance bolt on top of
bly to cause stem to come up. Place the seat and plug in place.
the diaphragm cover. Spin the nut up against the head of the bolt. Tighten
the bolt to extend the shaft and plug. DO NOT OVERTIGHTEN. Then push the bottom of the diaphragm assembly down far enough
to install the washers and stem nut on the stem. Tighten the stem
nut enough to hold against the diaphragm spring.
Fig. 5 Stem O-Ring Seals 6J. Align the diaphragm holes to the bolt holes (bottom half of the
Plug Seat Stem Packing Against Outlet housing). Install the upper diaphragm housing using the alignment
Washer(s)* marks from step 6B. Install the 8, 7/16" bolts and nuts. Tighten the
bolts evenly going from one bolt then 180° around to the next bolt,
then either 120°or 240° around to the next bolt and so forth until
all 8 bolts are evenly tight.
Stem O-Ring 6K. Using the 9/16” head maintenance bolt, tighten, pushing the stem
Nut Crush Washer Seal Seat butts into here out until the 9/16"bolt stops – DO NOT OVERTIGHTEN.
*Number of washers varies depending on the model from 1 to 3. 6L. Remove the stem nut holding the plug. (If old parts were used, pre-
pare to install the new parts now.)
Seal Washer Maintenance 7. Install the seat and plug. Place the O-ring on the stem, followed by the
Fig. 6 Bolt Diaphragm
Pressure Inlet washer and stem nut.
Housing 8. Tighten the stem nut. Loosen the 9/16” head maintenance bolt by at least one
Diaphragm 1/2" Nut
turn past the point where it is no longer in contact with the stem. Tighten the
9/16" jam nut holding the 9/16” head maintenance bolt.
9. Replace the crush washer and the O-ring hidden by the union nut.
NOTE: If pressure or fluid comes out the weep hole of the union nut,
either the O-ring under the union nut is leaking, or the packing could be
Backup leaking through the internal weep hole above that O-ring.
1-1/8" or Diaphragm 10. The assembly is ready to be re-installed. Check for relative position of
Plate Spring
1" round nut Stem Assembly the pneumatic input signal connections before tightening the union nut.

PRESSURE VS. FLOW CHART
Fig. 7 Pressure vs. Flow for DVU150 and DVU175 models only
250
250
200
200
150
150
Pressure (psid)
100
100
50
50
0
0 5 10 15 20 25 30 35 40 45
Flow (gpm)
SERVICE PARTS
Part No. Description Typical Diaphragm Repair Kit includes:

DVU2120 Diaphragm; Diaphragm Washer (upper), Diaphragm Nut, Diaphragm Plate
55-00-0237 Seal Kit (includes plug) (1 or 2 pcs.), Packing, “O” Ring, Stem, Seal Washer for Maintenance Bolt.
55-00-0236 Diaphragm Kit
The DVU Series Valve is included in the
DVU2115 following Scrubber Levels Systems.
55-00-0240 Diaphragm Kit (Includes L1200, L1200NDVOR, and DVU valve)
SLS2120: Includes DVU2120 valve
DVU2105
55-00-0245 Seal Kit (includes plug) SLS2115: Includes DVU2115 valve
DVU175 SLS175: Includes DVU175 valve
DVU150 -LR: Less Regulator option
55-00-0230 Seal Kit (includes plug) Warranty
55-00-0231 Diaphragm Kit A limited warranty on materials and workmanship is given with this FW
Typical Seal Kit includes: Nut, Washer (1 to 3), “O” Ring, Plug and Murphy product. A copy of the warranty may be viewed or printed by going
Seal, Seat, Crush Washer. to www.fwmurphy.com/support/warranty.htm

Page 1 of 4
W-K-M®
DynaSeal® 9
8
310F 2-Piece
6
5
4
Flanged End 3
2
11
Ball Valve
12
10 1
13
10
14
17
15
Table of Contents 16 310F 1"F thru 2" R
Scope ...................................................... 1
Nameplate Information ............................ 2
Storage...................................................... 2 8
Installation ............................................... 2-3 6
Operation .................................................. 3 5
Routine Maintenance ............................... 3 4

7
Trouble Shooting ..................................... 4
3
Item Description 11
1 Body 12
2 Packing
3 Compression Ring
4 Bonnet Cap
5 Cap Screws 1
17
6 Stop Plate
13
7 Retainer Ring
10 10
8 Handle/Lever 15
14
310F 2"F thru 4" R
9 Lock Nut 16
10 Seat Ring
11 Stem Seal Scope
12 Stem
The W-K-M DynaSeal 310F ball valve is designed to meet tougher
13 Ball industry requirements while maintaining key features of the W-K-M
14 Tailpiece Gasket floating ball valve. It has deep-pocketed seats, an adjustable,
15 Tailpiece replaceable stem packing and is available in carbon steel and
16 Nut stainless. The 310F is offered in sizes 1F" to 4"R and class 150, 300
17 Stud and 600 flanged ends.
W-K-M DynaSeal 310F 2-PieceBall Valve Publication

TC-1473
Page 2 of 4
Nameplate Information
W -K -M
Item Description Item Description

1 Assembly part number 6 Maximum operating pressure
2 Nominal valve size and type designation 7 Maximum working pressure
3 Model number 8 Maximum temperature
4 Ball-Stem material designation 9 Date of manufacture
5 Body & Seat-seal code designation
Storage Flanged-End valves may be bolted into the line

using two open or boxed end wrenches.
After valves are assembled and tested, they are 1. Threads of flange bolts and nuts should be
placed in the full open position, flange seal lubricated to obtain maximum loading of bolts.
surfaces and bores are greased and end protectors 2. Finger tighten all nuts first.
are installed. This will provide adequate protec- 3. When tightening bolts, use the crisscross
tion for indoor storage. Extended outdoor storage method and torque each bolt to ANSI or gasket
requires periodic inspection and the addition of a manufacturer specification.
corrosion inhibitor. Contact your CCV representa-
tive for extended storage guidelines. Valves Field testing, if performed after the valve has
should only be stored in the full open or full close been properly installed into the line, should be
position to prevent seat distortion. done in accordance with the following procedure:
Installation Caution: Ensure that all test fluids contain

corrosion inhibitors and are compatible with
DynaSeal 310F ball valves may be installed in any valve seat and seal material.
position with flow from either direction. How-
ever, for best service life there is a preferred 1. Preliminary Testing - Completely flush the
vertical or horizontal position to maximize sealing system or the line to minimize damage to the
and minimize the accumulation of sediment. In seats and ball surface which might be caused by
the vertical position it is preferred to have the weld slag or other foreign matter resulting
upstream pressure from above so the weight of from installation procedures.
the ball will assist the pressure in sealing. With the 2. Line Testing - When performing this test, the
run of the valve in a horizontal position, it is valve should be in the half-open position to
preferred to have the stem lying horizontal (i.e. ensure that the body cavity is completely filled
toward the viewer) with pressure from the right. with the test media and to prevent accidental
During operation, flow will act as a siphon and over pressure of the seats. NOTE: Line may be
minimize retention of sediment. tested at a maximum of 1-1/2 times the valve's
cold working pressure rating without consulting
When handling or installing a valve, keep the the factory.
valve in the full open position whenever possible 3. Seat Testing - When testing the seats with the
to prevent foreign object damage to the ball.
Publication W-K-M DynaSeal 310F 2-PieceBall Valve

TC-1473 Installation, Operation and Maintenance Manual
Page 3 of 4
valve in the closed position, do not exceed the

valve's cold working pressure rating.
Routine Maintenance
4. Upon completion of testing, purge all test fluids Due to its design and simplicity the 310F ball
from the valve. valve requires very little maintenance. It's non-
lubricated, self-cleaning ball can provide reliable,
leak-free performance over a long period of time.
Operation The only preventative maintenance recom-
DynaSeal 310F ball valves operate from fully open mended is to periodically inspect the valve for
to fully close by a 90-degree turn of the handle. leaks around the stem or actuator. Should a leak
The handle aligned with the pipe always means be noticed, the following procedure is for adjust-
the valve is open and with the handle perpendicu- ing the packing.
lar to the pipe means the valve is closed. Addition-
ally, the stems have flats that align the handle and Stem Packing Adjustment -
can be used to indicate ball position. The bore of 1. With an Allen wrench, snug up each of the two
the ball is parallel with the faces of the stem flats. packing adjustment screws in a clockwise
direction.
DynaSeal 310F valves may be power actuated. 2. Snug up each screw an equal amount only as
Pneumatic and hydraulic actuators, whether of the much as required to stop the leak, not to
fail-open, fail-close, or fail-last position type, have exceed the maximum specified in the follow-
"Open-Close" indicators on the top of each unit. ing table.
On a pneumatic actuator, make sure filters and 3. The following table gives torque values that
lubricators (if recommended by the actuator will seal stem packing in good condition.
manufacturer) are installed prior to valve and Torque values above this indicate seals are
actuator installation. Should any maintenance be worn and need replacement and excessive
necessary, obtain the part number from the unit's tightening will also cause an unacceptable
nameplate and contact Cooper Cameron Valves or increase in valve stem torque.
the nearest representative.
Torque Values for Packing

Adjustment Screws
Torque (Packing)
Valve Size Screw Size in-lb (kg-m)
1F 1/4-20 NC 36-60 (0.4-0.7)
1-1/2F & 2R 5/16-18 NC 60-120 (0.7-1.4)
2F & 3x2 3/8-16 NC 120-180 (1.4-2.1)
3F & 4R 1/2-13 NC 180-240 (2.1-2.8)
W-K-M DynaSeal 310F 2-PieceBall Valve Publication

TC-1473
Page 4 of 4
Warning: Valves should be placed in a partially open position prior to working on valve or
removing it from service to vent pressure or drain product that may be trapped in the body
cavity.
Troubleshooting Chart
Trouble Probable Cause Remedy
Will not open or close a. Iced up due to restricted flow a. Flush out with warm material.
or low temperature.
b. Pressure locked. (Condition in b. Reduce valve temperature or
which the body pressure pressurize line to rated working
exceeds the line pressure by pressure to reduce pressure
an excessive amount. differential sufficient to operate valve.
Hard to operate a. Accumulation or solidification a. Flush valve to get material out of body.
of material in the body b. Install correct trim.*
of valve. c. Apply penetration oil around stem. If
b. Swelling seats still won't operate disassemble valve
c. Corrosion between stem and polish stem.*
and valve body. d. Check operator.
d. Operator not installed
properly
Will not seal properly a. Worn or damaged seats and/ a. Replace worn parts.* (Requires valve
or ball. removal and disassembly)
b. Foreign matter between seat b. Operate several times to wipe clean.
and ball. c. Adjust stops to proper setting.
c. Operator stops not properly
set.
Valve leaking between a. Leaking tailpiece gasket a. Replace gasket.* (Requires valve
body and tailpiece b. Tailpiece and valve body are removal and disassembly)
not tightened together b. Tighten parts to specified torque.*
properly.
Leaking around stem a. Loose stem packing a. Adjust stem packing screws.
b. Worn or damaged stem b. Replace stem packing.*
packing.
*Contact your CCV representative for a Repair Manual
Headquarters USA Scotland

Cooper Cameron Valves Cooper Cameron Valves Cooper Cameron Valves
16500 South Main Street 845 S.E. 29th Street Houstoun Industrial Estate
Missouri City, TX 77489-1300 Oklahoma City, OK 73147 houstoun Road
Phone: 281-499-8511 Phone: 405-631-1321 West Lothian EH54-5BZ
800-323-9160 Fax: 405-629-0420 Livingston, Scotland
Fax: 281-499-6965 Phone: 44-1506-444-000
Fax: 44-1224-783-355
http://www.ccvalve.com
©Cooper Cameron Corporation, Cooper Cameron Valves Division, Printed in USA / 02-01 / TC-1473
W-K-M® and DynaSeal® are trademarks of Cooper Cameron Corporation
Publication W-K-M DynaSeal 310F 2-PieceBall Valve

TC-1473 Installation, Operation and Maintenance Manual
MODEL 15A GAGE VALVES
APPLICATION—
Pressure Rating: 3000 PSI @ -20°F to 100F 2850 PSI @ 300°F 2625 PSI @ 500°F
INSTALLATION—
DON’T Create additional misalignment.

DO Plumb
Some misalignment is usually present due
tailpieces to
to errors in concentricity of pipe threads,
avoid mis-
weld distortion in couplings, etc. Don’t
alignment.
make it worse!
DO Make up unions tight. Use at least an 18” wrench. Union is designed to crush solid metal along a high ridge, creating a “line”
seal between the taper and the flat surfaces.
Union will seal pressure without need for O-ring if alignment is good enough and if the installa-
tion torque has been efficiently transmitted into tightening the joint.
However, if there is significant misalignment in the piping arrangement then some of the “umpf”
experienced during make-up has been diverted into deflecting the piping. This causes resistance to further 1.5° TAPER (Union Nut
omitted for clarity)
turning of the nut and may leave insufficient tightness in the metal to metal seat of the union for sealing.
In this case the O-ring will finish the job. The joint needs to be tight enough (close enough) to close the
extrusion gap for O-ring to maintain its seal.
More severe MISALIGNMENT can lead to leaks at the union or broken pipe nipples or broken
tailpieces. If you are experiencing these difficulties ask for Inferno SPHERICAL UNIONS avail-
able as a separate male x male union or built into the valve itself.
DO Make up unions using a BACK-UP WRENCH on the valve body.
Failure to use back-up wrench causes excessive stress on the connecting nipple and can lead to
breakage of nipple or harmful twisting to sight glass.
BACK-UP WRENCH POINTS
OPERATION—
BALL CHECKS...
Open valves full open during operation to assure safety action of ball check in case of glass or gasket failure. Stem must be open
more than 1-1/2 turns before ball is allowed to back seat. Extension on end of stem will deny ball a seating position until valve is
opened sufficiently. At this point the extension of the stem retreats enough to allow ball to check
closed in event of sudden loss of pressure in the sight glass.
Ball checks are designed to limit flow from vessel in case of accidental glass or gasket failure. They can
be of great help in limiting the blow-out effect of pressure acting on a shattered glass. But— they are not
intended to provide a perfect seal. Dirt, trash and corrosion in the ball check cavity and back seat area
will limit the tightness of the emergency shut-off. In such cases there may be some degree of leakage past the ball checks.
Ball check will not activate in case of seepage caused by a leaky gasket. Ball check may not activate at all if cavity is packed with
M031196 sheet 1/2 1 1/03
Ball checks cont’d...
corrosion. Ball check requires pressure in the vessel to activate. About 7” head of water is sufficient pressure to check the ball in
water service with a full flow leak. More pressure is required to check with a choked off leak. Performance in other fluids will vary. Ball
check may not activate in extremely viscous fluids.
If in doubt as to whether ball checks are present in an existing installation or whether or not they are working properly you can test
as follows: Close off the upper gage valve. Leave the lower valve open. Open a drain valve rapidly and listen for the ball to make an
audible “click”. Now repeat process reversing the upper and lower valve position.
Restore fluid level in sight glass by closing drain and then moving both valves into the cracked open position. Cracking the valves
open will cause the stem extension to unseat the ball and allow it to drop back into its normal resting place.
If sight glass fails and balls are activated then manually close both valves. Be aware that a small amount of fluid will escape as the
balls are dislodged and before stem has a chance to fully close. Take necessary precaution.
BLOW-DOWN... DON’T blow down sight glass with valves open. High velocity flow will cut seat and lead to failure of valve to close
without leakage. This problem is especially common in steam and hot water applications. However if it is not convenient to blow-down
the hot water sight glass with valves in the closed position then DO install a second valve (ball or gate) to insure that a tight
shut-off can be made for maintenance purposes during normal plant operation. A double block system may be required if you experi-
ence cutting in the seat area.
Shut off upper and lower valves first, then blow down sight glass through the lower valve’s drain connection, or through an additional
outlet at the bottom of the sight glass. Restore fluid level in sight glass by closing vent and drain and then cracking open the upper
and lower valves. Cracking the valves open prevents nuisance ball checking. After level has been reestablished open the valves full
open. In the full open position the ball is able to check autmatically in case of glass failure. In cracked position it will not check.
SHUTDOWNS... It is usually best to leave valves in normal full open position as the system is de-pressurized. This prevents excessive
thermal stress on the sight glass and valves and prevents trapping high pressure fluid. During START-UP pressure and temperature
are allowed to equalize slowly in the sight glass.
Optional Materials
SPARE PARTS FORMODEL 15A— O-Ring, EPDM E0962-90, Size 2-116, for hot water & steam
O-ring, Viton™, Size 2-116 (90 durometer) P/N 4938
P/N 4761 O-Ring, Parofluor Ultra, Size 2-116, for hot water & steam to 525F
P/N 6965
Stem Packing, Grafoil™, over 500°F
3/4” NPT Tailpiece, Steel P/N 3509
P/N 4613
1/2” NPT New Item

Spherical Union- Corrects for angular misalignment in piping.. reduces all piping strain.Re-usable
Tailpiece, Steel joint seals gas-tight multiple times.
P/N 4612 Best when used with Close Hook-up (CH) level gages having side or back outlets. Position the
spherical union between the side or back outlets of the “CH” level gage and the gage valve. If
C-C does not match, rotate the vessel connection of the valves until the ball will fit into sock-
Union Nut, Steel et. By allowing the valves to rotate non-parallel to each other the spherical union will correct a
P/N 3882 relatively large C-C difference between assembly and vessel. Purpose of spherical joint between
gage and valve is to eliminate piping strain.
May also be used with CH level gage without valves for direct connection to vessel or piping
Should be used in conjunction with a plain, flat, “Floating Union” in a matched set. In this
Stem Packing, way angular misalignment and C-C difference may be overcome.
Teflon™ Available in Steel and Stainless, Std. O-Ring is Viton
standard, to 500°F 1/2” x 1/2”
P/N 4347 3/4” x 3/4”
1/2” x 3/4”
COMMENTS AND SUGGESTIONS WELCOME

INFERNO MFG. CORP. SHREVEPORT, LOUISIANA www.infernomfg.com
TEL: 318-221-8454 FAX: 318-222-4106 email: inferno@infernomfg.com M031196 sheet 2/2 1 1/03
OPERATING and MAINTENANCE MANUAL
SERIES 7100 “FLO-LIFT”© PISTON CHECK VALVE
SCOPE 2.0 DISASSEMBLY
This manual provides information on installation, operation, Note: Numbers in parentheses refer to items shown
maintenance, and parts for Norriseal Series 7100 Piston in figure 1 and figure 2.
Check Valve.
1. Remove nuts (14A) from bonnet studs (14B).
GENERAL DESCRIPTION Required wrench sizes are as follows:
The Series 7100 Piston Check Valve is designed for low- CHART I
pressure drop and positive prevention of backflow. It is STUD SIZE WRENCH SIZE
suitable for use with either gas or liquid systems. The 0.62 1.06
0.75 1.25
control orifice and ball check built into the plug provide a 0.88 1.44
cushioning or dampening effect for the plug making this 1.00 1.62
valve suitable for pulsating flows of gas or air. 1.12 1.81
1.25 2.00
1.38 2.19
1.0 INSTALLATION 1.50 2.38
2.00 3.12
1. Before installing the valve, inspect for shipping
damage and/or any foreign material that may have
2. Lift bonnet (6) straight up and remove from body
collected during crating and shipping. Remove
(13).
flange protectors.
3. Remove load spring (5) by lifting straight up and
2. Flush out inlet piping to remove pipe scale, chips,
out of body.
welding slag, and other foreign materials.
4. Valve plug (1), cage (3), and guide (4) may be
3. Valve must be installed so that flow is in direction
removed by means of lifting attachment (1D)
indicated by the arrow tag attached to the side of
screwed into top of plug.
body. Also note the word "INLET" engraved in
flange O.D. at inlet end of body.
5. After removal from body, the plug, cage, and guide
may be separated by lifting guide (4), then cage (3)
4. Install the valve using good piping practice. For
over top of plug.
flanged bodies, use a suitable gasket between the
body and pipeline flange.
6. Remove plug seal (11) from recess in lower end of
guide.
5. If continuous operation is required during
maintenance and inspection, install a conventional
7. Remove seat (2) and seat gasket (9) by lifting them
three-way bypass around the body.
out of recess in body.
6. The bodies are rated at 150, 300, 600, 900, 1500
and 2500 ANSI class. Do not install the valve in a 2.1 INSPECTION
system where the operating pressures exceed those
specified in the standards. Follow valve disassembly as outlined above;
carefully inspect individual components as follows:
2.0 NORMAL MAINTENANCE SCHEDULE
1. Plug Seal: Construction consists of a stainless steel
CAUTION: spring surrounded by a TFE jacket. Examine
Before starting any repair or maintenance, make sure that all spring to be sure it is not bent or permanently
pressure has been released from valve body. Before crimped. The TFE jacket should be carefully
unbolting bonnet, SLOWLY LOOSEN pipe plug in top examined under good lighting conditions. In order
center of bonnet. While loosening plug, listen for sound of to function properly, the jacket must be free of
gas pressure escaping around plug. Do not remove bonnet scratches, cuts, and tears.
until all trapped pressure, if any, has escaped.
Caution: Before disassembly or maintenance, all pressures in this device must be relieved. Failure to relieve
pressures may result in personal injury or device damage. The resulting uncontrolled venting or spilling of
line fluids may cause personal injury, loss of process control, or environmental contamination.
January 2002 707000M - © 2002 Page 1 of 6

P.O. Box 40525 – Houston, TX 77240-0525 Telephone: (713) 466-3552 Fax: (713) 896-7386 Web: www.norriseal.com
ITEM DESCRIPTION
1 Piston Assembly
2 Seat Valve
3 Cage Piston
4 Guide Piston
5 Spring Piston
6 Bonnet Valve
7 Gasket Bonnet
8 Gasket Guide
9 Gasket Seat
11 Seal Piston
12 Plug Vent
13 Body
14 Stud Bonnet w/Nut
15 Eye Bolts
FIGURE 1
.2B Composition (Non-Metallic)-to-Metal Seating

.2 Valve Plug: Inspect plug as follows: (Figure 3):
O.D. of plug slides through seal ring and therefore
must be free of nicks and scratches that could
damage the TFE jacket. Handle plug carefully to .1 1” valve size consists of five basic components
avoid damage during maintenance. Examine assembled and secured with a screw.
seating surface for scratches, nicks, or gouges that
could impair shutoff. If plug has a non-metallic soft .2 1.5” valve size consists of three basic
insert, this item should be closely examined, as it is components assembled and secured by a
particularly susceptible to damage. Construction castellated nut and cotter pin.
may be solid (1-piece), or may be an assembly of
three or more basic components as described .3 2.0” valve size consists of three basic
below. components assembled and secured with two
screws.
.2A Metal-to-Metal Seating (Figure 2)
.4 3” & 4” valve sizes consist of four basic
.1 1”, 1.5”, 2”, 3”, and 4” valve size: Plug is solid components assembled and secured by a
1-piece construction with integral seating screw.
surface machined near-bottom of plug.
.5 6” & 8” valve sizes consist of four basic
.2 6”, 8”, 10”, and 12” valve size: Plug is components assembled and secured by four
multi-piece construction with replaceable screws.
seating insert secured to plug butt with four
screws. .6 10” valve size consist of four basic
components assembled and secured by six
screws.
January 2002 707000M - © 2002 Page 2 of 6

HARD TRIM – FIGURE 2
ITEM DESCRIPTION
1A Orifice Plug
1B Check Plug
1C Nut Screw Lifting
1D Screw Lifting
1E Piston
1F Butt Piston
1G Retainer Piston
1I O-Ring Retainer
1J Screw Retainer
1L Washer Lock Spring
January 2002 707000M - © 2002 Page 3 of 6

SOFT TRIM – FIGURE 3
ITEM DESCRIPTION
1A Orifice Plug
1B Check Plug
1C Nut Screw Lifting
1D Screw Lifting
1F Butt Piston
1G Retainer Piston
1H Insert Piston
1I O-Ring Retainer
1J Screw Retainer
1L Washer Lock Spring
1M
1N
January 2002 707000M - © 2002 Page 4 of 6

.7 12” valve size consist of four basic back against seat. After inspection and cleaning,
components assembled and secured by twelve reinstall ball check in valve plug.
screws.
Examine orifice for presence of foreign matter and
If inspection of insert-type plug shows all components to be clean as required. Reinstall orifice plug in valve plug.
in good condition, it is not necessary to disassemble plug This completes inspection and maintenance of valve
and remove insert. However, if disassembling plug for plug.
replacement of insert, proceed as follows: (Refer to Figure
3). .3 Valve Seat: Beveled seating surface must be
free of nicks and scratches. Inspect under-side
A) Plug may be secured in inverted position in a vise for of seat for scratches or other imperfections that
disassembly. However, if using a vise, place blocks of would impair proper sealing against seat gasket.
wood or other soft material on both sides of plug to
protect surface finish. .4 Cage, Guide, and Load Spring: These
components should not suffer any adverse
B) Remove cap screws (1J) using wrench size from Chart effects from normal operation. However, with
2. valve disassembled, they should be examined to
verify that they are in good condition.
C) Remove retainer, insert, and o-ring seal from butt-plug.
.5 Valve Body: With seat and bonnet gaskets
D) To reassemble plug, install o-ring, insert, and retainer removed from body, inspect gasket recesses for
in their respective positions. scratches or foreign matter that would impair
gasket sealing. Clean gasket recesses as
E) Reinstall cap screws. Recommended values for required.
torquing cap screws are:
2.2 REASSEMBLY
Valve # Of Screw Torque Wrench
Size Screws Size (Ft. Lbs.) Size
1” 1 5/16-24 8 ½” NOTE: Each Series 7100 Piston Check Valve
1.5” 1 7/16-20 30 11/16” requires three (3) gaskets of three (3) different
2” 2 3/8-24 15 9/16” sizes.
3” 1
4” 1 ½-13 60 ¾”
.1 Place seat gasket in body recess, and install seat
6” 4
8” 4
on top of gasket.
10” 6 5/8-11 70 15/16”
12” 12 IMPORTANT: Seat must be oriented with 45
degree beveled surface facing upward.
Following reassembly of plug, place in upright .2 Place plug guide on work surface in inverted
position for inspection of orifice plug and ball check. position (deep recess facing upward).
All valves have one (1) orifice plug installed in top of
valve plug, but number of ball checks varies with .3 Install plug seal in deep recess in guide.
valve size as follows: Orientation of seal must be so that open side of
seal, with spring visible, faces upper end of
Valve Size # Of Ball Checks guide. Thus, with guide in inverted position,
1” 0 only the TFE jacket will be visible after seal is
1.5”, 2”, 3” 1 installed.
4” 2
6”, 8” 3 .4 Place valve plug on work surface in normal
10”, 12” 3 upright position. Place valve cage over plug
with extended shoulder on cage oriented toward
Orifice plug and ball check contain small fluid top of plug.
passages, which must be free of foreign matter for
proper valve operation. Ball check may be removed .5 Turn guide over to its normal position and slip
from valve plug using a socket or wrench. Examine over top of plug.
ball check and remove any foreign matter present. NOTE: Due to seal ring being squeezed
Operation of ball check may be verified by inserting a between guide and plug, it may be necessary to
small rod, less than 0.25" diameter from upper end. gently tap guide into place.
Only light finger pressure should be required to push
ball off seat. With pressure removed, ball should snap .6 Place smallest of three (3) gaskets into recess in
top of guide
January 2002 707000M - © 2002 Page 5 of 6

.7 Entire plug/cage/guide assembly may be picked
up by lifting attachment in center of plug. Place .12 Tighten bleeder plug (pipe plug) in top of
the assembly into valve body, carefully bonnet.
positioning cage over locating shoulder on seat.
This completes valve reassembly.
.8 Install load spring in recess in top of plug.
.9 Install remaining gasket in recess in top of body. 3.0 PREVENTIVE MAINTENANCE
.10 Install bonnet on top of body. .1 SEAT: Check seat every six (6) months if in
normal service, i.e., no sand or abrasives and low
.11 CAUTION: Tighten the bonnet-to-body bolts to pressure drop. If in severe service, i.e., high-
the recommended torques given in the following pressure drop and sanding condition, check every
table (Follow good bolting practice and lubricate sixty (60) days.
bolts).
.2 PISTON: Same as .1.
The Bonnet Bolt Torque Chart below shows stud
size in inches and recommended torque value in .3 GENERAL: When disassembling any portion of
FT-LBS for valve sizes and pressures classes, as valve, always check seal rings and gaskets for
listed. damage or wear before reassembly.
NOTE: Spiral wound gasket bolt-up .4 BODY: Under normal conditions, body should
characteristics are such that tightening of one last years. However, under severe conditions,
bolt may loosen an adjacent bolt. This will occur i.e., corrosion, sand and high-pressure drop,
on subsequent tightening of all the bolts until valve life could be numbered in days only.
the bonnet-to-body seal is made. This requires
several trials on each bolt until the nut does not
turn at the given torque.
BONNET BOLT TORQUE CHART

VALVE ANSI PRESSURE CLASS
SIZE 150 300 600 900 1500 2500
Stud .75” .88”
1”
Torque 110 120 250
Stud .62” .75”
1.5”
Torque 85 160
Stud .75” 1.00”
2”
Torque 75 80 175 375
Stud .75” 1.00” 1.38”
3”
Torque 90 140 275 875
Stud .88” 1.00” 1.50”
4”
Torque 145 225 280 1400
Stud .88” 1.25”
6”
Torque 280 375 680
Stud 1.12” 1.25” 1.38”
8”
Torque 425 465 1200
Stud 1.00” 1.12” 1.38” 1.88
10”
Torque 300 550 1000 2750
Stud 1.00” 1.25” 1.50” 2.00”
12”
Torque 375 750 1300 3600
January 2002 707000M - © 2002 Page 6 of 6

Section 9 – Control Panel and Instrumentation
Vendor Bulletin No.
Conduit and Sensor Assembly ....................................... Ajax 00-32-T010-367

Conduit for Thermocouples..............................................Ajax 00-32-T010-368
Vibration Switch and Conduit ......................................... Ajax 01-32-T020-318
Altronic Mag Pickup..........................................................Ajax 00-98-T000-307
Liquid Level Switch, L1200, O&M Bulletin.................................. Murphy 00-02-0175
Vibration Switch Bulletin, VS2 .................................................... Murphy VS-7037N
Control Panel Drawing ................................................... Murphy 50-30-7327
Centurion Panel Sequence of Operations......................................... Murphy
Centurion Panel Installation and Operation........................................Murphy 00-02-0590
Pressure Swichgage, OPLFC..................................................... Murph 00-02-0161
Pulsation Dampener, PD-8184................................................... Murphy PD-95145B
Manual Speed Pressure Murphygage ........................................ Murphy 00-02-0162
Pressure Regulator, Model 67CR-206 ....................................... Fisher 5469

00-02-0175
Section 15

GENERAL INFORMATION
Description **

Body
Pressure Rating
Temperature Rating
• Standard: -20/175°F (-29/79°C)
• Standard: -20/300°F (-29/149°C) ✗ ✗ ✗ ✗ ✗ ✗
• Optional: -20/400°F (-29/204°C)* ✗ ✗ ✗ ✗ ✗
Specific Gravity
Electrical
1/8 NPT in/out.
Operation:
2
DIMENSIONS

Regulator and Gage
11 in. Pressure
(279 mm) Regulator
Operator Assembly
p/n 15010216
2-3/16 in. See 1/8 NPT

(56 mm) Note 2
Operator Assembly
p/n 15000940
1/8 NPT
INLET
±0.25 in. (6 mm). (See Note)
L1100: 1-1/2 NPT
L1200: 2 NPT
Note 2: 1-9/16 (40 mm) 2-3/16 in.
L1100: 1-1/2 (38 mm) (40 mm)
L1200: 1-3/4 (44 mm) SF option=
1-3/4 in.
1/4 NPT 2" 11-1/2 NPT (44 mm)
3-1/2 in. (89 mm)
VENT SF= 3-3/4 in. (95 mm)
L1111
11-5/16 in.
(287 mm)
3-53/64 in.
(97 mm)
DVU150, DVU175, DVU2105/2115/2120
Series Dump Valves
2-3/16 in.
(56 mm)
See
Note A
Inlet Port Operator
(92 mm) ±0.25 in. (6 mm).
Note: 1-9/16 (40 mm)
Vent
B
F Drain
Connection C
E D
for reference only)
Model A B C D E F G
DVU2120 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2115 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU2105 7.50 (191) 8.0 (203) 2.75 (70) 1.0 (25) 2-11.5 NPT 1-11.5 NPT 1.03
DVU175 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 3/4”-14 NPT 1.03
DVU150 7.50 (191) 6.75 (171) 2.06 (52) 1.0 (25) 1-11.5 NPT 1/2”-14 NPT 1.03


Old DVO
Valve
Assembly
time.
Block
15050395.
L1200N
in place. Bleed
the float shaft.
New Dump Valve
p/n 15010216
kPa) [2.07-4.83 bar].
Collar Tank Wall
conduit seal
L1200N.
Hex Adjustment Nut
Basic Operation
(207 kPa) [2.07 bar]
300 psi (2.07 MPa)
Filter/Regulator
with MURPHYGAGE®
Trips Union
the equipment.

Manual Drain Valve

SPDT (Snap Switch)
Black N.O.
Black N.O.
Inductive/Resistive
15050421: Cam
0-75 psi (517 kPa) [5.17 bar]

ACCESSORIES
2-1/16 in
(52 mm) 2-1/2 in
(64 mm)
1-1/16 in 2-7/8 in
(27 mm) (73 mm)
3-5/8 in.
1 NPT (92 mm)
4-1/2 in
(114 mm)
2 NPT

3 in.
1-11.5 NPT (2 places) (76 mm)
2-11.5 NPT
10.5 in. 3 in.

(266 mm) (76 mm)
1/2-20 UNF-2B
(4 places)
7.55 in. 3.5 in.

(192 mm) (89 mm) 7.01 in.
(179 mm)

10-32 UNF
10-32 UNF
3/8 in
(10 mm)
1-3/8 in
(35 mm)
Warranty

VS-7037N
Revised 04-05
Shock/Vibration Control Switches Section 20

(00-02-0185)
Installation Instructions
Models: VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94
Please read the following instructions before installing. A visual inspection of this product for damage during shipping is recommended before
mounting. It is your responsibility to have a qualified person install the unit, and make sure installation conforms with NEC and local codes.
GENERAL INFORMATION
WARNING LISTED*

Model VS2EX
Description Remote Reset Feature (VS2EXR,

The Murphy shock and vibration switches are available in a variety of VS2EXRB and VS94 only)
models for applications on machinery or equipment where excessive Includes built-in electric solenoid which allows reset of tripped unit from a
vibration or shock can damage the equipment or otherwise poses a remote location. Standard on VS2EXR and VS2EXRB. Optional on
threat to safe operation. A set of contacts is held in a latched position VS94 (options listed below).
through a mechanical latch and magnet mechanism. As the level of -R15: Remote reset for 115 VAC
vibration or shock increases an inertia mass exerts force against the -R24: Remote reset for 24 VDC
latch arm and forces it away from the magnetic latch causing the latch
arm to operate the contacts. Sensitivity is obtained by adjusting the Time Delay Option (VS94 only)
amount of the air gap between the magnet and the latch arm plate. Overrides trip operation on start-up. For VS94 series models, the delay
Applications include all types of rotating or reciprocating machinery time is field-adjustable from 5 seconds up to 6-1/2 minutes with a 20-
such as cooling fans, engines, pumps, compressors, pump jacks, etc. turn potentiometer (15 seconds per turn approximately). Options listed
below:
Models -T15: Time delay for 115 VAC
VS2: Base mount; non hazardous locations. -T24: Time delay for 24 VDC
VS2C: C-clamp mount; non hazardous locations.
Space Heater Options (VS94 only)
VS2EX: Explosion-proof; Class I, Div. 1, This optional space heater board prevents moisture from condensing
Groups C and D. inside the VS94 Series case. Options listed below:
VS2EXR: Explosion-proof with remote reset. -H15: Space heater for 115 VAC
VS2EXRB: Explosion-proof; Class I, Div. 1, Group B; with -H24: Space heater for 24 VDC
remote reset.
VS94: Base mount; non hazardous locations, NEMA 4X/IP66. Warranty
A limited warranty on materials and workmanship is given with this FW
Murphy product. A copy of the warranty may be viewed or printed by going
to www.fwmurphy.com/support/warranty.htm
VS-7037N page 1 of 8
DIMENSIONS
VS2 VS2C
3 in. 4-3/4 in.
(76 mm) (121 mm) 3 in. 4-3/4 in.
Slotted (76 mm) (121 mm)
Sensitivity Slotted
Reset Adjustment Sensitivity
Push Reset Adjustment
4-19/32 in. Button Push
(116 mm) Plug 5-7/16 in.
(138 mm) Button Weatherproof
Strain Relief
Bushing
5-1/8 in. 1/4 x 1/2 in.

2-1/4 in. (130 mm) 27/32 in.
(6 mm x 13 mm) (21 mm)
(57 mm) Mounting Holes Slot 2 places
C-Clamp
VS2EX and VS2EXR

5-5/8 in.
(143 mm)
Reset
Push
1/2 NPT Button
Conduit 4-7/8 in.
Slotted (124 mm)
Sensitivity
1-3/4 in. Adjustment
(44 mm)
5-1/4 in.
3/8 in. 3 in. (133 mm)
(10 mm) (76 mm)
4 places Mounting Holes 6-3/8 in. Mounting Holes
(162 mm)
VS2EXRB
10-5/8 in. 8-5/8 in.

(270 mm) (219 mm)
6 in.
(152 mm)
1/2 NPT
Conduit
2-1/2 in.
(64 mm)
4-1/2 in. 9-1/8 in.
(114 mm) (232 mm)
Mounting Centers 10-3/16 in. Mounting Centers
(259 mm)
VS94
6-29/32 in.
(176 mm)
Manual
7-9/64 in. Reset
(181 mm) Push-button 4-5/8 in.
(118 mm)
6-1/2 in.
(165 mm) 3/4 NPT
1-5/8 in. conduit fitting
(41 mm)
4 in.
(102 mm)
Mounting slot
5/16 x 9/16 in. 4 in. 6-1/2 in.
(8 x 14 mm) (102 mm) (165 mm)
4-places.
SPECIFICATIONS
VS2 and VS2C additional SPDT switch); 5A @ 480 VAC; 2A resistive, 1A inductive,
• Case: Weatherproof (equal to NEMA 3R) suitable for non-hazardous areas. up to 30 VDC.
VS2: Base mount • Remote Reset:
VS2C: C-clamp mount. Includes 45 feet (13.7 meters), 2-conductor 16 Option Operating Current
AWG, 30 strands/0.25 mm strand dia. (1.5 mm2) cable, and five cable -R15: 350 mA @ 115 VAC
hold down clamps. -R24: 350 mA @ 24 VDC
• Contacts: SPDT double make leaf contacts, 5A @ 480 VAC. • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.
• Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.
VS94
VS2EX • Case: Polyester fiberglass reinforced; NEMA type 4 and 4X; IP66; CSA
• Case: Explosion-proof and weatherproof aluminum alloy housing; types 4 and 12.
meets NEMA 7/IP50 specifications; Class I, Division 1, Groups C & • Conduit Fitting: 3/4 NPT conduit fitting connection.
D; UL and CSA listed.* • Normal Operating Ambient Temperature:
VS2EX: base mount. 0 to 140°F (-18 to 60°C).
• Snap-switches: 2-SPDT snap-switches; 5A @ 480 VAC;* • Snap-switches: 2-SPDT snap acting switches; 5A @ 480 VAC; 2A
2A resistive, 1A inductive, up to 30 VDC. resistive, 1A inductive, up to 30 VDC.
• Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement. • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.
• Normal Operating Temperature: -40 to 140°F (-40 to 60°C). • Heater (optional):
Option Operating Current
VS2EXR H15 .023 A @ 115 VAC
• Case: Same as VS2EX. H24 .12 A @ 24 VDC
• Snap-switch: 1-SPDT snap-switch and reset coil; 5A @ 480 VAC;* 2A • Remote Reset (optional):
resistive, 1A inductive, up to 30 VDC. Option Operating Current
• Remote Reset (optional): R15 .17 A @ 115 VAC
Option Operating Current R24 .36 A @ 24 VDC
-R15: 350 mA @ 115 VAC • Time Delay (optional):
-R24: 350 mA @ 24 VDC Option Operating Current Standby Current
• Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement. T15 .360 A @ 115 VAC .01 A @ 115 VAC
• Normal Operating Temperature: -40 to 140°F (-40 to 60°C). T24 1.15 A @ 24 VDC .01 A @ 24 VDC
VS2EXRB • Time Delay/Remote Reset: Adjustable 20-turn potentiometer from
• Case: Explosion-proof aluminum alloy housing; rated Class I, 5 seconds to 6-1/2 minutes (15 seconds per turn approximately).
Division 1, Group B hazardous areas.
• Snap-switch: 1-SPDT snap-switch with reset coil (option available for *CSA and UL listed with 480 VAC rating.
INSTALLATION
orientation should be on a horizontal plane or with the sensitivity adjustment
WARNING: STOP THE MACHINE AND DISCONNECT ALL pointing down. Sensitivity adjustment for model VS2 is covered by a plug.
ELECTRICAL POWER BEFORE BEGINNING INSTALLATION.
The plug must be in place and tight to prevent moisture or dust intrusion.
The VS2 and VS94 series shock switches are sensitive to shock and
C-Clamp Installation (VS2C model only)
vibration in all three planes of motion - up/down, front/back and side/side.
Front/back is the most sensitive (The reset pushbutton is located on the A C-Clamp is supplied with the VS2C model only.
“front” of the unit). For maximum sensitivity mount the unit so that the The C-Clamp is shipped installed on the VS2C
front faces into the direction of rotation of the machine. (See Dimensions on but must be installed on the VS2EX and
page 2 for sensitivity adjustment location). VS2EXR switches.
The VS2 and VS94 Series must be firmly attached/mounted to the machine 1. The C-Clamp (B) will already be installed on C
so that all mounting surfaces are in rigid contact with the mounting surface a 1/4 in. (6 mm) thick steel mounting plate
of the machine. For best results, mount the instrument in-line with the (A). Bolt the VS2 switch to the mounting A
direction of rotating shafts and/or near bearings. In other words, the reset plate as illustrated — with four 5/16 in.
bolts, nuts, and washers. B
push button should be mounted pointing into the direction of shaft rotation
(see page 5). It may be necessary to provide a mounting plate or bracket to 2. The mounting location should provide
attach the VS2 and VS94 Series to the machine. The mounting bracket convenient access to the TATTLETALE® D
should be thick enough to prevent induced acceleration/vibration upon the push button (C).
VS2 or VS94 Series. Typically 1/2 in. (13mm) thick plate is sufficient. See 3. The hardened set screw and nuts (D) are used to
illustrations on page 5 for typical mounting locations. tighten the switch to an I-Beam or cross member such as a
Sampson post of an oilwell pumpjack.
CAUTION: A dust boot is provided on the reset pushbutton
for all series to prevent moisture or dust intrusion. The sensitivity
adjustment for model VS2EX is not sealed; therefore, mounting
Continued on next page.
INSTALLATION Continued
All Models allow the machine to stop. Turn the sensitivity adjustment 1/4 turn
clockwise, (adjustment for VS94 and VS2EXRB models is located within
WARNING: STOP THE MACHINE AND DISCONNECT ALL
the box, see DETAIL “B”).
ELECTRICAL POWER BEFORE BEGINNING INSTALLATION.
WARNING: MAKE THE AREA NON-HAZARDOUS BEFORE
1. Firmly secure the unit to the equipment using the base foot mount or OPENING THE EXPLOSION-PROOF (-EX) ENCLOSURES.
C-Clamp if applicable. See C-Clamp Installation page 3.
For oilwell pumpjacks attach the VS2 and VS94 Series to the Sampson Depress the reset button and restart the machine. Repeat this process until
post or walking beam. See Typical Mounting Locations page 5. the unit does not trip on start-up. DETAIL “B”
2. Make the necessary electrical connections to the vibration switch. See 5. If the instrument does NOT trip on start-
Internal Switches, page 6 for electrical terminal locations and page 7 for up, stop the machine. Turn the sensitivity Less Sensitivity
Sensitive adjustment
typical wiring diagrams. DO NOT EXCEED VOLTAGE OR CURRENT adjustment 1/4 turn counter-clockwise.
RATINGS OF THE CONTACTS. Follow appropriate electrical Repeat the start-up/stop process until the
codes/methods when making electrical connections. Be sure that the run of instrument trips on start-up. Turn the
electrical cable is secured to the machine and is well insulated from sensitivity adjustment 1/4 turn clockwise
electrical shorting. Use of conduit is recommended. (less sensitive). Restart the machine to
NOTE: If the electrical cable crosses a pivot point such as at the pivot of verify that the instrument will not trip on More Sensitive
the walking beam, be sure to allow enough slack in the cable so that no start-up.
stress is placed on the cable when the beam moves. 6. Verify that the unit will trip when abnormal shock/vibration exists.
If conduit is not used for the entire length of wiring, conduit should be
used from the electrical supply box to a height above ground level that VS94 Time Delay Adjustment
prevents damage to the exposed cable from the elements, rodents, etc. or 1. Apply power to the time delay circuit. (see
as otherwise required by applicable electrical codes. If conduit is not page 7 for time delay circuit). The time delay function will be initiated.
attached directly to the VS2 and VS94 Series switch, use a strain relief 2. Time the length of the delay with a watch. Let time delay expire. After it
bushing and a weatherproof cap on the exposed end of the conduit. A expires, the override circuit will de-energize the solenoid, allowing the latch
“drip loop” should be provided in the cable to prevent moisture from arm to trip. A clicking noise is heard.
draining down the cable into the conduit should the weathercap fail. WARNING: REMOVE ALL POWER BEFORE OPENING
ACCESS DOOR. IT IS YOUR RESPONSIBILITY TO HAVE A
Sensitivity Adjustment QUALIFIED PERSON ADJUST THE UNIT, AND MAKE SURE
IT CONFORMS WITH NEC AND LOCAL CODES.
WARNING: REMOVE ALL POWER BEFORE OPENING
THE ENCLOSURE. IT IS YOUR RESPONSIBILITY TO HAVE A 3. TURN THE POWER OFF TO RESET THE TIME DELAY CIRCUIT.
QUALIFIED PERSON PERFORM ADJUSTMENTS, AND MAKE NOTE: Allow 30 seconds bleed-time between turning the
SURE IT CONFORMS WITH NEC AND LOCAL CODES. DO power “OFF” and “ON”.
NOT ADJUST SENSITIVITY WHILE THE MACHINE IS RUNNING. STAND
4. Locate the time adjustment pot (DETAIL “C”). DETAIL “C”
CLEAR OF THE MACHINE AT ALL TIMES WHEN IT IS OPERATING.
The time is factory-set at the lowest setting (5
All models of the VS2 and VS94 Series cover a wide range of sensitivity. seconds approximately). To increase time,
Each model is adjusted to the specific piece of machinery on which it is rotate the 20-turn pot clockwise as needed
Turn to
installed. After the switch has been installed in a satisfactory location (see (15 seconds per turn approximately). decrease
page 5) the sensitivity adjustment will be increased or decreased so that the 5. Repeat the above steps as necessary to
switch does not trip during start-up or under normal operating conditions. obtain desired time delay.
Pot
This is typically done as follows: Turn to
NOTE: An external time delay can be used increase
1. REPLACE ALL COVERS, LIDS, AND with the remote reset feature of the VS2EXR
ELECTRICAL ENCLOSURES. series to provide a remote reset and override of the trip
2. Press the reset push button to engage the magnetic latch. To be sure the operation on start-up. Time delay must automatically disconnect after
magnetic latch has engaged, observe latch equipment start-up.
through the window on the VS2 and DETAIL “A”
VS2C (see DETAIL “A”). On the
VS2EX, VS94 series the reset button Reset Push button
will remain depressed meaning the

magnetic latch has engaged.
3. Start the machine.
4. If the instrument trips on start-up, Sensitivity
Adjustment
TYPICAL MOUNTING LOCATIONS
These are typical mounting locations for best operation. Other mountings are possible.
NOTE: See Installation section on page 3.
2-Throw Balance-Opposed Compressor Pumping Unit
Reset
NOTE: If installing on
cylinders, 2 vibration/shock Reset
switches are recommended-
1 for each cylinder.
Engine Reset “Y” Type

and Reciprocating
Vertical Compressor
Shaft
Pump
Reset
Reset
Generator Cooling Tower Fan or

Sets Reset Heat Exchanger
Reset
Engine Compressor
Turbine Centrifugal Reset
Compressor
Reset
INTERNAL SWITCHES
VS2 and VS2C VS2EXR

Remote Reset
Terminal
Sensitivity
Sensitivity Adjustment
Adjustment
NC NO COM
Ground
NO1 NC COM NO2 Terminal
SPDT Snap-Switch
SPDT Switch Terminals
VS2EX VS2EXB and VS2EXRB

Remote Reset
SPDT Snap-Switch Terminal
Sensitivity Sensitivity
Adjustment Adjustment
NC NO COM
NC NO COM NC NO COM
Ground
Ground Terminal
Terminal SPDT NC NO COM
SPDT Snap-Switch Snap-Switch Optional SPDT
Snap-Switch
(VS2EXRB only)
VS94
Time Delay and/or
Remote Reset
SPDT Terminal (Optional)
Snap-Switch
NC NO COM Ground
Terminal
NC NO COM Sensitivity
Adjustment
SPDT
Snap-Switch
Heater Board
Terminal (Optional)
ELECTRICAL
WARNING: REMOVE POWER BEFORE OPENING THE UNIT (ACCESS DOOR). STOP THE MACHINE AND DISCONNECT ALL
ELECTRICAL POWER BEFORE BEGINNING THE WIRING OPERATION. IT IS YOUR RESPONSIBILITY TO HAVE A QUALIFIED
PERSON INSTALL AND WIRE THE UNIT, AND MAKE SURE IT CONFORMS WITH NEC AND APPLICABLE CODES.
VS2 and VS2C VS2EX

Typical Wiring Diagram for Single or Dual CD Ignition Typical Wiring Diagram for Single or Dual CD Ignitions
SPDT Switch SPDT Switch
Contacts shown in the RESET position. (Optional 2-SPDT [DPDT])†
Contacts shown in the
RESET position
To good
NO1 NC COM NO2 CD Ignition engine
2 N.O. N.C. COM ground
CD Ignition Resistor
2 To good (100 Ω, 3 Watt)
Resistor engine ground
(100 Ω, 3 Watt)
CD Ignition
N.O. N.C. COM
1
CD Ignition
1
To good
engine ground
VS2EXR and VS2EXRB VS94

Typical Wiring Diagram for Single or Dual CD Ignitions Typical Wiring Diagram for Single or Dual CD Ignitions
SPDT Switch Time Delay or 2-SPDT
(Optional 2-SPDT [DPDT])† Remote Reset Switches (DPDT)
Contacts shown in the Momentary
Remote Reset Contact for (Optional) Contacts shown in the
RESET position 115 VAC or 24 VDC* RESET position
Remote
To good Reset only
Momentary engine To good
Push Button ground engine
N.O. N.C. COM
Maintained Time N.O. N.C. COM ground
†Additional Contact for Delay
Time Delay
Switch
115 VAC or Optional
24 VDC (Voltage on VS2EXRB
is specified N.O. N.C. COM only 115 VAC or
when ordered). 24 VDC* N.O. N.C. COM
*Voltage is specified Heater Board

CD Ignition To good (Optional) To good
2 engine ground when ordered.
engine ground
Resistor
(100 Ω, 3 Watt)
CD Ignition CD Ignition
CD Ignition 1 2
Resistor
1 (100 Ω, 3 Watt)
VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94 VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94
Typical Wiring Diagram for Electric Motors Typical Wiring Diagram for Distributor Ignition or Diesel
Contacts shown Switch Terminals Contacts shown
Switch Terminals in the RESET position NOTE: Terminal N.O. is in the RESET position
NOTE: Terminal N.O. is N.O. N.C. COM
N.O. N.C. COM terminal NO1 on models
terminal NO1 on models (see Note)
(see Note) VS2 and VS2C.
VS2 and VS2C.
Ignition
Switch
L1 L2 L3 Push-button
Station
Ammeter
HC
Diesel Fuel
Shutoff Valve Ignition Coil Distributor Battery
H A
MOTOR Hand Off

Automatic
Selector
HC
SERVICE PARTS
PART NO. DESCRIPTION PART NO. DESCRIPTION

VS2 VS2EXRB
20000030 Movement assembly 20010090 Snap-switch and insulator kit (1 switch per kit)
20000031 Glass and gasket assembly prior to September 1, 1995.*
20000032 Reset push button assembly 20000288 Snap-switch and insulator kit (1 switch per kit) for models
manufactured on September 1, 1995 or later.*
VS2C 20000057 Inside snap-switch and insulator kit (1 switch per kit) for
20000030 Movement assembly model VS2EXRB-D prior to September 1, 1995.*
20000031 Glass and gasket assembly 20000058 Outside snap-switch and insulator kit (1 switch per kit) for
20000032 Reset push button assembly model VS2EXRB-D prior to September 1, 1995.*
20050021 Mounting clamp 20000287 Outside snap-switch and insulator kit (1 switch per kit) for model
20000185 VS2C 5-clamp hardware package assembly. VS2EXRB-D manufactured on September 1, 1995 or later.*
20050465 2-Conductor electrical cable, 45 feet (13.7 meters) 20000290 Inside snap-switch and insulator kit (1 switch per kit) for model
VS2EXRB-D manufactured on September 1, 1995 or later.*
VS2EX 20050077 Adjustment shaft
20010091 Movement assembly 20000262 Movement assembly
20050087 Cover 20000049 Reset solenoid assembly (115 VAC)
00000309 Cover gasket 20000234 Reset solenoid assembly (24 VDC)
20010090 Snap-switch and insulator kit (1 switch per kit)
prior to September 1, 1995.*
VS94 Series
20000288 Snap-switch and insulator kit (1 switch per kit) for models
manufactured on September 1, 1995 or later.* 25050506 Dust boot
20000289 C-clamp conversion mounting kit 00000232 Conduit fitting
20010090 Snap-switch and insulator kit (1 switch per assembly)
VS2EXR prior to September 1, 1995.**
20000262 Movement assembly 20000288 Snap-switch and insulator kit (1 switch per assembly)
for models manufactured on September 1, 1995 or later.***
20050087 Cover
00000309 Cover gasket
* If no date code is found, refer to the old switch. Models with date 0895 and before use old switch.
20010090 Snap-switch and insulator kit (1 switch per kit) Dated 0995 after, use straight snap-switch arm, no rollers.
prior to September 1, 1995.* ** Models dated Q1 thru Q8 (formed snap-switch arm and rollers).
20000288 Snap-switch and insulator kit (1 switch per kit) for models ***Models date coded Q9 thru Q12 and R1 thru R12 (straight snap-switch arm, no rollers).
manufactured on September 1, 1995 or later.*
20000049 Reset solenoid assembly (115 VAC)
20000234 Reset solenoid assembly (24 VDC)
20000289 C-clamp conversion mounting kit
CONTROL SYSTEMS & SERVICES DIVISION FRANK W. MURPHY, LTD.

P.O. Box 1819; Rosenberg, Texas 77471; USA Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K.
+1 281 633 4500 fax +1 281 633 4588 +44 1722 410055 fax +44 1722 410088
e-mail sales@fwmurphy.com e-mail sales@fwmurphy.co.uk
FW Murphy www.fwmurphy.co.uk
INDUSTRIAL PANEL DIVISION
P.O. Box 470248 MURPHY DE MEXICO, S.A. DE C.V.
P.O. Box 470248
Tulsa, Oklahoma 74147 USA Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje
Tulsa, Oklahoma 74147 USA
+1 918 317 4100 fax +1 918 317 4266 San Luis Potosí, S.L.P.; México 78384
+1 918 317 4100 fax +1 918 317 4266
e-mail sales@fwmurphy.com +52 444 8206264 fax +52 444 8206336
e-mail sales@fwmurphy.com
Villahermosa Office +52 993 3162117
www.fwmurphy.com e-mail ventas@murphymex.com.mx Printed in U.S.A. 078792
www.murphymex.com.mx
SEQUENCE OF OPERATION
Centurion Controller
DRAWING# 50-30-7327
SEQUENCE# 50-32-7327 rev A
PROGRAM# 50-34-7327 rev A
CAMERON COMPRESSION
December 12, 2007

Revised December 14, 2007
TABLE OF CONTENTS
1.0 TYPE OF SYSTEM

2.0 STARTING SEQUENCE
3.0 RUNNING SEQUENCE
4.0 STOPPING SEQUENCE
5.0 SHUTDOWN SEQUENCE
6.0 CONTROLLER I/O
7.0 MODBUS ADDRESS LIST
8.0 MCONFIG PRO REPORT (refer to attached PDF file)
Page 1 of 15
1.0 TYPE OF SYSTEM
1.1 The control system for this project is one FWMurphy Centurion Configurable Controller with
custom firmware installed. This system is designed for use in Class I, Division 2 hazardous
areas, powered by user supplied 24VDC. The controller will monitor various analog and
switch inputs and shutdown the motor/compressor package as noted in this document. The
controller will interface with an Ajax Engine Driven Integral Reciprocating compressor.
1.2 GENERAL OPERATING INSTRUCTIONS
1.2.1 Upon powerup, the display will first show the “default” home page as configured
using Mconfig Pro software. To navigate the display, use the UP, DOWN,
RIGHT, and LEFT arrow keys. To start the unit in local mode, press the
RUN/STOP key to start and stop the start sequence. Pressing the RESET key will
reset any fault shutdowns.
1.2.2 From any main page, the HOME key can be used to return to the default home
page.
nd
1.2.3 Timers will be shown on the 2 to the bottom of the display. The panel state
message will be displayed across the bottom of the display.
1.2.4 The Class B1, B2, and S timers can be reset, or zeroed by pressing the RESET,
or TIMER 0 (Zero) key. The test mode can be initiated by pressing the TEST
key.
1.3 SETPOINTS
1.3.1 To edit setpoints within the controller, press the SETUP/ENTER key. The
appropriate numeric password must be entered to make changes to setpoints.
No password is necessary to view setpoints.
1.3.2 The Centurion uses a different approach to enter values than previous Murphy
controllers. Instead of holding in the arrow keys until the desired number is
displayed, the Centurion display allows individual editing of each position of the
desired number. This is accomplished by entering the Edit Mode and using the
UP/DOWN arrow keys (1) to adjust the number above the blinking cursor (2)
between 0 and 9. To edit another position, simply use the LEFT/RIGHT (3) arrow
keys to move the cursor to that position (4) and repeat the edit process until the
desired number is displayed. In this way, values are “built” rather than “scrolled”
through.
1.3.3 Some digits may not be allowed to increment if it would result in exceeding range
limits. Values which can be positive or negative will have a sign (±) to the left of
the number. To change the sign value simply move the cursor to the sign using
the LEFT arrow key and “toggle” between + and – using the U and DOWN arrow
keys. If the range of the value will exceed range limits the sign may not be
allowed to change. In this case, try reducing the number by decrementing the left
most digit by one or more and attempt to change the sign again.
1.3.4 In some instances, a word rather than a value is represented in the Edit Mode.
This works like the sign value as an ON/OFF or YES/NO prompt where the value
is “toggled” between choices using the UP/DOWN arrow keys. The value is not
active in the controller until the ENTER key has been pressed to send the value
to the controller. Pressing the ESC key will discard any changes and keep the
original value prior to entering the Edit Mode.
Page 2 of 15
2.0 STARTING SEQUENCE
2.1 When power is first applied, and if no class A or ESD shutdown conditions exist, the controller
will be in the “MANUAL STOP” state.
2.2 This panel is equipped with custom programming to control a nitrogen purge valve. A panel
mounted On-Off-Auto switch will control how this cycle works.
2.2.1 OFF-the nitrogen purge valve will not operate, and will remain closed. The max
purge timer is reset.
2.2.2 HAND- If the panel is in the MANUAL STOP or SHUTDOWN states, the nitrogen
purge valve will be immediately opened. It will remain open until switched back to
OFF, or unit the max nitrogen purge time delay expires (SETPOINT #49). During
this time, the RUN/STOP key will be ignored and no starting will be allowed. If
the panel is not in MANUAL STOP or SHUTDOWN states, the purge valve will
remain closed.
2.2.3 AUTO- If the panel has detected an ESD event type shutdown, the nitrogen purge
valve will be immediately opened. It will remain open until the RESET key is
pressed, or unit the max nitrogen purge time delay expires (SETPOINT #49).
2.3 The Sleep Control output will energize to latch power onto the control system. An external
programmable timer is used to break power from the system in the event of a shutdown after
a set time delay. NOTE: the programmable timer should be set longer than the MAX
PURGE TIME SETPOINT to ensure that the Nitrogen Purge cycle will complete before
losing power.
2.4 The Ignition and M5081-C-LS Fuel outputs will remain deenergized.
2.5 When the RUN/STOP key is pressed, the following start sequence will occur:
2.5.1 The state message will read “WAITING ON START”.
2.5.2 The Ignition G-Lead Output will energize to Un-ground the Ignition.
1.1.1 The M5081-C-LS Fuel Valve output will energize to allow the fuel valve to be
manually opened.
1.1.2 The controller will monitor for a run signal from the MPU input. Confirmation
must be received before the Waiting ON Start Timer expires otherwise the unit
will shutdown on “FAILURE TO START ENGINE”.
1.1.3 When the Engine RPM is seen above the Run RPM setting, the unit will be
considered running and the Running sequence will begin.
3.0 RUNNING SEQUENCE
3.1 The controller will read “RUNNING”.
3.2 The internal hourmeter will begin timing. The class B1, B2, and S lockout delays begin timing.
3.3 The RPM vs Suction pressure control loop is enabled.
3.4 The RPM vs Suction pressure is controlled by suction pressure. If the suction pressure drops
below the setpoint, the speed output to the engine decreases and vice-versa.
3.5 TEST MODE
Page 3 of 15
3.5.1 While the unit is running, a test mode feature will be available. When the TEST
key on the Centurion display is pressed, all functions identified as Class A, B1,
B2, or C shutdowns will be able to be tested without shutting down the Unit for the
duration of the Test timer. The test mode can be ended by pressing the TIMER
“0” key.
3.5.2 The tested points can be seen on the EVENTS page of the Mview display.
3.5.3 Some functions are designated as Class ESD, which will not be in the TEST
mode. An example is Panel ESD. It is never locked out.
3.5.4 All shutdowns must be clear, and the reset key must be pressed before the test
timer expires, or prior to exiting the test mode or else a shutdown will occur.
(note: this will also reset and restart the B1, B2 and S lockout timers)
4.0 NORMAL STOP SEQUENCE
4.1 Pressing the RUN/STOP key on the Centurion faceplate for 2 seconds and releasing will
signal a normal stop.
4.2 The controller will read “STOPPING”.
4.3 The M5081-C-LS Fuel Valve output will de-energize to close the fuel valve.
4.4 After the Ignition Off delay expires, the Ignition output will de-energize to ground the Ignition.
During this time, the state message will read “STOPPING”.
4.5 The unit state will return to “MANUAL STOP” and await the next start sequence.
5.0 FAULT SHUTDOWN SEQUENCE
5.1 The Class B1, B2, C and S shutdowns are disarmed.
5.2 The M5081-C-LS Fuel Valve output will de-energize to close the fuel valve.
5.3 After the Ignition Off delay expires, the Ignition output will de-energize to ground the Ignition.
During this time, the state message will read “STOPPING”. In cases of ESD type faults, this
delay is skipped.
5.4 The unit state will read to “SHUTDOWN”.
5.5 The cause of the shutdown will be displayed on the shutdown history page. Use the LEFT
and RIGHT arrow keys to navigate to this page. The shutdown event is stored in the
Shutdown History Page with an hourmeter time stamp. After the shutdown condition is
corrected, press the RESET key to clear the shutdown condition and return to “PANEL
READY”.
5.6 The Sleep Control output will deenergize upon a fault shutdown. An external programmable
time delay will remove power from the control system after a configured time. To restore
power to the system, Press and hold the “Power Up From Sleep” panel mounted pushbutton
for 3 seconds.
6.0 CENTURION CONTROLLER INPUTS/OUTPUTS
6.1 DIGITAL INPUTS
TB# TYPE IN# DESCRIPTION

30 NC DI-1 LOCAL EMERGENCY STOP
31 NO DI-2 SPARE DI02 SHUTDOWN
32 NO DI-3 REMOTE SHUTDOWN
Page 4 of 15
34 NO DI-5 ENGINE LUBRICATOR FLOW PULSE (PROXIMITY SWITCH)
35 NO DI-6 COMPRESSOR LUBRICATOR FLOW PULSE (PROXIMITY SWITCH)
36 NO DI-7 LOW ENGINE OIL LEVEL
37 NO DI-8 LOW COOLANT LEVEL
39 NO DI-10 HIGH SUCTION SCRUBBER LIQUID LEVEL
40 NO DI-11 HIGH INTERSTAGE SCRUBBER LIQUID LEVEL
41 NO DI-12 HIGH DISCHARGE SCRUBBER LIQUID LEVEL
43 NO DI-14 HIGH FRAME VIBRATION
44 NO DI-15 HIGH COOLER VIBRATION
50 NO DI-21 NOT USED
59 NO DI-30 NITROGEN PURGE AUTOMATIC SWITCH SELECTION
60 NO DI-31 NITROGEN PURGE ON SWITCH SELECTION
61 NO DI-32 NOT AVAILABLE-FIRMWARE USE
6.2 DIGITAL OUTPUTS
TB# TYPE OUT# DESCRIPTION

70 (NO) RELAY(1) 1 NOT USED
71 (COM)
72 (NC)
74 (COM)
75 (NC)
77 (COM)
78 (NC)
79 (NO) RELAY(4) 4 SLEEP CONTROL (ENERGIZED DURING NON-FAULT, DEENERGIZED ON
80 (COM) SHUTDOWN)
81 (NC)
82 (DC+) FET(1) 5 NOT USED
83 (+OUT)
84 (DC+) FET(2) 6 NOT USED
85 (+OUT)
86 (DC+) FET(3) 7 NITROGEN PURGE VALVE OPEN
87 (+OUT)
88 (DC+) FET(4) 8 M5081-C-LS FUEL VALVE (ENERGIZED TO RUN TO INTERFACE WITH
89 (+OUT) MAGNETIC SWITCH ADAPTER THROUGH A NC RELAY CONTACT TO
TRIP ON SHUTDOWN)
Page 5 of 15
90 (-OUT) IGBT(1) 9 NOT USED
91 (DC-)
92 (-OUT) IGBT(2) 10 IGNITION GROUND
93 (DC-)
6.3 ANALOG OUTPUTS
TB# TYPE OUT# DESCRIPTION

66 (DC +) 4-20mA AO-1 RPM VS SUCTION PRESSURE CONTROL
67 (OUT)
68 (DC +) 4-20mA AO-2 NOT USED
69 (OUT)
6.4 ANALOG INPUTS

18 4-20mA AI-1 SUCTION PRESSURE
19 4-20mA AI-2 INTERSTAGE PRESSURE
20 4-20mA AI-3 DISCHARGE PRESSURE
21 4-20mA AI-4 NOT USED
6.5 THERMOCOUPLE INPUTS

1(+) K TC-1 EXHAUST CYLINDER #1 TEMPERATURE
2(-)
3(+) K TC-2 EXHAUST CYLINDER #2 TEMPERATURE
4(-)
5(+) K TC-3 NOT USED
6(-)
7(+) K TC-4 DISCHARGE CYLINDER #1 TEMPERATURE
8(-)
9(+) K TC-5 DISCHARGE CYLINDER #2 TEMPERATURE
10(-)
11(+) K TC-6 NOT USED
12(-)
13(+) K TC-7 ENGINE COOLANT TEMPERATURE
14(-)
15(+) K TC-8 COMPRESSOR COOLANT TEMPERATURE
16(-)
7.0 MODBUS ADDRESS LIST
The Centurion uses MODBUS RTU protocol. Data is formatted as 16 bit Signed Holding Registers except
where noted. Port 1 is configurable for either 3 wire RS-232 or 2 wire RS-485 communication. Analog
Reading and Setpoints will be shown with no decimal place. Reference the Mconfig Pro Report or Mview
Display to determine the proper number of decimals places. Refer to the Mconfig Pro Report for event
enumerations, and engine state enumerations.
Page 6 of 15
Translated I/O Polling Description Read Only Data format
area Read/Write
42001 1-16 Core Digital Inputs Bitmap R Bit 1 = lsb…bit 16 = msb
42002 17-32 Core Digital Inputs Bitmap R Bit 1 = lsb…bit 16 = msb
42003 1 Core Analog Inputs R Scaled to engineering units as shown in
Mconfig Pro Report
42004 2 R
42005 3 R
42006 4 R
42007 5 R
42008 6 R
42009 7 R
42010 8 R
42011 9 R
42012 10 R
42013 11 R
42014 12 R
42015 13 (1) Expansion Analog Inputs R Scaled to engineering units as shown in
Mconfig Pro Report
42016 14 (2) R
42017 15 (3) R
42018 16 (4) R
42019 17 (5) R
42020 18 (6) R
42021 19 (7) R
42022 20 (8) R
42023 1 Core Thermocouple Inputs R Scaled to deg C or F as shown in Mconfig
Pro Report
42024 2 R
42025 3 R
42026 4 R
42027 5 R
42028 6 R
42029 7 R
42030 8 R
42031 9 (1) Expansion Thermocouple R Scaled to deg C or F as shown in Mconfig
Inputs Pro Report
42032 10 (2) R
42033 11 (3) R
42034 12 (4) R
42035 13 (5) R
42036 14 (6) R
42037 15 (7) R
42038 16 (8) R
42039 1-16 Core Digital Outputs Bitmap R Bit 1 = lsb…bit 16 = msb
42040 1 Core Analog Outputs R Percent x 100 (0 – 10000)
42041 2 R Percent x 100 (0 – 10000)
42042 3 (1) Expansion Analog Outputs R Percent x 100 (0 – 10000)
Page 7 of 15
42043 4 (2) R Percent x 100 (0 – 10000)
42044 5 (3) R Percent x 100 (0 – 10000)
42045 6 (4) R Percent x 100 (0 – 10000)
42046 Engine Speed R RPM
Status Polling area
40101 STATE R State enumeration (1 – 19) note: not all
states may be used, and may be renamed
for a specific application…refer to the
Mconfig Pro Report for state descriptions.
1 = PANEL READY (*MANUAL STOP)
2 = START DELAY
3 = PRE-HEAT
4 = PRE-LUBE
5 = START VALVE
6 = CRANK STOP
7 = CRANK (*READY TO START)
8 = CRANK REST
9 = MOTOR ON
10 = WARMUP
11 = WAIT FOR LOAD
12 = RUN LOADED (*RUNNING)
13 = COOLDOWN (*COOLDOWN)
14= STOP ENGINE (*STOPPING)
15 = MOTOR OFF
16 = STOP VALVE
17 = POST-LUBE
18 = RESTART DELAY
19 = SHUTDOWN (*SHUTDOWN)
40102 RPM R Engine RPM
40107 1-16 STATUS R Status bits
1 STATUS_FLT_SHTDWN 0x0001 Fault Shutdown in progress.
2 STATUS_ESD 0x0002 Emergency Shutdown in progress.
3 STATUS_ALARM 0x0004 Have Active alarms
4 STATUS_START 0x0008 Start/Stop indicator. 1=Start
5 STATUS_LCL_RMT 0x0010 1=Remote, 0=Local.
6 STATUS_TEST_TMR 0x0020 1=TEST timer is running.
7 STATUS_B1_TMR 0x0040 1=B1 timer is running.
8 STATUS_B2_TMR 0x0080 1=B2 timer is running.
9 STATUS_C_TMR 0x0100 1=C timer is running.
10 STATUS_S1_TMR 0x0200 1=S1 timer is running
11 STATUS_S2_TMR 0x0400 1=S2 timer is running
12 STATUS_S3_TMR 0x0800 1=S3 timer is running.
15 STATUS_NF_TMR 0x4000 1=NF timer is running.
16 STATUS_BAD_CONFIG 0x8000 1=Configuration is bad.
40108 STATE_TIMER R Timer for the current State
40109 TEST_TIMER R Test Mode Timer.
40110 B1 R Primary Lockout Timer
40111 B2 R Secondary Lockout Timer
40112 C R Class C Arming Timer
Page 8 of 15
40113 S1 R Special Timer; Like B1 for individual
assignment
assignment
assignment
assignment
assignment
40118 NF R No-Flow Delay Before Shutdown Timer
Hour Meter
40119 HOURMETER_HOURS R/W Hourmeter hours.
40120 HOURMETER_MINUTES R/W 0-59
40121 HOURMETER_SECONDS R/W 0-59
Shutdown Table (Single entry)

40144 SHUTDOWN R Enumeration, zero = none; (1 - 128)
Number of Active Alarms

40145 NUM_ALARMS R Number of active alarms
Miscellaneous
data
40146 BATTERY_VOLTAGE R In tenths of a volt
40147 NUM_CRANKS_LEFT R Number of crank attempts left
40148 CORE_AMBIENT_TEMP R Tenths of a degree
40149 EXP_AMBIENT_TEMP R Tenths of a degree
Control Output Auto/Manual

40151 1-8 CTL_OUT_AUTO R/W 1=Auto Mode, 0=Manual
PID status.
40152 1-4 PID_ENABLED R 1=Enabled, 0=Not Enabled
40153 1-4 PID_OVERRIDE R 1=Override on, 0=Override off
Bit flags indicating that a class of Faults is armed or not.

40154 1-9 CLASS_ARMED R Class Armed status.
1 B1_ARMED R 0x0001
2 B2_ARMED R 0x0002
3 C_ARMED R 0x0004
4 S1_ARMED R 0x0008
5 S2_ARMED R 0x0010
6 S3_ARMED R 0x0020
7 S4_ARMED R 0x0040
8 S5_ARMED R 0x0080
9 NF_ARMED R 0x0100
Page 9 of 15
Current percent open of control outputs
40155 CTL_OUT_1_PERCENT R Current percent Control output.
Manual Percent Change to Control Outputs

40163 CTL_OUT_CHG_1 R/W Percent to change Control Output
Current computed PID setpoint. (May have changed because of overrides.)

(See also PIDx_ADJUST at 40597-40600.)
40171 PID_TARGET_1 R Current computed target.
Digital Output Force Mode Timer. Fixed duration 5 minutes (300 seconds).
Zero means not in force mode, non-zero represents time left in force mode.
40175 DIG_FORCE_TIMER R In seconds. 5 minutes fixed.
Active Alarms (NUM_ALARMS has # of entries.)

Alarm enumerations explanation.
The top 1 bit of the alarm enumerations are masked off to get the enumeration.
The top 1 bit indicates if an alarm has been acked.
40201 ALARM1 R Enumeration, zero = none
Page 10 of 15
Maintenance Timers (time remaining)

Maintenance Timers have the Hours kept in the most significant word.
Minutes are in the high byte of the least significant word; Seconds in the low byte.
40301 MAINT1_HOURS R Hours
40302 MAINT1_MIN_SEC R Minutes, Seconds.
Shutdown History Log

6 bytes per entry including Hour Meter and Shutdown enumeration. A zero enumeration ends the list.
Note the list is sorted in descending order from most recent to oldest.
40401 SHUTDOWN1_HOURS R Hours
40402 SHUTDOWN1_MIN_SEC R Minutes, Seconds
40403 SHUTDOWN1_ENUM R Shutdown enumeration
Page 11 of 15
Page 12 of 15
Event History Log

6 bytes per entry including Hour Meter and Event enumeration. A zero enumeration ends the list.
Note the list is sorted in descending order from most recent to oldest.
40501 EVENT1_HOURS R Hours
40502 EVENT1_MIN_SEC R Minutes, Seconds
40503 EVENT1_ENUM R Event enumeration
Page 13 of 15
Page 14 of 15
PID adjustment calculations

Each cycle through a PID it should adjust these values.
40597 PID1_ADJUST R Percent 2 dec. places 0 to
10000
10000
10000
10000
40601 PROPORTIONAL_ADJ R Dynamically computed P
change.
40602 INTEGRAL_ADJ R Dynamically computed I
change.
40603 DERIVATIVE_ADJ R Dynamically computed D
change.
40604 LS16 ACCUM ERROR R
40605 MS16 ACCUM ERROR R
Setpoints range (1-128)
43516 – SETPOINT 01 – R/W
43644 SETPOINT 128
8.0 MCONFIGPRO REPORT (refer to attached PDF File)
Page 15 of 15
CENTURION™
Configurable Controller
Installation and Operations Manual
00-02-0590
10-10-06
Section 50
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our
specifications and designs at any time. The latest version of this manual can be found at www.fwmurphy.com.
Warranty - A limited warranty on materials and workmanship is given with this FW Murphy product. A copy of
the warranty may be viewed or printed by going to www.fwmurphy.com/support/warranty.htm
FW MURPHY has made efforts to ensure the reliability of the Centurion

controller and to recommend safe usage practices in system applications.
Please note that in any application, operation and controller failures can
occur. These failures may result in full control outputs or other outputs which
may cause damage to or unsafe conditions in the equipment or process
connected to the Centurion controller. Good engineering practices, electrical
codes, and insurance regulations require that you use independent external
protective devices to prevent potentially dangerous or unsafe conditions.
Assume that the Centurion controller can fail with outputs full on, outputs full
off, or that other unexpected conditions can occur.
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT:
• Please read the following information before installing the Centurion

controller. This installation information is intended for Centurion
controller only. Before installing, visually inspect the product for any
damage during shipping.
• Disconnect all power and be sure machine is inoperative before
beginning installation.
• Installation is to be done only by qualified technician.
• Observe all Warnings and Cautions at each section in these
instructions.
• Device shall be wired in accordance with Class I, Division 2 wiring
methods.
• This equipment is suitable for use in Class I, Division 2, Groups B, C,
and D hazardous Areas.
• WARNING–Explosion Hazard–Substitution of components may
impair suitability for Class I, Division 2.
• Please contact Murphy immediately if you have any questions.
Table of Contents
1 Overview ............................................................................................................................... 1
1.1 Basic Components and Key Features of the C3 Series .........................................2
1.2 Optional Components.............................................................................................3
2 Input/Output Types .............................................................................................................. 4
2.1 Power Supply Wiring ..............................................................................................4
2.2 Input/Output Types and Specifications for the Main I/O Module ............................5
2.3 Input/Output Types and Specifications for the Optional Expansion Module ...........9
3 Hazardous Area Operation ............................................................................................... 11
4 Hardware Installation and Wiring..................................................................................... 12
4.1 Mounting the Controller ........................................................................................12
4.2 Mounting the Display............................................................................................12
4.3 Wiring the Display ................................................................................................13
4.4 Wiring the Controller.............................................................................................14
5 Using the Display............................................................................................................... 16
5.1 Features ...............................................................................................................16
5.2 Operational Screens.............................................................................................21
5.3 Setup Screens and Menus ...................................................................................27
5.4 Additional Navigational Aids.................................................................................54
6 Communications................................................................................................................ 55
6.1 Communication Ports ...........................................................................................55
6.2 Downloading Configurations and Firmware Updates ...........................................56
6.3 Modbus™ RTU Protocol .......................................................................................62
6.4 Transferring Data in Modbus................................................................................63
6.5 Modbus Register Address Listings .......................................................................63
7 Replacement Parts and Assemblies................................................................................ 63
8 Accessories........................................................................................................................ 63
8.1 Configuration Software.........................................................................................63
9 Glossary.............................................................................................................................. 64
10 Appendices....................................................................................................................... 66
10.1 Back Panel LED Description ..............................................................................66
10.2 Controller Accuracies, and Tolerances...............................................................66
10.3 Restrictions on Numeric Values in Gage and PID Monitor Screens ...................67
10.4 Set Up Sheet......................................................................................................67
(THIS PAGE INTENTIONALLY LEFT BLANK)
1 Overview
The Centurion configurable controller is a display and controller combination expressly
designed to meet the requirements of three specific kinds of applications:
• Screw Compressors
• Reciprocating Compressors
• Pumps
The heart of the Centurion system is the main input/output (I/O) module or controller, which
can be mounted on a standard DIN rail. While it is designed to work with any Modbus (Master)
compliant HMI (Human Machine Interface) or with no operator interface at all, it is optimally
configured and field-configurable through MConfigPro™, powerful software developed to
configure the controller. Parameters can be modified in the field without special need for laptop
or software by utilizing Murphy’s specially programmed controller display.
The controller is designed to monitor, control, protect, and optimize small to medium sized gas
operated compressors and pumps in the field. Proper operation is maintained by monitoring
set points and digital, analog, and thermocouple input points and providing the logic to take
corrective and/or proactive steps.
The controller also allows for controlled shut down and no-flow monitoring as well as auto start
up, and engine control capabilities.
The controller provides real-time data via communications ports to a connected display and/or
supervisory system. This advanced system offers multiple options for remote communications
and operation. The industry standard RTU Modbus protocol means greater support for a wide
variety of communication equipment including radio and satellite communications systems.
Section 50 00-02-0590
10-10-06 -1-
1.1 Basic Components and Key Features of the C3 Series
The C3 series consists of a display module, a main I/O module, and optional expansion I/O
module. No special cables are required. The Centurion system is designed for use within a
weatherproof enclosure only.
Display module (C3-3) 128 x 64 LCD graphic display (-40 to 85) °C

• Power
10 - 32 VDC: 1W typical, 6W (max)
Storage power able to withstand 12V crank
NOTE: Maximum power ratings based on display heater operating at
maximum with 10V supply. Heater is only operational below -10C.
Typical based on 24V supply.
• Package and design
Same 5” x 5” design as annunciators
12 key keypad
• Communications
LED active indication for each port
RS232/485 (Modbus Master)
RS232/485/USB 1.1 compliant port
• Approvals
CSA, CLASS 1, DIVISION 2, Groups B, C and D certifications are
approved.
Main I/O module (C3-1)
• 32 digital inputs (DI)
• 10 digital outputs (DO)
• Direct input for analog and thermocouple inputs:
o 12 analog input (AI)
o 8 thermocouples (TC)
• 1 magnetic pickup (MPU)
Section 50 00-02-0590
10-10-06 -2-
1.2 Optional Components
The C3-1 hardware may be configured with 2 analog outputs and it may be augmented
through an expansion module (C3-2) which provides analog outputs and additional analog and
thermocouple inputs.
Main I/O Module with analog outputs (C3-1-A)

• Same specifications and I/O as C3-1, plus 2 analog outputs
Expansion I/O Module (C3-2)

• 8 analog inputs (AI)
• 8 thermocouple inputs (TC)
• 4 analog outputs (AO)
Section 50 00-02-0590
10-10-06 -3-
2 Input/Output Types
2.1 Power Supply Wiring
NOTE: Maximum power ratings based on all I/O operating in the ON
position with 10V supply. Typical based on 24V supply.
2.1.1 Centurion I/O Module

Requirements: (10 to 32) VDC: 30W (max)
There are two screw terminal connectors for power hookup at terminals 62 and 63, labeled B+
and B- respectively.
2.1.2 Centurion (Optional) Expansion I/O Module

Requirements: (10 to 32) VDC: 6W typical, 30W (max)
There are three screw terminal connectors for power hookup at terminals 134 to 136, labeled
B+, B and B- respectively.
NOTE: Run power directly from battery posts to controller power

terminals when battery is the power supply.
Section 50 00-02-0590
10-10-06 -4-
2.2 Input/Output Types and Specifications for the Main I/O Module
Section 50 00-02-0590
10-10-06 -5-
2.2.1 Digital Inputs (DI)
Number of devices: 32
Device types: discrete input, normally open (N/O) or normally closed (N/C), active high/active
low, non-incendive.
There is one screw terminal connector for each digital input.
Terminals 30 to 61 are DI terminals.
Green LEDs give visual indication of active input signal.
2.2.2 Analog Inputs (AI)

Device types: analog input, (4 to 20) mA or (0 to 5) V, 10 bit hardware.
There is one screw terminal connector for each analog input.
Terminals 18 to 29 are AI terminals.
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2.2.3 Thermocouple Inputs (TC)
Device types: thermocouple input, type J or K, 12 bit hardware.
Use ungrounded thermocouples only. Grounded thermocouples are not supported. Errors in
readings with grounded thermocouples can be the result of differences in grounding between
devices.
Open thermocouple detection: drives terminal reading high (max of scale).
Automatic cold junction compensation is built-in.
There are two screw terminal connectors for each thermocouple.
Terminals 1 to 16 are TC terminals where white or yellow indicate positive inputs and red
indicates negative inputs.
NOTE: An additional terminal connector is provided, identified as SHD, which

isolates thermocouple shields. This connection, at terminal 17, is intended to be
wired to an isolated bus bar for thermocouple shield wires. If shields are
grounded, do connect shields to SHD terminal. Connect all shields to SHD or to
ground but never both.
2.2.4 Magnetic Pickup (MPU)

Device types: magnetic pickup (MPU), (5 to 120) Vrms, (30 to 10k) Hz.
There are two screw terminal connectors for the magnetic pickup.
Terminals 64 and 65 are MPU terminals.
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2.2.5 Digital Outputs (DO)
Device types: discrete output, normally open (N/O) or normally closed (N/C)
• four (4) relay outputs, form C, dry contacts

• four (4) FETs (high speed)
• two (2) IGBTs (high power)
There are three screw terminal connectors for each relay output and two screw terminal
connectors for each FET and IGBT output.
Terminals 70 to 81 are for the four relay terminals.
Terminals 82 to 89 are for the four FET terminals.
Terminals 90 to 93 are for the two IGBT terminals.
Green LEDs give a visual indication of active output signal.
Warning: A heat sink is attached to the cover using acorn style nuts.
The surface area around these fasteners can become very hot. Avoid
contact.
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2.2.6 Optional Analog Outputs (AO)
Device types: analog output, (4 to 20) mA or (0-20)mA, 16 bit hardware
There are two screw terminal connectors for each analog output.
Terminals 66 to 69 are AO terminals.
The optional AO module is added to the C3-1 at the factory inside the DIN enclosure. While
these terminals are present on all models the feature may not be installed.
2.3 Input/Output Types and Specifications for the Optional Expansion Module
2.3.1 Analog Inputs (AI)
Device types: analog input, (4 to 20) mA or (0 to 5) V, 12 bit hardware.
There is one screw terminal connector for each analog input.
Terminals 126 to 133 are AI terminals.
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2.3.2 Thermocouple Inputs (TC)
Device types: thermocouple input, type J or K, 12 bit hardware
Open thermocouple detection: drives channel reading high (max of scale).
There are two screw terminal connectors for each thermocouple input.
Terminals 109 to 124 are TC channels where white or yellow indicate positive inputs and red
indicates negative inputs.
NOTE: An additional terminal connector is provided, identified as SHD, which

isolates thermocouple shields. This connection, at terminal 125, is intended to be
wired to an isolated bus bar for thermocouple shield wires. If shields are
grounded, do connect shields to SHD terminal. Connect all shields to SHD or to
ground but never both.
2.3.3 Analog Outputs (AO)

Device types: analog output, (4 to 20) mA or (0-20)mA, 16 bit hardware
There are two screw terminal connectors for each analog output.
Terminals 137 to 144 are AO terminals.
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3 Hazardous Area Operation
The Centurion certifications for CSA, CLASS 1, DIVISION 2, Groups B, C and D are approved.
Warning: Explosion hazard – Do not disconnect the equipment unless

the power has been switched off, or the area is known to be non-
hazardous.
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4 Hardware Installation and Wiring
4.1 Mounting the Controller
The Centurion controller can be mounted vertically or horizontally on a standard DIN rail.
Three clamp-type feet along the bottom of the controller attach to the DIN rail, however, rail
stops are recommended to prevent sliding.
4.2 Mounting the Display

The Centurion display can be mounted in the same hole cutout of other Murphy display
modules. Four screws attach the display bezel to the mounting surface.
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4.3 Wiring the Display
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4.4 Wiring the Controller
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Wiring the Controller (continued)
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5 Using the Display
The display module is a highly integrated

operator interface specially programmed to
complement and support the Centurion
controller. The primary purpose of the display is
to:
• view controller operational

information
• view/edit controller operational
parameters
• send commands to controller, such
as stop, edit, and reset
5.1 Features
5.1.1 Keypad Description and Navigation
The keypad for the display has 12 keys. The following table describes the keys and their
function for each of the three screen types:
• Operating status screens

• Setup screens (password required)
• Edit screens (password required)
Many of the keys have a modified action relative to the current location of the cursor and the
current page being displayed.
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Key ID Description
HOME Operating Status Screen
Allows the user to get to the first line of the current screen, or
if pressed again, to get to the default operating status screen.
Set Up Screen
Allows the user to get to the first line of the current screen.
Edit Screen
No associated action.
ESC/ACK Operating Status Screen
Acknowledge the active message/alarm that is currently
displayed in the alarm banner.
Acknowledges all active messages and alarms displayed in
the active alarm screen.
Set Up Screen
Exit Setup mode.
Edit Screen
Exit without saving changes to the current configuration.
Fn (Function Operating Status Screen
Key) Enter “Function mode” and display a dialog box with
additional available functions. Automatically cancels upon
moving to the next mode, or if no subsequent function is
chosen within five seconds.
Set Up Screen
Edit Screen
SETUP/ENTER Operating Status Screen
Enter Setup Mode.
Set Up Screen
Enter Edit mode or Sub-menu.
Edit Screen
Accept and save changes made to a current parameter before
exiting edit mode.
RESET Operating Status Screen
Reset any active timers and alarms/faults.
Set Up Screen
Edit Screen
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Key ID Description
RUN/STOP Operating Status Screen
Initiate or cancel a start sequence. (hold for 2 seconds)
Set Up Screen
No associated action in either shutdown mode, or remote
mode on standby. Initiate stop only sequence when held for
two seconds, if equipment is running.
Edit Screen
ARROW UP Operating Status Screen
Scroll up one line. Automatically repeats if held down
continuously until reaching the first line.
For history screens, scrolls up one history (for example:
shutdown or event).
Set Up Screen
Scroll up one line. Automatically repeats if held down
continuously until reaching the first line.
Edit Screen
Increase the digit selected by the cursor (from 0 to 9). The
user will not be allowed to increase the selected digit if it
would result in exceeding range limits.
ARROW DOWN Operating Status Screen
Scroll down one line. Automatically repeats if held down
continuously until reaching the final line.
For history screens, scrolls down one history (i.e. shutdown or
event).
Set Up Screen
Scroll down one line. Automatically repeats if held down
continuously until reaching the final line.
Edit Screen
Decrease the digit selected by the cursor (from 0 to 9). The
user will not be allowed to decrease the selected digit if it
would result in exceeding range limits.
ARROW LEFT Operating Status Screen
Display previous screen. Automatically repeats if held down
continuously until reaching the first screen.
Set Up Screen
Display previous screen. This key has no action when in a
sub-menu.
Edit Screen
Move the cursor left one position when a numeric value is
displayed.
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Key ID Description
ARROW RIGHT Operating Status Screen
Display next screen. Automatically repeats if held down
continuously until reaching the final screen.
Set Up Screen
Display next screen. This key has no action when in a sub-
menu.
Edit Screen
Move the cursor right one position when a numeric value is
displayed.
TEST Operating Status Screen
Enter test mode and start test timer. This is not applicable in
shutdown mode.
Set Up Screen
Edit Screen
TIMER “0” Operating Status Screen
Zero displayed timer (global timers, state timers, etc.)
Set Up Screen
Edit Screen
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5.1.2 Display Context
The graphic LCD displays are organized around operating status screens and setup screens.
The actual number of status screens will be related to the total number of end devices
configured for the controller. In either screen set, ten (10) lines are visible at a time; with up
and down arrow characters indicating more lines are available on the page. Also, for both
screen sets, navigation between screens is accomplished by pressing the left or right arrow
keys.
5.1.3 Numeric Entry

The Centurion display allows individual editing of each position of the desired number. This is
accomplished by entering the edit mode and using the UP/DOWN arrow keys (1) to adjust the
number above the blinking cursor (2) between 0 and 9. To edit another position, simply use the
LEFT/RIGHT (3) arrow keys to move the cursor to that position (4) and repeat the edit process
until the desired number is displayed.
In this way, values are “built” rather than “scrolled” through. Some digits may not be allowed to
increase if it would result in exceeding range limits. Values which can be positive or negative
will have a sign (±) to the left of the number. To change the sign value simply move the cursor
to the sign using the LEFT arrow key and “toggle” between + and – using the UP and DOWN
arrow keys. If the range of the value will exceed range limits the sign may not be allowed to
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change. In this case, try reducing the number by decreasing the left most digit by one or more
and attempt to change the sign again.
In some instances, a word rather than a value is represented in the Edit Mode. This works like
the sign value as an ON/OFF or YES/NO prompt where the value is “toggled” between choices
using the UP/DOWN arrow keys. The value is not active in the controller until the ENTER key
has been pressed to send the value to the controller. Pressing the ESC key will discard any
changes and keep the original value prior to entering the Edit Mode.
5.2 Operational Screens

In addition to the set up screens reviewed in the “Setup Screens and Menus” section, the
display offers a number of operational displays. On the Operating Status screens, the two
bottom lines display the state, hours, mode and active timer status. This information is key to
understanding the “status” of the controller.
Mode refers to the Operating Mode of the controller and can be LOCAL or REMOTE.
Depending on the configuration active in the controller, the operation may differ depending on
what Mode the controller is currently displaying.
NOTE: The Mode can be changed by pressing certain keys, if the

configuration allows for REMOTE mode.
Pressing RESET or RUN/STOP is a Local function and will change the
Mode to Local if it is in REMOTE.
Pressing Fn before pressing RESET or RUN/STOP is a REMOTE function
and will change the Mode to REMOTE if it is in LOCAL.
5.2.1 Default Operating Screen

After turning on the power, the user will view the Murphy logo screen for three seconds before
the next screen displays, which is a software-configured default operating screen. The
MConfigPro software allows users to configure up to five screens with controller I/O groupings.
Possible custom screen types that may have been configured as a default operating screen, or
which may be also displayed, include:
a) “Custom Line by Line” allows process data to be displayed in a list format with
description and value.
b) “Custom Gage” allows user to display four (4) most important pieces of data on a 2 x 2
table in larger font.
c) “Custom PID” up to 4 PID screens.
For more information on configuring the optional screens through the MConfigPro software,
please refer to the MConfigPro Installation and Operations Manual.
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5.2.2 Murphy Logo Screen
The Murphy logo is the first screen in the

sequence of display screens and can be
viewed by holding down the left arrow until
scrolling left ceases.
5.2.3 Corporate and Version Information Screen
Following the Murphy Logo screen is the

Murphy corporate contact information which
also lists firmware version information for the
Centurion display, the main I/O module and
the MConfigPro Software.
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5.2.4 Digital Input Status
The user can see the state of each digital

input in a table—whether it is open or closed.
5.2.5 Shutdown History Screen
The history of the last 20 shutdowns is

displayed on this screen, with the most recent
at the top of the list and the oldest at the
bottom.
Each event is displayed with the shutdown

label on one line and the hour meter reading
on the following line. Pressing the up/down
arrows will scroll up/down one shutdown at a
time rather than one line at a time.
The “1/3” at the right end of the top line

means the user is viewing shutdown one of a
total of three stored. The newest shutdown
will always be number one and it will push the
older shutdowns further down the list.
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5.2.6 Shutdown Snapshot
The shutdown snapshot screen is a capture

of the values displayed on the Line-by-Line
custom screen at the time of a Fault SD or
ESD event. These values will be retained
and display on the shutdown snapshot
screen until the next Fault SD or ESD event
occurs. An asterisk displayed instead of a
value indicates the shutdown snapshot has
not captured any data or is not functioning.
NOTE: Only the first Line-by-Line

screen configured will be captured. If
no Line-by-Line custom screen is
configured, the shutdown snapshot will
not function.
5.2.7 Event History Screen
The history of the last 32 events is displayed

on this screen, with the most recent at the top
of the list and the oldest at the bottom.
Events include shutdowns, starts, stops,

resets, etc.
The user easily can view the events (alarms,

etc.) logged before and after a shutdown.
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5.2.8 Active Alarms Screen
All active alarms and warnings will be

displayed on this screen.
If there are more than six active alarms, there

will be up/down arrow icons at the bottom of
the screen and the user can press the
up/down arrow keys to scroll up or down.
Unacknowledged alarms will be preceded by

a musical note character and acknowledged
alarms will have a bar through the staff of the
note.
Pressing ACK on this screen will

acknowledge all active alarms.
A maximum of twenty (20) active alarm will

be displayed.
NOTE: Alarms are warnings based on

setpoints and/or digital inputs which
are separate from shutdowns.
This screen shows the alarm annunciation as

it will appear on a status screen.
The alarm message(s) will overwrite the

bottom line of the active screen area and
then briefly clear once a second. This will
continue until it is acknowledged with the
ACK key, unless it is a self-clearing alarm. If
there is more than one unacknowledged
alarm active, each alarm will be displayed for
one second each until acknowledged. The
ACK key will acknowledge the alarm currently
displayed. Pressing the Fn key followed by
the ACK key will switch to the active alarms
screen.
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5.2.9 Gage Display
This is an example of a custom gage
display. MConfigPro software arranges the
data as needed.
This display provides larger characters for

easier viewing as well as a means to
prominently display items of interest.
Unacknowledged alarms will overwrite the
bottom half of the lower two gage boxes.
The two bottom lines are used to display

the mode, hours, state and active timer
status.
5.2.10 Line-By-Line
This is an example of a custom line-by-line

status screen. The MConfigPro software
arranges the data as needed.
Notice that there are no up/down arrows at

the bottom of the screen because there are
no additional lines to be displayed on this
screen.
This is an example of a custom line-by-line

status screen with more parameters.
If the parameters do not fit in the viewable

area of the screen, up/down arrow icons at
the bottom of the screen can be used to scroll
up or down.
The two bottom lines are used to display the

mode, hours, state and active timer status.
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5.2.11 Custom PID Screen
The user may choose to display any

configured PID functions in this convenient
format. The control output will be displayed
as a percentage of the range.
The bottom two lines are used to display the

mode, hours, state and active timer status.
5.3 Setup Screens and Menus

The setup screens provide access to system parameters. These settings can be modified with
appropriate password access. The two bottom lines in the setup screens display navigation
and command options available such as EDIT, ACCEPT, CANCEL and MORE MENUS.
5.3.1 Password Screen

Some settings are password protected, including the setup screens.
This is the first screen seen when the SETUP/ENTER key is pressed.
The password need only be entered once during any editing session. The password will reset
when the editing session is exited, or is timed-out due to keyboard inactivity.
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The cursor begins at the last digit on the right. The user can adjust the value of each digit with
the up/down arrows while the left/right arrows are used to select the digit to edit.
Passwords are assigned using the MConfigPro software and each digit can range from zero to
nine (except the first digit on the left) for a total range of 00000 to 65535 for the complete
password.
The user will not be allowed to increase the selected digit if it would result in exceeding range
limits.
NOTE: If the Standard password is not zero and a password of all zeroes
is entered, the user will have “view only” access.
Inactivity Timeout: Setup procedures must be started and completed in a timely manner.
NOTE: After 3 minutes without activity, the keypad returns the default
operational screen and a password must be re-entered to return to the
setup and edit menus.
There are three separate levels of passwords

to accommodate several security needs:
“Standard” password – Allows access to

every feature except the super user menu.
Valid standard passwords can be zero or any
number between 100 and 65535. If the
standard password is set to zero, the result is
that anyone can have read/write access to
setup menus.
“Super User” password – Adds the super

user menu to the standard menus. Valid
super user passwords can be in the range of
100 to 65535. The super user password can
not be the same as the standard password
and cannot be set to zero.
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“Download Only” password – This special
35 jump code allows access to a download
menu and is set to a fixed value of 35. This
allows a configuration to be downloaded in
the event that the current passwords are lost
or no initial configuration has been
downloaded.
5.3.2 Digital Input

For up to 32 configured digital input devices,
the user may edit:
a) Signal Type - Select normally open
(N/O) or normally closed (N/C).
b) Signal Filter - Select None to disable
filter function for the digital input. This
will not disable the digital input for
normal operation.
Select Pulse for lubricator divider
blocks with a proximity switch output.
Select DB to debounce or delay input
detection for unstable inputs such as
surge tank level.
c) Filter Timing - Delay time in seconds
for the selected filter type.
For Pulse, this delay is the transition
time for the lubricator divider block to
cycle.
For DB, this is the duration the digital
input must remain either ON or OFF
before the input will be recognized and
accepted as ON or OFF by the
sequence. If the input does not
remain ON or OFF for the duration of
the delay, the timer will reset.
d) Total Pulses - Total number of pulses
counted when the filter type is set to
Pulse. The value is expressed in
hundreds of pulses; a displayed
reading of 1 is equal to 100 pulses.
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5.3.3 Digital Output
Digital output: For up to 10 configured digital

output devices, the user may select whether
an output is normally open (N/O), or normally
closed (N/C).
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5.3.4 Analog Input
For up to 20 configured analog input

devices, the user may edit:
a) Moving Average Samples. (1, 2, 4).
b) Raw Count Offset to determine the

lowest reading expected from the device.
Typically 147 for 4-20mA or 0 for 0-5VDC
c) Raw Count Span to determine the span

from the lowest to highest reading
expected from the device. Typically 586
for 4-20mA or 1023 for 0-5VDC
d) Minimum to apply the appropriate

minimum engineering scale.
Example: 0 PSI for a 0-100 PSI PXT.
e) Maximum to apply the appropriate

maximum engineering scale.
Example: 100 PSI for a 0-100 PSI PXT.
NOTE: Minimum and Maximum

are used to define the input scaled
in engineering units. Dual scales
are not supported.
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5.3.5 Analog Output
For up to 6 analog output devices, the user

may edit:
a) Raw Count Offset, the lowest reading

expected from the device. Typically set to 0.
b) Raw Count Span to determine the span

from the lowest to highest reading expected
from the device. Typically set to 10000.
c) Minimum to apply the appropriate

engineering scale. In most cases, 0%
addresses a typical application and it is the
Centurion’s default value.
d) Maximum to apply the appropriate

engineering scale. In most cases, 100%
(10000) addresses a typical application and
it is the Centurion’s default value.
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5.3.6 Thermocouple Input
For up to 16 thermocouple devices, the user

may edit:
a) Thermocouple Type. Identify whether

the calibration type should be set to J or
K.
b) Thermocouple Offset. Assign the

thermocouple offset value.
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5.3.7 General Timer Setup
User may edit all general purpose timers.

Generally, global timers affect engine
operation. They also help define an event.
B1: All event types can be associated with,

and locked out by, a Bx timer. B1 is the first
global timer used for delaying an event
condition detection. The timer starts in a
running State (10 – 13) depending on
which timers have been marked “In Use”.
B1 is also known as the “Lockout Timer”,
start bypass or start/run timer.
B2: The second global timer used for

delaying event condition detection. B2 is
also known as a secondary “Lockout
Timer.”
NOTE: The Bx timers start after the

Start key has been pressed and the
controller has reached a "Running"
state. States 10-13 are the
"Running" states.
C: The delay allowing a clear reading

before beginning testing for the arming of
Class C events. The default and typical
time for most applications is 2 seconds.
S: Users have up to five (5) options to

assign additional special global timers to
signals. The Sx timers begin concurrently
with the Bx timers.
No Flow: The global delay used for

delaying the triggering of a no flow event.
This global no flow timer is enabled after
B1 expires, and begins timing after any of
the pulse transition times configured in the
digital input dialog expires.
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Test: Time given to allow for maintenance
testing of end devices without triggering a
fault or shutdown condition. The timer
initiates when switched to test mode.
Ignition Off Delay: Time delay before the

assigned ignition output turns off. This is
typically used to burn remaining fuel vapors
after the fuel valve is turned off.
Ignition On Delay: Time delay before the

assigned ignition output turns on. This is
typically used to delay ignition until engine
has started cranking (also known as a
purge delay).
Fuel On Delay: Time delay before the

assigned fuel valve output is turned on.
This is typically used to delay fuel until
ignition has been turned on.
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5.3.8 Maintenance Timer Setup
The user may access and edit the ten (10)

maintenance settings for timer duration.
The user may also access and reset all

timer duration and time remaining settings.
All maintenance timer units are in hours.
NOTE: While these are configured

through MConfigPro, they must be
manually initiated, or restarted, in
Centurion display.
To initiate or reset timers, position cursor on

TIME REMAINING and press the reset key.
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5.3.9 Setpoints Setup
User can edit any of the 128 setpoints that are configured.
Setpoints further configure variable input types such as MPU, analog, or thermocouples by
defining a threshold, exception or any other out-of-limit event that may require action. Multiple
setpoints are often applied to a process and they may be configured as often as needed to
meet changing conditions.
Common alarm and shutdown setpoints a user might have configured include:
• High shutdown (High-High)
• High warning (High)
• Open warning (Open or Fail)
• Low warning (Low)
• Low shutdown (Low-Low)
To edit a configured setpoint:
a) Assign numeric threshold that if crossed,

triggers the setpoint.
b) Adjust the sign of the threshold value as

plus (+) or minus (-) by moving the cursor to
the sign symbol position and use the up and
down keys to toggle the sign.
For more on setpoints, please refer to the

MConfigPro Installation and Operations
Manual.
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5.3.10 Control Output Setup
The Centurion controller allows users to define up to eight (8) outputs to augment control not
otherwise defined by digital output assignments.
The Centurion can be configured through MConfigPro software to define an analog output, a
digital output, a single pulsed digital output, or two pulsed digital outputs.
NOTE: Control outputs 1 through 4, are directly related to PID calculation

loops and are further defined in the PID dialog screens described in the
PID Setup section. For example, PID 1 is assigned its control from control
output 1, PID 2 from control output 2, and so on.
If the configured output is a pulsed cycle, the

user may edit those behaviors by assigning
values the following:
a) Increase Max On Time. Set limit of

maximum on-time for Increase pulses.
b) Increase Off Time. Set fixed off-time for

Increase pulses.
c) Increase Changeover On Time. Set fixed

on-time for single pulse on direction change
for Increase.
d) Increase Changeover Off Time. Set fixed

off-time for single pulse on direction change
for increase.
e) Decrease Max On Time. Set limit of

maximum on-time for decrease pulses.
f) Decrease Off Time. Set fixed off-time for

decrease pulses.
g) Decrease Changeover On Time. Set

fixed on-time for single pulse on direction
change for decrease.
h) Decrease Changeover Off Time. Set

fixed off-time for single pulse on direction
change for decrease.
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5.3.11 Proportional Integral Derivative (PID) Setup
Users may view and edit up to four (4) MConfigPro software configured PID calculation loops.
A PID provides a constant feedback loop, in which the PID can correct for a measured process
variable against a desired set point, output the corrective action to the process and wait for and
recalculate the next measurement.
The ultimate goal of the PID is to reduce the error to zero while maintaining the control setpoint
(e.g. speed, load, pressure).
NOTE: During the time a PID is enabled, the PID always overrides control
output settings found in the states dialog. PID 1 assumes control of control
output 1, PID 2 assumes control of control output 2, and so on.
To view and edit PID settings:
a) Setpoint: Assign the desired goal—the

target feedback base value.
b) DeadBand: Assign a value around the

setpoint during which the PID will not
calculate error or take action.
c) Ramp Time: Assign a time interval for the

PID to calculate error.
d) Max % of Change: Assign a percentage

rate of change of the output, greater than
which may cause harm to the system.
e) Minimum Output: Assign a percentage

as minimum output. Typically 0 (zero).
f) Maximum Output: Assign a percentage

as maximum output. Typically 10000
(100.00%)
g) Proportional: Assign a constant value for

the proportional coefficient of the PID loop
calculation that causes a portion of the output
to be a fixed amount proportional to the size
of the error.
h) Integral: Assign a value for the integral

coefficient of the PID loop calculation that
causes a portion of the calculated output to
change with accumulated error over time.
Section 50 00-02-0590
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i) Derivative: Assign a constant value for the
derivative coefficient of the PID loop
calculation that causes a portion of the
calculated output to change with the change
in the size of error versus time.
j) OverRide Ramp Time: Assign a time

interval value to wait before making the next
override adjustment.
NOTE: Override settings are only

used when there is a configuration
for overriding the primary PID control
loop with another process variable.
k) OverRide Ramp Amount: Determine the

increments in a given direction (positive or
negative) that the primary setpoint should be
altered to regain balanced processes. In the
example of the discharge and suction
pressure application, this value would
indicate how much the PID should resist its
goal in reaching the setpoint.
l) OverRide Max Change: Assign a

maximum allowed change. This represents
the total amount of change allowed into or out
of the ramp amount from the setpoint. The
maximum change value should be large
enough to effect change.
For more on PID, please refer to the

MConfigPro Installation and Operations
Manual.
Section 50 00-02-0590
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5.3.12 Initial RPM Setup
Assign values for:
a) Warmup RPM.
b) Wait to Load RPM.
c) Run Loaded RPM.
d) Cooldown RPM.
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5.3.13 Miscellaneous Setup
User can access and edit the miscellaneous
settings.
a) Crank Attempts (1-99): Define a value

for number of crank attempts after which an
over-crank sequence will be triggered in the
event logic.
b) Port 1 Slave Address (1-255): Provide

the value for the Modbus address for port 1.
The factory default is 1.
c) Port 1 Mode: Select communication port

1 as RS232, or RS485.
d) Port 1 Reply Delay (0-32767): To ensure

sufficient time for the Modbus reply, assign
appropriate time value for delay Modbus
reply port 1. Typically set to 18. This setting
only applies to Port Mode RS485.
e) Port 1 Baud Rate: Select appropriate

transmission baud rate (9600; 19200; 38400;
57600; 115200)
f) Port 2 Mode: Select communication port

2 as RS232, or RS485.
g) Port 2 Reply Delay (0-32767): To ensure

sufficient time for the Modbus reply, assign
appropriate time value for delay Modbus
reply port 2. Typically set to 18. This setting
only applies to Port Mode RS485.
h) Port 2 Baud Rate: Select appropriate

transmission baud rate (9600; 19200; 38400;
57600; 115200)
NOTE: All ports use:

-Parity: NONE
-Data Bits: 8
-Stop Bits: 1
Section 50 00-02-0590
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i) Flywheel Teeth: Define a value for
flywheel teeth (Pulses Per Revolution) used
to calculate RPM.
WARNING: The following cold

temperature offset values should only
be adjusted by personnel with a full
working knowledge of the Centurion in
conjunction with calibrated reference
equipment.
j) Core Cold Temp Offset: Enter a non-

zero value for core temperature adjustment
(in tenths) to adjust the temperature
readings for all thermocouple inputs on the
main I/O module (C3-1). Entering a non-zero
value will adjust the cold junction
compensation reading used to calculate
temperature.
k) Exp Cold Temp Offset: Enter a non-zero

value for expansion board temperature
adjustment (in tenths) to adjust the
temperature readings for all thermocouple
inputs on expansion I/O (C3-2). Entering a
non-zero value will adjust the cold junction
compensation reading used to calculate
temperature.
l) Hour Meter: The user may make hour

meter adjustments. The range is 0 – 65535
hours.
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5.3.14 Pulse Input Status
Pulsed inputs are designed to accept a

cycling digital output from a lubricator divider
block; typically from a general purpose
proximity switch.
The user may view information about the

pulsed inputs. If a digital input is designated
for use as a pulsed input, it will display how
much time elapsed before the last transition,
and how much time has elapsed since that
transition. If the input is not designated as a
pulsed input, there will be zeros displayed.
Both have a maximum value of 999.
5.3.15 Super User Menu

The super user menu will only be visible if the
super user password has been entered.
a) Com Fail Disable: Set to Yes to prevent

the Com Fail message from appearing when
communication is lost or cannot be
established.
b) Setup T/O Disable: Set to Yes to prevent

automatic logout from the Setup menus when
no keys are pressed for the timeout period.
c) Config Fail Disable: Set to Yes to prevent

the Invalid Configuration screen from
appearing when the display and controller
configurations do not match.
NOTE: Settings a thru c are for

troubleshooting purposes and are not
retained on power cycle.
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d) Reset Fault History: Set to Yes to clear
the Shutdown History screen.
e) Reset Event History: Set to Yes to clear

the Event History screen.
NOTE: The Reset History commands

do not permanently switch to Yes when
entered, but instead toggle back to No
after sending the command to the
controller.
Also, the message “HISTORY

CLEARED” will be displayed until
another key is pressed.
f) Restore Defaults: Set to Yes to overwrite

all settings changed through the display to the
original configuration settings from the last
download.
NOTE: The Restore Defaults

command does not permanently
switch to Yes when entered, but
instead toggles back to No after
sending the command to the
controller.
Also, the message “DEFAULTS

RESTORED” will be displayed until
another key is pressed.
g) Standard Password: Set to Yes to enter

the Standard User Password edit screen. The
current password is displayed and can be
changed.
h) Superuser Password: Set to Yes to enter

the Superuser Password edit screen. The
current password is displayed and can be
changed.
Section 50 00-02-0590
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NOTE: The Password commands do
not permanently switch to Yes when
entered, but instead toggle back to
No after returning from the Password
view/edit menu.
The P1 and P2 signify communication port 1

and communication port 2 and are for setting
up the RS485 interfaces on the display’s
serial ports.
i) & k) PU/PD designates internal pull-up and

pull-down resistors. These can be connected
or disconnected by these settings.
j) & l) TERMINATION designates internal

terminating resistors. These can be
connected or disconnected by these settings.
NOTE: By default, both PU/PD and

TERMINATION settings are set to
YES for both Port 1 and Port 2 to
enable these features for RS485.
m) P1 Config Download
n) P2 Config Download
o) USB Config Download
p) Firmware Download
NOTE: Items m thru p

communication port functions are
also available for the configuration
download menu. Refer to the section
“Downloading Configurations to the
Display” for details on download
functions.
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5.3.16 Configuration Download
This menu allows for download only and can
be accessed through the special jump code
35.
It is the only screen available by entering the

password 35.
New configurations can be downloaded to the

display by selecting the desired connection.
(Com 1 Config Download, COM 2 Config
Download, and USB Config Download)
After enabling the download, download
progress is indicated on the left side of the
edit box as a percentage complete. After
selecting Yes for download, and until No is
selected after download is complete, only the
enter key will be active.
See the “Operational Screens” section for

further details about downloading
configurations.
a) Com 1 Config Download: Selecting Yes

initiates configuration download through
communication port 1.
b) Com2 Config Download: Selecting Yes

initiates configuration download through
communication port 2.
c) USB Config Download: Selecting Yes

initiates configuration download through USB
port.
d) Firmware Download: Selecting Yes

initiates firmware download. This feature only
supports USB download. The USB cable
must be plugged into the USB port and
connected to a pc before activating this
selection. A firmware update mode screen
will remain until the unit has been reset by
remote command or a power cycle.
See section “Downloading Firmware Updates
to the display” for downloading new firmware.
Section 50 00-02-0590
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5.3.17 Display Board Status
The user may view diagnostic information

that reflects the operating conditions of the
display only.
a) Battery Volts - Indicates internal voltage

measurement of display VDC input.
b) Board Current - Indicates internal power
measurement of display. Typical current
measured at 24VDC is .04A or 40
milliamperes.
NOTE: This value is higher when
ambient temperature is below -10F.
During this time the LCD heater will
be active and consuming more
power.
c) Temperature - Indicates internal

temperature measurement of display. This is
used primarily to monitor ambient
temperature to operate LCD heater.
d) Heater PWM % - Refers to the LCD
heater which only operates in cold
temperature conditions.
e) Reset Source - Indicates the cause of the
last reset. Possible causes include external
reset, power-up, brown-out and watch dog.
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5.3.18 Digital Output Status
For each of the devices configured as “In

Use” by MConfigPro, the user can see the
state of each output and has the ability to
force an output for the purpose of testing. A
force is associated with a timeout so that it
will be automatically cancelled when
returning to normal operation. Each force
operation resets the timeout to 5 minutes.
The force timer expires after 5 minutes if no
other forces are activated or when the user
navigates away from the digital output status
screen.
The Force timer is shown in the bottom right

corner of the digital output status screen
when forces have been activated.
5.3.19 Analog Input Status

The user can view the raw counts of the
analog inputs for troubleshooting.
NOTE: These values are used to

establish the offset and span
settings.
Typical approximate raw readings for

4-20mA input:
4mA = 147
20mA = 733
The Span (16mA) is 586, therefore:

8mA = 293
12mA = 439
16mA = 585
Section 50 00-02-0590
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5.3.20 Analog Output Status
The user can see the state of each output,
and if in test mode, has the ability to force
an output for the purpose of testing.
To force the output, enter a value from

0.00% = 4mA to 100.00%.= 20mA
Any value in between will output a portion

of the 16mA span proportional to the
percent value.
Analog outputs under the control of PID or

other control output settings cannot be
forced. To force a PID controlled output,
place the PID in manual mode and
operate the manual output value.
Section 50 00-02-0590
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5.3.21 Thermocouple Status
The user may view the raw counts of the

thermocouple inputs for troubleshooting.
Section 50 00-02-0590
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5.3.22 Communication Status
Users may view the statistics for both of the

display unit serial ports, including Modbus
requests and responses.
a) P1 Receive Count
b) P1 Transmit Count
c) P1 Frame Errors
d) P1 HW Overruns
e) P2 SW Overruns
f) P2 Receive Count
g) P2 Transmit Count
h) P2 Frame Errors
i) P2 HW Overruns
j) P2 SW Overruns
k) Modbus Requests
l) Modbus Responses
m) Modbus Exceptions
n) Modbus Invalid Response
o) Modbus No Response
p) Clear Statistics
q) Modbus Register
Section 50 00-02-0590
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5.3.23 PID Diagnostics
For each of four (4) possible configured PIDs,

user may edit:
a) Display PID Bar Graph: Monitors the

results of modifying the PID components.
b) Proportional: Edit the proportional

coefficient value.
c) Integral: Edit the integral coefficient value.
d) Derivative: Edit the derivative coefficient

value.
e) Auto/Manual: Setting to manual mode

allows the corresponding Set Output value to
be adjusted.
f) Set Output (Manual): In manual mode

allows adjustment from 000.00 to 100.00.
The output will correspond to the control
output associated with the PID.
g) Reference Line Select: Setting to select

the display value that will appear on the line
above the separator line and below the PID
name.
This setting is useful for showing the process

value of a different analog, thermocouple, or
speed input that may be effected by changes
to the PID output.
Select from available analog, thermocouple,

or speed inputs or None to disable the
Reference Line Select feature.
Section 50 00-02-0590
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5.4 Additional Navigational Aids
5.4.1 Function Key
Pressing the function (Fn) key from any

screen will display a dialog box on the
bottom half of the screen. All available
function key commands will be displayed
there. The user can then press a single key
for the available commands.
In this case, the user can select from a

help screen, the alarms screen or issue a
remote mode command. If the Fn key is not
followed by another key press in five
seconds, function mode will time out and
the dialog box is replaced with the previous
screen.
NOTE: In all cases the Fn key options will

be context sensitive. Some options will only
be available from certain screens or under
certain conditions.
5.4.2 Help Key
This is the help screen the user will see by

pressing the HOME key from the Fn dialog
box or by pressing the Fn key followed by
the HOME key from a normal screen.
Section 50 00-02-0590
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6 Communications
6.1 Communication Ports
6.1.1 Port 1 (SERIAL)
Port 1 is intended as the primary port for the local device, the display, and should be utilized
for display in order for the boot loader mode to properly execute in pass-through mode.
Interface: Refer to the sequence of operations to determine how the communication port has
been configured.
Protocol: Modbus RTU (slave)
Connection: There are three (3) screw terminal connectors for RS485. These are identified as
A, B, and SHD.
There are three (3) screw terminal connectors for RS232. These are identified as RX, TX, and
DTR.
SHD is common for both ports.
6.1.2 Port 2 (SERIAL)

Interface: Refer to the sequence of operations to determine how the communication port has
been configured.
Protocol: Modbus RTU (slave), Proprietary (binary)
Connection: There are three (3) screw terminal connectors for RS485. These are identified as
A, B, and SHD.
There are three (3) screw terminal connectors for RS232. These are identified as RX, TX, and
DTR.
SHD is common for both ports.
Modbus RTU Slave Address Configuration: The operator may assign a unique Modbus
address to each controller (slave) unit that may be in the system. This allows the master
controller to differentiate between the modules. For example, to name the controller address
21, place the shunts on LK1, LK4, and LK16 (1 + 4 +16 = 21). Typically, this configuration is
set to (1) by the factory.
Section 50 00-02-0590
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6.1.3 Port 2 (USB)
Interface: USB 1.1 compliant port capable of emulating RS232 communications via royalty-
free pc driver.
Protocol/Services: Modbus RTU (slave), Proprietary (binary)
Connection: There is a USB type B connector.
Automatic selection of USB is provided when a signal is detected on the USB type B
connector. Connections for RS485 and RS232 will not be enabled on port 2 when USB is
connected.
6.1.4 Port 3 (CAN)

Protocol/Services: Proprietary (binary)
Connection: There are three (3) screw terminal connectors for CAN. These are identified as
HI, LOW, and SHD.
On Main I/O Module
Located next to the USB connector is the CAN OK (COP). When in the boot loader the COP
LED does not flash.
When the program is running properly the COP LED will flash on and off every 0.5 seconds. If
the checksum in the configuration file does not match the calculated checksum of the file, then
the program will flash the COP LED 3 times at 0.5 second intervals and then stay off for 1.5
seconds.
On the Expansion I/O Module
When the program is running properly the COP LED will flash on and off every 0.5 seconds.
6.2 Downloading Configurations and Firmware Updates

The Centurion controller and display are configured and upgradeable through software
transfers using a PC or laptop computer.
Configurations provide the necessary instructions to the controller and display and install
default parameters that can be adjusted through the display or Modbus RTU.
Firmware defines the available features that can be configured in the controller and display
using the MConfigPro software.
Since no chips are used to change the behavior of the equipment, Murphy can provide future
enhancements and support changes to process requirement for customers using a simple
email.
Section 50 00-02-0590
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6.2.1 Boot Loader
It is necessary for the Centurion controller to enter boot loader mode in order to receive
downloads for a firmware update, and configurations from MConfigPro. During boot loader
mode the Centurion is able to receive configuration updates from the MConfigPro software and
transmit configuration updates to display through pass-through.
Communications will operate according to default state parameters for configuration transfers.
During boot loader mode, the transfer rate is 9600, N, 8, 1 and assumes a serial
communication port setting of RS485 or a USB connection.
The controller recognizes whether the incoming data is for a configuration, or firmware update.
In order for the Centurion configurable controller to enter boot loader mode, the address
jumpers are removed during power up (power cycled). The display and third party HMI devices
will not receive a response to polls on port 1 while the boot loader is active.
Power on the Centurion must be cycled with the jumper installed to resume normal operation,
or run mode. See section “Port 2 (Serial)” in the Controller Communication Ports chapter for
more details on address jumpers.
6.2.2 Pass-through
During boot loader, the Centurion controller allows users to remain connected to both the PC
and the display and update the two devices with a single connection.
The Centurion controller accepts the message through one port (port 2) and passes it through
another port (port 1) directly to the display, as if the pc and display were directly connected.
Section 50 00-02-0590
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6.2.3 Downloading Configurations to the Display
All configuration downloads will use a baud
rate of 9600. The com 1 selection will use the
hardware setup of the current configuration.
The com 2 selection is a fixed hardware
setup for RS485. Selecting USB for
configuration download connects the USB
adapter to com 2 internally.
All normal communication with the controller

is stopped while in download mode.
The display will indicate the transfer is

complete by displaying 100%.
Special 35 Jump Code
In the case that no configuration has been

downloaded, or a password has been lost,
the display allows a “Download Only”
password that will allow access to the
download menu.
The password is set to a fixed value of 35.
6.2.4 Downloading Configurations via MConfigPro Software

The Centurion controller allows the user to easily download a configuration through the
MConfigPro software.
1. Connect your PC to the controller using either the RS485 or USB connection on Port 2.
For USB, a PC device driver must be installed. Upon initial connection to the WellPro, a
new Com Port will be activated on the PC device manager. Take note of the new Com
Port assignment to be used for all future communications with the WellPro.
2. Remove address jumpers from the controller located near the USB connector and cycle
power to the controller. Take note of the original location of the jumpers to re-install
them correctly after download.
3. Click on the Transfer menu, and then choose Configurations.
4. Select the configuration file supplied by FW Murphy from dialog and click Open. You
may need to change the selection for Files of Type to find the file type you wish to
download. In most cases, this will be *.MCP, however, other file types are available for
specific configuration types.
Section 50 00-02-0590
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5. After selecting the configuration file, the next dialog will provide a choice for the target
device and PC Com Port to transfer the data. Choose the appropriate Com Port and
controller as the target device and click next.
6. Click Begin Transfer from the dialog box that appears and the transfer will begin. When
the Status message displays Transmitting 148 lines, the connection has been establish
and should be providing a progress bar.
7. While the transfer is in progress, the display can be setup to accept the new
configuration.
8. From the display keypad, press SETUP and enter password 00035 and press ENTER..
9. The display will show the CONFIGURATION DOWNLOAD screen. Make sure the
cursor is positioned on the line COM 1 CONFIG DOWNLOAD and press ENTER.
10. Change the NO to YES in the edit line at the bottom of the screen using the UP
ARROW key and press ENTER. The display is now ready to accept a download..
11. At this step, wait for the controller download to complete and click close on the
MTransfer dialog.
12. Repeat steps 3 - 6 choosing the display as the target device in Step 5.
13. Click Begin Transfer from the dialog box that appears and the transfer will begin. When
the Status message displays Transmitting 655 lines, the connection has been establish
and should be providing a progress bar.
14. Once the transfer is complete click Close on the dialog and replace the address jumpers
on the controller.
15. Cycle power on the controller and display and the new configuration will be loaded and
running.
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6.2.5 Downloading Firmware Updates to the Display
Firmware updates for the display require a
USB connection. While boot loader mode for
the display is not required for configuration
downloads, it is required for firmware
updates.
The boot loader can be entered by menu

selection if the USB cable is currently
connected, otherwise the display will reset
and restart the current application firmware.
Optionally, the boot loader can be entered by
connecting the USB cable and cycling power.
(This method will leave the display blank
while in the boot loader.)
Upon entry to the boot loader, all

communication from the display to the
controller will stop. There is a red status LED
below the USB connector that will blink three
times and then remain on while the boot
loader is active.
While a file is being transferred, the com 2

transmit LED will be lit continuously. A
successful download should complete in
approximately five minutes.
Special 35 Jump Code
The Centurion display allows a “Download

Only” password that will allow access to the
download menu. The password is set to a
fixed value of 35. Once at the “Download
Only” screen on the display, the user will
select to download a firmware update.
Super User Menu
The super user menu is used to download
firmware updates.
All normal communication with the controller

is stopped while in download mode.
The display will indicate the transfer is

complete by displaying 100%.
Section 50 00-02-0590
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6.2.6 Error Messages
On occasion an invalid configuration error might display because the configuration between
the Centurion controller and its devices are out of synch -- the checksums do not match. The
invalid configuration screen will appear briefly after downloading configurations until
comparisons are made.
The user may direct the error message to be ignored through a setting at the super user menu.
At “CONFIG FAIL DISABLE”, the user would select Yes to ignore the data mismatch.
This setting is temporary. Once power is cycled-on, the error message will continue until
comparisons between the devices yield no configuration mismatch.
Two options are available for synchronizing data when fine-tuning changes are made in the
field. They are:
• A super user could choose to also download the configuration from the super user
menu on display.
• A user without access to the super user menu could activate the download
through the special jump code 35.
This screen indicates that the controller is not

responding to poll requests. There are only
two ways to exit this screen, either by normal
responses resuming or if the SETUP/ENTER
key is pressed.
Section 50 00-02-0590
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This screen will be displayed when a
configuration fault is detected.
Possible sources of the fault include a corrupt

or missing configuration in the display, a
corrupt or missing configuration in the
controller or a mismatch of configurations in
the display and controller.
This screen will appear briefly after

configuration downloads and may appear
briefly after initial communication is
established until comparisons are complete.
The fault can be resolved by downloading the

proper configuration to one or both devices
NOTE: This error message does not always

indicate a problem, but may only signify that
initial comparisons between devices do not
match.
6.3 Modbus™ RTU Protocol

The Centurion configurable controller was programmed with the Modbus protocol which is a
system based on a “master” and “slave” relationship. With Modbus protocol, the master and
slave are able to continue to communicate with each other through defined messages over a
variety of network types. The master initiates the queries or commands, and the slave
responds to the query with a message or takes action based on the query.
In this case, the master is either MConfigPro (or another Modbus client software), or display,
but never both simultaneously as there can only ever be a single Modbus master.
The Centurion system communicates through Modbus using remote terminal unit (RTU)
transmission mode to maximize data processing.
As with all numeric data defined within Modbus, the programming is limited to accepting
integers (whole numbers only, no decimals). This is important whenever a decimal point is
defined for analog inputs.
For example, for the controller to properly read “100.0” with an implied decimal point of 1, the
user would need to enter “1000” and 1000 would be stored in the appropriate Modbus register.
From the display, the value will be represented with a decimal in the fixed position.
For additional information, please refer to the “MConfigPro Configuration Software Installation
and Operations Manual”.
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6.4 Transferring Data in Modbus
Note that text visible in the MConfigPro software and on the display is not stored in the
Centurion controller. Except for the version description in the version and security dialog for
each configuration file, descriptions assigned in the configuration are not stored in the
Centurion controller. Descriptions for various I/O and processes are downloaded to the display
and reside as a configuration in that device only. Configurations of the display are one way
only.
Parameter changes made in the display are actually communicated to the Centurion controller
where the logic resides. No changes made through the display affect the display configuration
as the display merely reads from, and writes to the Centurion main I/O module. As such, the
display can write numeric parameters to the controller.
6.5 Modbus Register Address Listings

For a complete Modbus address map, please refer to the Centurion Modbus reference
document.
7 Replacement Parts and Assemblies

C3-1 Plug Kit (00000504) Printed replacement terminal plugs for Centurion Main I/O
module
C3-2 Plug Kit (00000505) Printed replacement terminal plugs for Centurion Expansion I/O
module
C3-3 Plug Kit (00000543) Printed replacement terminal plugs for Centurion display
module
Choke (50000774) Ignition noise (choke) filter
8 Accessories
8.1 Configuration Software
8.1.1 MConfigPro
MConfigPro is the configuration software for modifying sequence of operation, set points,
timers, faults, and displays* for Centurion. Includes file transfer utilities for configuration and
firmware upgrades.
CD, MConfigPro (50-70-0989) MConfigPro configuration software.
*Display configuration and other settings for display are only for use with the display Module.
Section 50 00-02-0590
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9 Glossary
Analog Input Terminals 18 to 29 are analog inputs on the Centurion Main I/O
module. Accepts voltage signals within the range of (0 to 5) VDC or (4
to 20) mA and are compared to controller set points and/or displayed.
Boot Loader Means by which the Centurion controller communicates with display
and MConfigPro to receive and transfer new or updated configurations
and firmware; and ensure data and configuration synchronization.
Controller Setpoints User defines normal operating range for the controller to optimize the
equipment. Setpoints can also define some other threshold, exception
or event that may require action. Multiple setpoints are often applied
to a process and they may be manipulated as needed to meet
changing conditions.
DeadBand The user set range at which input may fluctuate without the controller
taking any action. The range may be fixed or variable.
Digital Input Terminals 30 to 61 are the digital input channels. User selects whether
digital input is normally open (N/O), or normally closed (N/C). Users
may also associate these inputs with transition times for indicating no-
flow conditions on divider blocks.
Event Defines the action required by the controller in response to any

number of parameters. Event actions range from simple alarm
message to emergency shutdown (ESD).
No-flow Designed to protect against compressor or engine failures, the

controller monitors the cycle time of lubrication system cycles and if
that cycle time falls under a user assigned value, the controller will
activate a defined associated action such as an alarm or shutdown.
Offset User defined value to correct for known variance in the raw data.
Panel Ready In states, the first logical step in start up.
Permissive A process condition, (digital input or analog setpoint), that must be met
in order for the sequence to proceed to the next state.
Signal An electrical quantity of voltage or current that is used to represent or

signify some other physical quantity such as the state of a switch
(ON/OFF) or the status of a device (SHUTDOWN/OK)
Span The difference between the full scale output and the offset as raw data.
Start Delay A time delay function to prevent premature start up.
Section 50 00-02-0590
10-10-06 - 64 -
State Predefined step of multiple logical steps (or states) needed to
successfully start and operate a compressor.
Terminal Emulator Allows a user to modify the firmware to allow upload or download of a
record to either the display or the controller. Always download a
configuration after a firmware change.
Thermocouple A device for measuring temperature consisting of two dissimilar metals

of high purity for an accurate temperature/voltage relationship. User
defines whether the calibration is J or K. Terminals 1 to 17 are for
thermocouple inputs.
Type J uses Red (-) and White (+) insulation.

Type K uses Red (-) and Yellow (+) insulation.
Section 50 00-02-0590
10-10-06 - 65 -
10 Appendices
10.1 Back Panel LED Description
There are a total of seven (7) LED indicators on the back panel, labeled as follows:
10.1.1 (Port 1)
TX – Turned on while port 1 is transmitting data.
RX – Turned on while port 1 is receiving data.
10.1.2 (Port 2)
TX – Turned on while port 2 is transmitting data.
RX – Turned on while port 2 is receiving data.
10.1.3 USB LINK

Turns on while there is a USB connection to a computer.
10.1.4 STAT 1
Turns on for one half second and then turns off for one half second, repeating as long as there
is a valid configuration running.
NOTE: This indicator is not active while the boot loader is running.
10.1.5 STAT 2
This LED is only active while the boot loader is running. It flashes briefly three times when the
boot loader starts up and then stays on until leaving the boot loader.
10.2 Controller Accuracies, and Tolerances

Refer to the Centurion Configurable Controller Specification Sheet for a detailed breakdown of
specifications.
Section 50 00-02-0590
10-10-06 - 66 -
10.3 Restrictions on Numeric Values in Gage and PID Monitor Screens
Due to a combination of the limited space and the spirit of the design objectives, there are
certain restrictions imposed upon the formatted size of numbers in display screens.
• Positive numbers with no decimals can be displayed with up to four digits.

• Negative numbers are limited to three digits.
• Numbers of either sign with a decimal place are limited to three digits.
• Numbers with more than two decimal places will not be displayed at all, but will be
replaced with dashes.
If a number with decimals is larger than the imposed limits, the display algorithm will attempt to
adjust the precision so as to display as many of the most significant digits as possible.
10.4 Set Up Sheet

Refer to The Centurion Configuration Worksheet for a detailed workbook to document field
changes to configuration parameters.
Section 50 00-02-0590
10-10-06 - 67 -
Section 50 00-02-0590
10-10-06 - 68 -
MURPHY, the Murphy logo, Centurion™ and MConfigPro™ are registered and/or common law trademarks of
Murphy Industries, Inc. This document, including textual matter and illustrations, is copyright protected by Murphy
Industries, Inc., with all rights reserved. (c) 2006 Murphy Industries, Inc. Other third party product or trade names
referenced herein are the property of their respective owners and are used for identification purposes only.
Section 50 00-02-0590
10-10-06 - 69 -
CENTURION DISPLAY SCREEN MAP NAVIGATION
Use left and right arrow keys to move between top level screens.
OPERATIONAL
SCREENS
VERSION DIGITAL SHUTDOWN SHUTDOWN EVENT ACTIVE CUSTOM CUSTOM CUSTOM CUSTOM
LOGO
INFORMATION STATUS HISTORY SNAPSHOT HISTORY ALARMS 1 2 ... 5
CUSTOM SCREENS
Up to 5 custom screens can be configured using MConfig Pro.
Screens can be arranged in any order. However, all custom screens will appear after the ACTIVE ALARMS screen.
PASSWORD ENTRY
0 (zero) = Read ONLY access to the Setup Screens.
35 = Download ONLY FN HELP
PASSWORD
MENU SCREEN
Passwords for “Standard” and “Super User” are configured using
MConfig Pro. Refer to 00-02-0590 pg. 25 for additional
information on password functionality. NAVIGATION
SCREENS
SETPOINTS
SETUP
1-16 PULSE
GENERAL STATE MAINTENANCE INITIAL CONTROL DIGITAL DIGITAL
17-32 PID MISCELLANEOUS INPUT
TIMERS TIMERS TIMERS RPM OUTPUTS INPUTS OUTPUTS
33-48 STATUS
…...
SETPOINT MAINTENANCE CONTROL DIGITAL

PID #
###-### TIMER # OUTPUT # INPUT #
SUBMENU
SUBMENU SUBMENU SUBMENU SUBMENU
NAVIGATION
SCREENS
continued...
SETUP
SUPER DISPLAY DIGITAL ANALOG ANALOG PID

ANALOG ANALOG THERMOCOUPLE COMMUNICATION
THERMOCOUPLES USER BOARD OUTPUT INPUT OUTPUT DIAGNOSTICS
INPUTS OUTPUTS STATUS STATUS
MENU STATUS STATUS STATUS STATUS
ANALOG ANALOG THERMOCOUPLE

PID #
INPUT # OUTPUT # #
OPTIONS
SUBMENU SUBMENU SUBMENU
NAVIGATION
HOME
Up to 5 custom screens can be configured using MConfig Pro.
One custom screen is configured as the default or “HOME”

screen. While viewing the OPERATIONAL SCREENS, pressing
the HOME key will jump from the currently displayed screen to the
configured default screen.
NAVIGATION This function is not available in SETUP SCREENS. However,

Look for cues on screens to indicate pressing this key on any multi-line display when the first line is not
what navigation is possible. being displayed will jump to the top or “HOME” line on that
screen.
00-02-0161
Installation for 4-1/2 in. (114 mm) dial Revised 03-06

Section 05
Pressure Murphygage® and Swichgage® instruments

Model Series: OPLC, OPLG, OPLBP, 45APE, 45APEBP, PT167EX and 45 Series
Options: -OS, -ES, -P4 and -P6
Please read the following instructions before installing. A visual inspection is recommended before mounting. General Information
and these installation instructions are intended for all 4-1/2 in. (114 mm) dial pressure models.
GENERAL INFORMATION
Sensing Element: Bronze or 316 stainless steel bourdon tube.

Gage Accuracy:
WARNING All models and 45APE/45APEF between switch points:

±2% for first and last quarters of scale; middle half of scale is ±1%.
Model 45APE/45APEF
Indicating Pointer above or below set point:
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT Range Accuracy (±% F.S.) above and below s.p. only
<100 (except 15 psi) 10
✔ Disconnect all electrical power to the machine. 15 15
✔ Make sure the machine cannot operate during installation. 100-300 4
✔ Follow all safety warnings of the machine manufacturer. 400-1500 2
2000 12
3000-5000 8
Based on testing performed with switch point at mid scale which represents worst case.
OPLC and OPLFC Swichgage instruments have high and low limit HIGH SET POINT LOW SET POINT
POINTER LOCATION
POINTER LOCATION
contacts to monitor, alarm or shut down. The OPLC has a flanged case. A method
to override the low limit contact for start-up is provided on most models. See 50
50 40 60
Operation Test section–page 3. 40 60
INCREASING ERROR
OPLFC can be direct or panel mounted (see page 2). 300 400 FOR INDICATING 30 300 400 70
30 70 INCREASING ERROR POINTER
200 FOR INDICATING 200 500
OPLG and OPLFG Murphygage indication-only pressure instrument are 500 POINTER
PRESSURE
PRESSURE
20 80 20 80
similar to OPLC and OPLFC models, without switch (limit) contacts. 100 100
600 600
45 Series includes a magnetic switch to stop an engine or electric motor 10 90 10 90
0 0
each time the gage contact operates. A lockout push button overrides low kPa kPa
0 PSI 100 0 PSI 100
contact for startup. Other variations available.
MAXIMUM ERROR
MAXIMUM ERROR
45APE and 45APEF Series are versions of the OPLC Series
featuring 2 snap-acting SPDT switches instead of the pointer type contacts. Switch Point Accuracy: ±1.5% (45APE/45APEF).
These units do not include low contact lockout.
Switch Reset Deadband: Approximately 10% FS (45APE/45APEF).
OPLBP and 45APEBP are versions of the OPLC and 45APE Snap-Acting Switches: See wiring information (page 4) (45APE/45APEF).
featuring pilot duty limit switches connected to an internal latching control Overrange: Do not exceed 10% FS above full range.
relay for “on/off” control directly or through a motor starter.
Pressure Relief Disc: Back of case (except EX models).
PT167EX The Murphy PT167EX is a pressure Swichgage instrument Dry Relay Contact (“BP” Models): 10 A @ 28 VDC or 10 A @ 120 VAC.
connected to a threaded pressure diaphragm housing. The Swichgage instrument is Wire Connections (Surface Mount): 1/2 NPTF conduit/ terminal block.
enclosed in an explosion-proof case and is CSA rated for Class I, Division 1, Wire Connections (Panel Mount): Wire leads, 18 AWG (1.0 mm2) x 9 in. (229 mm) long.
Groups C and D.
Wire Connections (-ES, -OS): 1/2 NPTM conduit and wire leads,
Specifications All except 45APEF:
18 AWG (1.0 mm2) x 33 in. (838 mm) long.
Dial: White on black, dual scale, psi/kPa standard, 4-1/2 in. (114 mm) diameter. 45APEF
Case: Die cast aluminum, surface or panel mount. 24 AWG (0.22 mm2) x 33 in. (838 mm) long.
Process Connection: 1/4 NPTM thru 1000 psi; 1/2 NPTM 1500 - 10,000 psi. Item Weight: 5 lbs 6 oz (2.4 kg) approximately.
Explosion-proof models: 21 lb. (9.5 kg) approx.
Precautions: Do NOT exceed rated pressure range. Item Dimensions: 10 x 9 x 6 in. (254 x 229 x 152 mm) approximately.
Dope or use teflon tape on connection threads. Do not block Explosion-proof models: 12 x 12 x 9 in. (305 x 305 x 229 mm) approximately.
the inlet orifice. For direct mount into the process, a vertical
or ninety degree mounting is recommended.
Use wrench on shank to tighten or loosen connection. Do not twist
Warranty
case when installing, this will damage internal components and will A limited warranty on materials and workmanship is given with this
void the warranty. Do not overtighten. FW Murphy product. A copy of the warranty may be viewed or printed by
Use shock mounts as necessary to prevent excessive vibration. going to www.fwmurphy.com/support/warranty.htm.
If liquid in the system freezes, it will expand and will damage the tube. *Selected configurations are third party listed. Consult factory for details.
For 45APE Series – Low setpoint should be limited to the lower 1/2
scale and upper setpoint should be limited to the upper 1/2 scale.

OPL Series Wall Mount 45APE Series Wall Mount
Flanged case design intended for wall mount, it can also be
direct mounted. Shown with shock mounts and pulsation dampener. 8-7/16 in. 3-3/8 in.
(214 mm) (86 mm)
8-7/16 in (214 mm) 3-3/8 in.
4-1/32 in.
(102 mm)
(86 mm) 3-15/16 in.
(100 mm) 1/2NPTF
conduit
3-15/16 in.
(102 mm)
4-1/32 in.
(100 mm) 1/2 NPTF

Conduit
7-7/8 in.
(200 mm) 9/32 in.
(7 mm) dia.
3 places
1/4 NPTM or 1/2 NPTM
Pressure Connection
7-7/8 in.
(200 mm) 1/4 or 1/2 NPTF 45APE Series Flush Mount
9/32 in.
(7 mm) dia. 5-7/16 in. 2-57/64 in.
3 places DETAIL (138 mm) (73 mm)
FLOW
shock mount
gauge panel
6-3/4 in.
(171 mm)
pulsation -OS and ES
dampener 120 120
models only
1/4-20 nut & lockwasher
(2 each required)
1/4 in. (6 mm) dia.

OPL Series Flush Mount holes (3 places) on
5-1/4 in. (133 mm)
Round case design to be mounted in a panel from 1/32 in. (1 mm) to 1/8 in. B.C. 120° apart, 1/4 NPTM or 1/2 NPTM Optional (-BC) 1/2NPTM
(3 mm) thick. It can also be direct mounted. Shown with pulsation dampener. clocking as shown. Pressure Connection Pressure Connection
2-57/64 in. Options “OS” and “ES” (flush mount case)

5-7/16 in. (138 mm)
(73 mm) 5-7/16 in. 2-57/64 in.
(138 mm) (73 mm)
Mounting
6-3/4 in. Hole
(171 mm) 4-3/4 in.
(121 mm)
diameter
-OS and -ES 6-3/4 in.
120 120 (171 mm)
models only
120 120
1/2 in.
(13 mm)
conduit
1/4 in. (6 mm) dia.

120 Optional back
1/4 in. (6 mm) dia. holes (3 places) on connection
2-23/32 in.
Holes (3-places) on 5-1/4 in. (133 mm) (69 mm)
1/4 or 1/2 NPTM 5-1/4 in. (133 mm) Optional (-BC) 1/2 NPTM B.C. 120° apart,
Pressure Connection B.C. 120° apart, Pressure connection clocking as shown.
clockingas shown
Explosion-proof Case Mount Explosion-proof case can be mounted from face or rear.
8 in. 6-25/64 in. Flush mount/Wall mount*
(203 mm) (162 mm) 6-3/4 in.
(171 mm)
3-3/8 in.
(86 mm)
1/2 in. 7-35/64 in.
(13 mm) (192 mm)
optional diameter
rear or side
conduit 3-3/8 in.
(86 mm)
8 in.
(203 mm) *Mounting hole
not required for
Wall mount
13/32 in. 6-3/4 in.

(10 mm) (171 mm)
diameter
3/8-16 UNC-2B 4 places
thread
7/8 in. (22 mm)
deep, 8 plc's

OPTIONS
-OS and -ES (oil sealed and environment sealed case) for corrosive CAUTION: Do Not unscrew the green diaphragm Transmitting
environment, feature a panel mount case or screw directly into the process. capsule. Tube
See Case Mounting (p-2). Swichgage instrument
2. Tighten the bottom housing to the pressure source.
Housing
3. Tighten the eight housing bolts to 25±3 foot lbs. Bolts
-P6 Sealed mechanism with a typical application for by staggering the tightening for even clamping.
oil well lead lines. Its 2 NPT housing and diaphragm seal
4. Route capillary away from heat source such as
filled with silicon fluid attaches directly into a 2 NPT tee See Diaphragm
Note 1 exhaust manifold. Excess capillary should be
on the lead line. Tighten only the 2-5/8 in. (67 mm) hex Housing
carefully coiled and secured to avoid damage.
fitting.
CAUTION: Do not tamper with or break sealed CAUTION: Do Not cut capillary or make sharp bends.
2 NPT
connections.
-P4L is a remote seal mechanism with stainless steel armored capillary to

protect the gage from highly viscous and/or corrosive fluids.
1. Loosen the eight housing bolts until the bottom
housing is free to turn.
ADJUSTMENTS
OPL/45 Series Limit Contact Adjustments 45APE Series Pointer Adjustments

Facing the dial, left side knob is the “Low limit” contact and the “High To reset to zero or to a known value proceed as follows:
limit” contact is located to the right. To set the limit contacts simply turn the 1. Turn off electrical power. Remove the snap
fingertip type knob to the desired point on the scale. ring and very carefully remove the lens and DETAIL “B”
contact assembly (or open hinged cover).
45APE Series Trip Point Adjustments
The 45APE Series features a stacked limit indicator adjustments knob. The 2. Hold the the Switch Operator and the Turn CW to Turn CCW
bottom half knob adjusts the “Low” limit indicator, the top half is to adjust pointer hub with thumb and Raise Pointer to Lower
Pointer
the “High” limit indicator. To set the limit contacts simply turn the forefinger, then turn the Pointer
fingertip type knob to the desired point on the scale. Adjustment screw to the desired
point. See DETAIL “B”. Pointer
OPL and 45 Series Adjustment
Indicating Pointer Adjustments 3. If the Switch Operator needs adjustment,
To reset to zero or to a known value do as follows: hold the Switch Operator and the pointer
1. Turn off electrical power. Remove the snap DETAIL “A” hub with thumb and forefingers as show on
ring and very carefully remove the lens and Turn to lower DETAIL “C”, and turn the adjustment screw
pointer
contact assembly (or open hinged cover). until the Switch Operator aligns with the DETAIL “C”
2. Hold the pointer hub with thumb and indicating pointer.
forefinger then turn screw to desired 4. Replace the lens and contact assembly Turn CW to Lower Turn CCW
point. See DETAIL “A”. and the snap ring (or close hinged Switch Operator to Raise
Switch Operator
3. Replace lens and contact assembly and Turn to raise cover). Turn the power back on. Switch
Operator Adjustment
snap ring (or close hinged cover), and turn pointer
on the power.
OPERATION TEST INSTRUCTIONS
OPLC, OPLFC and OPLBP 45 Series

1. Perform operation test after the unit is installed and wired appropriately. 1. Repeat steps 1 and 2. (See OPLC operation test instructions.)
(See the typical wiring diagram, on page 4.) 2. Press the semi-automatic pushbutton located on the low contact knob.
2. When pressure is applied to the instrument, the pointer will travel in a 3. Reset the magnetic switch pushbutton.
clockwise direction. Adjust the limit contacts to the desired settings. 4. After the indication pointer rises above the low limit contact, the lockout -
3. To start, place the toggle switch in the “start”position or otherwise pushbutton automatically disengages and the low limit is armed.
override low contact. 5. Repeat steps 5 and 6. (See OPLC operation test instructions.)
4. After the indication pointer rises above the low limit contact, return the 45APE, 45APEF and 45APEBP
toggle switch or override device to the “run”position. 1. Repeat steps 1 and 2. (See OPLC operation test instructions.)
5. To test the limit contacts, turn the limit contact to be tested until it touches 2. To test the switches, turn the trip point indicator until it is aligned with the
the pointer. That will trip the control circuit. Swichgage pointer. This is the approximate trip point.
6. Reset the shutdown or alarm circuit device and repeat above sequence for each Continue to rotate until the snap switch operates.
contact/trip point. 3. Reset the shutdown or alarm circuit device.

TYPICAL ELECTRICAL DIAGRAMS
WARNING: PERFORM THE WIRING OPERATION WITH THE POWER SOURCE “OFF”. MAKE SURE THE VOLTAGE AND CURRENT
REQUIREMENTS ARE WITHIN THE SWICHGAGE RATINGS. BEFORE WIRING DETERMINE VOLTAGE AND POLARITY FOR THE
APPLICATION. USE THE APPROPRIATE WIRE SIZE. ALL CONNECTIONS SHOULD BE MADE USING A SPADE (FORKED) OR RING
TERMINALS. FOR PIGTAIL CONNECTIONS USE WIRE NUTS. CONDUIT IS RECOMMENDED TO PROTECT WIRES FROM DAMAGE.
OPLC and OPLFC OPLBP

Contact Rating: 1 SPDT, Center Off; 2 A, 30 VDC, 1 A, 125 VAC pilot duty. Contact Rating: SPDT dry relay contacts; 10 A, 125 VAC. NOTE: Diagram
OPLC OPLFC below shows the Swichgage pointer in the at rest (shelf) position.
YELLOW
BLUE
3 RESET
COMMON 4 1
7
= 18 GA.
9
BROWN
5 SET
6
= 16 GA.
Red White Black Red White Black
8
NOTE: Diagrams above show the Swichgage pointer in the at rest (shelf) WHITE
position. (-) NEUTRAL 1
B
A
45APE and 45APEF 120 VAC
ORANGE
12 VDC RED
24 VDC
Contact Rating: 2-SPDT snap-switches (one for high and low pressure),
2 A inductive, 250 VAC each switch. NOTE: Diagram below shows the LOW
Swichgage pointer in the at rest (shelf) position. Low setpoint should be (RESET)
HIGH
6
limited to the lower 1/2 scale and upper setpoint should be limited to the (+) LINE 2
BLACK
(SET)
upper 1/2 scale.
45APEBP
Contact Rating: SPDT dry relay contacts; 10 A, 125 VAC. NOTE: Diagram below
shows the Swichgage pointer in the at rest (shelf) position.
LOW SWITCH HIGH SWITCH
N.C.–Orange N.C.–Black YELLOW
3 6 BLUE
3 RESET
N.O.–Blue N.O.–Brown
COMMON 4 1
7
2 5
4
Common–Red Common–Yellow
1 4
3
= 20 GA.
= 18 GA.
9
BROWN
5 SET
6
45 Series with MS2100 = 16 GA.
Models available for Battery ignition, CD ignition, Magneto or 110VAC WHITE
8
ORANGE
systems. Contact Rating: 12/32 VDC coil, 10 A, 32 VDC battery ignition (-) NEUTRAL 1 6
A B
contacts; Magneto ignition coil, MS2100
BROWN
10 A magneto ignitions contacts;
BLUE
12 VDC 120 VAC

CD ignition coil, 10 A CD 24 VDC
ignition contacts; 120 VAC coil, LOW

(RESET)
10 A, 120 VAC contacts. RED
6 1 2 3 4 5 HIGH
NOTE: The diagram at right shows YELLOW (SET)
the Swichgage pointer in the (+) LINE 2
operating position.
G 1 2 3
Typical Circuit Transformer Relay Assemblies
To CD Ignition
or Magneto. For higher voltages, Murphy TR Assemblies can be used in conjunction
with any Swichgage instrument.
MURPHY, the Murphy logo, Murphygage® and Swichgage® are registered and/or common law trademarks of Murphy
Industries, Inc. This document, including textual matter and illustrations, is copyright protected by Murphy
www.fwmurphy.com Industries, Inc., with all rights reserved. (c) 2006 Murphy Industries, Inc. Other third party product or trade names
918.317.4100 Email: sales@fwmurphy.com referenced herein are the property of their respective owners and are used for identification purposes only.

PD-95145B
Revised 11-03
Pulsation Dampener Catalog Section 55

(00-02-0125)
PD8100 Series
■ Used On Controllers, Instruments and
Recorders to Dampen Pressure Pulsation
■ Eliminate Gage Pointer Flutter
■ Aids In Providing More Accurate
Pressure Indication
■ Decreases Wear On Gage’s
Geared Movement
NOT INTENDED FOR USE AS A SHUTOFF VALVE
Description Specifications Eliminate pointer flutter

The PD8100 Series eliminates pointer flutter See “How to Order” section for available inlet like this.
on pressure indicating SWICHGAGE® devices and outlet connections.
which are subject to pulsating pressure from PD8183: All wetted parts are Brass. Rated to MURPHY SWICHGAGE
RUN
reciprocating pumps or compressors. It also 3,000 psi (20.68 MPa) [206.80 bar].
allows a close setting of high and low contact
START
PD8184: All wetted parts are Carbon steel.

points providing for more accurate pressure Rated to 5,000 psi (34.47 MPa) [344.70
indication and control of equipment. bar]. MURPHY SW
The PD8100 Series decreases wear on geared PD8185: All wetted parts are 303 stainless
movements and increases the life of pressure steel. Rated to 10,000 psi (68.95 MPa)
indicating instruments by eliminating exces- [689.50 bar].
sive gage strain and unnecessary movement. PD8190: All wetted parts are 316 stainless
steel. Rated to 10,000 psi (68.95 MPa)
A necessity which quickly pays for itself by
[689.50 bar]. Meets NACE standard MR-
protecting any pressure indicating and control 01-75 for direct exposure to H2S.
instrument which is subject to pulsation.
Operating Temperature: MURPHY SWICHGAGE
PD8100 SERIES NOT FOR USE ON Make SWICHGAGE instruments
®
-15 to 400°F (-26 to 204°C)

OXYGEN OR LIQUID and recorders operate like this.
Shipping Weight (all models):
OXYGEN APPLICATIONS.
2 lbs.(0.9 kgs.)
Quality built with a large diameter valve stem MURPHY SWICHGAGE
Shipping Dimensions (all models):
wheel for ease of adjustment with clearly printed RUN
4-3/4 x 4-3/4 x 3-1/4 in. (121 x 121 x 83 mm)

operating instructions. Machined from 1-3/8 in. START
(35 mm) hex bar stock. A two degree taper on Warranty

valve and stem assure positive dampening. A limited warranty on materials and workmanship
Available in brass, carbon steel, 303 stainless is given with this FW Murphy product. A copy of
steel or 316 stainless steel to meet pressure the warranty may be viewed or printed by going to
www.fwmurphy.com/support/warranty.htm
and environmental requirements with either
1/2 NPT or 1/4 NPT inlet connections.
Service Parts
DESCRIPTION (see drawing–right) PD8183 PD8184 PD8185 PD8190
A. 1/2 NPT inlet x 1/4 NPT outlet* 65-05-0104 65-05-0210 65-05-0204 65-05-1136
1/2 NPT inlet x 1/2 NPT outlet* 65-05-0105 65-05-0212 65-05-0206 65-05-1135
B. Bonnet Fitting 65-05-0099 65-05-0209 65-05-0203 65-05-1139 C E
C. Valve Stem 65-05-0175 65-05-0208 65-05-0202 65-05-1140 D G
D. Packing Nut 65-05-0098 65-05-0211 65-05-0205 65-05-1137
E. Hand Wheel (with 10-32 nut) 55-00-0179 55-00-0179 55-00-0179 55-00-0179 B
A
F. Strainer Bushing Assembly † 55-00-0174 55-00-0173 55-00-0175 55-00-0206 H
INLET OUTLET
G. Molded Packing Gland 00-00-0936 00-00-0936 00-00-0936 00-00-0936
H. ‘O’ Ring Bonnet Seal 00-00-0302 00-00-0302 00-00-0302 00-00-0302
J. Stainless Steel Mesh Filter ** 65-05-0214 65-05-0214 65-05-0214 65-05-0214
†Provided only for units with 1/4 NPT inlet.
*For 1/4 NPT inlet use with strainer bushing assembly.

**Provided in units with 1/2 NPT inlet. F J
Dimensions How to Order

PD8185 - 1/4 x 1/4
Base Model
PD8183
3-7/8 in. PD8184
(99 mm) PD8185
PD8190
FLOW
Connection Size
1/4 x 1/4 = 1/4 NPT inlet x 1/4 NPT outlet
3 in. 1/4 x 1/2 = 1/4 NPT inlet x 1/2 NPT outlet
(76 mm) 1/2 x 1/2 = 1/2 NPT inlet x 1/2 NPT outlet
1/2 x 1/4 = 1/2 NPT inlet x 1/4 NPT outlet
Mounting for the OPLFC Pressure SWICHGAGE® and PD8100 Series
The PD8100 Series pulsation dampener is mounted directly below the OPLFC.
Precautions: Dope or use teflon tape on con-

nection threads. Do not block the inlet orifice.
4-3/4 in.
(121 mm) Shown at right, is a typical
OPLFC diameter
Mounting
Hole MURPHYMATIC® compres-
sor panel featuring three
Pulsation Dampeners and
1/4 in. (6 mm) dia. Murphy’s OPLFC gages.
holes (3 pls.) on
5-13/64 in. (132 mm)
B.C.,120° apart, 5-5/16 in. The PD's are recommended
clocking as shown (135 mm)
1/2 in.
for use on piston pumps and
radius compressors to eliminate
typical
PD8100 2 in. pointer contact flutter
Series
Mounting (51 mm) and gage wear.
Hole
1 in.
(25 mm)
P.O. Box 1819; Rosenberg, Texas 77471; USA Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. 1620 Hume Highway
+1 281 633 4500 fax +1 281 633 4588 +44 1722 410055 fax +44 1722 410088 Campbellfield, Vic 3061; Australia
e-mail sales@fwmurphy.com e-mail sales@fwmurphy.co.uk +61 3 9358 5555 fax +61 3 9358 5558
FW Murphy
MURPHY DE MEXICO, S.A. DE C.V. www.fwmurphy.co.uk e-mail murphy@macquarrie.com.au
P.O. Box 470248
Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje MURPHY SWITCH OF CALIFORNIA
Tulsa, Oklahoma 74147 USA
San Luis Potosí, S.L.P.; México 78384 41343 12th Street West
+1 918 317 4100 +52 444 8206264 fax +52 444 8206336 Palmdale, California 93551-1442; USA
D
RE
fax +1 918 317 4266 GI

E
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Printed in U.S.A.
PD-95145B page 2 of 2
Installation Instructions for Pressure and Vacuum 00-02-0162
Revised 02-06
Section 05
2 and 2-1/2 in. (51 and 64 mm) Dial Murphygage®
and Swichgage® Instruments. 20, 25, A20, A25 Series
Please read the following instructions before installing. A visual inspection of this product for damage during shipping is recommended.
GENERAL INFORMATION
Typical Mounting Dimensions

20 Series shown
WARNING Low Pressure

Port (DP Series)
A Mounting Hole
B D
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT 1/8-27 NPTM Mounting
✔ Disconnect all electrical power to the machine. Pressure Port
Clamp
✔ Read and follow all installation instructions. See Note
C
Description 20 Series A20 Series 25 Series A25 Series

The 2 and 2-1/2 in. (51 and 64 mm) dial size Murphygage and Swichgage instru- A 2-7/32 (56) 2-9/16 (65) 2-1/8 (54) 1-51/64 (46)
ments are diaphragm-actuated, pressure or vacuum gages with a 1/8-27 NPTM pres- B 2-15/64 (57) 2-1/4 (57) 3-1/8 (79) 2-29/32 (74)
sure port connection (2 pressure ports for differential pressure models).
Models with face-adjustable contact(s) are rated for 2 A @ 30 V (pilot duty). If the C 1-5/16 (33) 1-1/4 (32) 1-3/8 (35) 1-27/64 (36)
gage case is steel (20P, 25P, 20DP, 25DP etc.) the ground path for the contact circuit D 2-1/16 (53) 2-1/16 (53) 2-11/16 (68) 2-11/16 (68)
is through the case. Therefore, the case must be installed in the ground plane of the
electrical power supply. NOTES: 20/25 Series: 18 AWG pigtails. A20/A25 series: #4/#6
screws. The dimensions above are in inches and (millimeters).
If the case is polycarbonate (A20P, A20DP, A25P, A25DP etc.) the ground path
is isolated and is made through the “C” or “P” terminals on the back of the gage Panel Mounting
case (“C” for A20 models; “P” for A25 models). All models can be installed in a panel from 0.032 to 0.250 in. (1 to 6 mm) thick.
Models 20PE, 25PE, A20PE, A25PE etc. have a snap-acting switch instead of Remove the mounting bracket and insert the gage from the front side of the panel.
the face adjustable pointer type contact. Electrical rating is 3 A @ 30 VDC, 4 A Replace bracket and secure it. Do NOT overtighten. (See Figure 2).
@ 125 VAC. Reset differential for the switch is approximately 10% of the scale.
NOTE: Select a scale so your normal operating pressure is in the upper middle of the scale.
Connecting the Pressure Port
CAUTION: Certain dangers to human safety and to equipment may 1. Pressure tubing is generally not provided. Use of good quality flexible pressure
occur if some equipment is stopped without pre-warning. It is recom- tubing/hose and fittings is strongly suggested. Use at least 3/16 in. (5 mm) I.D.
mended that monitored functions be limited to alarm-only or to alarm tubing. If using copper or rigid tubing, install at least 12 in. (305 mm) flexible
before shutdown. hose from the gage to the rigid tubing. This prevents damaging vibration from
reaching the gage. For most models a pulsation orifice, within the pressure port,
Alarm Before Shutdown Models is provided and it is remov- Panel Mounting
The 20PABS, A20PABS, 25PABS and A25PABS feature a front limit contact for able for cleaning (Figure 2). Bracket
equipment shut-down and an internal SPDT snap switch for Alarm Before Shut- 2. Connect tubing to the 1/8-27
Down. When the low side (preset point) of the snap switch trips, the N.C. terminal NPTM port. Use of non-hard-
completes a circuit to activate an alarm. A continued decrease in pressure will com- ening thread sealing com-
plete the shutdown circuit. An increase in pressure of approximately 10% of scale is pound is recommended Gage
necessary before the snap-switch (alarm) will reset and open the circuit. although thread is “dry seal”. Pressure
NOTE: Face contact shut-down limit setting and snap switch low point are fac- IMPORTANT: Make sure Port tubing
or hose
tory-set; specify when ordering if setting is other than standard. NOT to foul pressure orifices Pulsation
Wire Lead Orifice
Typical Tattletale® Magnetic Switch with sealant. NEVER exceed Wrench
Murphy manufactures several, patented Magnetic Switches for protection of the pilot maximum pressure rating for
duty Swichgage contacts and to ensure positive shut-down of equipment. There are the gage range; see chart on p-2. Figure 2
magnetic switches for CD ignition, Magneto, Battery systems and electric motor dri-
ven equipment. Tattletale annunciators show the cause of shut-down. The first one to
trip will lockout all other Tattletale annunciators. Be sure the type of magnetic switch IMPORTANT: Swichgage instruments, magnetic switches and shutdown
or Tattletale annunciator matches the power source used to trip it. or alarm devices, properly used, are effective tools in any preventive maintenance
NOTE: At equipment start-up (for models not having a built-in time delay) the reset but- program. For optimum performance, check these tools periodically: look for
ton must be held in until normal operation occurs, or an external time delay may be frozen pointers, kinked/worn tubing, broken wiring or loose connections; operate
used. Instructions are packed with each Magnetic Switch orTattletale annunciator. the contacts and watch for expected results. Replace damaged/worn parts;
clean/repair as necessary. Check for correct/complete wiring, unbroken insulation
and no accidental grounds. Do not run shut-down wires with ignition wiring.
Products covered by this literature comply with EMC Council directive Check all tubing and connections for leaks. Mount magnetic switches and valves
89/336/EEC regarding electromagnetic compatibility except as noted. upright, to prevent moisture collection.
Pressure Ranges and Factory Settings
Ranges Available Std. Settings* Hi Settings** 20/25PABS Settings Start-up Lockout Settings
Maximum Low Alarm† Contact Lockout Release (max.)
psi Bar Pressure psi Bar psi Bar psi Bar psi Bar psi Bar psi Bar psi Bar
0-15 (103) 1.0 30 psi (21 MPa) 3 (21) 0.2 12 (83) 0.8 3 (21) 0.2 6 (41) 0.3 3 (21) 0.2 4 (28) 0.3 6 (41) 0.4
0-30 (207) 2.0 60 psi (21 MPa) 7 (48) 0.4 24 (165) 1.6 7 (48) 0.4 10 (69) 0.6 4 (28) 0.4 7 (48) 0.5 10 (69) 0.7
0-50 (345) 3.5 100 psi (21 MPa) 10 (69) 0.8 40 (276) 2.8 10 (69) 0.8 13 (90) 1.0 10 (69) 0.5 13 (90) 1.0 20 (138) 1.4
0-75 (517) 5.0 150 psi (21 MPa) 15 (103) 1.0 60 (414) 4.0 15 (103) 1.0 18 (124) 1.5 10 (69) 0.7 15 (103) 1.0 23 (159) 1.6
0-100 (690) 7.0 200 psi (21 MPa) 20 (138) 1.5 80 (552) 5.5 20 (138) 1.0 23 (159) 1.5 20 (138) 1.0 25 (173) 2.0 35 (241) 2.4
0-150 (1.0 MPa) 10 300 psi (3.4 MPa) 30 (207) 2.0 120 (827) 8.0 30 (207) 1.5 33 (228) 2.0 20 (138) 1.5 30 (207) 2.0 45 (310) 3.1
0-200 (1.4 MPa) 14 400 psi (3.4 MPa) 50 (345) 3.0 150 (1 MPa) 10 50 (345) 3.0 53 (365) 4.0 40 (276) 3.0 50 (345) 3.5 70 (482) 4.8
0-300 (2.1 MPa) 20 500 psi (3.4 MPa) 75 (517) 5.0 225 (1.6 MPa) 15 75 (517) 5.0 78 (538) 5.0 50 (345) 3.5 75 (517) 5.0 105 (724) 7.2
0-400 (2.8 MPa) 28 500 psi (3.4 MPa) 150 (1MPa) 7.0 300 (2.1 MPa) 20 75 (517) 5.0 150 (1MPa) 10 100 (690) 6.0 ––– 7.0 150 (1MPa) 10
Values in ( ) are mathematical conversions from psi to kPa/MPa–they do not reflect second scale range. U.S.A. standard scale is psi/kPa; U.K. standard scale is psi/bar. Consult factory for other scales.
* Standard setting for 20P/25P and 20PE/25PE models.
** Low settings for Hi/Lo option same as standard settings. Hi/Lo option available for 20P/25P models only.
† SPDT Snap-switch is the alarm switch.
Connecting Vacuum Models

The vacuum instruments measure intake manifold vacuum and gives an indica- Panel
tion of the load applied to the engine. Tube or
1. Mount the gage in a suitable location so that the face is visible and easily Port
Fittings
Tubing
accessible.
Gage
CAUTION: Make SURE NOT TO FOUL the pressure orifices with
pipe dope or dirt or the SWICHGAGE instrument will not operate.
2. Connect suitable tubing to the 1/8-27 NPT port of the gage and to an open Wire
Lead(s)
port in the intake manifold. Mounting kit V5179 is suggested and includes Intake
tubing and necessary fittings. The manifold fitting is 1/4 NPT. Figure 3 Manifold
Fittings
shows a typical mounting using V5179 kit. A Murphy PD2160 is also recom- PD2160
mended. Intake
Pulsation
Dampener
3. Be sure connections are tight—gage will not operate properly if line leaks. Figure 3 Manifold
Connecting Differential Pressure Models

Differential pressure models are typically applied to indicate restriction in oil/fuel fil- 2. You MUST use a second wrench on the Low Pressure port when tightening tube
ters. The “High” pressure port (center mounted) is piped to the Inlet side of the filter. fittings. (Figure 4). Notice that a wrench is used for holding the low pressure port
The “Low” pressure port (top center mounted) is piped to the Outlet side of the filter. while a second wrench will tighten the pressure tubing/hose fitting onto the port.
CAUTION: Make SURE NOT TO FOUL the pressure orifices with WARNING: Failure to use a second wrench on the low pressure
pipe dope or dirt or the SWICHGAGE® instrument will not operate. port when tightening tube fittings may result in damage to the internal
mechanisms.
1. To connect the high pressure tubing use at least 3/16 in. (5 mm) I.D. flexible
pressure tubing/hose and fittings. If using copper or rigid tubing, install at IMPORTANT: NEVER exceed maximum static pressure or differential pres-
least 12 in. (305 mm) flexible hose from the gage to the rigid tubing (to pre- sure ratings for your gage range; stated in chart below.
vent damaging vibration to the gage, see Figure 2).
DO NOT TWIST
Gage Case Low Pressure Port; Ranges* Max. Static Max. Differential Contact
Back View Hold Port with Wrench Available Pressure Pressure Setting
0-15 (0-103) [0-1.0] 200 (1.4) [14] 30 (207) [2.0] 10 (69) [0.8]
Figure 4 0-30 (0-207) [0-2.0] 300 (2.1) [20] 60 (414) [4.0] 20 (138) [1.0]
Attach tubing 0-50 (0-345) [0-3.5] 300 (2.1) [20] 100 (690) [7.0] 30 (207) [2.0]
with Wrench 0-75 (0-517) [0-5.0] 300 (2.1) [20] 150 (1.0) [10] 50 (345) [3.5]
0-100 (0-690) [0-7.0] 300 (2.1) [20] 200 (1.4) [14] 60 (414) [4.0]
*Values are shown in psi, (kPa/MPa) and [bar]. Values in kPa/MPa and bar are mathematical
High
High conversions from psi–they do not reflect actual second scale range.
Pressure
Pressure Port
Port

Setting the Swichgage Testing the Contacts
instrument contacts 1. With equipment running; use a 1/16 in. hex wrench to rotate contact until it
touches the pointer. Do NOT force contact against the gage pointer.
IMPORTANT:: If the Swichgage has a lockout push button Equipment should shut down and/or alarm should operate. Reset the contact
on the face, a contact setting higher than the factory setting will (See Figure 5).
make the lockout device inoperative.
2. VERY IMPORTANT Each time you start the machine, observe that the
For 20PE, 25PE, 25DPE, A20PE, A25PE and A25DPE models
the switch trip point CANNOT be set at either the lowest or the highest
SWICHGAGE® is indicating pressure or vacuum. Visual inspection and regu-
extremes of the scale. Trip point MUST allow for the switch reset differential. lar testing should be normal procedure to ensure proper operation and to
For adjustable switch versions, the switch point is adjustable ONLY achieve maximum results from your Swichgage instrument.
over the lower half of the scale.
PRESSURE
1. All contacts are set using a 1/16 in. hex wrench (Figure 5).
2. Some models such as A20PE, A25PE, etc. may not have field adjustment.
Consult the factory if in doubt. For adjustable models, 1/4 turn clock-
wise lowers switch operating point approximately 7% of scale.
3. Observe the “normal operating” pressure or vacuum readings. Set the contact
slightly below minimum reading observed or slightly above minimum pres-
Switch Adjustment
sure recommended by equipment manufacturer. For differential pressure mod- Figure 5 (if applicable)
els set the contact slightly below the desired maximum differential pressure.
Wiring Installation
WARNING: DISCONNECT ALL ELECTRICAL POWER BEFORE BEGINNING THE WIRING INSTALLATION.
FOR BATTERY IGNITION SYSTEMS, DISCONNECT THE BATTERY GROUND STRAP. FACE ADJUSTED POINT-
ER TYPE CONTACTS ARE PILOT DUTY. DO NOT EXCEED CONTACT RATINGS ON ANY SWICHGAGE® MODEL.
20 and 25 Series models wire leads are 18 AWG or 20 AWG, 12 in. (305 mm) The pictorial below shows typical wirings for each base model. Look for specific
long. A20 and A25 Series models have number 4 or number 6 screw terminals. typical wiring diagram with your base model number and wire accordingly.
When installing the Swichgage instrument on an ungrounded panel, you MUST The pointer is shown in the Shelf Position. Face adjusted pointer type contacts
provide a ground wire from the Swichgage instrument to a common ground. are rated pilot duty 2 A @ 30 VAC/DC. Snap-switch contacts are rated 3 A @
Install ONLY in a 12 or 24 V system. Warning lights or audible signal must be of the 30 VDC; 4 A @ 125 VAC.
same voltage as the battery. Current draw should never exceed Swichgage contact CAUTION: On some models pointer contact and ABS switch share the same
ratings. “Common”. Voltage source must be the same. Maximum voltage is 30 V. Consult
CAUTION: Ordinary incandescent lights are damaging to Swichgage contacts. We recom- factory for applications with 120 VAC systems.
mend using our direct connected alarms TL-7 flashing lamp and/or SAH mini-siren.
20DP and 20P-HL and 25P-HL 20PABS and 20PE, 20DPE,
20P and 25P 25DP 20V and 25V 25PABS 25PE and 25DPE
N. C. Red N. C. Red
C. White C. White
N. O. Black N. O. Black
LOW HIGH LOW HIGH LOW
Red Black Red Black Red
A20P A20DP A20P-HL and A20V A20PABS A20PE A20DPE
LOW HIGH LOW HIGH LOW ABS SET RESET RESET SET
N. C. C N. O. N. C. C N. O. N. C. C N. O. N.C. C N.O. N. C. C N. O. N. C. C N. O.
A25P-HL and A25PABS A25PABS-HL A25PE A25DPE

A25DP A25V N.C. C N.O. N.C. C
A25P N.O. N.C. C N. O. N.C. N.O.
SET RESET SET RESET SET RESET RESET SET
LOW HIGH LOW HIGH LOW LOW HIGH

L P H L P H L P H L P H L P H L P H L P H

Installing The Magnetic Switch
WARNING: DISCONNECT THE BATTERY OR POWER SOURCE BEFORE BEGINNING THE INSTALLATION.
SEE SPECIFIC WIRING INSTRUCTIONS PACKED WITH EACH MAGNETIC SWITCH OR TATTLETALE ANNUNCIATOR.
1. Mount with electrical lugs down. Drill mounting holes in panel. NOTE: Murphy components are easily wired and maintained. Use good quality
2. Clean away burrs and filings. Position the magnetic switch in the wire and terminals. The type of magnetic switch differs for various applications.
panel, making sure the pilot stud is in place. See typical wirings below. Wiring and instructions are packed with each magnet-
3. Add decal, then washer, then nut and tighten. ic switch.
20P Pressure 20P-F Pressure 20T-F Temperature 518PH Magnetic Switch
® ®
SWICHGAGE® 117 Magnetic Switch SWICHGAGE SWICHGAGE
Y SWICHGA Y SWICHGA Y SWICHGAG

PH GE PH GE
UR UR PH E®
UR
® ®
M PSI M PSI F
M
40 60 40 60
20
80
20
80 160 190 220
10
0
10
0 130 25
0 0
0 R
300 60 300 60 80 100 12
0 0 0 0 60 0
kPa kPa C G NC SW1 SW2 B
PRESSURE PRESSURE
C S B TEMPERATURE
N.O. SWICHGAGE®
instruments
_ +
Energized To Run Devices _ + Energized To Run Devices Battery
N.C. switches option
Battery
Troubleshooting
DO THIS FIRST: Look for broken wiring, frozen pointer, dirty contacts (will not make), burnt pointer or contact. Verify that all wiring is intact and con-
nections are tight. Verify that Swichgage has not been damaged (hit or dropped). Verify that there is pressure/vacuum supplied to the gage. Verify that the Swichgage
is operative (it reads). Verify that the alarm or shutdown device is fully operable; and check other components such as spark plugs, ignition, fuel pump and filter, etc.
Reset magnetic switch and verify that it stays latched.
SYMPTOM CAUSE TEST/REMEDY

Engine will not start. 1. Short or open circuit, be sure the magnetic switch latches and puts out power to 1. Reset magnetic switch and make sure it stays latched. Refer to install-
the run device or removes ground (ignition). Check for power/ground at run device. ation instructions for 518PH magnetic switch (provided with unit).
2. Control circuit overloaded by accessories (blown fuse in magnetic switch). 2. Find blown fuse and replace (use 14 A fuse). Reroute the accessories.
3. False ground in control circuit. 3. Repair.
False shutdown. 1. Swichgage circuit has intermittent open or short. 1. Check all wiring and repair/replace as necessary.
2. Vibration causes the Magnetic Switch to trip. 2. Repair and relocate the switch as needed.
Swichgage closes but does 1. Incomplete shutdown circuit. 1. Locate open circuit and repair.
not trip the magnetic switch 2. Dirty Swichgage contacts. 2. Clean and check that contacts make.
or kill the engine. 3. Ignition not providing power to primary terminal post. 3. Repair ignition.
4. Swichgage case may not be grounded. 4. Ground case.
5. Incorrect magnetic switch for type of power. 5. Replace with correct magnetic switch.
Magnetic switch tripped but 1. Open circuit between the magnetic switch and the shutdown device. 1.Check wiring from magnetic switch to shutdown device, repair or replace.
engine is still running. 2. Lost ground to kill the engine. 2. Check all wiring and connections and repair.
Pointer will not operate 1. Frozen pointer 1. Return for repair or replacement.
properly. Inaccurate reading. 2. Loose pointer spring (caused by hitting or dropping gage). 2. Return for repair or replacement.
3. Plugged pressure orifice. 3. Remove and clean.
4. Over Pressure 4. Return for repair or replacement.
Pointer/contact burned-in two. Without exception this condition is caused by incorrect wiring or short circuit. Recheck wiring; replace Swichgage or return for repair.
Warranty
MURPHY, the Murphy logo, and Murphygage® are registered and/or common law trademarks of Murphy Industries,
Inc. This document, including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with
www.fwmurphy.com all rights reserved. (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein
918.317.4100 Email: sales@fwmurphy.com are the property of their respective owners and are used for identification purposes only.

Instruction Manual
Form 5469 67C Series
May 2006
67C Series Instrument Supply Regulators
TYPE 67CF FILTER REGULATOR TYPE 67C OR67CR REGULATOR

WITH OPTIONAL GAUGE
Figure t Typical 6 7C Series Regulators
Introduction The Types 67C and 67CS are the standard instrument
supply regulatorswithout a filter or internal relief.
Scope of Manual The Types 67CF and 67CFS are equipped with a
filter for removing particles from the supply gas.
This manual provides instructions and parts lists for
67C Series instrument supply regulators. Instructions The Types 67CR and 67CSR have an internal
and parts lists for other equipment mentioned in this relief valve with a soft seat for reliable shutoff with no
instruction manual, as well as for other 67 Series discernible leakage.
regulators, are found in separate manuals. The Types 67CFR and 67CFSR have a filter and
internal relief valve with a soft seat for reliable shutoff
with no discernible leakage.
Product Descriptions
The 67C Series direct-operated regulators are Specifications
typically used to provide constantly controlled,
reduced pressures to pneumatic and electropneumatic Some general 67C Series ratings and other
controllers and other instruments. They are suitable specifications are given on page 2. A label on the
for most air or gas applications. Other applications spring case gives the control spring range for a given
include providing reduced pressures to air chucks, air regulator as it comes from the factory.
jets, and spray guns.
EMERSONL
Process Management
Section 10 – Lubrication System
Vendor Bulletin No.
Separators Drain Piping.................................................. Ajax 01-23-T01A-301
Crankcase Drain Piping....................................................Ajax 02-23-T010-317
Oil Reservoir Piping with Day Tank..................................Ajax TP 00-24-T01B-001
Kim Hotstart Oil Heater Piping..........................................Ajax TP 04-02-T010-317
Kim Hotstart O & M...........................................................KHT
Lube Op System Schematic........................................... Prog. 2802-MA-F-MCP
SMX Divider Valve Bulletin......................................................... Prog.
DLM-926 Operation and Wiring ................................................. Deliron DLM-926
Proximity Switch Bulletin ............................................................ Deliron 169LIT D-PRXSW
Rupture Disc Drawing .................................................... Ajax BM-21138
Lubricator Pump, Model P-55UR, ” ............................. Ajax BM-21136-1
Lubricator Pump, Model P-55UR, ¼” ............................. Ajax BM-21137-1
Operation and Maintenance of Divider Block Lubrication
Systems©2001(used with permission)
Crankcase Oil Level Controller & Switch, LM301
Installation and Operation........................................................ Murphy LM-92164N

Drain the air scavenging chambers
every 800 hours of operation.
WARNING
Do not open the scavenging chamber
Drain the compressor crosshead drains while the engine is running.
guides every 800 hours of operation.
Unstable combustion and rpm control
Record the amount of oil collected. may result.
Unusual amounts of oil indicate Record the amount of oil collected per
excessive cylinder or packing cylinder.
lubrication rates, or worn wiper
packing. Unusual amounts of oil indicate
excessive cylinder lubrication rates, or
worn wiper packing.
Drain the crankcase every 8000 hours of operation.
Perform crankcase maintenance requirements.
Refill with 30 gallons of oil per Engineering

Standard # ES 1006. DPC-2802 Crosshead Guide,
Scavenging Chamber,
Also, see TP 00-24-T01A-001 in Tab 10.
& Frame Drains
TP 01-23-T01A-301
DPC-2801 Crosshead Guide, Scavenging Chamber, & Frame Drains
TP 01-23-T01A-001

1 Ball Valve, ¾” NPT, 600# 2549 2065 2
2 Ball Valve, ¾” NPT, Locking Handle 2549 2075 1
3 Male Connector, ¾"Tube x ¾"NPT 2507 1606 6
4 SS Tubing, ¾” x 0.049” 5551 4912 164”
5 SS Tubing, ¾” x 0.049” 5551 4912 77”
6 SS Tubing, ¾” x 0.049” 5551 4912 118”
DPC-2801 Crosshead Guide, Scavenging Chamber, & Frame Drains

TP 01-23-T01A-001
Approximate crankcase oil capacity = 30 gallons (U.S.)
The correct full oil level is determined when the engine

is stopped.
Full crankcase oil level = 27.5” from the frame’s top

machined surface to the surface of the oil.
Set the level controller’s safety shutdown point while

the engine is running.
Crankcase oil level controller

& low level limit switch Frame Mounted Lube Oil Reservoir
p/n: BM-21072 TP 00-24-T01B-001 rev 1
Frame Mounted Lube Oil Reservoir
TP 00-24-T01B-001 rev 1

1 Oil Reservoir, 55 Gallons 6553 5500 1
2 Ball Valve, ½"NPT, 600# 2549 2094 3
3 Male Tubing Elbow, ½" Tube x ½" NPT 2507 4204 1
4 ¼" Flat Bar, 1" 7040 0210 4"
5 ¼" Flat Bar, 1" 7040 0210 8"
6 " Strap,1"x 51"L (Form To Fit Reservoir) 7040 0110 2
7 Male Connector , ½" Tube x ½" NPT 2507 1404 3
8 Pipe Nipple, Sch 80, ½"NPT x 3"L 2539 4414 1
9 Oil Reservoir Support Stand 800-1000-00013 1
10 Plug, ½" Tube Fitting 2513 9500 1
11 Rubber Pad, " Thk. x 3"W x 30"L 6840 3000 2
12 Street Elbow, Std, ½"NPT 2535 7004 1
13 ½" Tubing Tee 2507 6504 1
14 Tubing, 316SS, ½" x 0.035 Wall 5551 3508 23.3"
15 Tubing, 316SS, ½" x 0.035 Wall 5551 3508 66.4"
16 Tubing, 316SS, ½" x 0.035 Wall 5551 3508 2"
17 Tubing, 316SS, ½" x 0.035 Wall 5551 3508 64.1"
18 ½" Tubing Union 2507 8004 1
Connect to the Engine’s.prelube pipe cross fitting.
Refer to Manual’s Section 3, drawing “Modified 1704-000” Warning
Remove pipe plug, item 14, from pipe cross, item 13, and
install tube fitting, item 9, shown below. All repair and resetting of safety relief
valves should be performed by a National
Board certified valve repair shop holding a
“VR”stamp.
Replaceable element
p/n 6522 0005.
Connect to the
Oil Outlet of the
Connect to the Engine’s crankcase drain. Oil Heater
Refer to Manual’s Section 10, drawing TP 04-23-T01A-001 To Kim Hotstart Pressure Switch
Replace pipe elbow, item 5, at pipe nipple, item 8, with
pipe tee, item 16, shown below. Connect to the Oil Inlet
of the Oil Heater
See TP 04-02-T010-316 in Tab 5

for Connection Details
To Water Pump Housing
Circulating Heating System COLER 3180/0603-08B1
Refer to vendor’s Installation & Operating To Kim Hotstart Water Outlet

instructions included in Section 10.
Refer to the General Arrangement drawings for Circulating Heating System

To Kim Hotstart Water Inlet
mounting location. Inlet & Outlet Tubing
TP 04-02-T010-317
Circulating Heating System Inlet & Outlet Tubing
TP 04-02-T010-317

1 Ball Valve, ¾" NPT 2549 2065 3 35 Ball Valve 2549 2142 1
2 Ball Valve, 1" NPT 2549 2085 1 36 Bushing, 1-½" x 1-¼" 2527 1412 2
3 Bushing, 1½" x 1" NPT 2527 1410 1 37 Ball Valve, 1-½" 2549 2142 1
4 Bushing, 1" x ¾" NPT 2527 1006 4
5 Elbow, ¾" NPT 2535 4006 2
6 Tubing Elbow, Male, 1" Tube x 1" NPT 2507 4808 1
7 Kim Hotstart Oil Heater COLER 3180/0603-08B1 6390 2098 1
8 LHA Spin On Oil Filter 6522 0003 1
A Filter Element 6522 0005 1
9 Tubing Connector, Male, ¾" Tube x ¾" NPT 2507 1606 6
10 Tubing Connector, Male, 1" Tube x 1" NPT 2507 1808 3
11 Pipe Nipple, Sch 80, ¾" NPT x 2 " 2539 4508 9
12 Pipe Nipple, Sch 80, ¾" NPT x 3 " 2539 4514 2
13 Pipe, Sch 80, ¾" 4053 0065 14"
14 Relief Valve Set At 25 psig, 1" x 1" 63ME2M2FTA0025 1
15 Tee, ¾" NPT 2545 4006 4
16 Tee, 1½" NPT 2545 4014 1
17 Tee, 1" NPT 2545 4010 1
18 Tubing, 316SS, ¾" x 0.049 Wall 5551 4912 174"
19 Tubing, 316SS, ¾" x 0.049 Wall 5551 4912 30"
20 Tubing, 316SS, ¾" x 0.049 Wall 5551 4912 6"
21 Tubing, 316SS, 1" x 0.049 Wall 5551 4916 120"
22 Tubing, 316SS, 1" x 0.049 Wall 5551 4916 36"
23 Tubing, 316SS, 1" x 0.049 Wall 5551 4916 100"
24 Tubing, 316SS, ¾" x 0.049 Wall 5551 4912 120"
25 Union ¾" NPT 2547 5006 2
26 Union Tubing ¾" 2507 8006 1
27 Rubber Hose, 1¼" 3521 4018 1
28 Straight Hose Connector, 1¼" 2520 3020 2
29 Rubber Hose, 1" 3521 4016 1
30 Straight Hose Connector, 1" 2520 3016 2
31 Hose Clamp ¾" x 1¼" 2520 9106 4
32 Connector ¼" x ¼" 2507 1202 2
33 Tubing ¼" x .049 wall 5551 4904 20 ft
34 Bushing, 1-½" x 3" 2539 4814 2
OER & OWT
Oil Heating System
Installation & Operation Manual
216203-000 rev 3
KIM HOTSTART Mfg., Co., Inc.
P.O. Box 11245
Spokane WA 99211-0245
Customer Support: (509) 536-8660
NOTICE
When ordering replacement parts for your heating
system, always reference the heating system’s
Model Number and Serial Number.
CAUTION
ALL CONNECTIONS IN THE JUNCTION BOX SHOULD BE CHECKED
PRIOR TO INSTALLATION. VIBRATION DURING SHIPMENT CAN CAUSE
SCREWS TO LOOSEN. ALL CONNECTIONS IN THE JUNCTION BOX
SHOULD BE CHECKED AT REGULAR INTERVALS. EXCESSIVE
VIBRATION WILL EVENTUALLY CAUSE CONNECTIONS TO LOOSEN
OVER TIME.
WIRING TO HEATING SYSTEM TO BE PERFORMED BY A QUALIFIED

ELECTRICIAN AND CONFORM TO ALL NATIONAL, STATE AND LOCAL
ELECTRICAL CODES.
KIM HOTSTART MANUFACTURING COMPANY
EAST 5723 ALKI AVENUE • P.O. BOX 11245

SPOKANE, WASHINGTON • 99211-0245 • USA
Phone: (509) 534-6171 • Fax: (509) 534-4216
Notices
This manual was prepared to assist you with the installation, operation, and maintenance of two
Kim Hotstart oil heating systems: the Oil Water Tight (OWT) system, and the Oil Explosion
Resistant (OER) heating system. OWT systems comply with the NEMA 12 standard, and OER
systems comply with the Class 1, Group D, Division I and II explosion standard. We encourage
you to use this manual and the attached documentation in the appendix as your primary source of
information for your heating system. For additional information, contact:
Kim Hotstart Manufacturing Company

P.O. Box 11245
Spokane, WA 99211-0245
Telephone: (509) 536-8660
Fax: (509) 534-4216
The instructional material and the corresponding illustrations in this manual are based on the
typical OWT and OER heating systems with standard components and the most frequently
requested options. Your particular heating system configuration may vary from the heating
systems described in this manual. For your reference, available replacement parts and
component options are listed in this manual. See Appendix A in the back of this manual for your
system drawings and wiring diagrams.
Identifying Your System

Kim Hotstart OWT and OER oil heating systems are compact oil heating systems designed for
use in marine propulsion, diesel-powered generator sets, or any large-engine applications. These
models are pre-wired, pre-plumbed, and assembled on a steel plate and mounting channel. Each
heating system has an identification plate usually located next to the control box. An example of
the identification plate is shown on the following page.
NOTE: When ordering replacement parts, be sure to reference your heating system’s
model and serial numbers found on the identification plate.
Model numbers ending in other than –Xnn are custom systems. Reference the
drawings included with your system for parts specific to your system.
i
ii
iii
Table Of Contents
NOTICES........................................................................................................................................ i
IDENTIFYING YOUR SYSTEM ................................................................................................ i
HEATING SYSTEM OVERVIEW.......................................................................................... 1-1

Oil Water Tight (OWT) Standard Models .................................................................. 1-2
Oil Explosion Resistant (OER) Standard Models....................................................... 1-4
The Kim Hotstart System.............................................................................................. 1-5
Lube Oil Inlet/Outlet Process .................................................................................... 1-6
Lube Oil Flow Detection ........................................................................................... 1-7
INSTALLATION AND SYSTEM START-UP....................................................................... 2-1

Basic System Installation............................................................................................... 2-1
Main Power Supply.................................................................................................... 2-1
Oil Supply Line.......................................................................................................... 2-2
Oil Discharge Line..................................................................................................... 2-4
System Mounting Requirements .................................................................................. 2-5
Lube Oil Pump........................................................................................................... 2-5
System Start-Up ............................................................................................................. 2-6
Lube Oil Heating System Start-Up ............................................................................ 2-6
SYSTEM COMPONENTS ....................................................................................................... 3-1

Control Box..................................................................................................................... 3-1
Time Delay Relay ..................................................................................................... 3-2
Magnetic Contactors .................................................................................................. 3-2
Remote Control.......................................................................................................... 3-2
Motor Protective Switch ............................................................................................ 3-3
Other MPS Features................................................................................................... 3-4
Fuses ........................................................................................................................ 3-4
Transformer................................................................................................................ 3-4
Oil Heating Tank Assembly .......................................................................................... 3-5
Heating Tank Assembly Parts ...................................................................................... 3-6
Heating Element Replacement................................................................................... 3-6
High-Limit Thermostat Replacement ........................................................................ 3-8
System Thermostat Replacement............................................................................... 3-9
Tank O-Ring ............................................................................................................ 3-10
Flow Detection Switch............................................................................................. 3-10
Pump and Motor Assembly......................................................................................... 3-11
iv
Oil Pressure Switch...................................................................................................... 3-11
SYSTEM MAINTENANCE ..................................................................................................... 4-1

Control Box..................................................................................................................... 4-1
Plumbing Connections................................................................................................... 4-1
Electrical Connections ................................................................................................... 4-1
Electrical Contacts ......................................................................................................... 4-1
Heating Tank.................................................................................................................. 4-2
Flow Detection Switch ................................................................................................... 4-3
Pump and Motor Assemblies ........................................................................................ 4-4
System Mounting ........................................................................................................... 4-4
Troubleshooting ............................................................................................................. 4-5
APPENDIX A
SYSTEM DRAWINGS............................................................................................................. A-1
v
Heating System Overview
The Kim Hotstart Oil Water Tight (OWT) and Oil Explosion Resistant (OER) lube-oil
circulating heating systems for industrial engines are designed and constructed for ease of
operation and minimal maintenance. These heating systems are just a few of a variety of
products available to meet your cold start requirements. Each unit is a unique pre-heating system
that eliminates needless engine idling and results in:
• Quicker engine start-up in cold weather
• A reduction in engine oil consumption
• Significant operations and fuel savings
• Consistent engine temperature
• A reduction in engine wear
• Minimal maintenance
• Fail-safe protection
Engine
for Pre-Lubing
for Continuous Lubing
Oil Sump
Oil Outlet
Check Valve
Oil Heating
System
OFF ON
owtlg1.eps
Oil Inlet
Shut Off Valve engoil.eps
Section 1 Heating System Overview 1-1

Oil Water Tight (OWT) Standard Models
The OWT models shown on the following page are designed according to the NEMA 12
standard and come in three oil-pumping capacities: small, medium, and large. All
standard small-, medium-, and large-capacity OWT models share the same design in
operation and component layout. The major differences between models are the motor,
pump, and heating element (in the tank assembly). The standard OWT models are listed
below. Other features included are:
• Adjustable pressure switch or electronic signaling for automatic operation
• A universal mounting platform for compatibility with various mounting
configurations
• 80° to 100°F fixed-thermostats with 140°F high limit
• An ON/OFF switch for manual control. EP systems have a Hand/Off/Auto switch for
manual prelube.
• VITON mechanical seal pumps for extended seal life
• Flow detection switch for fail-safe operation
OIL WATER TIGHT (OWT) STANDARD MODELS
SMALL CAPACITY
Part No. Capacity (Gallons) KW Voltage Hertz Phase Amps. HP/GPM
OWT10252 25 to 100 2.5 240V 60 1 18.1 1 HP/2.8 GPM
OWT1025C 25 to 100 2.5 240V 50 1 18.1 1 HP/2.4 GPM
OWT3025D 25 to 100 2.5 380V 50 3 7.5 1 HP/2.4 GPM
OWT30254 25 to 100 2.5 480V 60 3 5.9 1 HP/2.8 GPM
MEDIUM CAPACITY
OWT10602 75 to 250 6 240V 60 1 33 1 HP/10 GPM
OWT1060C 75 to 250 6 240V 50 1 33 1 HP/8.3 GPM
OWT3060D 75 to 250 6 380V 50 3 12.9 1 HP/8.3 GPM
OWT30604 75 to 250 6 480V 60 3 10.2 1 HP/10 GPM
LARGE CAPACITY
OWT10902 200 to 500 9 240V 60 1 53.4 2 HP/20 GPM
OWT1090C 200 to 500 9 240V 50 1 53.4 2 HP/16 GPM
OWT3090D 200 to 500 9 380V 50 3 19.6 2 HP/16 GPM
OWT30904 200 to 500 9 480V 60 3 16.6 2 HP/20 GPM

OWT and OER Configurations

Oil Explosion Resistant (OER) Standard Models
All OER models are designed to meet Explosion Resistant Class 1, Group D, Division 1
and 2, and NEMA 4 standards. The OER models come in three oil-pumping capacities:
small, medium, and large. All standard small-, medium-, and large-capacity OER models
share the same design in operation and component layout. The major differences between
models are the motor, pump, and heating element (in the tank assembly). The standard
OER models are listed below. Other features included are:
• Adjustable pressure switch or 24VDC relay for automatic operation
• A universal mounting platform for compatibility with various mounting
configurations
• 80° to 100°F fixed-thermostats with 140°F high limit
• An ON/OFF switch for manual control. EP systems have a Hand/Off/Auto switch for
manual prelube
• PVC jacketed MI cabling (resistant to sour gas)
• VITON mechanical seal pumps for extended seal life and temperature operation (to
350°F)
• Flow detection switch for fail-safe operation
• An external motor-protective-switch RESET button
OIL EXPLOSION RESISTANT (OER) STANDARD MODELS
SMALL CAPACITY
OER10252 25 to 100 2.5 240V 60 1 18.1 1 HP/2.8 GPM
OER1025C 25 to 100 2.5 240V 50 1 18.1 1 HP/2.4 GPM
OER3025D 25 to 100 2.5 380V 50 3 7.5 1 HP/2.4 GPM
OER30254 25 to 100 2.5 480V 60 3 5.9 1 HP/2.8 GPM
MEDIUM CAPACITY
OER10602 75 to 250 6 240V 60 1 33 1 HP/10 GPM
OER1060C 75 to 250 6 240V 50 1 33 1 HP/8.3 GPM
OER3060D 75 to 250 6 380V 50 3 12.9 1 HP/8.3 GPM
OER30604 75 to 250 6 480V 60 3 10.2 1 HP/10 GPM
LARGE CAPACITY
OER10902 200 to 500 9 240V 60 1 53.4 2 HP/20 GPM
OER1090C 200 to 500 9 240V 50 1 53.4 2 HP/16 GPM
OER3090D 200 to 500 9 380V 50 3 19.6 2 HP/16 GPM
OER30904 200 to 500 9 480V 60 3 16.6 2 HP/20 GPM

The Kim Hotstart System
The Kim Hotstart standard OWT and OER medium pumping capacity models are shown
below. All models (small, medium, and large) are identical in operation. Each heating
system consists of a lube oil heating process. The oil is continuously circulated through
the heating tank. Only the heating element inside the tank is cycled on and off. The
heating element is controlled by a thermostat sensing unit located at the inlet of the
heating tank. The lube oil inlet/outlet and heating process is described on the following
page. All oil systems are designed to maintain warm-oil take over. They are not
designed to take over on a cold-oil start up.
Oil Water Tight (OWT) NEMA 12 Model

Oil Outlet
Oil Tank
OFF ON
NEMA 12 Oil Motor Oil Inlet

Control Box and Pump
Oil Explosion Resistant (OER) Model

Oil Outlet
Oil Tank
RESET
OFF ON
Oil Inlet
Explosion Resistant Oil Motor
Control Box and Pump 2med.eps
Heating Element in Tank
tank1.eps

Lube Oil Inlet/Outlet Process
Upon a system start-up, engine lube oil is taken from at least 2-inches above the lowest
point of the lube oil sump and circulated by a positive displacement rotary gear pump
through the oil heating tank and back to the engine. Options are available on the return
line. In most cases, heated oil is circulated directly back to the oil sump.
Other options include: continuous lubing and pre-lubing before start-up.
• The system must be mounted as low as possible to minimize suction lift to the pump.
• The size of the oil supply line must be calculated using the supplied table. Please refer to
section 2-2 and 2-3.
• The Oil supply line may be flexible or rigid and must be sized to the pump.
• The 7 to 10gpm pump must have at least a 1-inch I.D. line.
• The 16 to 30gpm pumps must have at least a 1½-inch I.D. line.
• Oil must be taken from at least two inches above the bottom of the sump.
• Place full-flow valves in the supply and discharge lines to allow for maintenance. Valve
size must conform to the line size.
Kim Hotstart heating systems should be mounted as near as possible to the suction port
on the oil sump. If possible mount the pump below the level of the oil to provide flooded
suction to the pump. The oil suction plumbing is critical to the proper operation of
the heating system. If the suction plumbing is under-sized, to long or has too many
fittings in it, the pump will not work correctly. Some of the problems this can cause are:
Pump seal leaking, cavitation, oil foaming and break down, noisy pump, excessive
vibration, and internal pump damage.

For heating, the heating system continuously pumps oil to the engine’s oil sump.
For pre-lubing, plumbing is routed back to the top of the engine in order to pre-lube the
engine prior to start-up. This is done by means of a teed junction with a manual or
solenoid valve.
NOTE: Kim Hotstart does not specify the volume or pressure of oil to the top of
the engine for pre-lubing. See engine manufacturer.
Lube Oil Flow Detection

Following lube oil’s inlet and
OWT Model
circulation through the heating tank, Flow Detection
the oil passes through a flow Switch
detection switch. The flow
detection switch immediately shuts
off the heating element anytime
there is an interruption or loss of
flow, and activates the time delay
OFF ON
relay located inside the control box.

L1 L2 L3
513
The pump continues to circulate the

oil to restore flow.
Time Delay Relay
If proper flow is not reestablished,
the time delay relay shuts down the
entire heating system according to a OER Model
Flow Detection
preset time. The time delay relay is Switch
adjustable from 0 to 180 seconds.
Upon an initial system start-up, the
time delay relay should be adjusted
to the maximum of 180 seconds. RESET
Once flow is achieved, Kim

Hotstart recommends a setting of 30 OFF ON
L1 L2 L3
seconds. trelay.eps
2inbx.eps
This automatic system shut-down Time Delay Relay

feature protects the heating element
and other major components from
damage. The time delay relay and flow detection are discussed in more detail in Time
Delay Relay and Flow Detection Switch sections of this manual.
NOTE: Heating elements vary. All standard voltages and a variety of wattage’s
are available. To accomplish any temperature range requirement, a
variety of thermostats are also available in our custom units.
Upon a system shut down, the heating system must be reset and restarted. For complete
system start-up instructions, refer to System Start-Up section in this manual.

Installation and System Start-Up
The Kim Hotstart OWT and OER heating systems come pre-wired and pre-plumbed for ease of
installation. This section describes proper installation of the basic OWT or OER heating
systems. Complete step-by-step instructions for system start-up are also included in this section.
If you need additional assistance installing or starting your particular system, please contact:
Kim Hotstart Manufacturing Company
(509) 536-8660
Basic System Installation

Following are complete instructions for proper installation of the:
• Main Power Supply
• Oil Supply Line
• Oil Discharge Line
CAUTION: VIBRATION DURING SHIPMENT OF THE HEATING SYSTEM CAN
CAUSE SCREWS IN THE CONTROL BOX TO LOOSEN. PLEASE
CHECK ALL CONNECTIONS IN THE CONTROL BOX AFTER
INSTALLATION AND PERIODICALLY DURING OPERATION.
Main Power Supply

Connect the specified voltage and phase to the terminal block located in the main control
box. For 3-phase applications, the terminal block is labeled L1, L2 and L3. For single
phase applications, the terminal block is labeled L1 and L3.
The heating element and the circulating pump of the heating system derive power from
the main power source to the system. The circuitry in the control box determines the duty
cycle of the heating element and circulating pump. A transformer, which drops the main
supply voltage to 120 VAC, powers the control circuit. The transformer and control
circuit are overload protected with fuses.
OWT Model OER Model
L1 L2 L3
L1 L2 L3
513
L123.eps
Transformer Fuses
Terminal Block Transformer Fuses Terminal Block
Section 2 Installation and System Start-Up 2-1

Oil Supply Line
Kim Hotstart heating systems should be mounted as near as possible to the suction port
on the oil sump. If possible, mount the pump below the level of the oil to provide
flooded suction to the pump. The oil suction plumbing is critical to the proper
operation of the heating system. If the suction plumbing is under-sized, too long or has
too many fittings in it, the pump will not work correctly. Some of the problems this can
cause are: Pump seal leaking, cavitation, oil foaming and break down, noisy pump,
excessive vibration, and internal pump damage.
The pump requires not more than 15inHg ( 7.5psi ) suction lift to the pump. The
factors that control that are: The height the pump is above the top of the oil in the sump,
the viscosity of the oil, the size and configuration of the suction line, and the altitude
(barometric pressure).
The suction line size must be determined using the following calculations:
Determine each of the 3 following values and add them together to determine if your
system meets the requirements of less than 7.5psi suction lift. SAE 40 motor oil is
used for these calculations. If your calculated value is too high, increase the line size or
move the heater closer to the suction port of the engine. These figures are only estimates.
The flow rate of the pump on your system is listed on page 1-4 of this manual. The table
on the next page shows friction losses in a smooth line at specified flows. Use the table
on 2-3 to determine the frictional losses in the line you intend to use.
If the pump is above the oil level to calculate the suction pressure multiply the number
of feet the pump is above the oil level by 0.38 to get the psi of the suction lift. If the
pump is below the oil level this can be negative.
Next, determine the altitude the pump will be at. For every 1000 feet above sea level
multiply that number by 0.5 to get psi loss for altitude (barometric pressure).
Add the three numbers together. If they are greater than 7.5 psi reduce your pipe length
or increase the diameter to reduce the frictional losses from the pipe. If they are less than
7.5psi your pump should work properly.
• If the oil supply line is excessively long or the heating tank is mounted higher than
the sump, install a check valve near the oil supply to prevent oil from draining back
to the sump when the heating system is off. Installation of a check valve also
eliminates repeated priming of the pump on heating system start-up. Make sure all
suction pipe connections are tight. A loose connection will not allow the pump to
circulate oil.
• To allow for heating system maintenance without draining the engine sump, install a
shut-off valve between the sump and the rotary gear pump.
• To minimize foreign material from entering the heating system, install the suction
line at least 2 inches above the lowest point of the oil sump.
NOTE: To avoid premature failure of the heating element, be sure to position the
heating tank so that a complete oil fill is accomplished while in operation.

VIKING OIL PUMP SUCTION LINE SIZING CHART
(SAE 40 MOTOR OIL AT 80 - 100 Of)
FIND LINE SIZE & LENGTH THAT WILL PROVIDE LESS THAN 7.5psi SUCTION LIFT
INCLUDING ADDERS FOR PUMP LEVEL AND ALTITUDE (SEE "ADD" BELOW)
2-3 gpm friction losses in 7 gpm friction losses in

length (psi) length (psi)
Line Size ID 5 6 7 8 9 10 5 6 7 8 9 10
0.75in 4.0 4.8 5.5 6.3
1in 1.5 1.8 2.2 2.5 2.8 3.1 3.1 3.7 4.3 4.9 5.5 6.2
1.25in 0.5 0.6 0.7 0.8 1.0 1.1 1.0 1.2 1.4 1.6 1.8 2.0
1.5in 0.6 0.7 0.8 0.9 1.0 1.1
10 gpm friction losses in length 20 gpm friction losses in

(psi) length (psi)
Line Size ID 5 6 7 8 9 10 5 6 7 8 9 10
1in 4.4 5.3 6.2 7.0
1.25in 1.5 1.8 2.1 2.4 2.7 3.0 2.9 3.4 4.0 4.6 5.1 5.7
1.5in 0.8 1.0 1.1 1.3 1.4 1.6 1.6 1.9 2.2 2.5 2.9 3.2
2in 0.6 0.7 0.8 0.9 1.0 1.1
25 gpm friction losses in length 30 gpm friction losses in

(psi) length (psi)
Line Size ID 5 6 7 8 9 10 5 6 7 8 9 10
1.25in 3.6 4.3 5.1 5.8 6.5 7.2 4.4 5.3 6.2 7.0
1.5in 2.0 2.4 2.8 3.2 3.6 4.0 2.3 2.7 3.2 3.7 4.1 4.6
2in 0.7 0.9 1.0 1.2 1.3 1.5 0.9 1.1 1.2 1.4 1.6 1.8
2.5in 0.4 0.5 0.6 0.7 0.8 0.9
ADD:
FOR EVERY FOOT PUMP IS ABOVE OIL LEVEL ADD: 0.38 psi / foot
FOR EVERY 1000 FOOT ABOVE SEA LEVEL ADD: 0.5 psi / 1000 feet

Oil Discharge Line
Connect a 1-inch or 1 1/2-inch N.P.T. line from the heating system outlet to the engine
sump. Size the pipe line according to the size of the pump’s outlet port. For large capacity
OWT and OER systems, the outlet port normally takes a 1 1/2-inch I.D. pipe. For small
and medium capacity OWT and OER systems, the outlet port normally takes a 1-inch
I.D. pipe.
Note: Upon completion of oil return line installation, top off oil levels to
compensate for the oil used to fill the lines and heating tank.

System Mounting Requirements
Be sure to mount the Kim Hotstart OWT or OER heating system as low as possible with
the discharge line exiting from the top of the OWT or OER heating system. This allows
the heating tank to completely fill at all times and prevents premature element failure.
Turn OFF the heating system before starting up the engine.
Lube Oil Pump

The Kim Hotstart OWT or OER heating system heats the lube oil and can continuously
heat the engine, or pre-lube it before start-up. On the suction side of the Kim Hotstart
lube oil pump, oil is taken from at least 2-inches above the lowest point of the oil sump
(not directly at the bottom of the oil sump) and pumped through the OWT or OER
system’s heater and discharged back to the engine. The discharge oil line should be sized
according to the size of the pump’s discharge port. The Kim Hotstart lube pump can be
configured for continuous heating, or teed off with (solenoid or manual) valving for pre-
lubing the engine prior to start-up.
NOTE: All oil pump relief valves are preset to 50 PSI.

System Start-Up
After system installation has been completed, follow these steps for proper OWT or OER
heating system start-up.
Lube Oil Heating System Start-Up

Step 1 Check and tighten all electrical and plumbing connections.
Step 2 Open the control box. Turn the control knob on the oil time delay relay inside
the control box clockwise to the maximum setting of 180 seconds.
OWT Model OER Model
Time Delay
Relay
Time Delay
Relay
L1 L2 L3
L1 L2 L3
513
trelay2.eps
Step 3 Energize the oil heating system by turning the switch on the control box to the
ON position. The red light on the control panel is lit. Bump start the system (by
rocking the power switch ON and OFF) and check for proper rotation of the
motor/pump assembly. If the pump motor is turning the wrong direction, switch
any two electrical leads on the POWER IN block located in the control box for 3
phase systems.
WARNING: DO NOT RUN THE MOTOR/PUMP ASSEMBLY DRY.
Step 4 If the minimum flow rate is not achieved or flow restriction in the suction line
has occurred, the heating system will automatically shut down approximately 3
minutes after start-up. Turn the system OFF and check plumbing lines for any
leaks or restrictions. Air entrapment may also occur in the oil lines or pump.
Repeat steps 2, 3, and 4.
NOTE: On initial start-up, it may take several attempts to achieve proper
flow.
Step 5 Once operation is satisfactory; turn the control knob on the oil time delay relay
to the desired setting. Kim Hotstart recommends a setting of 30 seconds. Turn
the heating system off and then back on to activate a new setting.

System Components
This section describes the components used in the Kim Hotstart OWT and OER heating systems,
including the:
• Control Box
• Heating Tank Assembly
• Pump and Motor Assembly
Control Box
The control boxes used in the Kim Hotstart OWT and OER heating systems are shown
below. Both models are identical in operation. The control boxes contain the electrical
control components for the lube oil heating system.
Following is an overview of operation and replacement instructions for the standard parts
located in the control box, including:
• Time Delay Relay
• Magnetic Contactors
• Motor Protective
Switch
• Fuses
• Transformer
Parts in the control box
may vary, depending on
the particular system
configuration you
purchased. For your
convenience, available
replacement parts are
listed.
NOTE: A Vaseline
type petroleum film
should be kept on the
machined surface of
OER boxes as a barrier
to external
contaminates. All bolts
must be kept in place
and torqued to 55 ft.
lbs.
Section 3 System Components 3-1

Time Delay Relay
The time delay relay is a safety device that works in conjunction with the flow detection
switch. If, for any reason, the heating system’s minimum flow rate (G.P.M.) is
interrupted, the flow detection switch immediately shuts off the heating element and
activates the time delay relay.
The time delay relay allows the pump/motor to operate for a preset length of time, from 0
to 180 seconds, in an attempt to restore the heating system’s minimum flow rate. The
recommended preset time is 30 seconds. If the minimum flow rate is not achieved by the
preset time, the time delay relay automatically shuts down the entire heating system,
preventing damage to the heating element and pump/motor. The system will then have to
be restarted manually. The time delay relays for OWT and OER models are shown in the
illustration on the previous page.
To reset the time delay relay, turn the system power OFF and follow the step-by-step
instructions for system start-up described in the Installation and System Start-Up section
of this manual. The time delay relay requires no maintenance. To order a replacement,
reference the replacement part number listed below.
Time-Delay Relay Replacement Part Number: PRP224046-000
Magnetic Contactors
Because of their low drop out voltage, definite purpose magnetic contactors (shown on
the previous page) are used as voltage switching controls in Kim Hotstart OWT and OER
heating systems. The contactors use 120 volt coils. In case of contactor failure, check
the coil voltage for continuity.
The contactor contacts are made of silver cadmium oxide and should be inspected
periodically for welding, arc erosion, and mechanical wear. If any of these conditions
exist, clean the contacts or replace the contactor.
Magnetic Contactor Replacement Parts

Amps Voltage Hertz Part Number
30 (32A Resistive) 120 50/60 PRP232047-000
60 (65A Resistive) 120 50/60 PRP232049-000
Remote Control
The OER and OWT systems are both equipped with a pressure switch or a 24VDC relay
for remote switching of the heater. The pressure switch is designed to plumb into the
engine’s oil system. This configuration allows the heater to disengage upon engine
startup and re-engage when the engine shuts down. The 24VDC relay works on the same
principle except it uses a 24VDC electrical signal to stop and start the heater. Please refer
to the wiring diagram in the Appendix for details.

Motor Protective Switch
The Motor Protective Switch (MPS) used in your Kim Hotstart heating system was
engineered to achieve a level of quality that is unsurpassed in the industry. The MPS
(shown below) provides short-circuit protection, thermal overload protection, switching
and signaling.
Short Circuit Protection
A wide variety of applications range from 0.1 to 25 FLA at voltages up to 600V. In the
event of a short circuit, the contacts are opened by non-adjusting, magnetic tripping
elements in less than 1 /1000 of a second. This results in the extremely rapid buildup of
an arc voltage that limits the current of the short circuit to a very low level. Because of
this superb current limiting capability, the MPS has an extremely high short-circuit
capacity of 50 KA at 600V.
Motor Overload Protection
Each MPS is calibrated at the factory for the smallest and largest current to ensure an
accurate time/current characteristic curve. In addition, the MPS is a “Class 10” device
that will trip within 10 seconds under a locked rotor condition (6 x FLA). The MPS
provides protection from single-phase conditions at a maximum of 1.25 x FLA.
Accurate adjustment of the overload trip ensures effective motor protection — even with
a phase loss. To maintain constant trip times, the MPS is also equipped with automatic
ambient temperature compensation that continually adjusts to surrounding temperatures.
Reset Buttons Motor Protective BUTTON POSITIONS
Switch NORMAL NEUTRAL
Both the OWT and OER 1 3 5 Switch tripped if both buttons are up
control boxes contain a TE
TE
motor protective switch to ST ST

L1 L2 L3
S
S
TA
TA
R
R
T
T
TEST
S ES
safeguard against overloads
S ES
TO E
TO E
R
R
P T
P T
START
and short-circuits. (GREEN)
STOP
On OER models, to reset RESET
(RED)
the switch, simply press the TO RESET THE SWITCH
T1 T2 T3
RESET button on the 1. Press red STOP RESET button.
control box’s lid. 2 4 6
TE
ST
2. Press the green START button.
On OWT models, it is
S
TA
R
T
S ES
TO E
R
necessary that you open the

P T
TE
ST
S
TA
R
T
control box to reset the

S ES
TO E
R
P T
motor protective switch: resetsw.eps
1. Check the position of

the green START and the red STOP RESET buttons on the motor protective switch.
In normal operation the red STOP RESET button is up and the green START button is
down.
2. If both buttons are up, the switch has been tripped. To reset, first press the red STOP
RESET button and then press the green START button.

Other MPS Features
• UL and CSA listed for group installations.
• Trip-free mechanism prevents manual closure on short circuits or overloads.
• “Tripped” ON and OFF push-button indicators are placed vertically on the device for
easy detection of which unit has tripped if using more than one MPS.
• A full line of snap-on accessories include side mount auxiliary contact blocks.
• The MPS requires no maintenance.
MPS Replacement Parts

Amps (Range) Part Number
1.0 (0.6 - 1.0) PRP232036-000
1.6 (1.0 - 1.6) PRP232036-001
2.5 (1.6 - 2.5) PRP232036-002
4.0 (2.5 - 4.0) PRP232036-003
6.3 (4.0 - 6.3) PRP232036-004
10 (6.3 - 10.0) PRP232036-005
16 (10.0 - 16.0) PRP232036-006
Fuses
There are two different types of fuses located in the control box:
Transformer Primary
This type of fuse provides short-circuit protection to the transformer.
Transformer Secondary
This type of fuse provides secondary current protection for the control components.
NOTE: The physical size and shape of the oil heating element fuses vary. Order
replacement fuses by system part number and serial number.
Transformer
The transformer is an electrical component that steps down the primary voltage to 120
volts. Wiring information is listed on the top of the transformer. This transformer is
normally overload protected with two fuses.

Transformer Replacement Parts
System Voltage Transformer Part Number
208 PRP235062-000
240 PRP235030-000
277 PRP236052-000
380 PRP235050-000
400 PRP235050-000
415 PRP235050-000
480 PRP235030-000
575 PRP235050-000
600 PRP235050-000
Oil Heating Tank Assembly

The lube oil heating tank Oil Water Tight (OWT) NEMA 12 Model
assembly is shown (right).
Oil Outlet
Following is an overview of
operation and replacement Oil Tank
instructions for the standard
heating tank assembly parts,
including:
OFF ON
• Oil Heating Element

• Oil High-Limit Thermostat
Sensing Unit
NEMA 12 Oil Motor Oil Inlet
• Oil System Thermostat Control Box and Pump
Sensing Unit
Optional lube oil heating tank
Oil Explosion Resistant (OER) Model
assembly parts include: Oil Outlet
• Solenoid Valves
Heating tank assembly parts Oil Tank
may vary slightly, depending on
your particular system
configuration. For your RESET
convenience, available
OFF ON
replacement parts are also

listed. Oil Inlet
Explosion Resistant Oil Motor
Control Box and Pump 2med.eps

Heating Tank Assembly Parts
Heating Element Replacement

The heating element, shown below, heats the engine oil. The oil tank has a high-limit
temperature sensing unit in the cup of the heating element housing. Instructions for
disassembling the high-limit sensor follow. To order a new oil heating element, refer
to the part number on the heating element label.
NOTE: The oil heating system is designed to maintain the temperature of warm
lubricating oil. Be sure to run the engine until the oil is warm prior to
starting the oil heating system. If the heating system is energized when the
engine is cold, you may trip the motor protective switch. If tripped, this
switch must be manually reset.
To replace the heating element or perform routine maintenance, follow these steps. Be
sure to allow at least 30 inches of space for element removal. The wattage and phase of
the heating element are listed on the identification label on the outside of the element.
WARNING
DISCONNECT ALL POWER AT THE SOURCE PRIOR TO PERFORMING ANY
MAINTENANCE TO THE HEATING SYSTEM.
Cap
Step 1 Turn the Kim Hotstart Heating system OFF.
Heating Element
Step 2 Drain the fluid from the heating tank. Wattage Information
Step 3 Remove the cap from the heating element.
Heating
Element
V-Clamp
O-Ring
Tank
elmntre.eps

Step 4 The wire connections inside the cup of the heating element correspond to one of
the phase configurations shown below. Note your unit’s phase configuration.
Remove the green-ground
and power electrical wires
from the posts inside the Ground
cup. (Green)
Step 5 Remove the conduit
conductor and electrical
wires from the heating
element.
Power
Step 6 Remove the V-clamp to (Black)
remove the heating
element from the heating
tank as shown on the
previous page. cup.eps
Step 7 Replace the heating

element or perform the Power
necessary cleaning (Black)
procedure.
To reassemble the heating element and tank, follow the steps listed above in reverse
order. Make sure the green-ground and power electrical wires are properly reconnected
using the washers, lug cups and nuts supplied.
To order a new heating element, refer to part number on the label of the element.
NOTE: When replacing the element, apply anti-ceasing or thread lubrication to the
elements that have a threaded adapter.
Single Phase
Metal Strap
Ground Screw
3 Phase WYE 3 Phase DELTA

cupphase.ai

High-Limit Thermostat Replacement
The High-Limit Thermostat Sensing Unit is a safety device designed to prevent over
heating of the oil in the event that the heating system’s System Thermostat fails. The
sensing unit is located inside the element housing and is fixed at 140°F (On)/160°F (Off).
To replace the high-limit thermostat sensing unit, follow these steps.
WARNING
MAINTENANCE TO THIS HEATING SYSTEM.
Step 1 Remove the enclosure
cover of the element
housing.
Step 2 For 3-phase applications
only, remove the element
Sensor Seat
jumper strap which
crosses over the top of the
high-limit sensing unit Heat Shrink Cover
(red wires).
Step 3 Pull the sensor and seat
Thermostat Sensor
straight out and
disconnect the sensor
from its seat.
Step 4 Reconnect the new
sensor.
Reassemble in reverse order.

hisenr2.eps
High-Limit Sensing Unit Replacement Parts
Sensing Unit Temp. On Temp. Off Part No.

LSU 14 140ºF (60ºC) 160ºF (71ºC) HLC 4*
*Replacement stats will come with lock ring and sensor seat.

System Thermostat Replacement
The System Thermostat Sensing Unit is located inside the thermostat housing at the inlet
end (bottom) of the oil heating tank as shown below. To replace the system thermostat,
follow these steps.
CAUTION
MAINTENANCE TO THIS HEATING SYSTEM.
Step 1 Remove the cover of the service entrance

enclosure.
Step 2 Pull the thermostat sensor and seat straight out
of the housing chamber. Tank
Step 3 Replace the sensor by pulling it off the seat.

Reassemble the new thermostat in reverse order. When
pushing in thermostat, take care not to warp the face of
Thermostat Housing
the thermostat. Reconnect the electrical connections
and the service entrance enclosure. Thermostat Sensor
Heat Shrink Cover

NOTE: Remove heat shrink tubing from old sensor
and place it on the new sensor before Sensor Seat
installing.
Lo_sensr2.eps
System Thermostat Sensing Unit Replacement

Sensing Unit Temp. On Temp. Off Part No.
LSU 4 40ºF (5ºC) 60ºF (15ºC) HLC 4
LSU 6 60ºF (15ºC) 80ºF (27ºC) HLC 6
LSU 8 80ºF (27ºC) 100ºF (38ºC) HLC 8
LSU 10 100ºF (38ºC) 120ºF (49ºC) HLC 10
LSU 12 120ºF (49ºC) 140ºF (60ºC) HLC 12
LSU 14 140ºF (60ºC) 160ºF (71ºC) HLC 14

Tank O-Ring
Shown below is an illustration for changing the O-ring found between the top and bottom
section of the heating tank.
CAUTION
DISCONNECT ALL POWER AT THE SOURCE PRIOR Tank
TO PERFORMING ANY MAINTENANCE TO THIS
HEATING SYSTEM.
Step 1 Drain the tank.

V-Clamp
Step 2 Remove the V-clamp that holds the tank and adapter
together.
Step 3 Replace the O-ring between the sections. O-Ring
Step 4 Reassemble the tank.
V-Clamp with O-Ring Replacement Part No: PRP215113-000 Adapter
O-Ring Replacement Part No: PRP203093-000
oring1.eps
Flow Detection Switch

The Flow Detection Switch (shown on OWT Model
right) is a safety device designed to Flow Detection
Switch
protect the heating and pumping
system. This switch is located on the
outlet end of the oil heating tank. If,
for any reason, the oil heating system’s
minimum flow rate (G.P.M.) is OFF ON
interrupted, the flow detection switch L1 L2 L3
513
immediately shuts off the heating

element and activates the time delay
Time Delay Relay
relay. The minimum flow rate required
for most heating systems is 2 GPM. To
order a flow detection switch, OER Model
Flow Detection
reference the part number listed on the Switch
following page. The 2.8 GPM systems
use a 0.5 GPM flow switch.
NOTE: The flow detection switch

RESET
should be checked periodically for

foreign matter that may build up on OFF ON
L1 L2 L3
the shuttle body. For cleaning trelay.eps
instructions, refer to page 4-3 in the 2inbx.eps
System Maintenance section of this Time Delay Relay

manual.

Standard: OWT Flow Detection Switch
Replacement Part No: PRP224033-000
Standard: OER Flow Detection Switch
Small OWT (2.8 GPM): Flow Detection Switch
Small OER (2.8 GPM): Flow Detection Switch
Pump and Motor Assembly

Pump and motor assemblies vary according to the customer’s need. Order replacement
parts using the system part number.
Oil Pressure Switch

Shown below is the pressure switch used on the OER heating system. The pressure
switch is normally connected to the pressure side of the engine - not the suction side.
When oil pressure drops below the switch’s lower limit, the switch turns On the oil
heating system; when oil pressure increases above its high limit, the switch turns Off the
oil heating system.
NOTE: When PRP224078-000 is used, the hex inlet fitting of the pressure switch
should never be turned when connecting the oil line. Hold the hex nut fitting
firmly when attaching the oil line.
Pressure Switch Replacement Part Numbers

Model Part Number Range
OER PRP224078-000 5 – 30 PSI
OWT PRP224008-000 8 – 20 PSI
pressw.eps
1/4-Inch N.P.T
DO NOT TURN.
Hold firmly when attaching oil line.

System Maintenance and Troubleshooting
This section describes maintenance procedures for the Kim Hotstart Model OWT/OER Heating
System and provides tips for troubleshooting.
System Maintenance
The following maintenance procedures are provided to ensure trouble-free operation of
your heating system:
• Control Box
• Plumbing Connections
• Electrical Connections and Contacts
• Heating Tanks/Elements
• Flow Detection Switch
• Pump & Motor Assemblies
• System Mounting
WARNING
DISCONNECT ALL POWER PRIOR TO PERFORMING ANY SYSTEM
MAINTENANCE.
Control Box
Periodically check gaskets for proper seals.
Check the control box for moisture (if necessary, add desiccant packets).
Plumbing Connections
Periodically check plumbing connections for leaks and, if necessary, tighten
connections. A loose connection on the suction side will cause a loss of flow.
Electrical Connections
Excessive vibration will eventually cause terminals to loosen. Tighten at startup and
check again in a week. Periodically tighten all electrical connections every 3
months.
Electrical Contacts
Inspect electrical contacts for wear. Worn contacts should be replaced with new
contactors.
Section 4 System Maintenance & Troubleshooting 4-1

Heating Tank
At least once per year, clean the interior of the heating tank and the heating element
with a wire brush and/or damp cloth. Periodically check the element for sediment
build-up around the hairpins. Any scaling or build-up will shorten element life.
Maintenance and replacement procedures for the heating element are described in
System Components of this manual.
Following lengthy system shut downs, remove the terminal covers of the element
assembly as shown in System Components and check for any moisture or
condensation. Electric tubular heating elements contain a granular refractory
material called magnesium oxide (MGO) to insulate the resistor coil from the outer
metal sheath. MGO is hygroscopic, which means it has the ability to absorb
moisture from the air. MGO contaminated with moisture reduces the insulating
value of the MGO which is measured with an Ohm meter and read as resistance on
the megohms range (1 meg-ohms = 1 million ohms = 1M Ohms) . Low resistance
(less than 1M Ohms) is a transient condition experienced on first heat-up under
normal periodic heater usage. Moisture absorption under normal conditions does
not affect heater efficiency or life.
The minimum required resistance value is 1.0M Ohms for full power voltage
operation. However, heating elements with a moisture barrier sealant such as RTV
silicone or epoxy potting will require a minimum value of 5.0M Ohms. Resistance
values should be measured with an Ohm meter by applying one lead to the
termination and the other to ground. When the heater does not meet the required
resistance value, the unit will have to be dried out prior to full power operation.
If the heater has 0.1M Ohms (100K Ohms), or better, but less than 1M Ohms, the
heater should be operated at half the rated voltage for 30 minutes to dissipate the
accumulated moisture. Disconnect the power after 30 minutes and check the
resistance. An alternative to applying voltage is to manually dry the heaters in an
oven at 300°F for 4 hours then check its resistance again.
If the resistance is higher than it was originally, repeat the process until the value
reaches the minimum requirement of 1M Ohms. The heater can then be operated at
full rated voltage.
A resistance reading of 0.0 megohms, or a reading lower than originally measured,
indicates the heater has absorbed a considerable amount of moisture. Remove the
wires and jumper straps from the element as shown in Heating Element
Replacement section of this manual and check element resistance to ground. After
drying, reassemble the element in reverse order.

Flow Detection Switch
Inspect the flow detection (flow control) switch periodically for foreign buildup on
the shuttle body. To clean the flow detection switch, follow these steps:
Step 1 Shut OFF the oil supply to the heating
system. Flow Detection Switch
Step 2 Remove the bonnet nut and lift out the

entire switch assembly. Bonnet Nut
Step 3 Remove accumulated sediment from the

switch body with a damp cloth.
Step 4 Check the switch for proper operation by
sliding the shuttle and magnet up over
the main shaft as shown below. If the
shuttle hangs up or does not slide
smoothly, remove the lock ring from the flowdect1.ai
bottom of the switch assembly and slide

the shuttle, magnet and spring off.
Step 5 Remove foreign matter and rough spots
from the shaft with denatured alcohol. Bonnet Nut
Step 6 Reassemble the switch and check it
again for proper operation (reference
step 4).
Step 7 To test operation of the switch assembly, Switch Body
turn ON the main power. When the
magnet on the shuttle is slid up the shaft,
the magnetic contactor that operates the
heating element should close.
CAUTION: When testing the flow switch,
Tension Spring
do not operate the heating system any
longer than 5 seconds or damage to the
Magnet
heating element may occur.
Step 8 Once the switch assembly is working Plunger Body
properly, reassemble the flow switch and
set the time delay relay to the desired Lock Ring
setting. The recommended setting is 30
seconds.
Base
flwdect2.ai

Pump and Motor Assemblies
Two different types of motors are used: one uses sealed bearings and the other ball
bearings. Sealed bearings require no maintenance. For ball bearing motors,
lubricate fittings periodically (usually every 6 to 12 months for normal
applications).
Pumps - replace seals and gaskets as required. See Appendix A.
Seal life is very difficult to estimate due to a variety of controlled and uncontrolled
conditions the seal operates in. Pump seals by nature will weep some even when
new.
The mechanical seal faces cannot be permitted to be in contact in a dry
environment. Some liquid must pass between the rotating and stationary face in
order to minimize friction and to carry away the heat generated. If this leakage
evaporates when reaching the atmosphere, then there is no visible leakage. If it
doesn’t, leakage in the order of 10 drops per day might be the best achievable.
Some seal manufacturers rely on high face loading to minimize leakage but at the
expense of seal longevity. Others do the opposite, which provides longer life but
greater leakage.
Field installation of the seals is not as exact a procedure as is possible when this is
done in a factory environment with experienced assemblers. It is possible to
experience some minor leakage on field installed seals. Excessive leakage can also
be an early indication of seal failure, warning of the need for impending
maintenance. Before installing, repairing, or performing maintenance on pumps,
read and understand the pump’s instructions completely. Undersized or excessively
long suction lines can cause excessive vacuum on the seal and cause leakage from
the seal. Please see page 2-2.
System Mounting
Excessive vibration may cause mounting bolts to loosen. Periodically check and
tighten all mounting bolts.
To allow air to escape, the system must be mounted with the outlet of the tank at the
top of the system.

Troubleshooting
The Fluid Does Not Heat
Probable Causes:
• No electrical power
• Blown fuse
• Problem with the flow switch
• Problem with the thermostat
• Problem with the heating element
Recommended Repairs:
Electrical Power - Make sure that the control box’s “ON/OFF” switch is in the
“ON” position. Observe the power light on the control box. If the power light is
not on, make sure that the main power supply and the 24 V supply are ON. If
the power supplies are ON but the power light on the control box is OFF,
troubleshoot the electrical system.
Fuses - Inspect the fuses for the main power supply. Inspect the fuses in the
control box. Replace any blown fuse. If the fuse is blown again, troubleshoot
the electrical system.
Flow Switch - If the flow switch is not operating properly, the flow switch can
improperly remove the power supply from the heating element.
Make sure that the flow switch is operating correctly. Inspect the flow switch
and clean the flow switch. For instructions, refer to page 4-3. Replace the flow
switch if necessary.
Thermostat - The thermostat’s contactor is normally open. If the temperature is
less than the thermostat’s rating, the thermostat’s contactor closes in order to
energize the heating element. If the temperature becomes greater than the
thermostat’s rating, the thermostat opens again.
To verify whether there is a problem with the thermostat, measure the
thermostat’s resistance at a temperature that is less than the thermostat’s closing
temperature. If the resistance is greater than 200,000 ohms, the contactor is
open.
Continue to measure the thermostat’s resistance and increase the temperature to
the thermostat’s closing temperature. If the resistance is less than 5 ohms, the
contactor is closed.
the thermostat’s opening temperature. If the resistance is greater than 200,000
ohms, the contactor is open.
For the thermostats’ operating temperatures, refer to page 3-9. If the thermostat
fails to operate correctly, replace the thermostat.

Heating Element - Deposits and moisture will reduce the heating element’s
efficiency. Clean the heating element and check the heating element for a short
circuit to ground. For instructions, refer to page 3-6.
The Flow of Fluid is Inadequate
Probable Causes:
• Closed ball valves
• Air leaks in the suction side
• Obstruction in the supply lines and/or the return lines
• The pump is not primed.
• Incorrect pump rotation
• No electrical power
• Blown fuse
• Problem with the flow switch
• Pump cavitation
• Improper impeller clearance or improper assembly
Ball Valves - If the ball valves are closed, the heater is isolated from the
engine’s fluid. Open the ball valves.
Air Leaks - Inspect the lines and the fittings on the suction side of the pump.
Repair any leaks. Make sure that the fittings are secure.
Obstruction in the Lines - Restriction of the suction lines will not allow the
pump to fill properly. Restriction of the return lines causes excessive resistance
to the pumping. Inspect the lines for obstructions and remove any restriction.
Pump Priming - An air pocket in the inlet side of the pump will prevent the
pump from operating properly. Open a port in the output side of the pump and
operate the pump for a few seconds in order to purge the air. When fluid
appears at the port, close the port.
Pump Rotation - Compare the pump rotation to the directional arrow on the
housing. If the rotation is incorrect, switch any two of the three wires from the
main power supply at the control box.
Electrical Power - Make sure that the control box’s “ON/OFF” switch is in the
“ON” position. Observe the power light on the control box.
If the power light is not on, make sure that the main power supply and the 24V
supply are ON.
If the power supplies are ON but the power light on the control box is OFF,
troubleshoot the electrical system.
Fuses - Inspect the fuses for the main power supply. Inspect the fuses in the
control box. Replace any blown fuse. If the fuse is blown again, troubleshoot
the electrical system.

Flow Switch - If there is a problem with the flow switch, the flow switch can
improperly activate the time delay relay and the power supply will be removed
from the pump motor.
Make sure that the flow switch is operating correctly. Inspect the flow switch
and clean the flow switch. For instructions, refer to page 4-3. Replace the flow
switch if necessary.
The Pump Motor is Overheating
Probable Causes:
• Obstruction in the supply lines and/or return lines
• Inadequate fluid flow
• Problem with the main power supply
• Problem with a thermostat
• Problem with the motor’s protective switch
• Problem with the pump shaft or the motor’s bearing
• Oil Viscosity
Obstruction in the Lines - Restriction of the suction lines and/or the return
lines causes excessive resistance to the pumping. The pump motor will work too
hard and the motor will overheat. Inspect the lines for obstructions and remove
any restriction.
Fluid Flow - The pump is partially cooled and lubricated by the fluid flow. An
inadequate fluid flow can result in overheating of the pump motor. If a problem
with the fluid flow is suspected, refer to “The Flow of Fluid is Inadequate”.
Main Power Supply - The pump motor must have the correct voltage and
frequency. Otherwise, the motor will attempt to compensate for the inadequate
supply and the motor will overheat. Check the quality of the main power supply
and compare the data to the motor’s rating. Make sure that the main power
supply is correct.
Thermostat - The thermostat’s contactor is normally open. If the temperature is
less than the thermostat’s rating, the thermostat’s contactor closes in order to
energize the heating element. If the temperature becomes greater than the
thermostat’s rating, the thermostat opens again.
open.

Motor’s Protective Switch - If there is a problem with the motor’s protective
switch, the switch can incorrectly remove power from the pump motor.
Exchange the switch with a switch that is known to be good.
Pump Shaft or Motor Bearing - A worn pump shaft and/or a worn motor
bearing will result in overheating. Inspect the parts for wear. Make the
necessary repairs.
Oil Viscosity – Viscosity of oil is too thick causing the motor to over-work. The
motor protective switch over heats and trips out. All oil systems are designed to
maintain warm oil takeover. They are not designed to take over on a cold oil
start-up.
The Pump’s Seal is Leaking
Probable Causes:
• Improper assembly
• Damaged seal
• Contaminated fluid
• High fluid temperature
• Dry operation
Damaged Seal - The seal is worn over time. The seal will eventually become
damaged from use. Replace the seal. For instructions on disassembly and
assembly of the pump, refer to pump vendor information in Appendix.
Contaminated Fluid - Abrasive material and/or corrosive chemicals in the
fluid will damage the seal. Other moving parts can also be damaged. Obtain an
analysis of the fluid. Replace the fluid, if necessary. Refer to the engine’s
Operation and Maintenance Manual. Replace the seal. For instructions on
disassembly and assembly of the pump, refer to pump vendor information in
Appendix.
High Fluid Temperature - If the temperature of the fluid is too high, there is
probably a problem with the thermostat.
The thermostat’s contactor is normally open. If the temperature is less than the
thermostat’s rating, the thermostat’s contactor closes in order to energize the
heating element. If the temperature becomes greater than the thermostat’s
rating, the thermostat opens again.

open.
Dry Operation - The pump is partially cooled and lubricated by the fluid flow.
A lack of fluid or an inadequate fluid flow can result in overheating of the
pump. This can damage the seal and the pump’s moving parts. If a problem with
the fluid flow is suspected, refer to “The Flow of Fluid is Inadequate”.
Excessive Noise or Vibration
Probable Causes:
• Improper assembly
• Problem with the pump shaft or the motor’s bearing
• Pump cavitation
Pump Shaft or Motor Bearing - A worn pump shaft and/or a worn motor
bearing will result in overheating. Inspect the parts for wear. Make the
necessary repairs.

System Drawings
This section contains system drawings specific to your heating system
Appendix A A-1
Progressive Equipment Telephone (713) 462-1061
Incorporated Fax (713) 462-4027 DropsA
14028 Aston Avenue Or Contact Us Via E-Mail: SMX Series
Houston, Texas 77040 USA sales@progressive-equipment.com
Divider
Valves
“Your Single Source For Any Lubrication Application”
GENERAL FEATURES
x Integral Porting Adapter for Simple Single to Twin

Outlet Conversion, Reduces Inventory Levels
x Air Bleeds Built Into Base Plate
x Maximum Pressure 7,200 PSI (500 BAR)
x Operates With Oil or Grease
x Full Monitoring Capability
x NPTF-Metric-BSP-SAE Threads Available
x Modular Design—Base and Metering Elements
x Zinc Plated Components
ADVANTAGES
x Modular Design Eliminates Tie Rods

x Metering Elements Can Be Serviced Without METERING ELEMENTS
Disturbing Piping or Tubing
x Internal Cross Porting The Metering Elements are fixed to the base by
x Auxiliary By-Pass Element Available means of two cap screws (provided).
x Easy Conversion From Twin to Single, No Need to
Stock Twin and Single Metering Elements The SMX Metering Elements are available in a wide
x No Limitation To The Maximum Number of range of deliveries (See Chart on Page 2). Cycle
Metering Elements Indicator Pins are available on most size elements
(See Chart on Page 2).
Notes:
1. A Minimum of 3 Metering Elements is Required to A By-Pass element is also available which allows an
Operate The Assembly. addition or reduction of lubrication points at any
2. Each Base And Metering Element Undergoes a time without having to disconnect any piping or
Thermal Explosive Process to Eliminate Foreign tubing.
Matter.
Bridge Elements (Internally Cross Ported) are
DESCRIPTION available. These interconnect and discharge into
DropsA’s SMX is a Modular Design Series Progressive the next element.
Divider Valve Consisting of Two Main Parts; the Base
and Metering Elements. The Metering Elements are supplied with either one
or two outlets, Conversion Plugs are available for
BASE
field conversion from one to two outlets (See Chart
The Base is made up of a minimum of three
Below).
segments:
All Metering Elements are fully interchangeable in
x Inlet Base Section various positions on the base.
x Intermediate Base Section
x End Base Section
Conversion Plugs
And can be increased in number by the addition of
Intermediate Base Sections. Plug Type Plug Part No. Plug Color
This revolutionary system makes the assembly easy

“S” Single Outlet 641708 Silver
and flexible; there is no need to determine in advance
the size of the base, just add on intermediate base
sections by means of Threaded Inserts and Cap “T” Two Outlets 641709 Gold
Screws (Patented).
Base Plate Assemblies Metering Elements
No. of Elements Part Number Metering Delivery In3 Delivery In3 Part
Element Size (Twin) (Single) Number
3 643523 SMX-08 .005 .010 641516
4 643524 SMX-12 .0075 .015 641790
5 643525
SMX-16 .010 .020 641517
6 643526
SMX-25 .015 .030 641518
7 643527
SMX-35 .020 .040 641519
8 643528
SMX-40 .025 .050 641520
9 643529
SMX-50 .030 .060 641521
Note: Bases For 10 or More Sections are available, SMX-60 .035 .070 641522
contact Progressive Equipment for Part Number and
Ordering Information. SMX-65 .040 .080 641523
SMX-00 By-Pass By-Pass 641514

TECHNICAL DATA
Note: 3 Working Metering Elements are Required
Maximum Pressure: 7,200 PSI (500 BAR) to Complete an Assembly. A By-Pass is not consid-
Minimum Pressure: 215 PSI (15 BAR) ered a Working Element.
O-Ring Material: Buna, Standard * Viton, Optional

Adapter Single/Twin
Temperature Range:
Buna Seals: -220 F (-300 C) to +2120 F (+1000 C)
Viton Seals: -40 F (-250 C) to + 3920 F (+2000 C)
Maximum No. of Strokes Per Minute: 500* Depend-

ing on Pressure and Delivery.
Oil Viscosity: Minimum 15 cSt (77.31 SSU) Top View of Metering Element
Grease: Maximum 200 ASTM (NLGI-4)
O-Ring (9 Per Element)

Weight of Single Element: .68 Lb. (0.31 Kg)
Inlet Thread: 1/4” NPT

Outlet Thread: 1/8” NPT
(Consult Pro-Gress for Metric Sizes)
MONITORING OF PISTON MOVEMENT

Bottom View of Metering Element
The following Types of Switches are available to
monitor
Piston movement:
x DNFT—Digital No-Flow Timers (Request DNFT

Brochure) PIN INDICATORS (High Pressure, Blocked or
Plugged Line Indication).
x Deliron Proximity Switch (Request The Deliron
Proximity Switch Brochure) x Pin Indicator, Pressure Type w/ Memory
Available in pressure ratings of: 1500, 2000,
x DELIRON—Magnetic Cycle Indicator (leak-proof) 2500, 3000, 3500, 4000 and 5000 PSI.
DLM-926-PM
DLM-926-PM PANEL MOUNT DELIRON MONITOR PANEL MOUNT
DELIRON
LUBRICATION
MONITOR
Features Specifications
Failsafe Open or Closed Modes Material: Aluminum
2-Line Digital Readout Displays Input Power w/ Power Interface Module

Engine and Compressor Oil 90-180 VDC @ .0005 AMPS
Consumption in Pints Per Day, 90-120 VAC @ .0005 AMPS
Total Cycles and Cycle Time
Input Power w/o Power Interface Module:
User Programmable Alarm Time 6-24 VDC @ .04 AMPS
(3 to 250 Seconds)
Alarm Switch Rating:
Fits Directly Into The 4-1/2” 6-240 VDC @ 10VA / 5-120 VAC @
Cutout In Your Control Panel 2.5VA
Monitors Engine & Compressor Operating Temperature: -200C to +700C

Lubrication (-40F to +1580F)
Model DLM-926-PM (Part No. 000551)

Description Consisting of:
1 Each DLM-926-PM Monitor DLM-926-PM Deliron Monitor
Progressive Equipment Incorporated is 2 Each DLM-D-PRX Proximity Switches With Glass Cover Removed
proud to announce the release of the 1 Each PM970 Power Interface Module
new DLM-926-PM Dual Zone Deliron
Lubrication Monitor for installation
directly into the 4-1/2” cutout in your
Control Panel. Programming Method Determining Divider Block Total
Four Switches mounted underneath the
The DLM-926-PM is a digital micro glass cover. Remove Glass Cover to To determine the divider block total add
processor control device specifically access switches. (Spanner Wrench Is the values shown below for each size
designed to protect Gas Compressors Required) metering element:
from damage due to loss of lubrication.
Lubrication to the Engine/Compressor MODE Metering Element Value
flows through a Divider Block Type Push to access program functions SMX-08 5
Lubrication System forcing an internal SMX-12 8
piston to cycle back and forth. UP
SMX-16 10
Push to increase parameter value
By installing a Proximity Switch on one SMX-25 15
of the Metering Elements on each of the Down SMX-35 20
Master Divider Blocks, the back and Push to decrease parameter value SMX-40 25
forth movement of the pistons result in
SMX-50 30
an On/Off state which the DLM-926-PM Exit
continuously analyzes. Push to exit program mode SMX-60 35
SMX-65 40
If no movement is detected within the PRESSING MODE & UP or DOWN
preset Alarm Delay Time (3 to 250 Changes from one menu item to next Examples:
Seconds, User Adjustable) a
“shutdown” of the compressor will occur PRESSING UP & DOWN (Mode 8) SMX-3 (35S-35S-16T) = 50
preventing damage to the engine and/or Pushed at the same time will zero the
compressor from loss of lubrication. stroke count and run time hours SMX-4 (16T-16T-08S-12T) = 33
Progressive Equipment Incorporated Menu Items (Modes 1 Through 8)

PO Box 40067
Houston, Texas 77240-0067 USA
www.progressive-equipment.com 1. Set Compressor Lube Block Total 5. Select Alarm Logic Mode
Tel (713) 462-1061 (18 to 144) (Open Loop or Closed Loop)
Fax (713) 462-4027
2. Set Engine Lube Block Total 6. Read Back of Last 100 Cycle Times
E-Mail:
sales@progressive-equipment.com (18 to 144) Compressor Lube Block
3. Set Compressor Alarm Time 7. Read Back of Last 100 Cycle Times
Manufactured By:
(20 to 244 Seconds) Engine Lube Block
DELIRON LIMITED - Odessa, Texas
Telephone (800) 337-3412 4. Set Engine Alarm Time 8. Reset Stroke Count and System
Website: www.noflo.com
(20 to 244 Seconds) Total Run Time
551LIT DLM926-3
Digital Lubrication Monitor

04.10.02
WIRING INSTRUCTIONS
Model DLM-926 - Part# 000551
DUAL DIVIDER BLOCK SYSTEM MONITOR

WITH RUN TIME HOUR METER & NO-FLOW SHUTDOWN
MAGNETO
TO ALARM -- COMPRESSOR
TO ALARM -- COMPRESSOR
TO ALARM -- ENGINE
TO ALARM -- ENGINE
COMPRESSOR ENGINE
ALARM
+
6-24 VDC
POWER
l
PROXIMITY SWITCH
COMPRESSOR ENGINE
COMPRESSOR ENGINE
PROXIMITY SWITCH PROXIMITY SWITCH
24S 24S
24S 24S
24S 24S
COMPRESSOR GREEN WIRE ENGINE GREEN WIRE

MASTER DIVIDER BLOCK GROUND SECURELY MASTER DIVIDER BLOCK GROUND SECURELY
Odessa, TX USA
1-800-337-3412 www.noflo.com
Manufactured and Assembled in the U.S.A. By DELIRON LIMITED
*ALL TRADEMARK NAMES ARE THE PROPERTY OF THEIR RESPECTIVE COMPANIES AND ARE NOT ASSOCIATED WITH DELIRON LIMITED.
PROXIMITY SWITCH 169LIT D-PRX SWI
07/18/01
DL-D-PRX
MAGNET SWITCH HOUSING
HOUSING (B) #24 AWG 18" LEADS (3)
(C)
YELLOW
YELLOW
1.125" (Switch
Connections)
MAGNET GREEN
(Ground)
(H)
3.250" ALLEN HEAD SPACER
SPRING
SET SCREWS
(A)
SPECIFICATIONS RATINGS
Part Number....................................................... 000169
CLASS 1, Div 1 Grps A,B,C,D
Material..................................Stainless Steel, Aluminum
o
Temperature Range..............................-40 F to +185 F
o
NRTL/C
LR108334-1
Switch Rating.....10 VA / 200 VDC ½ AMP MAX 125 VAC
...................................MINIMUM BREAKDOWN 300 VDC FOR
Epoxy Encapsulated............UL LISTED EL-CAST VFR 641 TRABON, LINCOLN
R R
MANZEL & DROPSA

R R
DIVIDER BLOCK LUBRICATION SYSTEMS
INSTALLATION AND ADJUSTMENT PROCEDURE 0-RING SWITCH HOUSING

INTERNAL VIEW OF (F) (B)
1. Loosen all (2) Allen head set screws (A) on switch housing (B) and remove DIVIDER VALVE HOUSING MAGNET
magnet housing (C). Do not remove magnet, spring, and spacer from (E) (H)
magnet housing. 24S
2. Remove end plug (D) from divider valve where proximity switch will be
installed. Proximity switch can be installed on any available divider valve 24S MAGNET
section. HOUSING WIRE LEADS
(C) (I)
3. Screw magnet housing (C) into end of divider valve. Torque to 15 foot 24S
END PLUG
pounds max. Be sure 0-ring or metal gasket (F) is in place on magnet (D)
housing (C) if required. DIVIDER VALVE
ASSEMBLY
4. Slide switch housing (B) all the way onto magnet housing (C). Connect (G)
ohmmeter to yellow switch leads. Do not tighten set screws at this time.
5.To properly adjust switch housing (B), divider valve assembly (G) must be ORDERING INFORMATION
cycling so magnet (H) is moving back and forth. This can be achieved with PART
MODEL DESCRIPTION
lubrication system functioning or by manually pumping clean oil through NUMBER
divider valve assembly with a hand pump.
DL-D-PRX DROPSA 000169
6. If a cycle is not detected, adjustment is made by sliding switch housing
(B) out in 1/16" increments. Continuity meter connected to yellow wires will
indicate a switch closure. Adjust 1/16" out until correct adjustment is DL-L-PRX LINCOLN - O-RING STYLE 000170
confirmed. Torque set screws to 25 inch pounds max. TRABON - GASKET STYLE
DL-TG-PRX “1994” AND EARLIER
000171
7. Use 10 to 12 inches of flexible conduit on the switch housing for ease of
TRABON - O-RING STYLE
adjustment or maintenance. All conduit and connections should be DL-TO-PRX “1995” AND LATER 000172
appropriate for area classification. CAUTION: Conduit and fittings must be
supported to avoid bending magnet assembly.
DISTRIBUTED BY
Odessa, TX USA
1-800-337-3412 www.noflo.com
Manufactured and Assembled in the U.S.A. By DELIRON LIMITED
*ALL TRADEMARK NAMES ARE THE PROPERTY OF THEIR RESPECTIVE COMPANIES AND ARE NOT ASSOCIATED WITH DELIRON LIMITED.
LM-92164N
Installation Instructions for Level Maintainers Revised 10-03
Section 15
(00-02-0176)
Model Series LM300

Read the following instructions before installing. A visual inspection of this product for
damage during shipping is recommended before mounting. These installation instructions are
intended for all LM300 series models.
GENERAL INFORMATION
LM301-EX
Shown with optional hose kit fittings
WARNING
**
Patent
LM300: Level Maintainer only (no switches). 5493086
LM301: Low switch contacts for low level shutdown or

alarm. Four wires, SPDT.
LM302: Two switches for low and high level shutdown or alarm. Four wires, Outlet Connection: 3/4-14 NPT left side, right side, and bottom.
DPST, wired N.O. in normal operating ranges. Crankcase Balance Vent Fitting: 1/2-14 NPT.
LM303: Two switches for low and high level shutdown or alarm. Four wires, Mounting: Accepts Murphy pipe mounting or universal mounting brackets.
DPST, wired N.C. in normal operating ranges. Lens: Clear “Frog Eye” non-staining, high impact, high temperature nylon; UV
LM304: Two switches. Alarm before shutdown on low level and shutdown on and heat stabilized.
low-low level. Four wires, DPST, wired N.O. in normal operating ranges. Dial: High visibility white background with green and white “index” lines for
LM305: Two switches. Alarm before shutdown on low level and shutdown on low- normal level indication.
low level. Four wires, DPST, wired N.C. in normal operating ranges. Test Knob: Rotate to test switch operation. Turn clockwise for low level test
and turn counterclockwise for high level test.
Specifications Flow Rate Test: Using SAE 30 @ 32°F (0°C).
Case/Cover: Die cast aluminum.
Switch Housing: Aluminum. Orifice Pressure Flow Rates
Diameter
Approval Rating: LM301 thru LM305 : CSA certified†† for non hazardous 4 ft. oil – 15 ft. oil 4.7 GPH - 31.0 GPH
1/4 in.*
locations. Enclosure Type 4 certified. (6 mm) (1.2 m oil – 4.6 m oil) (17.8 LPH - 117.3 LPH)
LM301-EX thru LM305-EX: CSA certified†† for Class I, Groups C and D;
10 psig – 30 psig
Class II, Groups F and G hazardous locations. Enclosure Type 4 certified. 1/8 in. (68.9 kPa – 207 kPa) 16.9 GPH - 32.1 GPH
Float: Rigid polyurethane foam. Polyurethane coated. (3 mm) [.69 – 2.07 bar] (63.7 LPH - 121.5 LPH)
Maximum Ambient Temperature: 250°F (121°C)
*Standard
Oil Inlet Connection: Top entry 1/2-14 NPT with built-in filter screen (removable NOTE: Friction losses due to piping NOT considered.
for cleaning).
Inlet Orifices: 1/4 in. (6 mm) standard. 1/8 in. (3 mm) available. Optional Hose Kit: 15000355
Wire (switch models): 18 AWG x 13 in. (1.0 mm2 x 330 mm). Quantity Description
Maximum Inlet Pressure (MIP):
Max. Differential: 2 in. (51 mm) between running and stationary oil level. 1 1/2 in. (13 mm) I.D. x
30 psi (207 kPa) [2.07 bar]. 3 ft. (914 mm) long hose
with 1/8 in. (3 mm) orifice. 1 1 in. (25 mm) I.D. x
15 ft. oil (4.6 m oil) 3 ft. (914 mm) long hose
with 1/4 in. (6 mm) orifice.
2 1/2 in. (13 mm) worm gear clamp
Maximum Case Pressure (MCP): 15 psi (103 kPa) [1.03 bar].
2 1 in. (25 mm) worm gear clamp
Orifice Seal†: Buna-N Thumb-Valve™
2 1/2 NPT x 1/2 in. (13 mm) barbed fitting
Switch Contact: Silver, SPDT snap acting, 10A @ 125, 250VAC; 10A @ 30VDC.
2 3/4 NPT x 1 in. (25 mm) barbed fitting
(1 only for low level; 2 only for high & low; or 2 only for low with alarm before shutdown)
††CSA certified with switch contacts rated at 10 A @ 250 VAC (standard).
** Products covered by this bulletin comply with EMC Council directive
89/336/EEC regarding electromagnetic compatibility except as noted.
LM-92164N page 1 of 4
DIMENSIONS
LM300 Series Enclosures Mounting Brackets with Hardware

The dimensions below are for the optional -EX model enclosure. The
standard model enclosure dimensions are the same except the height and 15000371 pipe bracket
width which are: 7 in. (178 mm) H, 7-7/8 in. (200 mm) W. Additional Hardware 5.20 in.
Oil Inlet Connection* 6 in. Supplied (132 mm)
1/2-14 NPT (152 mm) 4.50 in.
with removable (4) 3/8-16 UNC x 1 inch (114 mm) Hole .88 in.
screen
Crankcase Electrical (25 mm) screws (22 mm) dia.
Vent Conduit
1/2-14 NPT 1/2-14 (4) 3/8-16 nut
NPT
.376 in. 2.50 in.
(4) 3/8 I.D. lock washer (10 mm) (64 mm)
(2) 3/8 I.D. flat washer minimum
bottom surface
Test
Knob 2 places
1/4-20 NC
8-1/4 in. 2 places
(210 mm)
Monitoring Port Connection

*Applies to level maintaining models only. 3 places, 3/4-14 NPT 15000370 universal bracket
7-3/16 in. Slot, .390 in. (10 mm)
(183 mm) Additional Hardware
Supplied x 2 in. (51 mm)
Snap Switch
(2) 3/8-16 UNC x 1 inch 4 places (17 6.69
Case Assembly 0 m in.
(25 mm) screws m)
Slot, .390 in. (10 mm)
(4) 3/8 I.D. flat washer x3 4.71
places
in. (120 mm)
5 in
.
5-15/16 in. 1.7 mm)
(151 mm) (2) 3/8 I.D. lock washer (44
(2) 3/8-16 nut
3/8-16
(11 4.50
m n.
2-3/4 in.
)
i
m
UNC-2B
91 0
4 in
(1 7.5
(70 mm) Mounting (13 5.19 mm) .
Holes, 2 places 2 m in.
m)
5-3/16 in.
(132 mm)
TYPICAL INSTALLATION
Mounting (all LM300 Series models) Mounting with Universal Bracket

NOTE: Mount the LM300 series level maintainers as close as possible The universal bracket has two mounting methods: deck mounting and
to the crankcase. Also, excessive vibration can cause overfill. Be sure pan mounting.
mounting brackets are supported. Deck Mounting
The following instructions are based on the usage of the pipe and universal 1. Install the universal bracket to the deck as shown in Figure 2A with two
mounting brackets shown above. flat washers and two 3/8 inch (10 mm) diameter bolts (not supplied).
Pipe Bracket Mounting
1. Mount a nominal 1/2 inch (21 mm) diameter pipe to the deck of the engine.
2. Install the pipe bracket to the LM300 using two 3/8-16 UNC x 1 inch
bolts supplied. See Figure 1A.
3. Slip the LM300 onto the pipe and install the two adjustment bolts. Each Crankcase
adjustment bolt consists of a 3/8-16 UNC x 1 inch bolt and two nuts. See Universal
Bracket
Figure 1B. DO NOT tighten the adjustment screws too tightly because
you will have to adjust the LM300 later in the installation process.
Threaded Adjustment
Deck hole Bolts
Pipe
Bracket
Figure 2A Figure 2B
Adjustment 2. Mount the LM300 to the universal bracket using two 3/8-16 UNC x 1
Bolts
inch (25 mm) bolts supplied (Figure 2B). DO NOT tighten the
adjustment screws too tightly. You will have to adjust the LM300 later in
the installation process.
LM300 Pipe Crankcase
Figure 1A Figure 1B
TYPICAL INSTALLATION continued
Crankcase (Oil Pan) Mounting 4. Fill the crankcase to the proper oil levels. With the engine running and
1. Install the universal bracket to the crankcase using the existing warm, loosen the mounting bracket adjustment bolts and adjust the
crankcase bolts (Figure 3A). Crankcase bolt diameter must be no larger LM300 so that the oil level in the sight gauge is aligned with the white
than 7/16 inch (11 mm). “index line” on the dial (Figure 4). Tighten the adjustment bolts securely.
Connecting the LM300 to an Oil Supply Tank
Crankcase (level maintaining models only)
Bolt 1. Remove the caplug from the oil inlet connection. Be sure the filter, inside
Universal the connection, is clear of debris. Install the oil inlet connection.
Bracket
Crankcase
2. Connect a 1/2 inch I.D. (13 mm) or larger hose
Note Clearance to oil inlet fitting on the LM300 and to the shutoff Oil Supply
before mounting Tank
valve on the oil supply tank. See Figure 5. For
Adjustment models LM300 thru LM305 recommended
Bolt
minimum mounting of the oil supply
tank above the LM is 4 ft. (1.2m); Oil Inlet
Hose
Figure 3A Figure 3B maximum 15 ft. (4.6m). The
hose must maintain a
NOTE: Check clearance between crankcase and mounting bracket downward slope and not have
before installing the mounting bracket. If space between the crankcase low spots or droops.
and mounting bracket does not allow installation and access to the Maximum head pressure
adjustment bolts advance to Step 3. rating using standard 1/4 in. (6
2. Mount the LM300 to the universal bracket using two 3/8-16 UNC x 1 mm) orifice is 15 ft. (4.6
inch bolts supplied. DO NOT tighten the adjustment bolts too tight. You meters). See Flow Rate test on
will have to adjust the LM300 later in the installation process. page 1 for additional orifice pressure
3. If space between the crankcase and mounting bracket is narrow, install ratings.
Figure 5
the universal mounting bracket to the LM300 before installing to the 3. Before filling the supply tank with
crankcase oil pan. oil, be sure the tank is clean and dry andthe shutoff valve is closed.
Also, be sure all hoses and clamps are tight. Fill the tank with CLEAN
Connecting Fittings and Hoses oil.
The following instructions are for all LM300 series level maintainers. WARNING: Overfill condition can be caused by excessive
All steps that reference oil inlet or oil supply tank DO NOT apply to inlet pressure, (maximum inlet pressure depends on orifice),
non-level-maintaining models. Also, these instructions are based on the and/or improper “vent to crankcase” installation.
Murphy optional hose kit described on page 1. If you did not order the
See Flow Rate Test on page 1 for maximum pressure.
optional hose kit, gather the hoses, clamps and fittings as specified in
the optional hose kit. 4. After oil supply tank is full, open the shutoff valve.
1. Install the LM300 fittings in their proper locations. NOTE: Apply a
sealant such as teflon, to all threaded connections. Next, make the proper electrical connections for the application. See
2. Attach the 1 inch (25 mm) diameter, flexible monitoring hose to the contact ratings on page 1 and schematics on page 4.
crankcase and the monitoring port on the LM300. See Figure 4.
CAUTION: The hose must slope slightly downward from the LM300 Switch Test (switch models only)
and MUST NOT have any droop or low spots. To test the shutdown and/or alarm functions
perform the following:
NOTE: If the drain plug on the crankcase
is used for the connection, we 1. Unscrew protective boot from test knob.
IMPORTANT: Always replace boot after
recommend installation of a tee to Oil Inlet
testing.
allow draining of the crankcase Vent Hose
for service. Hose 2. Turn the test knob 1/4 turn to the right
Viewing (clockwise), for low test indication (Figure 6).
3. Install the 1/2 inch (13 mm) Lens
Running Figure 6
Engine 3. Turn the knob 1/4 turn to the left
I.D. x 3 ft. (914 mm) hose to Crankcase
(counterclockwise), for high test indication. DO NOT FORCE
the vent connection on the Oil Level
THE TEST KNOB TO TURN.
LM300 to the vent connection
on the crankcase. See Figure 4. NOTE: After the engine shuts down, you will notice that the oil in the
The vent connection on the Monitoring Hose sight gauge glass will rise above normal running level, possibly
crankcase must be well above the showing an overfill condition. This is a result of “drain-back” to the
regulated oil level. All hoses must engine crankcase and it is normal. Therefore, on models LM302 and
Figure 4 LM303 it may be necessary to wire the high level shutdowns into a
be clear of obstructions.
class “B” or “C” (bypass until first time safe) lockout, so as to allow a
BEFORE CONTINUING, VERIFY THAT ALL HOSE CLAMPS permissive start. After the engine is re-started the level will pull down
ARE TIGHT. to the normal running level and the shutdown features will be active. A
modulating valve (Thumb-Valve™) in the level maintaining models
will allow oil usage to be made-up continuously during operation.
SWITCH WIRING DIAGRAMS
WARNING: DISCONNECT ALL ELECTRICAL POWER BEFORE CONNECTING ANY WIRES.

LM301 LM302 LM303 LM304 LM305
SPDT High/Low N.O. High/Low N.C. Alarm before Alarm before
DPST DPST shutdown N.O. shutdown N.C.
DPST DPST
Green Green Green Green Green
Black Black Brown

High High Normal
Normal Normal
Yellow Normal Low
Normal Low
Red Low Brown Black Low-Low
Low Low Low-Low
High High Normal Normal

Float Yellow Blue Normal Orange Yellow Blue Orange
Normal Low
Low
Red Red
Low Low-Low
Low Low-Low
Float Float Float Float
OPERATING RANGES OF SWITCHES
This section applies only to models that have built-in switches. The illustrations
3/8 in.
below and to the right show the dials and their operating ranges of the switches. (10 mm)
If levels are within the designated zones the switch(es) will activate. Notice that High Zone
a switch is capable of activating approximately 3/8 in. (10 mm) from the top of 3/4 in. Shutdown or Alarm
(19 mm)
the high zone and 3/8 in. (10 mm) from the bottom of the low zone. The dial in Normal
Operating Range
Figure 9 shows that if level continues to drop into the low-low zone, a 3/4 in.
(19 mm) Low Zone
shutdown will occur. Shutdown or Alarm
NOTE: Color zones on dial face show approximate normal operating zones. 3/8 in.
Actual conditions may vary depending upon operating characteristics of the (10 mm)
engine. Placement of the LM300 according to the above instructions will

Figure 8: LM302/LM303
compensate for these conditions.
Normal Normal
Operating Range Operating Range
3/4 in. 3/4 in.
(19 mm) Low Zone (19 mm) Low Zone Alarm
Shutdown or Alarm Low-Low Zone Shutdown
3/8 in. 3/8 in. 1/4 in.

(10 mm) (10 mm) (6 mm)
Figure 7: LM301 Figure 9: LM304/LM305
Warranty
A two-year warranty on materials and workmanship is given with this FWMurphy product.
A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/warranty.asp.
® P.O. Box 1819; Rosenberg, Texas 77471; USA Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. 1620 Hume Highway
+1 281 633 4500 fax +1 281 633 4588 +44 1722 410055 fax +44 1722 410088 Campbellfield, Vic 3061; Australia
FWMurphy e-mail sales@fwmurphy.com e-mail sales@fwmurphy.co.uk +61 3 9358 5555 fax +61 3 9358 5558
P.O. Box 470248 MURPHY DE MEXICO, S.A. DE C.V. www.fwmurphy.co.uk e-mail murphy@macquarrie.com.au
Tulsa, Oklahoma 74147 USA Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje MURPHY SWITCH OF CALIFORNIA
+1 918 317 4100 San Luis Potosí, S.L.P.; México 78384 41343 12th Street West
fax +1 918 317 4266 +52 444 8206264 fax +52 444 8206336 Palmdale, California 93551-1442; USA
D
RE
GI
STER
E
e-mail sales@fwmurphy.com Villahermosa Office +52 993 3162117 +1 661 272 4700 fax +1 661 947 7570 USA–ISO 9001:2000 FM 28221
www.fwmurphy.com e-mail ventas@murphymex.com.mx e-mail sales@murphyswitch.com UK–ISO 9001:2000 FM 29422
www.murphymex.com.mx www.murphyswitch.com
Printed in U.S.A.
Section 11 – IGTB RPM Control
Vendor Bulletin No.
IGTB Assembly Illustrated Parts List ................... Ajax TP 1302-000-04
IGTB Operation and Problem
Diagnostics ..................................................... Ajax TP 1300-000r2
V1 System Junction Box Assembly ..................... Ajax TP YAE-5583
V1 System Junction Box Wiring Schematic ......... Ajax TP BM-21161-C
V1 System Panel Mounting ................................. Ajax 02-19-T01A-300
Alternator Output vs Engine RPM w/5.33:1 Ratio........... Ajax 11-24-03
V1 Alternator Installation Instructions ............................. Altronic ALT II 2-01
V1 Alternator Service Instructions................................... Altronic A24 SI 2-01

1302-000-04

1 IGTB Governor, 30mm, 24VDC BM-21152-30 1 ea 40 Magnetic Pick Up, -18 x 3" 2049 1291 1 ea
2* Cable & J-box Assembly YAE-5583 1 ea 41* Mag P/U Cable Assembly 3850 0033 1 ea
3 O-ring BM-21146 2 ea 42 Mag P/U Bracket 8025 9400 1 ea
4 Outlet Flange K-8256-A 1 ea 43 O-ring, Alternator Flange BM-16348-F-236 1 ea
5 Inlet Flange K-8256-C 1 ea 44 Plate A-1944-A-2 1 ea
6 SHCS #10-24 x 5 UNC BM-11473-0324-40 4 ea 45 Gasket Flat Oval A-2233 1 ea
7 Lock Washer, #10 BM-11782-A-03 4 ea 46 Trough A-2115 1 ea
8 Support Bracket K-8256-B 1 ea 47 Gasket Flat Oval A-2117 1 ea
9 HHCS, -11 UNC x 3¼ BM-11900-1011-26 2 ea 48 Stud K-8095-0813-16 2 ea
10 Flat Washer, " BM-11918-12-N 2 ea 49 Nut Plain Hex BM-11904-0813 2 ea
11 PCC Fuel Filter Bracket K-7889-1 1 ea 50 Bolt Hex Head BM-11900-0616-10 2 ea
12 Lock Washer, " BM-11782-A-06 2 ea 51 Elbow Tube Compn BM-11573-S-6-4 2 ea
13 HHCS, -16 UNC x 1 BM-11900-0616-08 8 ea 52 Bolt Hex head BM-11900-0813-10 5 ea
14 Needle Valve 2549 0057 2 ea 53 Tubing Welded BM-21071-3-035 1 3 ea
15 Gauge, 0-30 PSIG 2015 3312 2 ea 54 Union Tube Compn BM-11623-S-6-6 1 ea
16 Hex Head Plug, ¼" NPT BM-11950-02 1 ea
17 Male Tubing Elbow, ¼" BM-11573-S-4-4 1 ea
18 Flexible Hose, 1" K-8263-A-24 1 ea
19 Flexible Hose, 1½" K-8262-A-30 1 ea
20 Pipe Nipple, 1½" x 4"L BM-11932-12-09 1 ea
21 Street Elbow, 45º, 1" NPT BM-11969-08 1 ea
24 Alternator Drive Assy, 5.33:1 YAE-1561-E 1 ea
25 Drive Assembly Gasket K-6258-C 1 ea
26 Drive Gear, 5.33:1 System A-4658-A 1 ea
27 Set Screw BM-11095-A 1 ea
28 Stud, -16 UNC x 2¼"L K-8095-0616-18 4 ea Note: refer to Manual's section 11 for additional
29 Flat Washer, " BM-11918-08-W 8 ea information about the IGTB system.
30 Lock Washer, " BM-11782-A-06 6 ea
31 Hex Nut, -16 UNC BM-11904-0616 4 ea *shipped separately
32 V1 Alternator, 24VDC BM-21156 1 ea
34 HHCS, -16 UNC x 1¼"L BM-11900-0616-10 2 ea
37* Battery Pack BM-21158 1 ea
38 Lubricator Drive Assy, 5.33:1 YAE-5581 1 ea

1302-000-04 091205
The IGTB is a combination of a throttle and an electronic governor, therefore “integrated governor
throttle body” or IGTB. Its function is to maintain an established RPM set point through out the load
range of the engine.
Note: the throttle is not a shut off valve. There is enough clearance between the body and the throttle plate
to allow the engine to run under certain conditions at less than rated idle RPM when the governor is not
powered.
As shown in Figure 1, the governor measures the RPM with a magnetic pick up and compares it to the set
point RPM supplied by the pressure transducer.
24vdc
supply
3-15 psig =
300-440 RPM
294 pulses/rev
1-5vdc
MPU
Fuel Fuel
Inlet Outlet
IGTB
Figure 1
RPM set point is established by a pneumatic 3 to 15 psig signal to the pressure-to-voltage transducer:
RPM Voltage Pressure When the set point is changed to an increased value the rate of
300 1.8 3 acceleration to that value is 6 RPM/second.
335 2.6 6 When the set point is changed to a decreased value the rate of
370 3.4 9 deceleration is 12 RPM/second.
405 4.2 12
440 5.0 15 An attained RPM set point is maintained by PID values for best
response to changes in load.
The governor has an operating voltage range of 18 to 28 Vdc with a nominal voltage of 24V. The
governor consumes 32W maximum power at a peak current of 1.3A (24V) assuming 4 ohms stator
resistance at 77ºF.
Its operating temperature range is -40ºF to 221ºF.
Protect the system with a 6A fuse in the voltage supply line.
The governor will not consume power when the engine is stopped. However, if the engine will be out of
service for an extended time, it is best to disconnect the input power.
NOTE
Cooper Compression
The governor should not be used for engine shutdown. 2101 S.E. 18th Street
Oklahoma City, OK
73129-8351
Ground the ignition system and shut in the fuel supply
to assure engine shutdown. IGTB Operation
and Problem Diagnostics
TP 1300-000 r2
The governor’s tuning values (gain, reset, etc.) are optimized for conventional compressor RPM control
operations, and step load operations. The values are fixed, and are not field adjustable. Ring gear tooth count
and RPM set point vs set point voltage can be altered by use of a downloadable file from Woodward, a data
link wiring harness (p/n A-4669), and a PC’s RS-232 port. Instructions accompany the A-4669 data link
wiring harness.
When the engine is operating at rated load and speed, adjust the fuel supply pressure to be 4 to 6 psig above
the fuel pressure downstream of the governor. Assure that the engine will idle without load at that pressure
setting. If it does not, reduce the supply pressure slightly so that no load, idle RPM can be achieved.
Problem Diagnostics
Use the throttle’s fuel supply pressure gauge and fuel outlet pressure gauge to help analyze governor
performance. For example, notice the outlet pressure at engine light off, or the outlet pressure at typical
operating conditions. (Be certain that the isolation/dampening valves are adjusted for credible readings.)
When performing electrical diagnostics, use a digital voltmeter connected to the governor’s wiring harness
plug. The appropriate pin connections are listed in the table below, and on the wiring harness assembly
drawing. All voltages will be Vdc. If your voltmeter does not have an RMS function to measure the MPU
signal level, use Vac for that signal only. (Be certain that the engine’s ignition will be grounded, and the fuel
supply will be shut in for these tests.)
Problem Possible Cause Suggested Test/Correction
Engine does not start Power not applied Disconnect harness from governor. Test for
+24V between plug socket # 1 and # 5.
MPU gap too large Rotate engine manually to check for 0.020” to
0.030” gap.
MPU signal connection Disconnect harness from governor. Reset the
open annunciator. Test for at least 2 Vrms between
pin 11 and pin 3 during cranking.
Stuck throttle shaft Remove the governor. Move throttle by hand.
Assess smoothness, friction, and return spring
force.
Engine starts, but shuts down. MPU gap too large Rotate engine manually to check for 0.020” to
0.030” gap.
Engine starts, but does not accelerate to Inadequate electrical Assure that 18-28Vdc is supplied to governor
idle RPM power pin connections #1 (+Vdc) and #5 (–Vdc).
Manually switch off governor power. Then
switch it on, and restart the engine. If RPM
control does not occur, replace the governor.
Engine starts and runs, but is unstable Ignition misfire Troubleshoot the ignition system
Precombustion Chamber Check for normal PCC fuel pressure, and
fuel supply fouled or stuck check valves
Gas Injection Valve Using combustion pressure measurement,
Adjustment balance the firing pressures.
Unable to attain rated RPM with a slight Pressure transducer output A 3-15 psig input signal should produce a 1.8-
load. low 5vdc output signal. Apply 15 psig to the
transducer input. If 5vdc is not measured
between plug’s pin 8 (Vdc+) and pin 3 (Vdc-),
replace the transducer.
Unable to develop full load RPM Low fuel pressure Increase the fuel supply pressure
Unable to idle at no load High fuel pressure Decrease the fuel supply pressure
NOTE
The governor should not be used for engine shutdown. Cooper Compression
2101 S.E. 18th Street
Ground the ignition system and shut in the fuel supply Oklahoma City, OK
to assure engine shutdown. 73129-8351
IGTB Operation
and Problem Diagnostics
TP 1300-000 r2
Socket # Wire Color Label Signal Value
1 Red +24vdc 18-28vdc
2 Not used ------ --------- RPM Set Point vs Signal (Vdc or PSIG)
MPU- &
3 Black Electrical ground RPM Vdc PSIG
Aux-
4 Not used ------ --------- 300 1.8 3
5 Black -24vdc Electrical ground 335 2.6 6
6 Not used ------ --------- 370 3.4 9
7 Not used ------ ---------
8 White Aux+ 5vdc (max) @ 15 psi input
405 4.2 12
9 Not used 440 4.9 15
10 Not used ------ ---------
11 Red MPU+ 5-8vdc at 100 RPM (min)
12 Not used ------ ---------
------ Green Shield Electrical ground
To MPU cable and

panel’s electrical ground
Do not allow the cable to be strained.
Support it if necessary.

A Junction Box Assy BM-21161 1 Cooper Compression
B Wiring Schematic BM-21161-C 1 2101 S.E. 18th Street
C Aux 24vdc Warning BM-21161-D 1 Oklahoma City, OK
D Nameplate BM-21161-B 1 73129-8351
E Governor Cable BM-21152-A-25 1
F Voltage Reg Cable BM-21159 1
To 24Vdc battery ONLY
Cable & Junction Box Assembly
G Voltage Regulator BM-21157 1
IGTB with V1 Alternator System
H V1 Alternator Cable BM-21160 1
J Pressure Transducer 2515 0063 1 TP YAE-5583 r2
Note
If an electrical RPM set point signal is desired instead of
a 3-15 psig pneumatic set point, connect the 1-5vdc from
the set point’s source to Terminal 6, (WH).
An electrical ground common with the j-box is necessary.
Cooper Compression
2101 S.E. 18th Street
Oklahoma City, OK
73129-8351
IGTB with V1 Alternator 24VDC

Input from V1 System
Supply System – J-box Wiring
Battery Box only.
TP BM-21161-C r3i
RPM vs Alternator Current @ 5.33:1
460
440
420
400
380
Engine RPM
360
340
320
300
280
260
240
2.0 2.5 3.0 3.5 4.0
Alternator Current
ALTR0N86 24VDC ALTERNATOR
ENGINE DRIVEN POVdER PACWGES
1.I The Aitoonic 24VDC alternatorlregulator packages provide a reliable, engine-mounted source of DC power for
ABtronic DC-power& digital Igwt~ionsystems, dher Altronic engine accessories and Alcrsnic Controls panels.
There are two versions available.
VERSION I - The 590110 series (coupSing driven) or 5901 $ 6 series (belt driven) provide up to 70 watts
(3 amps) output ar 1,800 RPM.
VERSION 81 -The 5WI 11 ssries (coupling driven) or 5W1 I7 series (beEr driven) provide direct power for the
AIPronic CDI, CPU-90 and DlSN ignition system thus @ofistilutinga self-power&, digital ignition system.
1.2 The SslEowing components are required:
1. Alternaios Unit
2. Regulator (586 501 or 581502)
3. Cable A s s ~ ~ b i y
4. Battery Pack (591100) - used only wtth Version 6 series alternators
2.0 ALTERNATOR UNlT

2.1 COUPLING DRIVEN UNIT: The alternator is available with several flange assembiies to facilitale mounting to
most engines h a v i n ~a Range magneto drive. The alternator shou%abe secured to the mounting using 318"-16
screws; tighten the screws securely.
2.2 BELT DRIVEN UNIT: The alternator must be driven with a pulley having an adjustable 518" I.D. hub. Use a p~lYey
diameter Po achieve a speed necessary to satisfy the ~ r i l p urequirements
t of %heapplication - refer to the chart
on drawing 509 0598 persion I) or 509 OBOA (Version El). The alternator should be secured to a mounting
bracket using two 318"-16 screws; tighten the screws securely.
2.3 The maximum recomrmended continuous operating RPM for the alternator drive shafi is 2,000 WPM.
3.1 Be sure ;he regulator is the ccprrecr model for the alternator being used; the regulator pari no. must match that
printed on the alternator label.
3.2 Locate a suitabse m o u n t i ~ gposition for the regulator unit within reach of the cable assembly and where the
ambient temperature does not exceed 150" F. (65" C.).
3.3 Secure the regulator with four 114" screws
4.0 BABrERV PACK (used oniy wlth Version l series alternator and 581501 regulator)
,
ismitic;; c;r the banct\l !-~ack
bocs$e3 sL&ebIa mcdf-;r.;,i-tg i~\iithinrest?? oi c&;e e$se;;-;oii,
"
4.1 z,iqc i ~ ; ? ~ :I;,;
re
an-ib~enttempersture does nor exceed 122' F. (5$ C.).
4.2 The battery pack IS fum3shec.v~ilthshock mounts and 314" mounting l-iardware. Tighten all isui rzt~tssee2ie3y
5.8 NfIRGNG HOOK-UP

5.f Refer l o the drawil-igs for rnouriting dimensions for the various system componei?;s:
- For alternator dimensions, see drawing 509 056A.
- For regciator dims.&~ns, see drawing 509 357A.
- For battery pack dimensions, see drawing 509 058.
5.2 Refer l o fi-ie diagrams for the proper wiring hook-up for the particlala; altemator1reguiaPor version 5sing ~s2j-4:
- For the Version i system, see drawing 509 053A or 503 063W (shielded system).
- For the Vswior: il system, see drawing 509 060A or 509 0644 (shielded system).
~ E R S I O NI
MODEL
I VERSION II
MODEL
I PILOT DIAMETER *D" / FLANGE
ORIENTATION 1 NO. OF
.44 S L O J
5901 10/590111 SERIES
r-i
b:
MAX. SYSTEM WTPUT
NOTE:
1. MUST BE USED M T H A BATTERY BACK-UP:
A) ALTRONIC BATTERY PACK 591100; OR
B) TWO BATTERIES POWER SONIC MODEL PS-1242 OR
EQlJlVALENT 12V, 4.0 AMP-HR., WRED IN SERIES
2. POWER FOR ALTRONIC CD1, CPU-90. DlSN SYSTEMS ONLY.
I AmRNAToR~-
usE p ~l
ONLY WITH
REWUlW WTFWT
l - 27 WC
NO', k i G u L A T O R >I WULD BE MOUNTED IN A L0CATlCI.I WHERE MAXIMUM AMBlENr TEMPERATURE DOES NOT EXCEED 1 5 0 F
1 MENc10L!5 lh INCHES AND (MM)

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AJAX® Engine-Compressor Package Service Manual

Section 1 – Supplementary Documentation

Section 2 – Package Drawings

Section 4 – Fuel System

Section 5 – Cooling System

Section 8 – Process Gas Equipment

Section 9 – Control Panel and Instrumentation

Section 10 – Lubrication System

Section 11 – IGTB RPM Control

Engine-Compressor Package Service Manual

Vendor Bulletin No.

Mathematical Conversion Tables ................................... Ajax

Lube Oil & Low Temp Starting

Recommendations .................................................... Ajax ES 1006

Trimming for Sour Gas Applications............................... Ajax ES 25

Installation of Sheave and Flywheel ............................... Ajax ESS-F-961

Flywheel Installation and Ignition Timing........................ Ajax ESS-F-963

Jet Cell Operation and Maintenance............................... Ajax ESS-L-981

Jet Cell System Installation..............................................Ajax ESS-L-983

General PM Schedule .................................................... Ajax TIB 020326

Component Wear Limits................................................. Ajax TIB 020718

% Load vs Engine Coolant Temperature........................ Ajax TIB 030910

Hydraulic Fuel Injection System Purging........................ Ajax TIB 031104

Lubrication Rates ........................................................... Ajax TIB 040910

Installation Design for Permanent Packages.................. Ajax TIB 061115

Engine Operating with Fuel Containing H2S................... Ajax TIB 050610

Torque Tables for Ajax Fasteners....................................Ajax TIB 061212

Engine-Compressor Package Service Manual

Warranties To Original Purchaser (Non-Transferable).

a) "Material and Workmanship Warranty": The Seller warrants

c) "OSHA" Warranty": The Seller warrants for installations

DAMAGES. "IN NO EVENT SHALL SELLER BE LIABLE FOR SPECIAL,

MATHEMATICAL CONVERSION TABLE

Liters Cubic Inches (in3) 61.023

T Newton Meters Foot Pounds (Ft-lb) 0.7376

F Standard Cubic Feet per Minute Cubic Meters/Hr (m/h) 1.70

MATHEMATICAL CONVERSION TABLE

Liters Cubic Inches (in3) 61.023

T Newton Meters Foot Pounds (Ft-lb) 0.7376

F Standard Cubic Feet per Minute Cubic Meters/Hr (m/h) 1.70

 .# / +,

7 2  # 

      

 1 +,  , # 

Engineering Sales &

Keyless Flywheel Installation and Ignition Timing

Page 1 of 4 Released: 6/8/99

Finding TDC and Timing Degree Marks

Page 2 of 4 Released: 6/8/99

Power Cylinder Horizontal

Page 3 of 4 Released: 6/8/99

Engineering Sales &

Setting Timing Of the Flywheel

2804 (DPC-800) Engines Only

Page 4 of 4 Released: 6/8/99

Date: July 13,1998

AJAX JET CELL OPERATION AND MAINTENANCE

JET CELL OPERATION

FUEL ADMISSION CHECK VALVES

Date: July 14, 1998

1. PISTON & HEAD INSTALLATION:

C) Install cylinder head (with gasket) and torque to 600 ft-lbs.

D) Using solder, set piston-to-head striking clearance at 0.110″ (± 0.010″). This is

2. GAS CAM TIMING:

.# /+,

7 2 #

1 +,, #