2009 C300 Operators and Maintenance Manual

OPERATION,
MAINTENANCE AND PARTS MANUAL
TRUCK, TANK, FUEL SERVICING
ISOMETRICS MODEL 505T1200
CONTRACT GS-30F-1032D
ISOMETRICS, INC.
Post Office Box 660
Reidsville, North Carolina 27320

(Rev. H, Dec 2008)
1
TABLE OF CONTENTS
TITLE PAGE
CHAPTER 1. INTRODUCTION 3
1-1. Scope 3
1-2. Physical Description 3
1-3. Functional Description 3
1-4. Warranty Information 5
1-5. Shipping, Handling and Storage Data 5
1-6. Preparation for Use 5
CHAPTER 2. OPERATING INSTRUCTIONS 6
2-1. Scope 6
2-2. Safety Interlocks 6
2-3. Bonding 6
2-4. Prefueling Check 6
2-5. Bottom Loading 7
2-6. Top Loading 8
2-7. Gravity Drain, Unmetered 9
2-8. Fueling Procedure 10
2-9. Tank Loading using the Truck Pump, Unmetered 11
2-10. Defueling 12
2-11. Gravity Drain, Metered 13
CHAPTER 3. MAINTENANCE AND SERVICING 15
3-1. Scope 15
3-2. Cleaning 15
3-3. Lubrication 15
3-4. Inspection 15
3-5. Troubleshooting 15
3-6. Component Repair 15
3.7. Service 15
3.8. Ready for Air Transport 16
CHAPTER 4. PARTS LIST AND COMMERCIAL LITERATURE 20
4-1. General 20
4-2. Parts List 20
CHAPTER 5. SCULLY OVERFILL PREVENTION 23
LIST OF ILLUSTRATIONS
Figure Title page
2-1 Piping Schematic 14
4-1 Pumping Compartment 21
4-2 Pump/PTO Diagram 21
4-3 Top of Tank 22
4-3 Cable Diagram 22
4-5 Electrical Schematic (Lights) 22
4-6 Scully System Schematic 23
LIST OF TABLES page

Table Title
3-1 Daily Inspection 18
3-2 Periodic Checks and Services 18
3-3 Troubleshooting 19
2
CHAPTER 1
INTRODUCTION
1-1. SCOPE. This manual contains operating procedures, service and repair instructions and
and replacement parts for the fuel servicing tank truck manufactured by Isometrics, Inc.,
Reidsville, North Carolina. This manual does not cover components of the truck chassis.
Refer to the chassis manuals provided with the vehicle pertaining to operation, maintenance,
and parts listings of the cab and chassis.
1-2. PHYSICAL DESCRIPTION. The fuel truck consists of a single compartment tank with
baffles mounted on a commercial chassis, a bottom loading system, and a pumping system
with fuel metering capability, and filtration.
a. The pumping system includes a PTO driven pump with internal bypass, a strainer assembly,
a flow meter with reset counter and totalizer, a suction stub, dispensing hose reel, hose,
and a trigger type automatic shutoff nozzle.
b. The bottom loading system includes inlet adapters, a bottom loading valve, an electronic
level sensor with onboard shutoff control and fill stand connections.
c. The bottom loading valve is located in the bottom of the fuel tank. The majority of all other
components are mounted in a pumping compartment between the cab and tank. The pump,
strainer, and associated plumbing are located underneath the fuel tank. The filtration system is
located in the underslung cabinet on the driver's side of the truck. All other pumping system and
bottom loading components are located in the cabinet on the curb side of the truck.
d. Physical data:
1. Model No.: 505T1200

4x2 4x4
2. Tare Weight: 16,700 LBS. 17,700 LBS.
3. Dimensions: 270"L X 96"W X 96"H 270"L X 96"W X 99"H
4. Shipping Cube: 1440 Cu. Ft. 1485 Cu. Ft.
5. Environmental Conditions: -20 to 125 degrees F
1-3. FUNCTIONAL DESCRIPTION.
a. General.
(1) The pumping system provides for a fuel servicing capacity of 75 U.S. gallons per
minute (GPM) at the discharge end of the nozzle.
(2) The truck provides plumbing and controls for bottom loading, pressure off-loading,
and gravity off-loading, both metered and unmetered. A suction stub is also provided to facilitate
self-loading and defueling.
b. Pumping System.
(1) During fueling, fuel flows from the tank through the emergency valve, through the
strainer to the pump. Fuel from the outlet side of the pump flows through the filter/separator,
meter, hose reel, and hose and nozzle assembly.
(2) The pump is driven by a power take-off (PTO) mounted on the side of the transmission.
3
CAUTION
To avoid running the pump dry make sure the emergency

valve is open prior to engaging the PTO. Refer to the
operating instructions for this procedure.
(3) The emergency valve operator, located in the curb side pumping compartment,
opens the emergency valve. This control also serves to close the valve in
an emergency. Striking or pushing the handle allows an internal valve spring to close the
emergency valve. Emergency controls, operable for closing the emergency valve only, are
located at the right rear of the truck, at the driver's door, and on top of the tank. They are marked
with red square decals with 2-inch instruction letters.
(4) Two each 40 GPM filters (if so equipped) are located in the cabinet on the driver's side of
the truck. They are connected in parallel from the discharge side of the pump to allow for a total flow of
80 GPM. They filter solids and separate any water in the fuel. Drains at the bottom of each filter
allow for water and solids removal on a periodic basis. Each filter is equipped with a heater for
cold weather applications. The heaters are activated by a toggle switch located to the left
side of the steering column on the dash.
(5) An air eliminator flow meter assembly is located downstream of the filters in the curb side
cabinet. It is rated for 100 GPM and comes complete with reset counter and totalizer.
(6) Next is the hose reel, hose, and nozzle assembly. The hose reel is of the manual rewind
type with 100 feet of 1-1/2 inch commercial grade fuel hose. A 1-1/2 inch trigger type automatic
shutoff nozzle rated at 75 GPM is attached to the hose.
c. Bottom Loading System.
(1) The bottom loading valve, located in the bottom of the tank also serves as the emergency
valve. Air pressure from the emergency valve operator or the bottom loading interlock opens it.
It is a balanced type valve that will remain closed, regardless of fill stand pressure, if there is no
air source to open it.
(2) A bottom loading manifold, located on the left side of the truck, is provided for the fill stand
connection to perform the bottom loading task. Each leg of the manifold serves as a quick disconnect
drybreak connection. In order to connect the fill stand coupler, a valve lever must be moved to the
side. This action opens the air vent on top of the tank, sets the truck brakes, and opens the bottom
loading valve unless the tank is already full. One leg of the manifold is a D-1 nozzle adapter and
the other leg is a 4-inch API commercial bottom loading adapter.
(3) An electronic level sensor is installed in the top of the tank. When fuel contacts
this probe, an electrical signal is transmitted to a control module located on a bracket in the curb side
cabinet. A socket array is also provided to interface with the appropriate fill stand connection.
When fuel contacts the sensor, the fill stand controls stop the fuel flow into the tank.
If fill stand controls are unavailable, the onboard system will automatically stop the flow by
closing a solenoid air valve plumbed between the bottom loading valve and the brake interlock.
Air will exhaust and the bottom loading valve will close.
4
d. Top Loading. The tank may be loaded from the top by opening the fill cover in the manhole
cover located on the top of the tank and inserting the fill hose into this opening. The hose should
reach the bottom of the tank to avoid static charge buildup.
e. Vent Valve. A vent valve, located in the top of the tank, vents the tank to atmosphere
during loading and off loading. The vent valve opens whenever the emergency valve operator is
engaged or the bottom loading interlock is activated. This valve is pneumatically controlled.
The vent is equipped with an interlock feature so that pumping operations cannot be performed
unless the vent is open. The vent is open to the atmosphere via vapor recovery piping that
is open at the rear of the tank. A sealed flexible hood is located over the vent valve on top of the
tank. The hood is connected to a header and tubing that terminates at the rear curb side of the
vehicle. Three and four inch open flanged outlets are provided for connection to the vapor
recovery system, if available, at the bottom loading facility.
f. Gravity Unloading. Gravity unloading can be accomplished by attaching a hose to the

2-1/2 inch faucet and opening the bottom loading valve and faucet. Gravity unloading through the
faucet is unmetered.
g. Self-loading and Defueling. Loading the tank using the onboard pumping system or
removing fuel from an item can be accomplished by attaching a suction type hose to the fuel
source or item and the 2-1/2 inch faucet, opening the appropriate valves, and starting the pump.
Fuel will enter the tank via the bottom loading valve.
1-4. WARRANTY INFORMATION. See the warranty page at the end of this manual. For
warranty claims contact the Purchasing Department @ 336.349.2329.
1-5. SHIPPING, HANDLING, AND STORAGE DATA.
a. Shipping. When shipping the vehicle on an open top trailer or rail car, the axles and
landing gear should be used for securing purposes. Insure all product is removed from the tank
and pumping system. A standard single drop trailer is suitable for transport. Refer to paragraph
1-1(d) for weights and dimensions.
b. Handling. The only special handling procedures for this equipment is to insure that all
combustible and flammable liquids are removed from the vehicle prior to shipment. Use API
(American Petroleum Institute) Publication 2013, "Cleaning Mobile Tanks in Flammable or
Combustible Liquid Service" as a guide for purging the tank. To obtain a copy contact:
American Petroleum Institute

1220 L Street, Northwest
Washington, D.C. 20005
(202) 682-8375
Attention: Publications and Distribution Section
c. Storage. For long term storage, it is recommended that the vehicle be prepared as in
the handling section (b) above.
1-6. PREPARATION FOR USE. The vehicle has been completely serviced and adjusted prior
to shipment.
5
CHAPTER 2
OPERATING INSTRUCTIONS
2-1. SCOPE. This chapter contains instructions for the operation of the controls required to
perform tank loading and various fueling operations. Refer to separate truck publications for
information on proper operation of truck controls, and instruments and operation of the
vehicle when in motion.
2-2. SAFETY INTERLOCKS. This unit is equipped with interlocks to prevent movement when
performing a fueling operation. Whenever the valve lever positioned in front of the bottom loading
adapters is moved to the side or the emergency valve operator control is pulled out, the
truck brakes will be applied. Either action also results in the opening of the air operated vent on
top of the tank.
2-3. BONDING. After stopping the vehicle and setting the parking brake, connect a static
reel cable to unit to be refueled.
WARNING
Always establish the static bond between the tank vehicle
and the unit to be refueled. Never attempt any fueling
operation until bonding is complete.
NOTE
Some activities require that grounding also be
accomplished. The static reel is equipped with a
second clamp end for connection to a suitable ground post.
2-4. PREFUELING CHECK. Prior to filling the tank or performing any fueling operation,
perform the following checks:
Note: Refer to Fig. 2-1 for identification and relative location of components.
NOTE
The butterfly valves are closed when the lever is 90

degrees to the piping and open when the lever is
parallel with the fuel flow.
a. Open the cabinet doors on to gain access to the fuel system components.
b. Check that the bottom loading adapters (19) and (20) dust caps, the 2-1/2 inch faucet (17)
dust plug, and the 2 inch faucet (14) dust cap are in place.
c. Check that the lever on the interlock air valve (18) is positioned to interfere with the fill stand
coupler connection.
d. Verify all valves in the pumping compartment are closed.
6
e. Check the manual emergency valve operating handle as follows:
(1) Pull the valve operating handle (22) to its out (open) position and release. A minor
amount of tension should be felt and the handle(s) should remain in the out position. Easily strike
or push the valve handle toward the in (closed) position. The internal valve spring should enable
the handle to move to the in position and thus close the valve. This demonstrates the correct
procedure to close the valve in an emergency. During normal use the handle can simply be
guided to the in position.
(2) Pull the valve operating handle to the out position. Go to the right rear of the truck
and pull the emergency release handle. Check to see if the valve operating handle returned
to the in position.
(3) Pull the valve operating handle to the out position. Go to the left front of the tank,
near the driver's door, and pull the emergency release handle. Check to see if the valve operating
handle returned to the in position.
(4) Pull the valve operating handle to the out position. Go to the top front of the tank
to the in position.
f. Make sure the hose is properly stowed on the reel and that the nozzle is properly
stowed.
g. Visually inspect all components and piping connections for evidence of damage, leakage,
or loosening. (Periodically check nuts and bolts for proper tightness as vibration may cause them to
loosen. Visual inspection will not verify tightness, physically check the fasteners to verify.)
h. Reset the visual counter on the flow meter to zero by depressing the knob on the right side
and rotating it clockwise as viewed into the knob.
2-5. BOTTOM LOADING.
a. After the truck is stopped in the desired location, set the parking brakes from the cab.
b. Shut down the engine and engage the Scully system (if unit is so equipped) by engaging the pull
type switch (overfill control) on the dash. The light near the switch will light when switch is on.
c. Perform the prefueling check in paragraph 2-4.
d. Electrically bond the refueler to the fill stand.
e. Move lever on interlock air valve (18) to side.
f. Connect the fuel supply line to the bottom loading adapter (19) or (20).
g. Make the necessary connections to the Scully socket, if available
7
h. Start filling the tank and make sure system is working properly by pushing the precheck
switch (23). It is located on the left end of the Scully control module, in the center. Hold the
button in until flow stops. After flow stops, release switch to resume flow. Again, this is if unit is so
equipped, not all trucks have Scully overfill prevention systems.
WARNING
If the flow does not stop soon after the precheck

button is depressed, stop flow from the fill stand
immediately to avoid a fuel spill. The system
is not operating properly and needs repair.
i. Fill the tank at a rate not to exceed 600 GPM unless the fill cover in the manhole is open.
WARNING
Do not load at a rate exceeding 600 GPM (gallons

per minute) without opening the 10-inch fill cover
in the manhole assembly. Tank over-pressure-
ization could result.
NOTE
An indication that the tank is full is a sudden

flexure of the supply hose as the bottom
loading valve closes.
j. The flow will stop when the liquid contacts the probe located in the top of the tank if unit is Scully
equipped. The onboard control system will close the bottom loading valve and the fill stand connection,
if available, will shut down the flow from the fill stand.
k. When the tank is full disconnect the fuel supply line from the bottom loading adapter and, if
applicable, disconnect all fill stand control lines.
l. Install the dust cap on the bottom loading adapter (19) or (20).
m. Move the interlock valve (18) lever back in front of the bottom loading adapter.
n. Remove fill stand bonding cable and disengage Scully system.
2-6. TOP LOADING.
b. Shut down the engine.
8
WARNING
If a top loading rack is not available for fueling,

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

When stowing the cable, hold to it and walk back to the
trailer as it winds onto the reel.
9
2-8. FUELING PROCEDURE. Perform the following procedures when fueling from the tank
truck is to be accomplished.
WARNING
If at any time during the fueling operation an

emergency occurs, close the emergency valve
by performing one of the following procedures:
1. Push the emergency valve operator to the
in position or close the cabinet doors.
One of the cabinet doors will push the EV
operator handle, when closed.
2. Pull the emergency release at the right
rear of the tank.
3. Pull the emergency release at the left
front of the tank, near the driver's door.
4. Pull the emergency release at the front
top of the tank.
Note: Fully open valve 16 (sectionalizing valve) prior to any pumping operation. This will reduce
pump start-up pressure. Pump pressure and flow can then be regulated as required by
adjusting valve 16.
a. After the truck is stopped in the desired location, set the parking brakes from the cab
and place the transmission in neutral.
b. Perform the prefueling check in paragraph 2-4.
c. Connect one of the static bond cables to a suitable connection.
d. Engage the PTO control (4) located in cab.

NOTE: The PTO will not engage until the EV operator handle is pulled out.
e. Note: all pumping will be done at idle speed (700 rpm).
f. Reset meter (13) to zero (rotate knob on register clockwise).
g. Open valves (24), (15), and (11) and, if your truck is so equipped, 3 way valve (29).
h. Pull the emergency valve operator (22) handle to the open (out) position.
i. Unwind hose reel (9) as required and dispense fuel by opening nozzle (10) to flow.
Regulate pressure and flow by adjusting valve (16) as required.
j. When fueling is complete, rewind hose onto reel (9).
k. Push the emergency valve operator (22) handle to the closed (in) position.
l. Close valves (24), (15), and (11) and, if your truck is so equipped, valve (29).
m. Disengage the PTO control (4) located in cab.
10
n. Disconnect and stow the static cable.
CAUTION

truck as it winds onto the reel.
2-9. TANK LOADING USING THE TRUCK PUMP, UNMETERED. Perform the following
procedures when self-loading the truck tank is required.
b. Engage the Scully system (if unit is so equipped) by engaging the pull type switch (overfill
control) on the dash. The light near the switch will light when switch is on.
e. Connect 2-1/2 inch suction hose(s) to faucet (17) stub. Four each suction hoses are stored in
the hose tubes at the rear of the truck. Connect opposite end of hose(s) to fuel source.
f. Engage the PTO control (4) located in cab.

NOTE: The PTO will not engage until the brake interlock valve (18) is activated.
g. Open valve (16) and faucet (17). If truck has filter/separator and canister filters, with valve (29)
located upstream of filters, open this valve also.
h. Open brake interlock air valve (18) by moving lever to side. This action will engage the PTO
and pumping will begin.
i. Start filling the tank and make sure system is working properly by pushing the precheck
button in until flow stops. After flow stops, release switch to resume flow. Again, this applies only if the
unit is equipped with a Scully system, not all trucks are so equipped.
WARNING

button is depressed, stop flow by closing brake
interlock valve (18) immediately to avoid a fuel spill.
The system is not operating properly and needs repair.
j. The flow will stop when the liquid contacts the probe located in the top of the tank.
The onboard control system will close the bottom loading valve and flow will stop.
NOTE: Flow into the tank will be nonmetered.
k. Close brake interlock air valve (18) by moving lever to side. This action will disengage
the PTO.
l. Close valve (16) and faucet (17). Close valve (29) if opened (see step h above).
11
n. Disconnect 2-1/2 inch suction hose(s) from faucet (17) stub and fuel source. Stow hoses
in the hose tubes at the rear of the truck.
q. Disconnect and stow the static cable.
CAUTION

2-10. DEFUELING. A device can be defueled and the product delivered to the tank using the
onboard pump by performing the following procedures.
e. Connect 2-1/2 inch suction hose(s) to faucet (17) stub. Four each hoses are stored in the
hose tubes at the rear of the truck. Connect opposite end of hose(s) to the unit to be defueled.

g. Open valve (16) and faucet (17). If truck has filter/separator and canister filters, with valve (29)
located upstream of filters, open this valve also..
h. Open brake interlock air valve (18) by moving lever to side. This action will engage the PTO
i. Start filling the tank and make sure system is working properly by pushing the precheck
button in until flow stops. After flow stops, release switch to resume flow. Again, this applies if unit is
Scully equipped, not all trucks have Scully systems.
WARNING

j. The flow will stop when the liquid contacts the probe located in the top of the tank.
k. Close brake interlock air valve (18) by moving lever to side. This action will disengage
the PTO.
l. Close valve (16) and faucet (17). Close valve (29) if opened.
12
n. Disconnect 2-1/2 inch suction hose(s) from faucet (17) stub and defueled unit. Stow hoses
o. Disconnect and stow the static cable.
CAUTION

2-11. GRAVITY DRAIN - METERED. Fuel can be gravity drained from the tank by performing
e. Connect a fuel hose to the 2-inch faucet (14) and place opposite end of hose into a
suitable container.
g. Open valves (15) and (16) and faucet (14). If truck has both canister filters and a filter/separator
and valve (29) is upstream of the filters, it will not be necessary to open valve (29).
h. When draining is complete, close valves (15), (16) and faucet (14).

CAUTION

13
Fig. 2-1 Schematic
14
CHAPTER 3
MAINTENANCE AND SERVICING
3-1. SCOPE. This chapter contains instructions for inspection, lubrication, cleaning, and
routine servicing procedures.
3-2. CLEANING. Should the need arise to perform welding or cutting operations on the tank,
tank cleaning should be in accordance with API Publication 2013 (Cleaning Mobile Tanks in
Flammable or Combustible Liquid Service). This is a safety measure to insure the tank is vapor
free.
DANGER
If the tank is not free of flammable vapors

prior to and during the performance of hot
work on it, an explosion resulting in serious
bodily injury or death could result.
3-3. LUBRICATION. Lubricate hose reel crank, static reel, and emergency valve operator
cables weekly using MIL-C-7118 grease or equivalent.
3-4. INSPECTION. Table 3-1 lists inspections to be made daily, before, during, and after
operation to insure that the fuel trailer is safe to operate and to identify any malfunction. Table
3-2 lists periodic checks and services to be made in addition to daily inspections at intervals as
specified in the tabulated listing.
3-5. TROUBLESHOOTING. This section contains instructions for troubleshooting the fuel system.
Table 3-3 provides a list of malfunctions that may occur. Each potential malfunction is followed by
a probable cause or list of probable causes. Each probable cause is followed by a corrective action
procedure.
3-6. COMPONENT REPAIR. Commercial literature for the major active components in the
fueling system is provided at the end of this manual, in chapter 4. Refer to this information as
necessary for maintenance, repair, servicing and adjusting, calibration, and parts listing for the affected
item.
3-7. SERVICE. See tables 3-1 (Daily Inspections), 3-2 (Periodic Checks and Services) and 3-3
(Troubleshooting) for applicable servicing information.
15
3.8 Ready for Air Transport
This chapter gives instructions for making vehicle air transportable. This requires lowering the
height of the vehicle using following methods.
a. Pull down front suspension

Using ratcheting mechanism provided, pull front suspension down as shown.
Connect this end

to chain wrapped This end
around hooks
axle/spring over
frame rail
Wrap chain around spring/axle and connect to ratcheting mechanism. Hook other end of tool
around frame rail and pull vechicle down. After pulling down the second side, recheck the first
side to make sure it is still tight.
b. Release air from tires
Release air from tires until pressures are: 35 psi front, 25 psi rear
16
c. Dump air from air bumper under cab.
AFTER
DISCONNECT DISCONNECTING
THIS LINKAGE, USE THIS
LINKAGE FROM LEVER TO RELEASE
LEVER
17
Table 3-1 Daily Inspections
Before During After Item Check

Operation Operation Operation
Fuel System Check plumbing and components
X X Plumbing and for leaks while the unit is operating.
Components
Sump Drain Place a suitable container under
Valve the sump drain valve and open the
valve briefly. Check the contents of
X the container for water. If no water
is present, the unit is ready for
operation. If water is present,
repeat the procedure until fuel only
(no water) is drawn into the
container.
X Fueling Hose and Check that all detachable
Nozzles equipment is present and properly
stored.
X Fire Extinguishers Check that all fire extinguishers are
charged and inspections are up to
date.
Table 3-2 Periodic Checks

Checks and Services Weekly Other Intervals
1. Clean and inspect nozzle,
bottom loading adaptor and fuel X
strainer.
2. Check tank for operation of
manhole fill cover latch, debris or x
foreign matter in tank and
operation of vent(s).
3. Service Lube Points (see
paragraph 3-3). X
4. Check accuracy of meter and
register using a graduated Annually
container.
5. Calibrate Meter When material being pumped is
changed, when maintenance is
performed on meter or register
or when unit is obviously not
measuring correctly.
6. Check tightness of bolts on
valve flanges. Visual inspection Monthly
will not verify tightness,
physically put a wrench on these
bolts.
7. Check Torque of tie down Check initially upon receipt of
bolts. Torque all but the spring truck, recheck after one month,
loaded bolts to 90 ft lb. Tighten followed by annual inspection.
the spring loaded bolts until the
spring compressed length is
3 1/2”.
18
Table 3-3 Troubleshooting
Malfunction Probable Cause Corrective Action
1. Pump operates, but system 1. Tank is empty 1. Fill the tank
will not pump fuel 2. Incorrect Valve Positions 2. Reset Valve settings, insure
the settings are correct
3. Strainer Clogged 3. Clean Strainer
4. Emergency Valve Cable 4. Check valve travel
stretched or broken underneath truck, adjust as
needed or replace cable.
5. Inoperative Nozzle 5. Repair or replace nozzle
6. Obstruction in Piping 6. Locate and remove
7. Defective Hose Valve obstruction
7. Repair or replace valve
2. Pump operates, but output is 1. Partially clogged strainer 1. Clean or replace strainer
below normal 2. Engine Speed too slow 2. Increase engine speed
3. Emergency Valve Cable 3. Check underneath truck for
stretched cable travel. Adjust or replace
cable as needed
3. Pump operates, flow is as 1. Vent valve closed or 1. Pull emergency valve
expected, but slows or stops clogged operator to see if vent opens
after only a few minutes of 2. If vent does not open, check
operations air lines between E/V and
vent. And repair or replace as
needed
3. Clean or replace vent as
needed
4. Hydraulic motor rotates, but 1. Valves not positioned 1. Reset valve settings, insure
system will not pump fuel correctly that valve settings are correct.
2. Pump to motor coupling 2. Replace defective coupling
defective
3. Defective pump 3. Repair or replace pump.
5. Meter does not register 1. Rotor Shaft pin sheared 1. Replace pin
2. Broken Rotor 2. Replace Rotor
6. Meter registers erratically 1. Stripped gear teeth or broken 1. Replace defective gears
teeth in the gear. 2. Replace gear plate ass’y or
2. Worn gear plate ass’y shafts gears
7. Pump pressure too high or too 1. By Pass Valve out of 1. Adjust to correct pressure by
low adjustment turning screw on top of valve.
Turn in to increase pressure,
turn out to decrease pressure.
19
CHAPTER 4
PARTS LIST AND COMMERCIAL LITERATURE
4-1. GENERAL. This chapter contains information that will be of assistance during repair and
maintenance of vehicle components, such as identification and location of major parts. Also included is
literature on various commercial components provided on this unit.
4-2. PARTS LIST.
FIG. & DESCRIPTION PART NUMBER QTY

INDEX NO.
4-1-1 Valve, B/F, 3-inch WD301ALV 3
-2 API Bottom Loading Adapter F5000-001 1
-3 D-1 Bottom Loading Adapter 61528BC 1
-4 Brake Interlock Valve 3418 1
-5 Valve, Check, 1/2" (inside tank) 61-103-01 1
-6 Hose Reel C1115-25-15L 1
-7 Nozzle CV90-001 1
-8 Valve, B/F, 2-inch (Victaulic) 700 1
-9 Flow Meter M7C1 1
-10 2-inch Faucet Dust Cap MS27028-11 1
-11 2-1/2 inch Faucet Dust Cap MS27028-13 1
-12 Static Reel DMI-75G40-20 1
-13 Valve, Faucet WD201ALV 1
-14 Scully Shut-Off System 09356 1
-15 Powerise Air-Springs GSS-18-21UB 4
4-2-1 Pump TXD02A 1

-2 End Yoke 10-4-123 1
-3 Driveshaft N10270-SF 1
-4 End Yoke 10-4-103 1
-5 PTO CS20-41006-H1BX 1
4-3-1 Hood, Vapor Recovery VR45962BU 1

-2 Vent AV46850ALFTS 1
-3 Manhole Cover, 20" PPVL863BXB346 1
-4 Probe, Scully Shut-off Kit 09356 1
4-4-1 Remote Trip Handle 35603SL 3

-2 Valve, Water Drain 3721X1 1
-3 Valve, Emergency / Bottom Load 64055A 1
-4 Operator, EV 41158-A 1
4-5-1 Light, Cabinet 570006 2

-2 Light, Clearance 500012 4
-3 Light, Stop, Turn, Tail 400017 2
-4 Light, Back-up 500011 2
-5 Light, I.D. 200013 1
-6 Junction Box 470041 1
20
1 2 8
5
IN TANK
7
9 10
Fig. 4-1 Pumping Compartment
Fig. 4-2 Pump/PTO Diagram
21
1
3
4
2
Fig. 4-3 Top of Tank
Fig. 4-4 Cable Diagram
Fig. 4-5 Electrical (Lights)
22
Fig.4-6 Scully System Schematic
Chapter 56
Scully “IntellliCheck” Overfill Prevention System
5-1 Scully Operation Procedures
a. The Scully system is fully self contained and should function automatically when the switch in
the cab is turned on. The pilot light near the switch should illuminate.
b. A good way to check the system to see if all components were properly installed and are
properly functioning is to turn on the system with the switch in the cab and to place a small cup of liquid
around the probe (water should work but a darker liquid such as Coke may be required, fuel will
definitely work). The probe can be accessed through the manhole fill cover. When the liquid contacts
the probe listen for air exhausting from the solenoid valve. This indicates that the system is functioning
properly.
c. Further testing should be conducted at the fill stand using the onboard pre-check system.
Engaging the push button switch on the left side of the Scully Intellicheck module should cause the flow
from the fill stand to stop. This check should be performed at 100 to 300 gallons into the bottom loading
task.
23
WARRANTY
Isometrics, Inc. (Company) hereby warrants its products to be free from defects
in materials and workmanship for a period of one (1) year from the date of original
purchase. If, upon examination by the Company, any part or parts are determined to be
defective, the Company will provide, free of charge, for the repair or replacement of said
items, as the Company may elect. This warranty is subject to the following exceptions
and limitations:
I . The customer shall be responsible for normal maintenance and minor

adjustment of the product. Notification to the Company of the need for warranty
service shall be performed and any transportation charge and/or delivery of the
product to and from the place where warranty service is to be
performed must I-cave prior written approval from the Company.
2. This warranty does not apply to component parts or accessories applicable to

the cab and chassis and tractors, which carry the warranty of the manufacturer
thereof.
3. This warranty applies only to products which are placed in normal

use, and does not apply to any product which has been mistreated, neglected or
damaged by accident.
4. This warranty does not apply to any product repaired or altered by anyone
other than a Company representative, unless such repair or alteration has been
authorized by the home office.
For warranty service, contact any Company representative. For the name and location
of the nearest representative, and for further warranty information, write or call:
ISOMETRICS, INC.
P.O. BOX 660
1266 NORTH SCALES STREET
REIDSVILLE, NORTH CAROLINA 27320
PH: 336-349-2329
FAX: 336-349-4744
Attn. David McCollum
email: dmccollum@isometrics-inc.
24
Carter Ground Fueling Division
Argo-Tech Corporation
671 West Seventeenth Street

Costa Mesa, CA USA 92627-3605
Ph: (949) 764-2200 • Fax: (949) 631-2673
Email: cgf_sales@jccarter.com • Web: www.argo-tech.com
SM64055
MAINTENANCE MANUAL
FOR CARTER
PART NUMBERS 64055 & 64143
4” INTERNAL/BOTTOM LOADING VALVES,
March 1, 2001, New Release

SM64055 March 1, 2001
SUMMARY OF REVISIONS
DATE OF E.O. NO. REV. PARA. OR DESCRIPTION APPROVED
CHANGE PAGE NO.
3/1/2001 - NEW RELEASE
-2-
SM64055 March 1, 2001
TABLE OF CONTENTS
1.0 INTRODUCTION................................................................................................ 4
2.0 EQUIPMENT DESCRIPTION ............................................................................ 4
3.0 AVAILABLE OPTIONS ..................................................................................... 4
4.0 DISASSEMBLY .................................................................................................. 5
5.0 INSPECTION....................................................................................................... 5
6.0 REASSEMBLY ................................................................................................... 6
7.0 TEST .................................................................................................................... 6
8.0 ILLUSTRATED PARTS CATALOG.................................................................. 7
FIGURE 1A, 64055 & OPTIONS............................................................................ 10
FIGURE 1B, 64143A & OPTIONS ......................................................................... 11
FIGURE 2, 64055 PARTS BREAKDOWN ............................................................ 12
FIGURE 4, PILOT VALVE PARTS BREAKDOWN ............................................ 14
FIGURE 5 - DIAPHRAGM INSTALLATION POSITION .................................... 15
FIGURE 6 - DIAPHRAGM TORQUE SEQUENCE .............................................. 15
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SM64055 March 1, 2001
MAINTENANCE, OVERHAUL & TEST INSTRUCTIONS

CARTER PART NUMBERS 64055 & 64143 INTERNAL/BOTTOM LOADING VALVES
1.0 INTRODUCTION
This manual furnishes detailed instructions covering the B can also be used with optic probe (s) using solenoid
maintenance and overhaul of Carter Part Numbers 64055, valve (s) to effect the control of the pilot valve (s). If so
and 64143 4” Internal/Bottom Loading Valves. This service manuals for these components should be
manual assumes that the valves will be used with a Carter requested from the manufacturer of the items used. Carter
64079 Level Sensor, however the 64055A, B, 64143A or does not provide such items.
2.0 EQUIPMENT DESCRIPTION
The Carter 64055 family of 4” valves can be used either pressure forces, plus the spring force will keep the piston
as a straight internal valve or for bottom loading control. (valve) closed.
The 64055 mounts directly into a 4” TTMA Tank Sump
If the piston chamber is vented through an open pilot
Ring. The 64055A is used with the Carter 64079 Level
valve, options A or B, the pressure drop across the inlet
Sensor for bottom loading control with a single control
orifice reduces the piston chamber pressure significantly.
pilot valve. Option “B” adds two-stage level control with
The resultant balance of forces will cause the piston to
two pilot valves. (Note: Early units contained provisions
open, hence the valve.
for only single pilot valves with the dual capability
available at a later date.) Option “B” requires either the When the piston chamber is once again closed [pilot
use of 64079B, C or two 64079 Level Sensors. A Carter valve (s) closes], the balance of forces again causes the
Vent, 64078, is also available to complete the system valve to close.
requirements. A straight 64055 Internal Valve can be
The 64055 or 64143 A or B is normally utilized with the
converted to a bottom loading valve, 64055A, by adding
64079 Level Sensor. If so desired, a solenoid valve (s)
a pilot valve.
can be used in the system to provide or deprive the pilot
The 64143 4” Bottom Loading Valve is used only for valve of pressure (usually routed from the bottom loading
bottom loading. The difference between the 64055 and adapter) to cause the opening and closing of the valve. In
the 64143 is the absence of an off-loading cylinder on the this way the valve can be used with any optic type sensing
64143 and a different orifice system in the piston. probe to detect the desired tank level for closure.
The units are spring loaded “overbalanced” piston valves. On the 64055, a separate air operated piston is provided
Fuel inlet pressure is routed to the inside of the piston to effect off-loading as desired. The direction of air
chamber through a two-staged orifice in the center of the pressure to this piston will cause it to pull open the main
piston. If the piston chamber has no exit, the areas inside piston to allow for off-loading flow. When the air
the piston chamber (outer diameter of the piston) is larger pressure is depleted, the spring forces will close both the
than the face seal of the piston, hence the balance of air and main pistons.
3.0 AVAILABLE OPTIONS

The 64055 Basic Valve is designed for use as an internal The “B” option (64055B or 64143B) adds two pilot
valve and has no other functional controls. The 64055 can valves to the basic unit to close the valve in two-stages.
be opened for off-loading by application of air pressure to An orifice in the secondary pilot valve will continue to
the cylinder provided. The 64143 can only be used as vent the piston chamber after the primary pilot valve has
option A (64143A) since it has no off-loading capability. closed. This orifice restricts the pressure escaping from
the piston chamber to maintain the piston in a partially
The “A” option (64055A or 64143A) adds a pilot valve
open position hence flow into the tank is reduced
to the basic unit making it a bottom loading control valve.
significantly. This provides a more accurate final shutoff
Again the 64055A can also be used for off-loading by the
and also helps control surge pressure on final shutoff.
application of air pressure to the provided cylinder.
-4-
SM64055 March 1, 2001
4.0 DISASSEMBLY
4.1 Refer to Figures 1, 2 or 3 for exploded views of the 4.5.3 Unless replacement is needed it is recommended
unit. that Set Screw (27) and Nut (26) in the face of the
piston not be removed.
4.2 Remove the six Screws (8) and Washers (9) from
the Bonnet (23) or (24) and put a side for reuse. 4.6 64055 & 64143 - Remove and discard O-ring (29)
and Seal (30) from Body (28).
4.3 Rotate the bonnet slightly in either direction and
pull it from the Body (28). On the 64055 the Piston 4.7 Unless the Screen (33) is damaged and needs
(12) and its attaching parts will come out of the replacement, do not remove it from the Body (28).
Body (28) with the bonnet as Piston Assembly If it needs replacing then remove Screws (31) and
(10).. Continue on with the next paragraph if the Nuts (32) to do so.
unit being disassembled is the 64055. Ship to
4.8 On the basic unit, remove the Plug (3) only if it has
paragraph 4.5 if it is a 64143.
been leaking. If it is removed, then discard Gasket
4.4 64055: (4).
4.4.1 Find the Pin (17B) in the Shaft Assembly (17). Use 4.9 On 64055 or 64143A - Unscrew Pilot Valve Assy
the spring pin to hold the shaft in place and remove (2) from Bonnet (23) or (24) and remove and
Rod (11) by unscrewing it, being careful not to discard Gasket (4). On “B” option to either unit,
drop Piston (12). Remove Piston (12) and Spring remove secondary Pilot Valve Assy (2). Orifice (5)
(13). and Gasket (6) will be found under the secondary
Pilot Valve Assy (2). Remove them and discard
4.4.2 Remove Ring (14), Spring Pad (15) and Spring
Gasket (6).
(16). Remove O-ring (22) from Bonnet (23) and
discard it. 4.10 Pilot Valve Assy (2) may be replaced as a
complete unit or overhauled as follows:
4.4.3 Using the pin used in paragraph 4.4.1 hold the
Shaft Assembly (17) while unscrewing Housing 4.10.1 Remove six Screws (34) and Washers (35).
(18). Pull Housing (18) off of Bonnet (23).
4.10.2 Using a thin blade screwdriver, pry the Cover (36)
4.4.4 Remove Wipe Ring (20) and Quad-Ring (21) from from the assembly. Be careful not to scratch the
Bonnet (23). Discard both items. Skip to paragraph flanged surface of either metal part holding the
4.6. diaphragms in place.
4.5 64143: 4.10.3 Remove and discard the two Diaphragms (37).
4.5.1 Remove Bonnet (24) then remove Spring (13). 4.10.4 Remove Pressure Pad (38) from Poppet (40) shaft.
Remove O-ring (22) from Bonnet (24) and discard
4.10.5 Remove Ring (39), which retains Spring (42) and
it.
Washer (41) in place. This will free up the
4.5.2 Reach into body (28) opening and carefully extract remaining parts for removal.
the Piston Assy (25).
5.0 INSPECTION
5.1 It is recommended that all O-rings (19), (22), (29); the Shaft (17A) and the Piston (12) can be polished to
Gaskets (4), (6); Quad Ring (21); Wipe Ring (20); remove minor scratches by using a very fine emery cloth
Diaphragms (37) and Seal (30) be replaced at each while the parts are rotated. Do not polish local areas of
overhaul. these diameters. Unless proper equipment is available to
accomplish this task and to polish the inner diameter of
5.2 The outer diameters of the Shaft (17A), and Piston
the Housing (18) it is recommended that the parts be
(12) along with the inner diameter of Housing (18) should
replace, If polishing is attempted, do not break through
be inspected for scratches that might cause leakage. The
the hard anodized surface of the Piston (12). If scratches
piston seat in the Body (28) shall also be free of pits,
are too pronounced, the parts should be replaced. Replace
scratches or gouges that would cause leakage. Inspect all
any part with damage exceeding 15% of local wall
other metal parts for dings, gouges, abrasions, etc. On all
thickness. Use Alodine 1200, or similar chem film
parts except the ones listed above, use 320 grit paper to
treatment, to touch up bared aluminum.
smooth and remove sharp edges. The outer diameter of
-5-
SM64055 March 1, 2001
The flat surfaces of the Fitting (43) and Cover (36) may parts flat during polishing and to not raise any burrs on
be polished to remove minor scratches by using a flat the inside diameters that bare on the diaphragms.
plate and very fine emery cloth. Be careful to keep the
6.0 REASSEMBLY
6.1 Reassembly is accomplished in essentially the the number 1 screw to 1.6 in-lbs. (1.8 Kg-cm), followed
reverse order of disassembly noting the following: by tightening screws number 5, 3, 6 and 4 in that order.
Then repeat the tightening sequence to 3.2 in-lbs. (2.1
6.1.2 Light lubrication of all O-rings and seals, using
Kg-cm) and then 5.3 in-lbs. (6.1 Kg-cm) respectively.
petroleum jelly is recommended to facilitate installation.
Let the assembly stand for a minimum of 15 hours
6.1.3 When reassembling the Pilot Valve Assy (2) use
retighten the screws as above to the 5.3 in-lbs. (6.1 Kg-
the following procedure to assure proper diaphragm
cm) setting.
retention:
6.1.4 When installing the Seal (30) onto O-ring (29) in
6.1.3.1 Once the Poppet (40), Spring (42), Washer (41)
Body (28) be sure to smooth the surface evenly with a
and Ring (39) are in place, be sure that the Pressure Pad
finger. See note on Figures 2 and 3.
(38) is placed onto the Poppet (40) shaft with the smaller
end placed onto the shaft first. The larger flat surface 6.1.5 On the 64055 - Use Locktite 24221 (17C) on the
should be facing away from the shaft. thread of Shaft (17A) before screwing on Housing (18).
Note the thread of both parts should be cleaned with the
6.1.3.2 The two Diaphragms (37) are placed such that
recommended Locktite cleaning solution prior to using
the loops in the diaphragms are facing the Pressure Pad
24221. Read the instructions on 24221 before using.
(38).See Figure 5 for an illustration. [In operation, the
loops always face in the direction in which the pressure 6.1.6 Once the Piston/Bonnet Assy (10) has been
from the Level Sensor or solenoid valve is applied.] inserted into the Body (28) the Rod (11) must be adjusted
Smooth out the Diaphragms (37) place onto the Fitting to provide a gap of 0.012±0.005 (.305±.127 mm)
(43) and align the six holes in all three parts. Carefully between the under side of the hex head of the rod and the
place the Cover (36) onto this assembly aligning the mating flat surface of the Piston (12). A feeler gage
holes. should be used for this purpose. This will assure that the
proper surge control during shutoff will be effective. On
6.1.3.3 Start the six Screws (34) with the Washers (35)
the 64143 if the Set Screw (27) and Nut (26) were
in place by hand until resistance is met. Note that if no
removed it will be necessary to adjust the face of the Set
resistance is met in attempting to hand tighten the screws,
Screw (27) to .409 ± .005 inches (10.388 ± .127 mm)
it is recommended that the Screws (34) be replaced. They
from the face of the Nut (26).
are self-locking and some resistance should be felt.
6.1.7 If the Screen (33) was removed and replaced, the
6.1.3.4 Observing the Cover (36) from the outside end
replacement will be provided in a flat condition and it
(look at the threaded port in the middle), mentally number
will be necessary to carefully shape it to fit the Body (28).
the holes in a clockwise direction from one to six. Refer
top Figure 6. Using a properly set torque wrench, tighten
7.0 TEST
7.1 The following test procedures will be Tee off the inlet pressure line to the primary pilot valve
accomplished after overhaul: and to the secondary pilot valve on “B” option units.
Install a small ball valve between the inlet pressure source
7.2 Test conditions
and each pilot valves. Install a bleed valve between the
7.2.1 Test media shall be odorless kerosene, Jet A or pilot valve (s) and the ball valve. Gauges should be
equivalent at 75° + 15°F. installed in the pressure line to the main valve’s inlet and
in the line to the pilot valve (s).
7.3 Functional Test - If testing prior to reinstalling the
unit in the refueler is desired conduct the following tests: 7.3.2 On the 64055 connect the air port to a 100-psig air
pressure source with a gauge in the line.
7.3.1 Connect the inlet of the unit to a test media
pressure source with a minimum of 150-psig available.
-6-
SM64055 March 1, 2001
7.3.3 Bleed all air from the valve by applying 10-psig 7.3.5 On the 64055, following the above test with the
test media pressure to the inlet and opening the bleed valve still full of liquid apply air pressure to the unit
valve (s) in the lines to the pilot (s). Once the air is bled, starting at 35-psig and slowly increasing slowly until the
close the valve in the line to the pilot (s) and bleed all valve opens. The valve should open at an air pressure of
liquid trapped in the line (s). 50-psig maximum. If testing the 64143 skip this
paragraph and go on to 7.3.6. Shutoff the air pressure and
7.3.4 Increase the pressure to the valve to approximately
bleed it to atmosphere. The valve should return to the
25-psig for one minute and then increase it to 150-psig
closed position.
for one minute. Observe for external leakage during the
test period. No leakage except from the main piston shall 7.3.6 Apply liquid pressure slowly to the valve inlet and
be allowed. This leakage should be limited to 100 simultaneously to the pilot (s). Observe when the main
cc/minute. piston opens. The valve shall open with an inlet pressure
of 15-psig or less.
8.0 ILLUSTRATED PARTS CATALOG
Table 1.0 tabulates the parts and sub-assemblies table are keyed to the exploded views of the unit
comprising the various versions of both the 64055 and diagrammed in Figures 1, 2 or 3.
64143 Valves with all options. The item numbers of the
TABLE 1.0
64055 & 64143 Bottom Loading Valves & Options
Refer to Figures 1A and 1B
Figure Item Part Number Description Units Per Option Spares/10

Assembly Units/Yr.
1A 1 64055 Internal Valve, Bottom Loading and
Off-loading (Figure 1A).................... 1 - -
1A 3 GF814-10D Plug................................................... 2 Basic -
4 MS29512-10 Gasket ............................................... 2 Basic 20
2 47097 Pilot Valve, Primary (FIGURE 4) .... 1 A -
3 GF814-10D Plug................................................... 1 A -
4 MS29512-10 Gasket ............................................... 2 A 20
2 47097 Pilot Valve, Secondary (FIGURE 4) 2 B -
4 MS29512-10 Gasket ............................................... 2 B 20
5 221087 Orifice............................................... 1 B -
6 MS29512-08 Gasket ............................................... 1 B 10
1B 1 64143 Internal Valve, Bottom Loading Only
(Figure 1B) ....................................... 1 - -
3 GF814-10D Plug................................................... 1 A -
4 MS29512-10 Gasket ............................................... 2 A, B 20
5 221087 Orifice............................................... 1 B -
6 MS29512-08 Gasket ............................................... 1 B 10
-7-
SM64055 March 1, 2001
TABLE 2.0
Parts Breakdown, 64055 & 64143 Basic Valves

Assembly Units/Yr.
2, 3 8 GF35275-265 Screws............................................... 8 All -
9 GF35338-138 Washers ............................................ 8 All -
2 10 No number Piston/Bonnet Assy........................... 1 64055 -
11 220447 Rod........................................... 1 64055 -
12 47096 Piston ....................................... 1 64055 1
13 220436 Spring....................................... 1 64055 -
14 GF16633-4050 Ring.......................................... 1 64055 -
15 220438 Spring Pad................................ 1 64055 -
16 220437 Spring....................................... 1 64055 -
17 47095 Shaft Assembly ........................ 1 64055 -
17A 220448 Shaft.................................. 1 64055 -
17B GF16562-238 Pin..................................... 1 64055 -
17C 24221 Locktite .................................... 1 64055
18 220450 Housing .................................... 1 64055 -
19 MS29513-112 O-ring....................................... 1 64055 10
20 220453 Wipe Ring ................................ 1 64055 10
21 Q4325-366Y Quad Ring ................................ 1 64055 10
22 MS29513-157 O-ring....................................... 1 64055 10
23 47099 Bonnet...................................... 1 64055 -
3 22 MS29513-157 O-ring ............................................... 1 64143 10
24 221108 Bonnet .............................................. 1 64143 -
25 47284 Piston Assy ....................................... 1 64143 1
12 47096 Piston ....................................... 1 64143 1
26 GF51971-3 Nut ........................................... 1 64143 -
27 221109 Set Screw, Orifice .................... 1 64143 -
13 220436 Spring ............................................... 1 64143 -
2, 3 28 220458 Body ................................................. 1 All -
29 MS29513-248 O-ring ............................................... 1 All 10
30 220456 Seal ................................................... 1 All 10
31 GF515C4-5 Screw ................................................ 2 All -
32 GF20365D440 Nut .................................................... 2 All -
33 220431 Screen ............................................... 1 All -
-8-
SM64055 March 1, 2001
TABLE 3.0
Pilot Valve Parts Breakdown

Assembly Units/Yr.
1A, 1B 2 47097 Pilot Valve Assy, Primary................. 1 A&B -
4 34 LP35275-230 Screw........................................ 6 A&B -
35 GF620C6 Washer ..................................... 6 A&B -
36 220441 Cover........................................ 1 A&B -
37 220445 Diaphragm................................ 2 A&B 20
38 220443 Pressure Pad ............................. 1 A&B -
39 GF16633-4018 Ring.......................................... 1 A&B -
40 220434 Poppet ...................................... 1 A&B -
41 220442 Washer ..................................... 1 A&B -
42 220444 Spring....................................... 1 A&B -
43 220433 Fitting....................................... 1 A&B -
1 5 47097 Pilot Valve Assy, Secondary............. 1 B -
4 34 LP35275-230 Screw........................................ 6 B -
35 GF620C6 Washer ..................................... 6 B -
36 220441 Cover........................................ 1 B -
37 220445 Diaphragm................................ 2 B 20
38 220443 Pressure Pad ............................. 1 B -
39 GF16633-4018 Ring.......................................... 1 B -
40 220434 Poppet ...................................... 1 B -
41 220442 Washer ..................................... 1 B -
42 220444 Spring....................................... 1 B -
43 220433 Fitting....................................... 1 B -
There are several kits of parts designed to provide the necessary items to overhaul the units as described below.
KIT NUMBER DESCRIPTION
KD64055-1 Kit, seal replacement for 64055A Valve. Contains items 4, 19, 20, 21, 22,
29, 30 & 37.
KD64055-2 Kit, seal replacement for 64055 Basic Valve. Contains items 4, 19, 20, 21,
22, 29 & 30.
KD64055-3 Kit; seal replacement for 64055B Valve. Contains items 4, 6, 19, 20, 21, 22,
29, 30 & 37.
KD64129-3 Kit; Overhaul for 47097 Pilot Valve Assy. Contains items 4 & 37.
KD64143-1 Kit; seal replacement for 64143A Valve. Contains items 4, 22, 29, 30 & 37.
KD64143-2 Kit; seal replacement for 64143B Valve. Contains items 4, 6, 22, 29, 30 &
37.
Notes: 1. All part numbers beginning with "GF" Are interchangeable with those beginning with either "AN" or "MS".
If three numbers follow the “GF” it is interchangeable with an "AN" part, otherwise it is interchangeable
with an "MS" part of the same number.
2. The recommended spare parts shown Above Are the number required to support 10 units for one year or
each overhaul whichever is sooner. These quantities do not include replacement spares for intermediate
replacement of parts required by Abuse or misuse of the equipment. The recommended quantities are based
on the ratio of spare parts sold for each unit during A one-year period of time. The actual quantity required
will vary from location to location.
-9-
SM64055 March 1, 2001
FIGURE 1A
64055 & OPTIONS
- 10 -
SM64055 March 1, 2001
FIGURE 1B - 64143A & OPTIONS
- 11 -
SM64055 March 1, 2001
FIGURE 2
64055 PARTS BREAKDOWN
- 12 -
SM64055 March 1, 2001
FIGURE 3
- 13 -
SM64055 March 1, 2001
FIGURE 4
PILOT VALVE PARTS BREAKDOWN
- 14 -
SM64055 March 1, 2001
FIGURE 5
DIAPHRAGE INSTLLATION POSITION
FIGURE 6
DIAPHRAGM TORQUE SEQUENCE
- 15 -
4” BOTTOM LOADING COMPONENTS

MODELS 64055, 64079, 64143
The Carter 4” family of Bottom Loading Valves
and accompanying Level Sensor are designed for
use in refuelers where bottom loading/off-loading
rates of up to 800 gpm are desired. There are two 64079A
internal valves in the family, one for use in Level Sensor
loading and off-loading while the other is strictly
used for loading. Off-loading requires the use of
air pressure to open the internal valve. Both are
used with the Carter 64079 Level Sensor or as an
alternative they can be used with an optic probe
control. Bottom loading control is accomplished
automatically, as in all Carter units when the tank
liquid level reaches the pre-set level sensor. See
accompanying brochure 64055 for detail
information on the operation of all Carter bottom
loading units.
Both of the available internal valves can be
purchased to use with either a single or dual level 64055A 4”
sensor as explained below. Internal Valve
FEATURES:
❏ Pilot valve is identical on all Carter Bottom Loading components for lower maintenance costs. There is no
through hole in the diaphragm in the pilot to cause leakage and ultimate failure.
❏ Either single level or dual level control available. Dual level control, when used with 64079B Level Sensor
provides better shutoff level accuracy and lower surge pressures resulting from closing at very high rates of
flow.
❏ 50-psi min. air pressure and standard air controlling valves (not furnished by Carter) required for off-loading
- 64055. No off-loading control provided on the 64143.
❏ Internal Valve mates standard TTMA sump flange.
❏ Can be used with optic sensing system.
❏ Low pressure loss:
Bottom Loading – 4.5 psi at 600 gpm
Off-loading - 1.5 psi at 600 gpm
Bulletin 64143 9/2000
671 W. 17th St., Costa Mesa, CA 92627 • Ph (949) 764-2200 • Fax (949) 631-2673 • E-mail cgf_sales@jccarter.com
www.argo-tech.com • ISO 9001 Certified
ORDERING INFORMATION:
64055 (basic configuration) - 4” INTERNAL OFF-LOADING VALVE - provides off-loading by use of air pressure.
64143A (no basic configuration available) - 4” BOTTOM LOADING VALVE - For use for loading the refueler only, no off-
loading capability.
One or more of the following options may be added to change the function or configuration of the units above:
OPTION DESCRIPTION
A Adds pilot valve to basic unit (64055 only, 64143A only unit available) to provide bottom loading control when
used with Carter 64079 Jet Level Sensor or optic sensing probe system.
B Adds dual pilot valves to either unit for use with either two 64079 or one 64079B Level Sensors to improve
accuracy of the tank shutoff level or to reduce surge at closure.
64079 LEVEL SENSOR

There are no moving parts or seals in the Carter Level Sensor which, when used with 64055A or 64143A
Bottom Loading Valve will provide high level bottom loading control. There are no wearing parts in the
unit hence it lasts indefinitely. Truck vibration will have no affect on the unit, unlike float valves, which
are subject to vibration damage. It is available with an optional mounting stud for adjustable level control.
The stud is located outside of the collector/drain can for better level control. A collector/drain can and
precheck feature are provided as standard equipment.
One of the following options may be added to the basic 64079 part number to achieve the degree of
customization desired when used with either the 64055A or 64143A:
OPTION DESCRIPTION .
A Adds stud to basic unit to provide mounting and level adjustment., ½-13 UNC-2B thread
B Adds second Level Sensor with accompanying single mounting stud for use with 64055B or 64143B, ½-13 UNC-
2B thread.
EQUIVALENT PART NUMBERS – WHITTAKER TO CARTER

The following table presents the equivalent part numbers for Carter units to replace Whittaker units:
ITEM DESCRIPTION WHITTAKER CARTER COMMENTS – APPLICABLE TO
PART NO. PART NO. CARTER UNITS
4” Internal Valve for Off-loading F614 64055 Air pressure required for off-loading.
only
4” Internal Valve for Bottom F614A or B 64055A or B Either single or dual pilots available.
Loading and Off-loading Air required for off-loading
4” Internal Valve for Bottom None 64143A No off-loading capability, a separate
Loading only. internal valve has to be used.
Level Sensor, no options F613 64079 Precheck and collector drain cans
standard on Carter unit.
Level Sensor with mounting stud F613A 64079A Mounting stud located outside of
precheck and drain cans for better
control.
Dual Level Sensor with mounting F613B 64079B Same comment as above.
stud
AVERY HARDOLL EQUIVALENT UNITS - The Carter 4” 64143 bottom loading valve and 64079A Level
Sensor can be used in lieu of the 4” Avery Hardoll Jet Able Bottom Loading Valve. Bot systems function basically
the same.
ALTERNATIVE BOTTOM LOADING UNITS

Carter also provides bottom loading equipment for 3” and 6” installations. See Brochure 64055 for complete
information on this type of equipment.
INSTALLATION TIPS
❐ Install the internal valve from the outside of the tank with sufficient flexible line between the pilot (s) and the
level sensor for easier removal and maintenance.
❐ Inlet line to 64079 Level Sensor from pressure source (adapter) must be at least 3/8” diameter tubing. It should
be routed from a port on the bottom loading adapter, such as Carter’s 6958, or 61528 that have ports designed for
this application. (See brochure 60373 for adapter choices). Routing the inlet pressure source closer to the internal
valve may not allow sufficient pressure for the system to function correctly. If the optional mounting stud (option
A) is used sufficient length of flexible tubing should be used to allow for adequate adjustment.
❐ Line between the pilot on the 64129A and the 64079 should be 1/4” diameter for best operation. Pressure surging
may occur if larger tubing is used.
❐ If desired a separate precheck system may also be routed from the adapter to the precheck port on the 64079
although the same affect can be achieved by installing a 3/8” spring loaded normally open ball valve in the inlet
pressure line. It will be necessary to adjust the precheck gate in the bottom of the 64079 to make the precheck
effective in either case. This is a trial and error adjustment. Note that there are no “tuning” plugs on the Carter
64079 as on the Whittaker F613. A simple “gate” type valve in the bottom of the precheck can provides adjusting
of the precheck flow.
❐ It is essential for safety reasons to install a plastic tube to the drain fitting on the bottom of the 64079 Level
Sensor. Draining fuel from the Level Sensor if not collected and drained properly could generate a static
discharge, which could lead to a fire.
❐ The optional mounting stud is located outside of the precheck and drain cans on the Carter unit. Unlike the
Whittaker F613 there is not holes to plug with loose o-rings if the stud is used. If not used the can on the Carter
unit is already sealed and there are no plugs to install. If installed correctly the level in the tank can be adjusted
over a wide range simply by screwing the stud up or down to the desired level.
❐ If the Carter Internal Valve is to be used with an optic probe system a three-way solenoid valve must be installed
in the pressure line from the adapter. When the tank level is below the probe the inlet pressure should be routed to
the pilot on the internal valve to cause it to open. When the optic probe is sensing fuel (level below the probe) the
pilot on the internal valve must be vented to tank and the inlet pressure shutoff. This will cause the internal valve
to close and stop the bottom loading process.
ENVELOPE DIMENSIONS
64055 INTERNAL VALVE
64079 LEVEL SENSOR


Ph: (949) 764-2200 • Fax: (949) 631-2673
SM6958
MAINTENANCE MANUAL
FOR CARTER
PART NUMBERS 6958, 61272, 61409, 61528, 61529 & 64040
BOTTOM LOADING & RECIRCULATION ADAPTERS
Revised December 1, 1994
Supercedes manual issued July 1, 1992

SM6958 December 1, 1994
TABLE OF CONTENTS
PAGE
1.0 INTRODUCTION ........................................................................3
2.0 EQUIPMENT DESCRIPTION .....................................................3
3.0 TABLE OF OPTIONS ..................................................................3
4.0 DISASSEMBLY ...........................................................................4
5.0 INSPECTION................................................................................4
6.0 REASSEMBLY ............................................................................4
7.0 TEST .............................................................................................4
8.0 ILLUSTRATED PARTS LIST .....................................................5
FIGURE 1.....................................................................................................6

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

These Carter units are all of similar design in that to 350°F. The seal on the MS24484-2 is suitable
they all utilize the 2½ inch MS24484 type refueling for temperatures up 160°F.
modular adapter. This type of adapter is only suited
for bottom loading and recirculation or other • The bayonet flange to which the nozzle connects
relatively low pressure type applications. For on the MS24484-5, has a greater tensile strength
Hydrant System applications one should use Carter requirement required by the 350°F requirement.
60195 or 60373 for 2½ inch installations or 60505 Again, the MS24484-2 was designed for service
or 61526 Adapters for the 4 inch API type at temperatures up to 160°F.
applications. These adapters consist of a cast
aluminum housing in which is mounted either the The MS24484-5 is only manufactured by specifically
commercial version, MS24484-2, or the current QPL qualified suppliers, among which is our parent
version, MS24484-5, refueling modular adapter. company, J. C. Carter. The MS24484-2, a previously
Both of these MS24484 units are dimensionally listed qualified product is made by Carter Ground
identical. The only differences lie in two areas, both Fueling Co.
related to high temperature applications normally
seen in fighter aircraft applications: All of the models discussed herein, except for the
basic module, 61529, are similar, varying mainly in
• Poppet seal on the MS24484-5 is of a high the outlet mounting configuration.
temperature elastomer for use in temperatures up
3.0 TABLE OF OPTIONS

Each of the basic units may be obtained in various configurations by adding one or more of the options listed in
the table below.
Option Letter Description Comments
A Adds Pressure Dust Cap (61531) In lieu of Option B on all models.

B Adds Plastic Dust Cap (41607) In lieu of Option A on all models.
C Adds Commercial MS24484-2 Adapter In lieu of Option D on all models except 61529.
(Either C or D must be specified to obtain a
complete unit).
D Adds Military MS24484-5 Adapter In lieu of Option C on all models except 61529.
complete unit).
G Adds 2-1/2" - 8 NPT Female Outlet In lieu of Option H on 6958 only. (Either G or H
must be specified to obtain a complete unit).
H Adds 2-1/2" - BSPP Female Outlet In lieu of Option G on 6958 only (Either G or H
4.0 DISASSEMBLY
Refer to Figure 1 for an exploded view of the Unit. 4.3 Noting the warning below, carefully remove the six
Screws (6) from the Adapter Module (2 or 2A).
4.1 Remove six Screws (1). Pull Adapter Module (2 or
2A) from Housing (3) and remove and discard O-
ring (4). Remove Cap (11 or 11A) from Adapter WARNING
Module (2 or 2A). If present (available only on The Spider (7 or 7A) is spring loaded and care should
some units), do not remove the two pipe Plugs (5) be exercised in removing the attaching Screws (6).
from the Housing (3) unless replacement is
required.
4.2 Spare parts for the Cap (11 or 11A) are not
available. If it is faulty replace as a complete unit.
5.0 INSPECTION
5.1 Special Tools - Use Adapter Wear Gauge, 61657-2 5.3 Check Cap (11) for aging cracks or other damage.
to check the Flange (9 or 9A) of Adapter Module Replace as needed.
(2 or 2A) for suitability for continued use. Refer to
Service Manual SM61657 for instructions on its 5.4 Inspect Poppet (8 or 8A) for damage to the seal.
use. This gauge will indicate whether the slots and The seal is bonded into the metal poppet and is not
lugs of the Flange (9 or 9A) of Adapter Module (2 removable. Replace Poppet (8 or 8A) as needed.
or 2A) are worn beyond safe use.
5.2 Check the seal on Cap (11A) for deterioration, cuts

or nicks. Replace the Cap (11A) if such aberrations
are apparent.
6.0 REASSEMBLY
6.1 Reassembly is accomplished in essentially the 6.4 Place the O-ring (4) in the groove in Adapter
reverse order of disassembly noting the following: Module (2 or 2A) before installing in the Housing
(3). Torque Screws (1) to 20 ± 2 in-lbs (.23 m-kg).
6.2 Light lubrication of all O-rings and seals, using
petroleum jelly is recommended to facilitate 6.5 Reattach Cap (11 or 11A) to tab on Adapter
installation. Module (2 or 2A) if utilized.
6.3 Reassemble Adapter Module (2 or 2A).
7.0 TEST
7.1 The following test procedures will be

accomplished after overhaul: 7.3.1 Attach adapter to a 120 psi fluid pressure source
through the outlet (flanged or threaded end).
7.2 Test conditions Attach a Carter 60427 or 61428 type nozzle to
the inlet Adapter Module (2 or 2A). The nozzle
7.2.1 Test media shall be Stoddard Solvent (Federal shall be plugged at the inlet end with a plug and a
Specification P-D-680), JP-4 per MIL-J-5624D small petcock or hand valve. With the nozzle and
at 75° + 15°F, Jet A or equivalent. petcock open, slowly increase the pressure into
the adapter outlet to fully bleed the air from the
7.3 Functional Test test unit. Close the petcock and increase the test
-4-
pressure to 120 psi. Check for external leakage

from the joint between the nozzle and adapter 7.3.3 Slowly increase the system pressure again to 120
and from the adapter housing and joints. psi and check for leakage from the Adapter
Module (2 or 2A) Poppet (10 or 10A).
7.3.2 Bleed the pressure from the test unit and remove
the nozzle.
Table 1.0 tabulates the parts and sub-assemblies comprising the various adapters covered by this manual. The
item numbers of the table are keyed to the exploded views of the Units diagrammed in Figure 1.
TABLE 1.0
Number Spares/10
Item Part Number Description Required Units/Yr. Used on
1 GF24693C73 Screw ........................................ 6 6 All except 61529
2 61529 Adapter Module (MS24484-2) . 1 - All except Option D
6 LP500-6-5 Screw ................................. 6 6 All
7 20876 Spider................................. 1 - All
8 2753 Spring ................................ 1 - All
9 20748-2 Flange ................................ 1 1 All except Option D
10 20780 Poppet................................ 1 2 All except Option D
2A 61247 Adapter Module (MS24484-5) . 1 - Option D only
6 LP500-6-5 Screw ................................. 6 6 All
7 20876 Spider................................. 1 - All
8 2753 Spring ................................ 1 - All
9A 20748-1 Flange ................................ 1 1 Option D only
10A 208197 Poppet................................ 1 2 Option D only
3A 24176 Body, 2½" NPT ........................ 1 - 6958 Option G only
3B 204563 Body, 2½" BSPP...................... 1 - 6958 Option H only
3C 210201 Body, 4" TTMA........................ 1 - 61272 only
3D 210136 Body, 4" ANSI.......................... 1 - 61409 only
3E 210216 Body, 3" TTMA........................ 1 - 61528 only
4 MS29513-153 O-ring........................................ 1 10 All (not furnished with
61529)
3F 220288 Body, 3" ANSI 1 - 64040 only
5 210462 Plug........................................... 2 - Some 6958, 61272 and
61528 only
11 41607 Cap, Plastic ............................... 1 3 Option B only
11A 61531 Cap, Metal Sealing.................... 1 1 Option A only
Notes: 1. All part numbers beginning with "GF" are interchangeable with those beginning with either "AN" or
"MS". If the "GF" is followed by three numbers it is interchangeable with and "AN" part, otherwise it
is interchangeable with an "MS" part of the same number.
2. The recommended spare parts shown above are the number required to support 10 Units for one year.
The recommended quantities are based on the ratio of spare parts sold for each unit during a one year
period of time. The actual quantity required will vary from location to location.
-5-
Morrison Bros. Co. www.morbros.com
Fig. 507 Emergency Valve Operator

Specification Sheet
DESCRIPTION Figure 507
Remote control of emergency valves through flexible cable. Maxi-

mum 3/16" cable. Replaceable fuse adaptor releases at 210°F.
Threaded take-up for cable slack adjusts conveniently in place.
Choice of 15/8 " or 23/8" cable travel positions. Dual trip levers provide
shutoff of emergency valves from two locations.
Figure 507AO
SPECIFICATION OPTIONS:
I.D. NUMBER A B C D E F WT.

507---0100 AO 1 N P 16 3/4 4 13/16 12 1/8 6 CHART KEY:
507---0200 AO 2 N P 16 3/4 4 13/16 12 1/8 8 A—Compartment: 1, 2, 3, 4, 5
507---0300 AO 3 N P 16 3/4 8 3/8 12 1/8 11.5 B—Air Operated: Y for Yes, N for No
507---0400 AO 4 N P 16 3/4 8 3/8 12 1/8 13.25 C—Material/Coating: P for Powder
507---0500 AO 5 N P 16 3/4 8 3/8 12 1/8 15
Coated.
507AO-0100 AO 1 Y P 20 1/2 6 3/16 12 1/8 7
D—Length
507AO-0200 AO 2 Y P 20 1/2 6 3/16 12 1/8 10
507AO-0300 AO 3 Y P 20 1/2 9 3/4 12 1/8 13
E—Width
507AO-0400 AO 4 Y P 20 1/2 9 3/4 12 1/8 15 F—Height
507AO-0500 AO 5 Y P 20 1/2 9 3/4 12 1/8 17 Weight—Shipping Weight
P.O. Box 238 • Dubuque, Iowa 52004-0238

563.583.5701 (tel) • 800.553.4840 • 563.583.5028 (fax)
w w w . m o r b r o s . c o m
AIR ELIMINATOR
FROM PUMP
TO PIPING
HEATER
JUNCTION
BOX
SENSOR
FILTERS
R
20” PAF 406-98 OFFSET MANHOLE

With Integral Relief Valve/10” Fill
INTEGRAL RELIEF VALVE/10” FILL
TEST PRESSURE 36 PSIG
BETTS INDUSTRIES, INC.

MEETS DOT 178.345-5
WARREN, PA. U.S.A.

COVERED BY PATENTS
ISSUED AND PENDING
CT-0040
LESS THAN 1 LITER LEAKAGE
SET PRESSURE ADJUSTMENT
INCREASED FLOW RATE
SECONDARY SAFETY LATCH
Pressure Relief Valve setting 3.63 psig

Rated Pressure Actuated Emergency Venting:
494,084 cu. ft. free air per hour @ 6.25 psig
Rated Liquid Flow Capacity 1335 gpm @ 5.0 psig
PAF manholes with integral latch style surge suppression relief valves are designed for use on DOT406 and replacement on
MC306 specification cargo tanks. Manholes are certified and marked in accordance with 49CFR178.345-5 with a test
pressure of 36 psig. Manhole covers are 7 gage steel or stainless and are secured to the tank weld collar with a clamp ring
and bolt which can be easily removed to provide access into the tank.
The integral 10” relief valve provides emergency pressure relief and meets the 1 liter surge leakage limit imposed by
49CFR178.345-10(b)(3)(ii). The relief valve also serves as a 10” latch style fill which can be easily opened to provide access
for filling the tank or for inspection. Relief valves contain an adjustment feature to allow for fine-tuning of set pressure in the
field. Other standard features include a heavy duty clamp ring, secondary safety latch and model 6496ALB pressure-vacuum
vent mounted in the 10” relief valve cover.
Manholes are available with a self-latching feature that allows the 10” relief valve/fill cover to drop and securely latch upon
movement of the tank if the cover is inadvertently left open. For self-latching model substitute L863 for L820 in assembly
number.
1
Note: 3 /2” Vent and Liquid Level Switch not included in assembly.
Clamping Ring,
Cover Relief Clamping Ring Wt.
Bolt, Washer, Normal Vent Assembly No.
Plate Valve Nut (lb.)
Strongback, & Latch
Steel Zinc Plt. Alum. Steel Zinc Plt. Brass Alum. 29.7 PPVL820BXB
Stnls 304 Alum. Stnls 304 Stnls 304 Alum. 30.2 PPVL820CXB
Stnls 316 Alum. Stnls 304 Stnls 304 Alum. 30.2 PPVL820DXB
Note: Manhole assemblies, as listed above, have Buna-N gaskets (suffix “B”). For variation in gasketing change last letter of
assembly number as follows.
Suffix “V” indicates Viton collar gasket & Viton 10” fill gasket
Suffix “W” indicates White Hypalon collar gasket & White Hypalon 10” fill gasket
Suffix “T” indicates Teflon envelope collar gasket & Tef-Sil 10” fill o-ring
Manhole collars are available in aluminum, steel, and stainless steel. Please see parts page for correct numbers.
When welding collars to tank, care should be exercised to insure collar remains flat and round.
TM
INDUSTRIES, INC. Sept 1999 Section 86 Page 19A

WARREN, PA.
PLAN VIEW DIMENSIONS
1
PARTS LIST A 4 /4” Dia. (107.95mm)
7
B 8 Holes-.390 Dia. (9.90mm) on 4 /8” (123.83mm) B.C.
3
C 2 /8” Dia. (60.325mm) Hole
20” PAF 406-98 MANHOLE D
1
/4” N.P.T. Coupling
Self-Latching Model Illustrated E 7” Rad. (177.8mm)
3
F 6 /8” (161.93mm)
3
G 4 /4” (120.65mm)
1
H 3 /4” (82.55mm)
No. Description Material Part No. No. Description Material Part No.
1 Fill Cover Alum/E-Coated 8297ALEY 9 Vent Assembly Aluminum 6496ALB
1a Fill Cover (O-Ring Grvd.) Alum/E-Coated 8297ALEY389 10 Gasket Buna-N 3716BN
Buna-N 3119BN 11 Cylinder Assembly Aluminum 6657AL
Gasket -
2 Viton 3119VT 12 Piston Aluminum 6654AL
Integral Relief Valve
Wh. Hypalon 3119WH 13 Stem Stnls 304 6688SL
2a O-Ring Tef-Sil 3902TS 14 Spring Steel 4122MS
1
Steel Zinc Plt. 3029ZC 15 /2” NPT Plug Zinc Plt. Steel Zinc Plt. 9V4907
3 Bolt-Clamp Ring
Stnls 304 3029SL 17 Stem O-Ring -112 Buna-N 4118BN
Brass 3030BR 18 Cylinder O-Ring –137 Buna-N 4015BN
4 Nut-Clamp Ring
Stnls 304 9Q5809 19 Piston O-Ring –137 Tef-Sil 4015TS
Steel Zinc Plt. 3031ZC 20 O-Ring Retainer Alum/E-Coated 4117ALEY
5 Washer-Clamp Ring
Stnls 304 3031SL 21 Retainer Ring Stnls 304 9Q4961
Steel 3036MS 22 Bellows EPDM 4020EPDM
7
6 Clamping Ring Steel Zinc Plt. 3036ZC 23 Lockwasher Ext. Tooth /16” Stnls 304 9Q5961
7
Stnls 304 3036SL 24 Nut Hex /16x20 Stnls 304 9Q5960
Buna-N 3560BN 25 Plastic Plug Polyethylene 9Z6163
3
Viton 3560VT 26 /8-16 Hex Nut w/ Insert Steel Zinc Plt. 9Q5896
Manhole Gasket
7 Wh. Hypalon 3560WH
Channel Type
Teflon Env. Gasket Maximum Temperature
3033TF Buna-N (Nitrile) 250°F
w/ Wh. Hypalon
Steel 3176MS Viton 400°F
Manhole Collar Aluminum 3176AE White Hypalon 250°F
8 Teflon-Silicone 400°F
Channel Type Stnls 304 3176SL
Stnls 316 3176SS Teflon Envelope w/ White Hypalon Insert 250°F
Replace oil cylinder using Automatic Transmission Fluid Dexron III/Mercon, SAE 5W-20 with viscosity of 177 SUS at
100°F and a pour point of no greater than –45°F.
MAINTENANCE: Manhole assemblies should be inspected with sufficient frequency to insure 10” Integral Relief Valve
functions properly. Any worn, damaged or missing parts must be replaced. Gaskets should be replaced if their
effectiveness to insure a liquid tight seal is impaired in any way. Replacement gaskets must be compatible with
products carried.
WARNING Consult PAF406-98 maintenance manual prior to disassembly of this relief valve.
Use only genuine Betts Industries Inc. replacement parts. Use of substitute parts can impair the proper
functioning of this product.
TM
INDUSTRIES, INC. Sept 1999 Section 86 Page 19B

WARREN, PA.
Betts Industries, Inc.
Warren, PA 16365
Phone: 814-723-1250
MAINTENANCE MANUAL
FOR
PAF 406-96 & 406-98
SURGE
RELIEF VALVE
Section 1: Identification of Adjustable PAF 406-96 & 98
Section 2: Maintenance and Testing for PAF 406-96 & 98
Section 3: Set Pressure Adjustment of PAF 406-96 & 98
Section 4: Removal of PAF 406-96 & 98 from Closure Assembly
Section 5: Disassembly of PAF 406-96 & 98
Section 6: Assembly of PAF 406-96 & 98
9/16/99
Warren, PA 16365
Phone: 814-723-1250
SECTION 1:
IDENTIFICATION OF ADJUSTABLE
PAF S URGE RELIEF VALVE (PAF 406-96 & 98)
Betts PAF Surge Relief Valves (PAF 406-96 and PAF 406-98) meet or exceed all U.S. DOT
requirements for primary pressure relief valves on DOT406 cargo tanks as contained in
49CFR178.345-10 and 49CFR178.346-3 of the Code of Federal Regulations. The Betts PAF
Surge Relief Valve is able to withstand a brief pressure surge and contain lading (liquid cargo)
leakage to less than one liter (per TTMA RP NO 81).
Betts PAF Surge Relief Valve (PAF 406-96 & 406-98) protects the cargo tank from rupture due to
over-pressurization caused by overfilling or fire and is, therefore, crucial to the safe operation of
the tank. In order to maintain your Betts PAF Surge Relief Valve in proper working condition, the
following procedures must be followed.
All PAF 406-96’s are cast with

“MODEL PAF 406-96 ”
And PAF 406-98’s are cast with
“MODEL PAF 406-98”
HEX
PLASTIC CAP
The adjustable PAF
DETAIL 406-96 & 98 have an
internal hex at the top
of the stem under the
plastic yellow cap, as
well as, a Black E-
coated cover.
BLACK E-COATED
COVER
Warren, PA 16365
Phone: 814-723-1250
SECTION 2:
MAINTENANCE AND TESTING
FOR PAF S URGE RELIEF VALVE 406-96 & 98
A. U.S. DOT Requirements: This portion of the manual refers to the DOT regulations and is intended to
serve as an interface to relate the manual to the code. This manual does not take the place of the Code
of Federal Regulations. A current copy of the Code of Federal Regulations should be reviewed and
followed to insure the requirements are met for each individual case.
There are three basic tests/inspections mandated by 49CFR Part 180 for MC306 and DOT406 cargo tanks.
Test/Inspection Interval Period Code Paragraph

External Visual Inspection 1 year 49CFR180.407(d)
Leakage Test 1 year 49CFR180.407(h)
Pressure Retest 5 year 49CFR180.407(g)
1. External Visual Inspection: As part of the annual external visual inspection, 49CFR180.407(d)(3)
requires that all pressure relief valves, be visually inspected for any corrosion or damage which might
prevent the valve from functioning. If the cargo tank is used to haul product that is corrosive to the
relief valve, the valve must be removed from the cargo tank for inspection and bench testing.
Note: Betts recommends that the external visual inspection of vents be performed monthly.
1.1. Visually inspect all external surfaces of the manhole and PAF, which includes opening the
Latch (1) and Strongback (5).
NOTE: If any corrosion or damage to the PAF or manhole is observed, it must be repaired and
successfully bench tested prior to returning to service. Refer to 3.5 for PAF bench test procedure.
1.1.1. Clean and inspect the bottom side of the PAF for signs of damage, corrosion, or product
gumming that could effect the operation of the Relief Valve.
1.1.2. Closely inspect the Cylinder (10) for any damage or dents. Also, insure Cylinder (10) is
threaded tightly to the Cover (9). See figure 1.
1.1.3. Inspect and clean the Normal Vent (8).
1.1.4. Inspect the 10” Seat (25) for damage or corrosion. Build-up or grim on the seat should be
removed. Nicks on the 10” seat may cause the gasket not to seal.
1.1.5. Inspect the 10” Fill Gasket (24) for signs of wear or degradation. Replace gasket if required.
1.1.6. Inspect the Clamp Ring Gasket (26) for evidence of product seepage. Replace any gaskets
where seepage is detected.
COVER (9) Inspect & clean

Inspect CYLINDER (10) GASKET (24)
Inspect & clean

NORMAL VENT (8)
STRONGBACK (5)
Inspect SEAT (25)
Inspect GASKET (26)

for leakage
Figure 1
Warren, PA 16365
Phone: 814-723-1250
2. Leakage Test: 49CFR180.407(h) requires tanks to be tested annually at 80 % of the tank design
pressure or MAWP, whichever is marked on the tank certification or specification plate. All tank
components must remain in place during this test, except any re-closing pressure relief valve with a set
pressure less than the leakage test pressure must be removed or rendered inoperative during the test.
Betts Normal Vents, therefore, must be removed during the leakage test.
2.1. Remove Normal Vent from manhole cover and plug opening with Betts Plug No. 3013.
2.2. Apply test pressure in accordance with 49CFR180.407(h)
2.3. Inspect all gasket joints on PAF and manhole for leaks. If PAF leaks, adjust in accordance with
Set Pressure Adjustment instructions (Section 3 of this manual) and retest the unit. Replace
damaged or worn gaskets as required.
3. Pressure Retest: As part of the pressure retest, 49CFR180.407(g)(ii)(A) requires that all re-closing
pressure relief valves be removed from the tank for inspection and bench tested to verify that the
relief valve is functioning properly. The pressure retest and the relief valve bench test must be
performed at least every five years.
Note: Betts recommends that the PAF 406-96 and PAF 406-98 be bench tested annually.
3.1. Pressure Retest Procedures:

3.1.1. 49CFR180.407(g)(1)(vii) requires that all closures except pressure relief devices must be in
place during the test.
3.1.2. Manholes must remain in place during pressure test.
3.1.3. Open 10” PAF Relief Valve.
3.1.4. Install Betts Retest Fixture (part no. 6556LCB) to seal the 10” opening. See figure 2.
3.2. Betts Push and Air Operated Vapor Recovery Valves remain in place during the test.
NOTE: If vapor recovery valves from other manufactures are installed, refer to the
manufacturers’ instructions to see if they should be removed.
3.3. After preparing the rest of the tank, perform the pressure test in accordance with the regulations.
Inspect all parts of manhole assembly for leakage. Repair or replace parts as required.
3.4. Remove all clamps or plugs from relief valve immediately after test is completed.
Retest Fixture
(Part No. 6556LCB)
Inspect for Clamp Channel

Leakage Here Inside of 10” Fill
Figure 2
Warren, PA 16365
Phone: 814-723-1250
3.5. Bench Test Procedure for PAF Surge 406-96 & 98
3.5.1. Remove manhole assembly from tank by removing the clamp ring bolt and clamp ring.
3.5.2. Remove Normal Vent (8) and plug port with Betts Plug (No. 3013)
3.5.3. Attach manhole assembly to appropriate Betts PAF 406-96 Test Fixture (No. 6685SL.)
3.5.4. Apply a soap solution around the perimeter of the DoveTail 10” Gasket.
3.5.5. Gradually apply pressure to the tank and observe the pressure at which bubbles first appear.
3.5.6. Per 49CFR178.346-3(c) the set pressure must not be less than 3.63 psig and not more than
4.55 psig for a tank with a MAWP of 3.3 psig.
3.5.7. Slowly release the pressure from the test fixture and verify the PAF reseals not less than the
MAWP of the tank.
3.5.8. Replace or adjust any relief valve that fails the set pressure test requirements. Refer to
instructions for Set Pressure Adjustment (Section 3 of this manual) to adjust the set
pressure, and retest the unit.
4. Model 6496AL (Normal vent for DOT 406) Test Procedure:

A Normal Vent Test Tank (Part No. 6687AL) must be used to test the Normal Vents.
Note: A regulator must be used to slowly apply pressure to the tank.
4.1. Pressure Test: 49CFR 178.346-3(b)(2) states that the normal vent for a DOT 406 must be set to
open at not less than 1 psig.
4.1.1. Screw the Normal Vent into the lid of the test tank as shown in figure 3 A. In order to
detect leakage, attach the reducer bushing, compression fitting, and tubing. Place the end of
the tubing in a water jar. The water jar is not included with the test tank.
4.1.2. Slowly apply pressure to the tank. Bubbles will indicate the opening pressure of the vent.
4.1.3. A properly functioning 6496AL Normal Vent should open between 1.0 to 1.5 psig, but in no
case open less than 1 psig.
4.2. Vacuum Test: 178.346-3(c)(2) states that the normal vent for a DOT 406 must be set to open at
no more than 6 ounces vacuum (.375 psig).
4.2.1. Screw the Normal Vent into the lid of the test tank as shown in figure 3 B.
4.2.2. Slowly apply pressure to the tank and inspect the top opening for pressure release. Apply
soapy water to the top of the vent in order to detect the point at which the vent opens.
4.2.3. A properly functioning 6496AL Normal Vent should vacuum relieve between 0.25 to 0.375
psig, but in no case more than 0.375 psig.
4.3. Repair or replace any Normal Vent that does not meet the specifications.
Tubing
Pressure Release
Pressure Release
Reducer Bushing
Test Tank
6687AL
Seal
Air out to Air out to

Air in from manometer Air in from manometer
regulator or gage. regulator or gage.
Water Jar Bubbles

Indicate
Leakage
PRESSURE TEST VACUUM TEST

Figure 3A Figure 3B
Warren, PA 16365
Phone: 814-723-1250
SECTION 3:
OF PAF S URGE RELIEF VALVE
NOTE: THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL 306-98, 406-98 AND PAF
406-96 W/ BLACK E-COATED COVER AND STEM WITH INTERNAL HEX AT THE TOP.
1. Relieve vapor pressure or vacuum from cargo tank.

Failure to relieve tank pressure may result in sudden,
unexpected loss of pressure. Severe personal injury or
death may result.
2. Open Latch (1) to expose yellow Plastic Plug (2) as shown in figure 4.
3. Remove yellow Plastic Plug (2).
4. Place an 11/16 box end wrench over Hex Nut (3).
5. Place a 7/32 allen wrench into the hex socket of the Stem (4).
6. Hold the allen wrench stationary and rotate the box end wrench counterclockwise to
loosen the Hex Nut (3) two full turns.
7. At this point, the PAF can be adjusted by rotating the Stem (4) with the allen wrench.
8. To increase the set pressure, turn the Stem (4) clockwise.
Note: The Stem (4) must fully engage threads of Hex Nut (3) when nut is tightened.
Loosen
Nut
Increase Set
Pressure
Warren, PA 16365
Phone: 814-723-1250
9. To decrease the set pressure, turn the Stem (4) counter-clockwise.

Note: The amount of adjustment in the counter-clockwise direction is limited by
a shoulder stop on the Stem (4).
10. The adjustment feature is sensitive, so that, one turn of the stem may increase the set
pressure significantly. Adjust stem ¼ turn at a time, until the desired setting is
achieved.
Never adjust the relief valve so that a person must stand on

the Strongback (5) to operate the Latch (1). This could cause
a person to loose their balance and fall, if there is any
residual pressure in the tank when the relief valve is opened.
11. After adjusting the PAF surge relief valve, use the box wrench to tighten the Hex Nut
(3), while using the allen wrench to hold the stem stationary.
12. Replace the Plastic Plug (2).
13. After adjustment, test the set pressure to verify that it falls within the required range.
13.1. Per 49CFR178.346-3(c) the set pressure for models PAF406-96 & 406-98
must not be less than 3.63 psig and not more than 4.55 psig for a tank with
a MAWP of 3.3 psig.
13.2. Per 49CFR178.341(d)(2) the set pressure of model PAF306-98 must not be
less than 3.0 psi for a MC306 tank
14. If the adjustment does not achieve the desired pressure setting, check the following:
14.1. Inspect the 10” metal seat. Remove any build up and repair any nicks.
14.2. Replace the 10” gasket.
14.3. Insure strongback is not bent or damaged.
14.4. Insure the collar that is welded to the tank is not excessively warped.
14.5. Insure closure assembly was mounted correctly to manhole collar.
14.5.1. Unbolt clamp-ring and loosen closure assembly from collar seat.
14.5.2. Release latch to relieve force on 10” fill cover.
14.5.3. While the 10” fill is opened, tighten clamp-ring bolt while
tapping circumference of clamp-ring with a hammer.
14.5.4. Close 10” fill and latch.
Warren, PA 16365
Phone: 814-723-1250
SECTION 4:
REMOVAL OF PAF S URGE RELIEF VALVE
FROM CLOSURE ASSEMBLY
NOTE: THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL PAF 406-96 & 98 WITH
BLACK E-COATED COVER AND STEM WITH INTERNAL HEX AT THE TOP.

death may result.
2. Open latch to expose Yellow Plug (2) as shown in figure 5.
4. Use an 11/16 socket or box end wrench to remove Hex Nut (3).
5. Remove Star Washer (6).
6. Open fill assembly as shown in figure 6.
7. Place a 7/32 allen wrench in the hex socket of the Stem (4).
8. By rotating the stem clockwise, the PAF assembly can be unscrewed from the closure
assembly. NOTE: During removal, care should be taken not to damage the last
threads on the stem, by supporting the PAF with a hand under the cylinder.
9. Remove the Bellow (7).
10. At this point, further disassembly should be conducted at a workbench. Follow the
procedure “Disassembly of PAF Surge Relief Valve” if disassembly of the cylinder is
required.
DISASSEMBLE
DISASSEMBLE
SUPPORT HERE
Warren, PA 16365
Phone: 814-723-1250
SECTION 5:
DISASSEMBLY OF PAF S URGE RELIEF VALVE
NOTES:
Ø THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL PAF 406-96 & PAF
406-98 WITH BLACK E-COATED COVER AND STEM WITH INTERNAL HEX AT THE TOP.
Ø UNDER NORMAL CIRCUMSTANCES, THE DISASSEMBLY OF THE SPRING CYLINDER IS

NOT REQUIRED NOR RECOMMENDED, UNLESS ALL OTHER ATTEMPTS TO REPAIR THE
RELIEF VALVE HAVE FAILED. IT IS RECOMMENDED THAT THE VALVE BE RETURNED TO
BETTS INDUSTRIES FOR REPAIR.
Ø A PAF SURGE DISASSEMBLY TOOL (PART # 6684MS) IS REQUIRED TO DISASSEMBLE

THE SPRING CYLINDER.
1. Remove the PAF surge relief valve assembly from the closure assembly by following
the steps outlined in the procedure “Removal of PAF Surge Relief Valve from Closure
Assembly”.
2. Remove Normal Vent (8) by griping with slip joint pliers and unscrewing from Cover (9).
See figure 7.
The cylinder contains a compressed spring, which could cause

injury, if the cylinder is removed improperly. Review the following
section carefully before attempting to remove cylinder.
3. The Cylinder (10) contains Hydraulic Oil (11) that must be drained.
4. Use a 3/8 allen wrench to remove the ½ in. NPT Plug (12) while holding the Cylinder
(10) stationary by gripping with slip joint pliers within one inch from the bottom. It is
very important that the cylinder does not unscrew from the cover at this time.
5. If the unit has a 1/8 in. NPT Plug (13) remove it at this time.
6. Drain the oil that is on the top and bottom of the Piston (14).
Insure CYLINDER
Does NOT Unscrew
Grip Here to Remove
Grip With Slip-Joint

Pliers Here.
Warren, PA 16365
Phone: 814-723-1250
7. Insert the 3/8 female thread end of the Disassembly Tool (15) (part # 6684MS) into the
½ in. NPT opening as shown in figure 8.
8. Thread the Disassembly Tool (15) onto the 3/8 male thread of the Stem (4) that extends
from the Lock Nut (16). See figure 8. The tool should engage at least four threads.
Note: Use a 7/32 allen wrench on the bottom of the tool and one at the top
of the stem to tighten tool completely down.
Screw Tool to
End of STEM (4)
3/8 Female
Thread of Tool
NOTE: Tool is Shown Shorter

Than Actual Length
9. At this point, a 7/32 allen wrench must be used to hold the shaft of the tool stationary
with respect to the cylinder, while an 11/16 wrench is used to turn the Tool Nut (17)
clockwise. Once the nut has made contact with the cylinder, turn the nut two complete
turns to compress the Spring (18). See figure 9.
Tool Must Thread

Completely to Nut
Two Turns Clockwise

To Compress Spring
Hold Shaft
Stationary
Warren, PA 16365
Phone: 814-723-1250
10. The Cover (9) can now be unscrewed from the Cylinder (10). Do NOT unscrew the
stem from the tool. If slip joint pliers are required to grip the cylinder, only grip
within one inch from the end. See figure 10.
After the cover is removed, the spring is still under load

in the cylinder. Do NOT point the open end of the tube
toward yourself or a bystander.

Than Actual Length Unscrew Nut
Grip Cylinder Hold Shaft

On This End Stationary
11. To release the spring, hold the allen wrench stationary with respect to the
cylinder, and turn the Tool Nut (17) counter-clockwise. It is imperative that the
shaft of the tool does not unscrew from the Stem (4) during disassembly process.
Continue to back off the Tool Nut (17) until the piston is extended beyond the
length of the spring. See figure 11.
12. At this point insure the spring tension is released, and the Tool (15) can be
unscrewed from the Stem (4).
Warren, PA 16365
Phone: 814-723-1250
13. Disassemble the stem/piston assembly by inserting a 7/32

allen wrench into the top of the Stem (4) and unscrew the
LockNut (16) using a 9/16 socket. See Figure 12. Note: The
piston may appear different than shown depending on the
model you may have.
Apply petroleum
14. If the Piston O-ring (19) requires removal, cut the o-ring with jelly here during
a razor blade, being careful not to damage the piston groove. re-assembly.
15. The Stem O-ring (22) and O-ring Retainer (21) are removed
by using a snap ring tool to remove Snap Ring (20). See
figure 13.
16. If the Cylinder O-ring (23) requires removal, cut the o-ring
with a razor blade being careful not to damage the o-ring
groove.
17. If the 10” Fill Gasket (24) requires removal, cut a small slot
in the center of the gasket and use a screwdriver to pry gasket
out of dovetail groove, being careful not to damage groove.
See figure 13.
Slice Gasket as Shown &

Pry Out with Screwdriver.
For maintenance or assembly instructions consult appropriate procedures.

Warren, PA 16365
Phone: 814-723-1250
SECTION 6:
ASSEMBLY OF
PAF S URGE RELIEF VALVE
NOTE: THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL PAF 406-96 & PAF
1. Preparation of O-Rings and Components:

1.1. All parts should be cle aned and degreased to insure the removal of all product build up.
1.2. All components should be inspected for damage or wear.
1.3. To insure integrity of the seals, all o-rings and gaskets should be replaced using Betts’
replacement parts.
1.4. Inspect all o-ring grooves for damage (nicks, scratches, or burrs).
2. Cover sub-assembly: Refer to figure 14.

2.1. Insert Stem O-ring (22) into Cover (9).
2.2. Insert O-ring Retainer (21) and use a snap ring tool to insert the Snap Ring (20) into
groove.
2.3. Place black Buna Cylinder O-ring (23) into o-ring groove on Cover (9).
2.4. Use Betts’ Dove Tail Gasket Tool (26) (part # 6504AL) to place 10” Fill Gasket (24)
into Cover (9). See figure 14.
2.4.1. Lubricate the gasket and dovetail groove with a soap solution.
2.4.2. Using fingers, pinch the back side of the gasket together and insert a small section
of the gasket into the groove.
2.4.3. Use short strokes with the Dove Tail Gasket Tool (26) to insert the gasket.
2.4.4. The last portion of the gasket will need to be pushed in with fingers.
Note: The gasket can also be installed by hand. A 10” o-ring (4100BN) is also available
for use as a replacement for the dovetail gasket and can be installed in the groove.
Apply petroleum
jelly here.
Apply never-seize here.

Warren, PA 16365
Phone: 814-723-1250
3. Piston/Stem sub-assembly: Refer to figure 12 of section 5.

3.1. Inspect Stem (4) for signs of wear or corrosion. Replace as required.
3.2. Insert 3/8 end of Stem (4) into counter sunk hole of Piston (14). Note: The piston may
appear different depending on which model you have.
3.3. Insert a 7/32 allen wrench into the top of the Stem (4) and tighten the Lock Nut (16)
completely down using a 9/16 socket. Note: The Stem (4) MUST turn freely in the
Piston (14) after the nut is tightened.
3.4. Pre-heat the orange Tef-Sil Piston O-ring (19) in warm water and immediately slide the
o-ring over the Piston (14) and position it into groove.
3.5. Smear a thin layer of petroleum jelly around the Piston O-ring (19) to facilitate ease of
installing the piston into the cylinder.
4. Loading the Spring: Refer to figure 11 of section 5.

4.1. Inspect the inside of the Cylinder (10) for damage (dents, scratches, or corrosion). If the
cylinder is damaged it must be replaced.
4.2. Insert the 3/8 female thread end of the Disassembly Tool (15) (part # 6684MS) into the
½ “ NPT opening of the Cylinder (10).
4.3. Place the Spring (18) into the Cylinder (10).
4.4. Thread the 3/8 stub that extends from the Piston/Stem assembly into the Disassembly
Tool (15) and tighten with two allen wrenches. NOTE: Ensure the end of tool is tight
against the Lock Nut (16) as shown in figure 11 of section 5.
4.5. Compress the Spring (18) by using a 7/32 allen wrench to hold the shaft of the tool
stationary with respect to the cylinder, while an 11/16 wrench is used to turn the Tool
Nut (17) clockwise. (See figure 11 of section 5.) Insure the threads are not damaged on
the cylinder when the piston is pulled into the top of the cylinder.
After the spring is compressed in the cylinder, do NOT

point the open end of the tube toward yourself or a
bystander.
4.6. Continue to turn the Tool Nut (17) until the top of the piston is at least 7/8“ below the
top of the Cylinder (10). See figure 10 of section 5.
5. Installing the Cover (9):

5.1. Smear a thin amount of never-seize compound on the threads of the Cover (9) as shown
in figure 14.
5.2. Smear petroleum jelly around Cylinder O-ring (23) as shown in figure 14 and the top of
the Stem (4) as shown in figure 12 of section 5.
5.3. Position the Cover (9) over the Stem (4) as shown in figure 12 of section 5.
5.4. Slowly screw the Cover (9) onto the Cylinder (10). Care should be taken not to damage
the threads of the cylinder or cover. Beware of cross threading. Ensure that the cover is
screwed completely down to the cylinder so there is NO gap. See figure 15.
The Cylinder must be threaded completely on the Cover

prior to the Disassembly Tool being removed.
5.5. The Spring (18) can now be released by holding the allen wrench stationary with respect
to the Cylinder (10) and turning the Tool Nut (17) counter-clockwise.
5.6. Once the Tool Nut (17) has released the spring pressure, the tool can be unscrewed and
removed from the Cylinder (10).
Warren, PA 16365
Phone: 814-723-1250
6. Re-filling the hydraulic oil: Refer to figure 15.

Note: Replace the oil in the cylinder with Automatic Transmission Fluid
DexronIII/Mercon SAE 5W-20 with a viscosity of 177 SUS at 100°F and a pour
point of no greater than –45°F.
6.1. If this unit has a 1/8” NPT, place thread sealant on the 1/8” NPT Plug (13) and insert it
in the Cover (9).
6.2. Turn the PAF upside down and pour ATF fluid through the ½” NPT opening at the
bottom of the Cylinder (10).
6.3. It is very important that this lower chamber is completely full of oil, with NO air
pockets.
6.4. Place thread sealant on the ½” NPT Plug (12) and insert it into the bottom of the
Cylinder (10). Tighten the plug using a 3/8 allen wrench.
7. Smear a small amount of never-seize compound on the threads of the Normal Vent (8) and
screw it into the opening of the Cover (9).
NO Oil in this
Chamber
Ensure
NO Gap
Fill the Bottom

Chamber Completely
8. To attach the PAF Relief Valve to the closure assembly, refer to figure 6 of section 4.
8.1. Place the Bellow (7) over the Stem (4).
8.2. Thread Stem (4) into Wobble Support (27) on Strongback (5). NOTE: Use an 7/32 allen
wrench inserted from the top of the Wobble Support (27) and turn counterclockwise to
screw in the stem.
8.3. Insure the first thread is not damaged as the stem is started into the wobble support.
8.4. As the stem is threaded in, insure the Locating Ears (28) are aligned at the hinge side of
the Strongback (5) and straddle the strongback as shown in figure 4 of section 3.
Tighten the stem all the way in.
8.5. Insert Lock Washer (6) and thread Hex Nut (3) onto Stem (4) as shown in figure 6 of
section 4.
8.6. To adjust the set pressure and tighten down the stem, refer to Section 3 of this manual.
OPERATION,
MAINTENANCE AND PARTS MANUAL
TRUCK, TANK, FUEL SERVICING
ISOMETRICS MODEL 505T1200
CONTRACT GS-30F-1032D
ISOMETRICS, INC.
Post Office Box 660
Reidsville, North Carolina 27320

(Rev. G, Oct 2008)
1
TABLE OF CONTENTS
TITLE PAGE
CHAPTER 1. INTRODUCTION 3
1-1. Scope 3
1-2. Physical Description 3
1-3. Functional Description 3
1-4. Warranty Information 5
1-5. Shipping, Handling and Storage Data 5
1-6. Preparation for Use 5
CHAPTER 2. OPERATING INSTRUCTIONS 6
2-1. Scope 6
2-2. Safety Interlocks 6
2-3. Bonding 6
2-4. Prefueling Check 6
2-5. Bottom Loading 7
2-6. Top Loading 8
2-7. Gravity Drain, Unmetered 9
2-8. Fueling Procedure 10
2-9. Tank Loading using the Truck Pump, Unmetered 11
2-10. Defueling 12
2-11. Gravity Drain, Metered 14
3-1. Procedure 16
CHAPTER 3. MAINTENANCE AND SERVICING 17
3-1. Scope 17
3-2. Cleaning 17
3-3. Lubrication 17
3-4. Inspection 17
3-5. Troubleshooting 17
3-6. Component Repair 17
3.7. Service 17
3.8. Ready for Air Transport 18
CHAPTER 4. PARTS LIST AND COMMERCIAL LITERATURE 23
4-1. General 22
4-2. Parts List 22
CHAPTER 5. SCULLY OVERFILL PREVENTION 25
LIST OF ILLUSTRATIONS
Figure Title page
2-1 A Piping Schematic (for Trucks with Filters) 15
2-1 B Piping Schematic (for Trucks without Filters) 15
4-1 Pumping Compartment 23
4-2 Pump/PTO Diagram 23
4-3 Cable Diagram 24
4-5 Electrical Schematic (Lights) 24
4-6 Scully System Schematic 25
LIST OF TABLES page

Table Title
3-1 Daily Inspection 20
3-2 Periodic Checks and Services 20
3-3 Troubleshooting 21
2
CHAPTER 1
INTRODUCTION
1-1. SCOPE. This manual contains operating procedures, service and repair instructions and
and replacement parts for the fuel servicing tank truck manufactured by Isometrics, Inc.,
Reidsville, North Carolina. This manual does not cover components of the truck chassis.
Refer to the chassis manuals provided with the vehicle pertaining to operation, maintenance,
and parts listings of the cab and chassis.
1-2. PHYSICAL DESCRIPTION. The fuel truck consists of a single compartment tank with
baffles mounted on a commercial chassis, a bottom loading system, and a pumping system
with fuel metering capability, and filtration.
a. The pumping system includes a PTO driven pump with internal bypass, a strainer assembly,
a flow meter with reset counter and totalizer, a suction stub, dispensing hose reel, hose,
and a trigger type automatic shutoff nozzle.
b. The bottom loading system includes inlet adapters, a bottom loading valve, an electronic
level sensor with onboard shutoff control and fill stand connections.
c. The bottom loading valve is located in the bottom of the fuel tank. The majority of all other
components are mounted in a pumping compartment between the cab and tank. The pump,
strainer, and associated plumbing are located underneath the fuel tank. The filtration system is
located in the underslung cabinet on the driver's side of the truck. All other pumping system and
bottom loading components are located in the cabinet on the curb side of the truck.
d. Physical data:
1. Model No.: 505T1200

4x2 4x4
2. Tare Weight: 16,700 LBS. 17,700 LBS.
3. Dimensions: 270"L X 96"W X 96"H 270"L X 96"W X 99"H
4. Shipping Cube: 1440 Cu. Ft. 1485 Cu. Ft.
5. Environmental Conditions: -20 to 125 degrees F
1-3. FUNCTIONAL DESCRIPTION.
a. General.
(1) The pumping system provides for a fuel servicing capacity of 75 U.S. gallons per
minute (GPM) at the discharge end of the nozzle.
(2) The truck provides plumbing and controls for bottom loading, pressure off-loading,
and gravity off-loading, both metered and unmetered. A suction stub is also provided to facilitate
self-loading and defueling.
b. Pumping System.
(1) During fueling, fuel flows from the tank through the emergency valve, through the
strainer to the pump. Fuel from the outlet side of the pump flows through the filter/separator,
meter, hose reel, and hose and nozzle assembly.
(2) The pump is driven by a power take-off (PTO) mounted on the side of the transmission.
3
CAUTION
To avoid running the pump dry make sure the emergency

valve is open prior to engaging the PTO. Refer to the
operating instructions for this procedure.
(3) The emergency valve operator, located in the curb side pumping compartment,
opens the emergency valve. This control also serves to close the valve in
an emergency. Striking or pushing the handle allows an internal valve spring to close the
emergency valve. Emergency controls, operable for closing the emergency valve only, are
located at the right rear of the truck, at the driver's door, and on top of the tank. They are marked
with red square decals with 2-inch instruction letters.
(4) Two each 40 GPM filters (if so equipped) are located in the cabinet on the driver's side of
the truck. They are connected in parallel from the discharge side of the pump to allow for a total flow of
80 GPM. They filter solids and separate any water in the fuel. Drains at the bottom of each filter
allow for water and solids removal on a periodic basis. Each filter is equipped with a heater for
cold weather applications. The heaters are activated by a toggle switch located to the left
side of the steering column on the dash.
(5) An air eliminator flow meter assembly is located downstream of the filters in the curb side
cabinet. It is rated for 100 GPM and comes complete with reset counter and totalizer.
(6) Next is the hose reel, hose, and nozzle assembly. The hose reel is of the manual rewind
type with 100 feet of 1-1/2 inch commercial grade fuel hose. A 1-1/2 inch trigger type automatic
shutoff nozzle rated at 75 GPM is attached to the hose.
c. Bottom Loading System.
(1) The bottom loading valve, located in the bottom of the tank also serves as the emergency
valve. Air pressure from the emergency valve operator or the bottom loading interlock opens it.
It is a balanced type valve that will remain closed, regardless of fill stand pressure, if there is no
air source to open it.
(2) A bottom loading manifold, located on the left side of the truck, is provided for the fill stand
connection to perform the bottom loading task. Each leg of the manifold serves as a quick disconnect
drybreak connection. In order to connect the fill stand coupler, a valve lever must be moved to the
side. This action opens the air vent on top of the tank, sets the truck brakes, and opens the bottom
loading valve unless the tank is already full. One leg of the manifold is a D-1 nozzle adapter and
the other leg is a 4-inch API commercial bottom loading adapter.
(3) An electronic level sensor is installed in the top of the tank. When fuel contacts
this probe, an electrical signal is transmitted to a control module located on a bracket in the curb side
cabinet. A socket array is also provided to interface with the appropriate fill stand connection.
When fuel contacts the sensor, the fill stand controls stop the fuel flow into the tank.
If fill stand controls are unavailable, the onboard system will automatically stop the flow by
closing a solenoid air valve plumbed between the bottom loading valve and the brake interlock.
Air will exhaust and the bottom loading valve will close.
4
d. Top Loading. The tank may be loaded from the top by opening the fill cover in the manhole
cover located on the top of the tank and inserting the fill hose into this opening. The hose should
reach the bottom of the tank to avoid static charge buildup.
e. Vent Valve. A vent valve, located in the top of the tank, vents the tank to atmosphere
during loading and off loading. The vent valve opens whenever the emergency valve operator is
engaged or the bottom loading interlock is activated. This valve is pneumatically controlled.
The vent is equipped with an interlock feature so that pumping operations cannot be performed
unless the vent is open. The vent is open to the atmosphere via vapor recovery piping that
is open at the rear of the tank. A sealed flexible hood is located over the vent valve on top of the
tank. The hood is connected to a header and tubing that terminates at the rear curb side of the
vehicle. Three and four inch open flanged outlets are provided for connection to the vapor
recovery system, if available, at the bottom loading facility.
f. Gravity Unloading. Gravity unloading can be accomplished by attaching a hose to the

2-1/2 inch faucet and opening the bottom loading valve and faucet. Gravity unloading through the
faucet is unmetered.
g. Self-loading and Defueling. Loading the tank using the onboard pumping system or
removing fuel from an item can be accomplished by attaching a suction type hose to the fuel
source or item and the 2-1/2 inch faucet, opening the appropriate valves, and starting the pump.
Fuel will enter the tank via the bottom loading valve.
1-4. WARRANTY INFORMATION. See the warranty page at the end of this manual. For
warranty claims contact the Purchasing Department @ 336.349.2329.
1-5. SHIPPING, HANDLING, AND STORAGE DATA.
a. Shipping. When shipping the vehicle on an open top trailer or rail car, the axles and
landing gear should be used for securing purposes. Insure all product is removed from the tank
and pumping system. A standard single drop trailer is suitable for transport. Refer to paragraph
1-1(d) for weights and dimensions.
b. Handling. The only special handling procedures for this equipment is to insure that all
combustible and flammable liquids are removed from the vehicle prior to shipment. Use API
(American Petroleum Institute) Publication 2013, "Cleaning Mobile Tanks in Flammable or
Combustible Liquid Service" as a guide for purging the tank. To obtain a copy contact:
American Petroleum Institute

1220 L Street, Northwest
Washington, D.C. 20005
(202) 682-8375
Attention: Publications and Distribution Section
c. Storage. For long term storage, it is recommended that the vehicle be prepared as in
the handling section (b) above.
1-6. PREPARATION FOR USE. The vehicle has been completely serviced and adjusted prior
to shipment.
5
CHAPTER 2
OPERATING INSTRUCTIONS
2-1. SCOPE. This chapter contains instructions for the operation of the controls required to
perform tank loading and various fueling operations. Refer to separate truck publications for
information on proper operation of truck controls, and instruments and operation of the
vehicle when in motion.
2-2. SAFETY INTERLOCKS. This unit is equipped with interlocks to prevent movement when
performing a fueling operation. Whenever the valve lever positioned in front of the bottom loading
adapters is moved to the side or the emergency valve operator control is pulled out, the
truck brakes will be applied. Either action also results in the opening of the air operated vent on
top of the tank.
2-3. BONDING. After stopping the vehicle and setting the parking brake, connect a static
reel cable to unit to be refueled.
WARNING
Always establish the static bond between the tank vehicle
and the unit to be refueled. Never attempt any fueling
operation until bonding is complete.
NOTE
Some activities require that grounding also be
accomplished. The static reel is equipped with a
second clamp end for connection to a suitable ground post.
2-4. PREFUELING CHECK. Prior to filling the tank or performing any fueling operation,
perform the following checks:
Note: Refer to Fig. 2-1 for identification and relative location of components.
NOTE
The butterfly valves are closed when the lever is 90

degrees to the piping and open when the lever is
parallel with the fuel flow.
a. Open the cabinet doors on to gain access to the fuel system components.
b. Check that the bottom loading adapters (19) and (20) dust caps, the 2-1/2 inch faucet (17)
dust plug, and the 2 inch faucet (14) dust cap are in place.
c. Check that the lever on the interlock air valve (18) is positioned to interfere with the fill stand
coupler connection.
d. Verify all valves in the pumping compartment are closed.
6
e. Check the manual emergency valve operating handle as follows:
(1) Pull the valve operating handle (22) to its out (open) position and release. A minor
amount of tension should be felt and the handle(s) should remain in the out position. Easily strike
or push the valve handle toward the in (closed) position. The internal valve spring should enable
the handle to move to the in position and thus close the valve. This demonstrates the correct
procedure to close the valve in an emergency. During normal use the handle can simply be
guided to the in position.
(2) Pull the valve operating handle to the out position. Go to the right rear of the truck
to the in position.
(3) Pull the valve operating handle to the out position. Go to the left front of the tank,
near the driver's door, and pull the emergency release handle. Check to see if the valve operating
handle returned to the in position.
(4) Pull the valve operating handle to the out position. Go to the top front of the tank
to the in position.
f. Make sure the hose is properly stowed on the reel and that the nozzle is properly
stowed.
g. Visually inspect all components and piping connections for evidence of damage, leakage,
or loosening. (Periodically check nuts and bolts for proper tightness as vibration may cause them to
loosen. Visual inspection will not verify tightness, put a wrench on the fastener to verify.)
h. Reset the visual counter on the flow meter to zero by depressing the knob on the right side
and rotating it clockwise as viewed into the knob.
2-5. BOTTOM LOADING.
b. Shut down the engine and engage the Scully system (if unit is so equipped) by engaging the pull
type switch (overfill control) on the dash. The light near the switch will light when switch is on.
e. Move lever on interlock air valve (18) to side.
f. Connect the fuel supply line to the bottom loading adapter (19) or (20).
g. Make the necessary connections to the Scully socket, if available.

7
h. Start filling the tank and make sure system is working properly by pushing the precheck
button in until flow stops. After flow stops, release switch to resume flow. Again, this is if unit is so
equipped, not all trucks have Scully overfill prevention systems.
WARNING

button is depressed, stop flow from the fill stand
immediately to avoid a fuel spill. The system
is not operating properly and needs repair.
i. Fill the tank at a rate not to exceed 600 GPM unless the fill cover in the manhole is open.
WARNING
Do not load at a rate exceeding 600 GPM (gallons

per minute) without opening the 10-inch fill cover
in the manhole assembly. Tank over-pressure-
ization could result.
NOTE
An indication that the tank is full is a sudden

flexure of the supply hose as the bottom
loading valve closes.
j. The flow will stop when the liquid contacts the probe located in the top of the tank if unit is Scully
equipped. The onboard control system will close the bottom loading valve and the fill stand connection,
if available, will shut down the flow from the fill stand.
k. When the tank is full disconnect the fuel supply line from the bottom loading adapter and, if
applicable, disconnect all fill stand control lines.
l. Install the dust cap on the bottom loading adapter (19) or (20).
m. Move the interlock valve (18) lever back in front of the bottom loading adapter.
n. Remove fill stand bonding cable and disengage Scully system.
2-6. TOP LOADING.
8
WARNING
If a top loading rack is not available for fueling,

two men will be required to perform filling the tank
through the manhole fill cover - one to insure the
fuel supply hose does not slip out of the fill opening
and observe the tank level and one to manually stop
the fuel flow from ground level. The man on top of
the tank must signal the other when the tank is full.
e. Open the manhole fill cover, insert the fuel supply hose as close to the bottom of the tank
as practicable, and start the fueling operation.
f. Coordinate fuel shutoff with the fuel supply operator when the tank is full.
g. Remove the fuel supply hose and close the fill cover.
h. Remove fill stand bonding cable.
2-7. GRAVITY DRAIN - UNMETERED. Fuel can be gravity drained from the tank by performing
e. Connect a fuel hose to the 2-1/2 inch faucet (17) and place opposite end of hose into a
suitable container.
g. Open faucet (17).
h. When draining is complete, close faucet (17).
CAUTION

9
2-8. FUELING PROCEDURE. Perform the following procedures when fueling from the tank
truck is to be accomplished.
WARNING
If at any time during the fueling operation an

emergency occurs, close the emergency valve
by performing one of the following procedures:
1. Push the emergency valve operator to the
in position or close the cabinet doors.
One of the cabinet doors will push the EV
operator handle, when closed.
2. Pull the emergency release at the right
rear of the tank.
3. Pull the emergency release at the left
front of the tank, near the driver's door.
4. Pull the emergency release at the front
top of the tank.
Note: Open valve 16 (sectionalizing valve) approximately 1/2 turn prior to any pumping
operation. This will reduce pump start-up pressure. Pump pressure can then be regulated as
required by adjusting valve 16.
a. After the truck is stopped in the desired location, set the parking brakes from the cab
and place the transmission in neutral.
b. Perform the prefueling check in paragraph 2-4.
c. Connect one of the static bond cables to a suitable connection.
d. Engage the PTO control (4) located in cab.

NOTE: The PTO will not engage until the EV operator handle is pulled out.
e. Set the throttle for the desired pumping rate (1000 rpm maximum).
NOTE: 1000 rpm will result in around 75-80 gpm flow. To increase throttle, turn
the cruise control rocker switch to the left of the steering column ON. Engine
speed is increased by holding the RESUME / SET rocker switch in the RESUME /
ACCELERATE position and releasing when the desired speed is obtained. Holding
the switch in the SET / COAST position will reduce speed. To bring the engine to
idle, turn the cruise control switch OFF.
f. Reset meter (13) to zero (rotate knob on register clockwise).
g. Open valves (24), (15), and (11).
h. Pull the emergency valve operator (22) handle to the open (out) position.
i. Unwind hose reel (9) as required and dispense fuel by opening nozzle (10) to flow.
Regulate pressure by adjusting valve (16) as required.
j. When fueling is complete, rewind hose onto reel (9).
10
k. Push the emergency valve operator (22) handle to the closed (in) position.
l. Close valves (24), (15), and (11).
m. Set throttle to idle. NOTE: Turn OFF cruise control.
n. Disengage the PTO control (4) located in cab.
o. Disconnect and stow the static cable.
CAUTION

2-9. TANK LOADING USING THE TRUCK PUMP, UNMETERED. Perform the following
procedures when self-loading the truck tank is required.
e. Connect 2-1/2 inch suction hose(s) to faucet (17) stub. Four each suction hoses are stored in
the hose tubes at the rear of the truck. Connect opposite end of hose(s) to fuel source.

g. Set the throttle for the desired pumping rate (1000 rpm maximum).
NOTE: 1000 rpm will result in around 100 gpm flow. To increase throttle, turn
h. Open valve (16) and faucet (17). If truck has filter/separator and canister filters, with valve (15)
located upstream of filters, open this valve also.
i. Open brake interlock air valve (18) by moving lever to side. This action will engage the PTO
j. Start filling the tank and make sure system is working properly by pushing the precheck
button in until flow stops. After flow stops, release switch to resume flow. Again, this applies only if the
unit is equipped with a Scully system, not all trucks are so equipped.
11
WARNING

k. The flow will stop when the liquid contacts the probe located in the top of the tank.
l. Close brake interlock air valve (18) by moving lever to side. This action will disengage
the PTO.
m. Close valve (16) and faucet (17). Close valve (15) if opened (see step h above).
n. Set throttle to idle. NOTE: Turn OFF cruise control.
o. Disengage the PTO control (4) located in cab.
p. Disconnect 2-1/2 inch suction hose(s) from faucet (17) stub and fuel source. Stow hoses
CAUTION

2-10. DEFUELING. A device can be defueled and the product delivered to the tank using the
onboard pump by performing the following procedures.
e. Connect 2-1/2 inch suction hose(s) to faucet (17) stub. Four each hoses are stored in the
hose tubes at the rear of the truck. Connect opposite end of hose(s) to the unit to be defueled.

12
g. Set the throttle for the desired pumping rate (1000 rpm maximum).
NOTE: 1000 rpm will result in around 100 gpm flow. To increase throttle, turn
h. Open valve (16) and faucet (17). If truck has filter/separator and canister filters, with valve (15)
located upstream of filters, open this valve also..
i. Open brake interlock air valve (18) by moving lever to side. This action will engage the PTO
j. Start filling the tank and make sure system is working properly by pushing the precheck
button in until flow stops. After flow stops, release switch to resume flow. Again, if unit is Scully
equipped, not all trucks have Scully systems.
WARNING

k. The flow will stop when the liquid contacts the probe located in the top of the tank.
l. Close brake interlock air valve (18) by moving lever to side. This action will disengage
the PTO.
m. Close valve (16) and faucet (17). Close valve (15) if opened.
n. Set throttle to idle. NOTE: Turn OFF cruise control.
o. Disengage the PTO control (4) located in cab.
p. Disconnect 2-1/2 inch suction hose(s) from faucet (17) stub and defueled unit. Stow hoses
CAUTION

13
2-11. GRAVITY DRAIN - METERED. Fuel can be gravity drained from the tank by performing
e. Connect a fuel hose to the 2-inch faucet (14) and place opposite end of hose into a
suitable container.
g. Open valves (15) and (16) and faucet (14). If truck has both canister filters and a filter/separator
and valve (15) is upstream of the filters, it will not be necessary to open valve (15).
h. When draining is complete, close valves (15), if used, (16) and faucet (14).

CAUTION

14
Fig. 2-1A Schematic
(for trucks with filters)
15
Fig. 2-1B Schematic
(for trucks without filters)
16
CHAPTER 3
MAINTENANCE AND SERVICING
3-1. SCOPE. This chapter contains instructions for inspection, lubrication, cleaning, and
routine servicing procedures.
3-2. CLEANING. Should the need arise to perform welding or cutting operations on the tank,
tank cleaning should be in accordance with API Publication 2013 (Cleaning Mobile Tanks in
Flammable or Combustible Liquid Service). This is a safety measure to insure the tank is vapor
free.
DANGER
If the tank is not free of flammable vapors

prior to and during the performance of hot
work on it, an explosion resulting in serious
bodily injury or death could result.
3-3. LUBRICATION. Lubricate hose reel crank, static reel, and emergency valve operator
cables weekly using MIL-C-7118 grease or equivalent.
3-4. INSPECTION. Table 3-1 lists inspections to be made daily, before, during, and after
operation to insure that the fuel trailer is safe to operate and to identify any malfunction. Table
3-2 lists periodic checks and services to be made in addition to daily inspections at intervals as
specified in the tabulated listing.
3-5. TROUBLESHOOTING. This section contains instructions for troubleshooting the fuel system.
Table 3-3 provides a list of malfunctions that may occur. Each potential malfunction is followed by
a probable cause or list of probable causes. Each probable cause is followed by a corrective action
procedure.
3-6. COMPONENT REPAIR. Commercial literature for the major active components in the
fueling system is provided at the end of this manual, in chapter 4. Refer to this information as
necessary for maintenance, repair, servicing and adjusting, calibration, and parts listing for the affected
item.
3-7. SERVICE. See tables 3-1 (Daily Inspections), 3-2 (Periodic Checks and Services) and 3-3
(Troubleshooting) for applicable servicing information.
17
3.8 Ready for Air Transport
This chapter gives instructions for making vehicle air transportable. This requires lowering the
height of the vehicle using following methods.
a. Pull down front suspension

Using ratcheting mechanism provided, pull front suspension down as shown.
Connect this end

to chain wrapped This end
around hooks
axle/spring over
frame rail
Wrap chain around spring/axle and connect to ratcheting mechanism. Hook other end of tool
around frame rail and pull vechicle down. After pulling down the second side, recheck the first
side to make sure it is still tight.
b. Release air from tires
Release air from tires until pressures are: 35 psi front, 25 psi rear
18
c. Dump air from air bumper under cab.
AFTER
DISCONNECT DISCONNECTING
THIS LINKAGE, USE THIS
LINKAGE FROM LEVER TO RELEASE
LEVER
19
Table 3-1 Daily Inspections
Before During After Item Check

Operation Operation Operation
Fuel System Check plumbing and components
X X Plumbing and for leaks while the unit is operating.
Components
Sump Drain Place a suitable container under
Valve the sump drain valve and open the
valve briefly. Check the contents of
X the container for water. If no water
is present, the unit is ready for
operation. If water is present,
repeat the procedure until fuel only
(no water) is drawn into the
container.
X Fueling Hose and Check that all detachable
Nozzles equipment is present and properly
stored.
X Fire Extinguishers Check that all fire extinguishers are
charged and inspections are up to
date.
Table 3-2 Periodic Checks

Checks and Services Weekly Other Intervals
1. Clean and inspect nozzle,
bottom loading adaptor and fuel X
strainer.
2. Check tank for operation of
manhole fill cover latch, debris or x
foreign matter in tank and
operation of vent(s).
3. Service Lube Points (see
paragraph 3-3). X
4. Check accuracy of meter and
register using a graduated Annually
container.
5. Calibrate Meter When material being pumped is
changed, when maintenance is
performed on meter or register
or when unit is obviously not
measuring correctly.
6. Check tightness of bolts on
valve flanges. Visual inspection Monthly
will not verify tightness,
physically put a wrench on these
bolts.
7. Check Torque of tie down Check initially upon receipt of
bolts. Torque all but the spring truck, recheck after one month,
loaded bolts to 90 ft lb. Tighten followed by annual inspection.
the spring loaded bolts until the
spring compressed length is
3 1/2”.
20
Table 3-3 Troubleshooting
Malfunction Probable Cause Corrective Action
1. Pump operates, but system 1. Tank is empty 1. Fill the tank
will not pump fuel 2. Incorrect Valve Positions 2. Reset Valve settings, insure
the settings are correct
3. Strainer Clogged 3. Clean Strainer
4. Emergency Valve Cable 4. Check valve travel
stretched or broken underneath truck, adjust as
needed or replace cable.
5. Inoperative Nozzle 5. Repair or replace nozzle
6. Obstruction in Piping 6. Locate and remove
7. Defective Hose Valve obstruction
7. Repair or replace valve
2. Pump operates, but output is 1. Partially clogged strainer 1. Clean or replace strainer
below normal 2. Engine Speed too slow 2. Increase engine speed
3. Emergency Valve Cable 3. Check underneath truck for
stretched cable travel. Adjust or replace
cable as needed
3. Pump operates, flow is as 1. Vent valve closed or 1. Pull emergency valve
expected, but slows or stops clogged operator to see if vent opens
after only a few minutes of 2. If vent does not open, check
operations air lines between E/V and
vent. And repair or replace as
needed
3. Clean or replace vent as
needed
4. Hydraulic motor rotates, but 1. Valves not positioned 1. Reset valve settings, insure
system will not pump fuel correctly that valve settings are correct.
2. Pump to motor coupling 2. Replace defective coupling
defective
3. Defective pump 3. Repair or replace pump.
5. Meter does not register 1. Rotor Shaft pin sheared 1. Replace pin
2. Broken Rotor 2. Replace Rotor
6. Meter registers erratically 1. Stripped gear teeth or broken 1. Replace defective gears
teeth in the gear. 2. Replace gear plate ass’y or
2. Worn gear plate ass’y shafts gears
7. Pump pressure too high or too 1. By Pass Valve out of 1. Adjust to correct pressure by
low adjustment turning screw on top of valve.
Turn in to increase pressure,
turn out to decrease pressure.
21
CHAPTER 4
PARTS LIST AND COMMERCIAL LITERATURE
4-1. GENERAL. This chapter contains information that will be of assistance during repair and
maintenance of vehicle components, such as identification and location of major parts. Also included is
literature on various commercial components provided on this unit.
4-2. PARTS LIST.
FIG. & DESCRIPTION PART NUMBER QTY

INDEX NO.
4-1-1 Valve, B/F, 3-inch WD301ALV 3
-2 API Bottom Loading Adapter F5000-001 1
-3 D-1 Bottom Loading Adapter 61528BC 1
-4 Brake Interlock Valve 3418 1
-5 Valve, Check, 1/2" (inside tank) 61-103-01 1
-6 Hose Reel C1115-25-15L 1
-7 Nozzle CV90-001 1
-8 Valve, B/F, 2-inch (Victaulic) 700 1
-9 Flow Meter M7C1 1
-10 2-inch Faucet Dust Cap MS27028-11 1
-11 2-1/2 inch Faucet Dust Cap MS27028-13 1
-12 Static Reel DMI-75G40-20 1
-13 Valve, Faucet WD201ALV 1
-14 Scully Shut-Off System 09356 1
-15 Powerise Air-Springs GSS-18-21UB 4
4-2-1 Pump TXD02A 1

-2 End Yoke 10-4-123 1
-3 Driveshaft N10270-SF 1
-4 End Yoke 10-4-103 1
-5 PTO CS20-41006-H1BX 1
4-3-1 Hood, Vapor Recovery VR45962BU 1

-2 Vent AV46850ALFTS 1
-3 Manhole Cover, 20" PPVL863BXB346 1
-4 Probe, Scully Shut-off Kit 09356 1
4-4-1 Remote Trip Handle 35603SL 3

-2 Valve, Water Drain 3721X1 1
-3 Valve, Emergency / Bottom Load 64055A 1
-4 Operator, EV 41158-A 1
4-5-1 Light, Cabinet 570006 2

-2 Light, Clearance 500012 4
-3 Light, Stop, Turn, Tail 400017 2
-4 Light, Back-up 500011 2
-5 Light, I.D. 200013 1
-6 Junction Box 470041 1
22
1 2 8
5
IN TANK
7
9 10
Fig. 4-1 Pumping Compartment
Fig. 4-2 Pump/PTO Diagra
23
1
3
4
2
Fig. 4-3 Top of Tank
Fig. 4-4 Cable Diagram
Fig. 4-5 Electrical (Lights)
24
Fig.4-6 Scully System Schematic
Chapter 56
Scully “IntellliCheck” Overfill Prevention System
5-1 Scully Operation Procedures
a. The Scully system is fully self contained and should function automatically when the switch in
the cab is turned on. The pilot light near the switch should illuminate.
b. A good way to check the system to see if all components were properly installed and are
properly functioning is to turn on the system with the switch in the cab and to place a small cup of liquid
around the probe (water should work but a darker liquid such as Coke may be required, fuel will
definitely work). The probe can be accessed through the manhole fill cover. When the liquid contacts
the probe listen for air exhausting from the solenoid valve. This indicates that the system is functioning
properly.
c. Further testing should be conducted at the fill stand using the onboard pre-check system.
Engaging the push button switch on the left side of the Scully Intellicheck module should cause the flow
from the fill stand to stop. This check should be performed at 100 to 300 gallons into the bottom loading
task.
25
WARRANTY
Isometrics, Inc. (Company) hereby warrants its products to be free from defects
in materials and workmanship for a period of one (1) year from the date of original
purchase. If, upon examination by the Company, any part or parts are determined to be
defective, the Company will provide, free of charge, for the repair or replacement of said
items, as the Company may elect. This warranty is subject to the following exceptions
and limitations:
I . The customer shall be responsible for normal maintenance and minor

adjustment of the product. Notification to the Company of the need for warranty
service shall be performed and any transportation charge and/or delivery of the
product to and from the place where warranty service is to be
performed must I-cave prior written approval from the Company.
2. This warranty does not apply to component parts or accessories applicable to

the cab and chassis and tractors, which carry the warranty of the manufacturer
thereof.
3. This warranty applies only to products which are placed in normal

use, and does not apply to any product which has been mistreated, neglected or
damaged by accident.
4. This warranty does not apply to any product repaired or altered by anyone
other than a Company representative, unless such repair or alteration has been
authorized by the home office.
For warranty service, contact any Company representative. For the name and location
of the nearest representative, and for further warranty information, write or call:
ISOMETRICS, INC.
P.O. BOX 660
1266 NORTH SCALES STREET
REIDSVILLE, NORTH CAROLINA 27320
PH: 336-349-2329
FAX: 336-349-4744
Attn. David McCollum
email: dmccollum@isometrics-inc.
26

Ph: (949) 764-2200 • Fax: (949) 631-2673
SM64055
MAINTENANCE MANUAL
FOR CARTER
PART NUMBERS 64055 & 64143
4” INTERNAL/BOTTOM LOADING VALVES,
March 1, 2001, New Release

SM64055 March 1, 2001
SUMMARY OF REVISIONS
DATE OF E.O. NO. REV. PARA. OR DESCRIPTION APPROVED
CHANGE PAGE NO.
3/1/2001 - NEW RELEASE
-2-
SM64055 March 1, 2001
TABLE OF CONTENTS
1.0 INTRODUCTION................................................................................................ 4
2.0 EQUIPMENT DESCRIPTION ............................................................................ 4
3.0 AVAILABLE OPTIONS ..................................................................................... 4
4.0 DISASSEMBLY .................................................................................................. 5
5.0 INSPECTION....................................................................................................... 5
6.0 REASSEMBLY ................................................................................................... 6
7.0 TEST .................................................................................................................... 6
8.0 ILLUSTRATED PARTS CATALOG.................................................................. 7
FIGURE 1A, 64055 & OPTIONS............................................................................ 10
FIGURE 1B, 64143A & OPTIONS ......................................................................... 11
FIGURE 4, PILOT VALVE PARTS BREAKDOWN ............................................ 14
FIGURE 5 - DIAPHRAGM INSTALLATION POSITION .................................... 15
FIGURE 6 - DIAPHRAGM TORQUE SEQUENCE .............................................. 15
-3-
SM64055 March 1, 2001

CARTER PART NUMBERS 64055 & 64143 INTERNAL/BOTTOM LOADING VALVES
1.0 INTRODUCTION
This manual furnishes detailed instructions covering the B can also be used with optic probe (s) using solenoid
maintenance and overhaul of Carter Part Numbers 64055, valve (s) to effect the control of the pilot valve (s). If so
and 64143 4” Internal/Bottom Loading Valves. This service manuals for these components should be
manual assumes that the valves will be used with a Carter requested from the manufacturer of the items used. Carter
64079 Level Sensor, however the 64055A, B, 64143A or does not provide such items.
The Carter 64055 family of 4” valves can be used either pressure forces, plus the spring force will keep the piston
as a straight internal valve or for bottom loading control. (valve) closed.
The 64055 mounts directly into a 4” TTMA Tank Sump
If the piston chamber is vented through an open pilot
Ring. The 64055A is used with the Carter 64079 Level
valve, options A or B, the pressure drop across the inlet
Sensor for bottom loading control with a single control
orifice reduces the piston chamber pressure significantly.
pilot valve. Option “B” adds two-stage level control with
The resultant balance of forces will cause the piston to
two pilot valves. (Note: Early units contained provisions
open, hence the valve.
for only single pilot valves with the dual capability
available at a later date.) Option “B” requires either the When the piston chamber is once again closed [pilot
use of 64079B, C or two 64079 Level Sensors. A Carter valve (s) closes], the balance of forces again causes the
Vent, 64078, is also available to complete the system valve to close.
requirements. A straight 64055 Internal Valve can be
The 64055 or 64143 A or B is normally utilized with the
converted to a bottom loading valve, 64055A, by adding
64079 Level Sensor. If so desired, a solenoid valve (s)
a pilot valve.
can be used in the system to provide or deprive the pilot
The 64143 4” Bottom Loading Valve is used only for valve of pressure (usually routed from the bottom loading
bottom loading. The difference between the 64055 and adapter) to cause the opening and closing of the valve. In
the 64143 is the absence of an off-loading cylinder on the this way the valve can be used with any optic type sensing
64143 and a different orifice system in the piston. probe to detect the desired tank level for closure.
The units are spring loaded “overbalanced” piston valves. On the 64055, a separate air operated piston is provided
Fuel inlet pressure is routed to the inside of the piston to effect off-loading as desired. The direction of air
chamber through a two-staged orifice in the center of the pressure to this piston will cause it to pull open the main
piston. If the piston chamber has no exit, the areas inside piston to allow for off-loading flow. When the air
the piston chamber (outer diameter of the piston) is larger pressure is depleted, the spring forces will close both the
than the face seal of the piston, hence the balance of air and main pistons.
3.0 AVAILABLE OPTIONS

The 64055 Basic Valve is designed for use as an internal The “B” option (64055B or 64143B) adds two pilot
valve and has no other functional controls. The 64055 can valves to the basic unit to close the valve in two-stages.
be opened for off-loading by application of air pressure to An orifice in the secondary pilot valve will continue to
the cylinder provided. The 64143 can only be used as vent the piston chamber after the primary pilot valve has
option A (64143A) since it has no off-loading capability. closed. This orifice restricts the pressure escaping from
the piston chamber to maintain the piston in a partially
The “A” option (64055A or 64143A) adds a pilot valve
open position hence flow into the tank is reduced
to the basic unit making it a bottom loading control valve.
significantly. This provides a more accurate final shutoff
Again the 64055A can also be used for off-loading by the
and also helps control surge pressure on final shutoff.
application of air pressure to the provided cylinder.
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SM64055 March 1, 2001
4.0 DISASSEMBLY
4.1 Refer to Figures 1, 2 or 3 for exploded views of the 4.5.3 Unless replacement is needed it is recommended
unit. that Set Screw (27) and Nut (26) in the face of the
piston not be removed.
4.2 Remove the six Screws (8) and Washers (9) from
the Bonnet (23) or (24) and put a side for reuse. 4.6 64055 & 64143 - Remove and discard O-ring (29)
and Seal (30) from Body (28).
4.3 Rotate the bonnet slightly in either direction and
pull it from the Body (28). On the 64055 the Piston 4.7 Unless the Screen (33) is damaged and needs
(12) and its attaching parts will come out of the replacement, do not remove it from the Body (28).
Body (28) with the bonnet as Piston Assembly If it needs replacing then remove Screws (31) and
(10).. Continue on with the next paragraph if the Nuts (32) to do so.
unit being disassembled is the 64055. Ship to
4.8 On the basic unit, remove the Plug (3) only if it has
paragraph 4.5 if it is a 64143.
been leaking. If it is removed, then discard Gasket
4.4 64055: (4).
4.4.1 Find the Pin (17B) in the Shaft Assembly (17). Use 4.9 On 64055 or 64143A - Unscrew Pilot Valve Assy
the spring pin to hold the shaft in place and remove (2) from Bonnet (23) or (24) and remove and
Rod (11) by unscrewing it, being careful not to discard Gasket (4). On “B” option to either unit,
drop Piston (12). Remove Piston (12) and Spring remove secondary Pilot Valve Assy (2). Orifice (5)
(13). and Gasket (6) will be found under the secondary
Pilot Valve Assy (2). Remove them and discard
4.4.2 Remove Ring (14), Spring Pad (15) and Spring
Gasket (6).
(16). Remove O-ring (22) from Bonnet (23) and
discard it. 4.10 Pilot Valve Assy (2) may be replaced as a
complete unit or overhauled as follows:
4.4.3 Using the pin used in paragraph 4.4.1 hold the
Shaft Assembly (17) while unscrewing Housing 4.10.1 Remove six Screws (34) and Washers (35).
(18). Pull Housing (18) off of Bonnet (23).
4.10.2 Using a thin blade screwdriver, pry the Cover (36)
4.4.4 Remove Wipe Ring (20) and Quad-Ring (21) from from the assembly. Be careful not to scratch the
Bonnet (23). Discard both items. Skip to paragraph flanged surface of either metal part holding the
4.6. diaphragms in place.
4.5 64143: 4.10.3 Remove and discard the two Diaphragms (37).
4.5.1 Remove Bonnet (24) then remove Spring (13). 4.10.4 Remove Pressure Pad (38) from Poppet (40) shaft.
Remove O-ring (22) from Bonnet (24) and discard
4.10.5 Remove Ring (39), which retains Spring (42) and
it.
Washer (41) in place. This will free up the
4.5.2 Reach into body (28) opening and carefully extract remaining parts for removal.
the Piston Assy (25).
5.0 INSPECTION
5.1 It is recommended that all O-rings (19), (22), (29); the Shaft (17A) and the Piston (12) can be polished to
Gaskets (4), (6); Quad Ring (21); Wipe Ring (20); remove minor scratches by using a very fine emery cloth
Diaphragms (37) and Seal (30) be replaced at each while the parts are rotated. Do not polish local areas of
overhaul. these diameters. Unless proper equipment is available to
accomplish this task and to polish the inner diameter of
5.2 The outer diameters of the Shaft (17A), and Piston
the Housing (18) it is recommended that the parts be
(12) along with the inner diameter of Housing (18) should
replace, If polishing is attempted, do not break through
be inspected for scratches that might cause leakage. The
the hard anodized surface of the Piston (12). If scratches
piston seat in the Body (28) shall also be free of pits,
are too pronounced, the parts should be replaced. Replace
scratches or gouges that would cause leakage. Inspect all
any part with damage exceeding 15% of local wall
other metal parts for dings, gouges, abrasions, etc. On all
thickness. Use Alodine 1200, or similar chem film
parts except the ones listed above, use 320 grit paper to
treatment, to touch up bared aluminum.
smooth and remove sharp edges. The outer diameter of
-5-
SM64055 March 1, 2001
The flat surfaces of the Fitting (43) and Cover (36) may parts flat during polishing and to not raise any burrs on
be polished to remove minor scratches by using a flat the inside diameters that bare on the diaphragms.
plate and very fine emery cloth. Be careful to keep the
6.0 REASSEMBLY
6.1 Reassembly is accomplished in essentially the the number 1 screw to 1.6 in-lbs. (1.8 Kg-cm), followed
reverse order of disassembly noting the following: by tightening screws number 5, 3, 6 and 4 in that order.
Then repeat the tightening sequence to 3.2 in-lbs. (2.1
6.1.2 Light lubrication of all O-rings and seals, using
Kg-cm) and then 5.3 in-lbs. (6.1 Kg-cm) respectively.
petroleum jelly is recommended to facilitate installation.
Let the assembly stand for a minimum of 15 hours
6.1.3 When reassembling the Pilot Valve Assy (2) use
retighten the screws as above to the 5.3 in-lbs. (6.1 Kg-
the following procedure to assure proper diaphragm
cm) setting.
retention:
6.1.4 When installing the Seal (30) onto O-ring (29) in
6.1.3.1 Once the Poppet (40), Spring (42), Washer (41)
Body (28) be sure to smooth the surface evenly with a
and Ring (39) are in place, be sure that the Pressure Pad
finger. See note on Figures 2 and 3.
(38) is placed onto the Poppet (40) shaft with the smaller
end placed onto the shaft first. The larger flat surface 6.1.5 On the 64055 - Use Locktite 24221 (17C) on the
should be facing away from the shaft. thread of Shaft (17A) before screwing on Housing (18).
Note the thread of both parts should be cleaned with the
6.1.3.2 The two Diaphragms (37) are placed such that
recommended Locktite cleaning solution prior to using
the loops in the diaphragms are facing the Pressure Pad
24221. Read the instructions on 24221 before using.
(38).See Figure 5 for an illustration. [In operation, the
loops always face in the direction in which the pressure 6.1.6 Once the Piston/Bonnet Assy (10) has been
from the Level Sensor or solenoid valve is applied.] inserted into the Body (28) the Rod (11) must be adjusted
Smooth out the Diaphragms (37) place onto the Fitting to provide a gap of 0.012±0.005 (.305±.127 mm)
(43) and align the six holes in all three parts. Carefully between the under side of the hex head of the rod and the
place the Cover (36) onto this assembly aligning the mating flat surface of the Piston (12). A feeler gage
holes. should be used for this purpose. This will assure that the
proper surge control during shutoff will be effective. On
6.1.3.3 Start the six Screws (34) with the Washers (35)
the 64143 if the Set Screw (27) and Nut (26) were
in place by hand until resistance is met. Note that if no
removed it will be necessary to adjust the face of the Set
resistance is met in attempting to hand tighten the screws,
Screw (27) to .409 ± .005 inches (10.388 ± .127 mm)
it is recommended that the Screws (34) be replaced. They
from the face of the Nut (26).
are self-locking and some resistance should be felt.
6.1.7 If the Screen (33) was removed and replaced, the
6.1.3.4 Observing the Cover (36) from the outside end
replacement will be provided in a flat condition and it
(look at the threaded port in the middle), mentally number
will be necessary to carefully shape it to fit the Body (28).
the holes in a clockwise direction from one to six. Refer
top Figure 6. Using a properly set torque wrench, tighten
7.0 TEST
7.1 The following test procedures will be Tee off the inlet pressure line to the primary pilot valve
accomplished after overhaul: and to the secondary pilot valve on “B” option units.
Install a small ball valve between the inlet pressure source
7.2 Test conditions
and each pilot valves. Install a bleed valve between the
7.2.1 Test media shall be odorless kerosene, Jet A or pilot valve (s) and the ball valve. Gauges should be
equivalent at 75° + 15°F. installed in the pressure line to the main valve’s inlet and
in the line to the pilot valve (s).
7.3 Functional Test - If testing prior to reinstalling the
unit in the refueler is desired conduct the following tests: 7.3.2 On the 64055 connect the air port to a 100-psig air
pressure source with a gauge in the line.
7.3.1 Connect the inlet of the unit to a test media
pressure source with a minimum of 150-psig available.
-6-
SM64055 March 1, 2001
7.3.3 Bleed all air from the valve by applying 10-psig 7.3.5 On the 64055, following the above test with the
test media pressure to the inlet and opening the bleed valve still full of liquid apply air pressure to the unit
valve (s) in the lines to the pilot (s). Once the air is bled, starting at 35-psig and slowly increasing slowly until the
close the valve in the line to the pilot (s) and bleed all valve opens. The valve should open at an air pressure of
liquid trapped in the line (s). 50-psig maximum. If testing the 64143 skip this
paragraph and go on to 7.3.6. Shutoff the air pressure and
7.3.4 Increase the pressure to the valve to approximately
bleed it to atmosphere. The valve should return to the
25-psig for one minute and then increase it to 150-psig
closed position.
for one minute. Observe for external leakage during the
test period. No leakage except from the main piston shall 7.3.6 Apply liquid pressure slowly to the valve inlet and
be allowed. This leakage should be limited to 100 simultaneously to the pilot (s). Observe when the main
cc/minute. piston opens. The valve shall open with an inlet pressure
of 15-psig or less.
Table 1.0 tabulates the parts and sub-assemblies table are keyed to the exploded views of the unit
comprising the various versions of both the 64055 and diagrammed in Figures 1, 2 or 3.
64143 Valves with all options. The item numbers of the
TABLE 1.0
64055 & 64143 Bottom Loading Valves & Options
Refer to Figures 1A and 1B

Assembly Units/Yr.
1A 1 64055 Internal Valve, Bottom Loading and
Off-loading (Figure 1A).................... 1 - -
1A 3 GF814-10D Plug................................................... 2 Basic -
4 MS29512-10 Gasket ............................................... 2 Basic 20
3 GF814-10D Plug................................................... 1 A -
4 MS29512-10 Gasket ............................................... 2 A 20
4 MS29512-10 Gasket ............................................... 2 B 20
5 221087 Orifice............................................... 1 B -
6 MS29512-08 Gasket ............................................... 1 B 10
1B 1 64143 Internal Valve, Bottom Loading Only
(Figure 1B) ....................................... 1 - -
3 GF814-10D Plug................................................... 1 A -
4 MS29512-10 Gasket ............................................... 2 A, B 20
5 221087 Orifice............................................... 1 B -
6 MS29512-08 Gasket ............................................... 1 B 10
-7-
SM64055 March 1, 2001
TABLE 2.0
Parts Breakdown, 64055 & 64143 Basic Valves

Assembly Units/Yr.
2, 3 8 GF35275-265 Screws............................................... 8 All -
9 GF35338-138 Washers ............................................ 8 All -
2 10 No number Piston/Bonnet Assy........................... 1 64055 -
11 220447 Rod........................................... 1 64055 -
12 47096 Piston ....................................... 1 64055 1
13 220436 Spring....................................... 1 64055 -
14 GF16633-4050 Ring.......................................... 1 64055 -
15 220438 Spring Pad................................ 1 64055 -
16 220437 Spring....................................... 1 64055 -
17 47095 Shaft Assembly ........................ 1 64055 -
17A 220448 Shaft.................................. 1 64055 -
17B GF16562-238 Pin..................................... 1 64055 -
17C 24221 Locktite .................................... 1 64055
18 220450 Housing .................................... 1 64055 -
19 MS29513-112 O-ring....................................... 1 64055 10
20 220453 Wipe Ring ................................ 1 64055 10
21 Q4325-366Y Quad Ring ................................ 1 64055 10
22 MS29513-157 O-ring....................................... 1 64055 10
23 47099 Bonnet...................................... 1 64055 -
3 22 MS29513-157 O-ring ............................................... 1 64143 10
24 221108 Bonnet .............................................. 1 64143 -
25 47284 Piston Assy ....................................... 1 64143 1
12 47096 Piston ....................................... 1 64143 1
26 GF51971-3 Nut ........................................... 1 64143 -
27 221109 Set Screw, Orifice .................... 1 64143 -
13 220436 Spring ............................................... 1 64143 -
2, 3 28 220458 Body ................................................. 1 All -
29 MS29513-248 O-ring ............................................... 1 All 10
30 220456 Seal ................................................... 1 All 10
31 GF515C4-5 Screw ................................................ 2 All -
32 GF20365D440 Nut .................................................... 2 All -
33 220431 Screen ............................................... 1 All -
-8-
SM64055 March 1, 2001
TABLE 3.0
Pilot Valve Parts Breakdown

Assembly Units/Yr.
1A, 1B 2 47097 Pilot Valve Assy, Primary................. 1 A&B -
4 34 LP35275-230 Screw........................................ 6 A&B -
35 GF620C6 Washer ..................................... 6 A&B -
36 220441 Cover........................................ 1 A&B -
37 220445 Diaphragm................................ 2 A&B 20
38 220443 Pressure Pad ............................. 1 A&B -
39 GF16633-4018 Ring.......................................... 1 A&B -
40 220434 Poppet ...................................... 1 A&B -
41 220442 Washer ..................................... 1 A&B -
42 220444 Spring....................................... 1 A&B -
43 220433 Fitting....................................... 1 A&B -
1 5 47097 Pilot Valve Assy, Secondary............. 1 B -
4 34 LP35275-230 Screw........................................ 6 B -
35 GF620C6 Washer ..................................... 6 B -
36 220441 Cover........................................ 1 B -
37 220445 Diaphragm................................ 2 B 20
38 220443 Pressure Pad ............................. 1 B -
39 GF16633-4018 Ring.......................................... 1 B -
40 220434 Poppet ...................................... 1 B -
41 220442 Washer ..................................... 1 B -
42 220444 Spring....................................... 1 B -
43 220433 Fitting....................................... 1 B -
There are several kits of parts designed to provide the necessary items to overhaul the units as described below.
KIT NUMBER DESCRIPTION
KD64055-1 Kit, seal replacement for 64055A Valve. Contains items 4, 19, 20, 21, 22,
29, 30 & 37.
KD64055-2 Kit, seal replacement for 64055 Basic Valve. Contains items 4, 19, 20, 21,
22, 29 & 30.
KD64055-3 Kit; seal replacement for 64055B Valve. Contains items 4, 6, 19, 20, 21, 22,
29, 30 & 37.
KD64129-3 Kit; Overhaul for 47097 Pilot Valve Assy. Contains items 4 & 37.
KD64143-1 Kit; seal replacement for 64143A Valve. Contains items 4, 22, 29, 30 & 37.
KD64143-2 Kit; seal replacement for 64143B Valve. Contains items 4, 6, 22, 29, 30 &
37.
Notes: 1. All part numbers beginning with "GF" Are interchangeable with those beginning with either "AN" or "MS".
If three numbers follow the “GF” it is interchangeable with an "AN" part, otherwise it is interchangeable
with an "MS" part of the same number.
2. The recommended spare parts shown Above Are the number required to support 10 units for one year or
each overhaul whichever is sooner. These quantities do not include replacement spares for intermediate
replacement of parts required by Abuse or misuse of the equipment. The recommended quantities are based
on the ratio of spare parts sold for each unit during A one-year period of time. The actual quantity required
will vary from location to location.
-9-
SM64055 March 1, 2001
FIGURE 1A
64055 & OPTIONS
- 10 -
SM64055 March 1, 2001
FIGURE 1B - 64143A & OPTIONS
- 11 -
SM64055 March 1, 2001
FIGURE 2
- 12 -
SM64055 March 1, 2001
FIGURE 3
- 13 -
SM64055 March 1, 2001
FIGURE 4
PILOT VALVE PARTS BREAKDOWN
- 14 -
SM64055 March 1, 2001
FIGURE 5
DIAPHRAGE INSTLLATION POSITION
FIGURE 6
DIAPHRAGM TORQUE SEQUENCE
- 15 -
4” BOTTOM LOADING COMPONENTS

MODELS 64055, 64079, 64143
The Carter 4” family of Bottom Loading Valves
and accompanying Level Sensor are designed for
use in refuelers where bottom loading/off-loading
rates of up to 800 gpm are desired. There are two 64079A
internal valves in the family, one for use in Level Sensor
loading and off-loading while the other is strictly
used for loading. Off-loading requires the use of
air pressure to open the internal valve. Both are
used with the Carter 64079 Level Sensor or as an
alternative they can be used with an optic probe
control. Bottom loading control is accomplished
automatically, as in all Carter units when the tank
liquid level reaches the pre-set level sensor. See
accompanying brochure 64055 for detail
information on the operation of all Carter bottom
loading units.
Both of the available internal valves can be
purchased to use with either a single or dual level 64055A 4”
sensor as explained below. Internal Valve
FEATURES:
❏ Pilot valve is identical on all Carter Bottom Loading components for lower maintenance costs. There is no
through hole in the diaphragm in the pilot to cause leakage and ultimate failure.
❏ Either single level or dual level control available. Dual level control, when used with 64079B Level Sensor
provides better shutoff level accuracy and lower surge pressures resulting from closing at very high rates of
flow.
❏ 50-psi min. air pressure and standard air controlling valves (not furnished by Carter) required for off-loading
- 64055. No off-loading control provided on the 64143.
❏ Internal Valve mates standard TTMA sump flange.
❏ Can be used with optic sensing system.
❏ Low pressure loss:
Bottom Loading – 4.5 psi at 600 gpm
Off-loading - 1.5 psi at 600 gpm
Bulletin 64143 9/2000
671 W. 17th St., Costa Mesa, CA 92627 • Ph (949) 764-2200 • Fax (949) 631-2673 • E-mail cgf_sales@jccarter.com
www.argo-tech.com • ISO 9001 Certified
ORDERING INFORMATION:
64055 (basic configuration) - 4” INTERNAL OFF-LOADING VALVE - provides off-loading by use of air pressure.
64143A (no basic configuration available) - 4” BOTTOM LOADING VALVE - For use for loading the refueler only, no off-
loading capability.
One or more of the following options may be added to change the function or configuration of the units above:
OPTION DESCRIPTION
A Adds pilot valve to basic unit (64055 only, 64143A only unit available) to provide bottom loading control when
used with Carter 64079 Jet Level Sensor or optic sensing probe system.
B Adds dual pilot valves to either unit for use with either two 64079 or one 64079B Level Sensors to improve
accuracy of the tank shutoff level or to reduce surge at closure.
64079 LEVEL SENSOR

There are no moving parts or seals in the Carter Level Sensor which, when used with 64055A or 64143A
Bottom Loading Valve will provide high level bottom loading control. There are no wearing parts in the
unit hence it lasts indefinitely. Truck vibration will have no affect on the unit, unlike float valves, which
are subject to vibration damage. It is available with an optional mounting stud for adjustable level control.
The stud is located outside of the collector/drain can for better level control. A collector/drain can and
precheck feature are provided as standard equipment.
One of the following options may be added to the basic 64079 part number to achieve the degree of
customization desired when used with either the 64055A or 64143A:
OPTION DESCRIPTION .
A Adds stud to basic unit to provide mounting and level adjustment., ½-13 UNC-2B thread
B Adds second Level Sensor with accompanying single mounting stud for use with 64055B or 64143B, ½-13 UNC-
2B thread.
EQUIVALENT PART NUMBERS – WHITTAKER TO CARTER

The following table presents the equivalent part numbers for Carter units to replace Whittaker units:
ITEM DESCRIPTION WHITTAKER CARTER COMMENTS – APPLICABLE TO
PART NO. PART NO. CARTER UNITS
4” Internal Valve for Off-loading F614 64055 Air pressure required for off-loading.
only
4” Internal Valve for Bottom F614A or B 64055A or B Either single or dual pilots available.
Loading and Off-loading Air required for off-loading
4” Internal Valve for Bottom None 64143A No off-loading capability, a separate
Loading only. internal valve has to be used.
Level Sensor, no options F613 64079 Precheck and collector drain cans
standard on Carter unit.
Level Sensor with mounting stud F613A 64079A Mounting stud located outside of
precheck and drain cans for better
control.
Dual Level Sensor with mounting F613B 64079B Same comment as above.
stud
AVERY HARDOLL EQUIVALENT UNITS - The Carter 4” 64143 bottom loading valve and 64079A Level
Sensor can be used in lieu of the 4” Avery Hardoll Jet Able Bottom Loading Valve. Bot systems function basically
the same.
ALTERNATIVE BOTTOM LOADING UNITS

Carter also provides bottom loading equipment for 3” and 6” installations. See Brochure 64055 for complete
information on this type of equipment.
INSTALLATION TIPS
❐ Install the internal valve from the outside of the tank with sufficient flexible line between the pilot (s) and the
level sensor for easier removal and maintenance.
❐ Inlet line to 64079 Level Sensor from pressure source (adapter) must be at least 3/8” diameter tubing. It should
be routed from a port on the bottom loading adapter, such as Carter’s 6958, or 61528 that have ports designed for
this application. (See brochure 60373 for adapter choices). Routing the inlet pressure source closer to the internal
valve may not allow sufficient pressure for the system to function correctly. If the optional mounting stud (option
A) is used sufficient length of flexible tubing should be used to allow for adequate adjustment.
❐ Line between the pilot on the 64129A and the 64079 should be 1/4” diameter for best operation. Pressure surging
may occur if larger tubing is used.
❐ If desired a separate precheck system may also be routed from the adapter to the precheck port on the 64079
although the same affect can be achieved by installing a 3/8” spring loaded normally open ball valve in the inlet
pressure line. It will be necessary to adjust the precheck gate in the bottom of the 64079 to make the precheck
effective in either case. This is a trial and error adjustment. Note that there are no “tuning” plugs on the Carter
64079 as on the Whittaker F613. A simple “gate” type valve in the bottom of the precheck can provides adjusting
of the precheck flow.
❐ It is essential for safety reasons to install a plastic tube to the drain fitting on the bottom of the 64079 Level
Sensor. Draining fuel from the Level Sensor if not collected and drained properly could generate a static
discharge, which could lead to a fire.
❐ The optional mounting stud is located outside of the precheck and drain cans on the Carter unit. Unlike the
Whittaker F613 there is not holes to plug with loose o-rings if the stud is used. If not used the can on the Carter
unit is already sealed and there are no plugs to install. If installed correctly the level in the tank can be adjusted
over a wide range simply by screwing the stud up or down to the desired level.
❐ If the Carter Internal Valve is to be used with an optic probe system a three-way solenoid valve must be installed
in the pressure line from the adapter. When the tank level is below the probe the inlet pressure should be routed to
the pilot on the internal valve to cause it to open. When the optic probe is sensing fuel (level below the probe) the
pilot on the internal valve must be vented to tank and the inlet pressure shutoff. This will cause the internal valve
to close and stop the bottom loading process.
ENVELOPE DIMENSIONS
64055 INTERNAL VALVE
64079 LEVEL SENSOR


Ph: (949) 764-2200 • Fax: (949) 631-2673
SM6958
MAINTENANCE MANUAL
FOR CARTER
PART NUMBERS 6958, 61272, 61409, 61528, 61529 & 64040
Revised December 1, 1994
Supercedes manual issued July 1, 1992

TABLE OF CONTENTS
PAGE
1.0 INTRODUCTION ........................................................................3
2.0 EQUIPMENT DESCRIPTION .....................................................3
3.0 TABLE OF OPTIONS ..................................................................3
4.0 DISASSEMBLY ...........................................................................4
5.0 INSPECTION................................................................................4
6.0 REASSEMBLY ............................................................................4
7.0 TEST .............................................................................................4
8.0 ILLUSTRATED PARTS LIST .....................................................5
FIGURE 1.....................................................................................................6

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

These Carter units are all of similar design in that to 350°F. The seal on the MS24484-2 is suitable
they all utilize the 2½ inch MS24484 type refueling for temperatures up 160°F.
modular adapter. This type of adapter is only suited
for bottom loading and recirculation or other • The bayonet flange to which the nozzle connects
relatively low pressure type applications. For on the MS24484-5, has a greater tensile strength
Hydrant System applications one should use Carter requirement required by the 350°F requirement.
60195 or 60373 for 2½ inch installations or 60505 Again, the MS24484-2 was designed for service
or 61526 Adapters for the 4 inch API type at temperatures up to 160°F.
applications. These adapters consist of a cast
aluminum housing in which is mounted either the The MS24484-5 is only manufactured by specifically
commercial version, MS24484-2, or the current QPL qualified suppliers, among which is our parent
version, MS24484-5, refueling modular adapter. company, J. C. Carter. The MS24484-2, a previously
Both of these MS24484 units are dimensionally listed qualified product is made by Carter Ground
identical. The only differences lie in two areas, both Fueling Co.
related to high temperature applications normally
seen in fighter aircraft applications: All of the models discussed herein, except for the
basic module, 61529, are similar, varying mainly in
• Poppet seal on the MS24484-5 is of a high the outlet mounting configuration.
temperature elastomer for use in temperatures up
3.0 TABLE OF OPTIONS

Each of the basic units may be obtained in various configurations by adding one or more of the options listed in
the table below.
Option Letter Description Comments
A Adds Pressure Dust Cap (61531) In lieu of Option B on all models.

B Adds Plastic Dust Cap (41607) In lieu of Option A on all models.
C Adds Commercial MS24484-2 Adapter In lieu of Option D on all models except 61529.
complete unit).
D Adds Military MS24484-5 Adapter In lieu of Option C on all models except 61529.
complete unit).
G Adds 2-1/2" - 8 NPT Female Outlet In lieu of Option H on 6958 only. (Either G or H
H Adds 2-1/2" - BSPP Female Outlet In lieu of Option G on 6958 only (Either G or H
4.0 DISASSEMBLY
Refer to Figure 1 for an exploded view of the Unit. 4.3 Noting the warning below, carefully remove the six
Screws (6) from the Adapter Module (2 or 2A).
4.1 Remove six Screws (1). Pull Adapter Module (2 or
2A) from Housing (3) and remove and discard O-
ring (4). Remove Cap (11 or 11A) from Adapter WARNING
Module (2 or 2A). If present (available only on The Spider (7 or 7A) is spring loaded and care should
some units), do not remove the two pipe Plugs (5) be exercised in removing the attaching Screws (6).
from the Housing (3) unless replacement is
required.
4.2 Spare parts for the Cap (11 or 11A) are not
available. If it is faulty replace as a complete unit.
5.0 INSPECTION
5.1 Special Tools - Use Adapter Wear Gauge, 61657-2 5.3 Check Cap (11) for aging cracks or other damage.
to check the Flange (9 or 9A) of Adapter Module Replace as needed.
(2 or 2A) for suitability for continued use. Refer to
Service Manual SM61657 for instructions on its 5.4 Inspect Poppet (8 or 8A) for damage to the seal.
use. This gauge will indicate whether the slots and The seal is bonded into the metal poppet and is not
lugs of the Flange (9 or 9A) of Adapter Module (2 removable. Replace Poppet (8 or 8A) as needed.
or 2A) are worn beyond safe use.
5.2 Check the seal on Cap (11A) for deterioration, cuts

or nicks. Replace the Cap (11A) if such aberrations
are apparent.
6.0 REASSEMBLY
6.1 Reassembly is accomplished in essentially the 6.4 Place the O-ring (4) in the groove in Adapter
reverse order of disassembly noting the following: Module (2 or 2A) before installing in the Housing
(3). Torque Screws (1) to 20 ± 2 in-lbs (.23 m-kg).
6.2 Light lubrication of all O-rings and seals, using
petroleum jelly is recommended to facilitate 6.5 Reattach Cap (11 or 11A) to tab on Adapter
installation. Module (2 or 2A) if utilized.
6.3 Reassemble Adapter Module (2 or 2A).
7.0 TEST
7.1 The following test procedures will be

accomplished after overhaul: 7.3.1 Attach adapter to a 120 psi fluid pressure source
through the outlet (flanged or threaded end).
7.2 Test conditions Attach a Carter 60427 or 61428 type nozzle to
the inlet Adapter Module (2 or 2A). The nozzle
7.2.1 Test media shall be Stoddard Solvent (Federal shall be plugged at the inlet end with a plug and a
Specification P-D-680), JP-4 per MIL-J-5624D small petcock or hand valve. With the nozzle and
at 75° + 15°F, Jet A or equivalent. petcock open, slowly increase the pressure into
the adapter outlet to fully bleed the air from the
7.3 Functional Test test unit. Close the petcock and increase the test
-4-
pressure to 120 psi. Check for external leakage

from the joint between the nozzle and adapter 7.3.3 Slowly increase the system pressure again to 120
and from the adapter housing and joints. psi and check for leakage from the Adapter
Module (2 or 2A) Poppet (10 or 10A).
7.3.2 Bleed the pressure from the test unit and remove
the nozzle.
Table 1.0 tabulates the parts and sub-assemblies comprising the various adapters covered by this manual. The
item numbers of the table are keyed to the exploded views of the Units diagrammed in Figure 1.
TABLE 1.0
Number Spares/10
Item Part Number Description Required Units/Yr. Used on
1 GF24693C73 Screw ........................................ 6 6 All except 61529
2 61529 Adapter Module (MS24484-2) . 1 - All except Option D
6 LP500-6-5 Screw ................................. 6 6 All
7 20876 Spider................................. 1 - All
8 2753 Spring ................................ 1 - All
9 20748-2 Flange ................................ 1 1 All except Option D
10 20780 Poppet................................ 1 2 All except Option D
2A 61247 Adapter Module (MS24484-5) . 1 - Option D only
6 LP500-6-5 Screw ................................. 6 6 All
7 20876 Spider................................. 1 - All
8 2753 Spring ................................ 1 - All
9A 20748-1 Flange ................................ 1 1 Option D only
10A 208197 Poppet................................ 1 2 Option D only
3A 24176 Body, 2½" NPT ........................ 1 - 6958 Option G only
3B 204563 Body, 2½" BSPP...................... 1 - 6958 Option H only
3C 210201 Body, 4" TTMA........................ 1 - 61272 only
3D 210136 Body, 4" ANSI.......................... 1 - 61409 only
3E 210216 Body, 3" TTMA........................ 1 - 61528 only
4 MS29513-153 O-ring........................................ 1 10 All (not furnished with
61529)
3F 220288 Body, 3" ANSI 1 - 64040 only
5 210462 Plug........................................... 2 - Some 6958, 61272 and
61528 only
11 41607 Cap, Plastic ............................... 1 3 Option B only
11A 61531 Cap, Metal Sealing.................... 1 1 Option A only
Notes: 1. All part numbers beginning with "GF" are interchangeable with those beginning with either "AN" or
"MS". If the "GF" is followed by three numbers it is interchangeable with and "AN" part, otherwise it
is interchangeable with an "MS" part of the same number.
2. The recommended spare parts shown above are the number required to support 10 Units for one year.
The recommended quantities are based on the ratio of spare parts sold for each unit during a one year
period of time. The actual quantity required will vary from location to location.
-5-
Morrison Bros. Co. www.morbros.com
Fig. 507 Emergency Valve Operator

Specification Sheet
DESCRIPTION Figure 507
Remote control of emergency valves through flexible cable. Maxi-

mum 3/16" cable. Replaceable fuse adaptor releases at 210°F.
Threaded take-up for cable slack adjusts conveniently in place.
Choice of 15/8 " or 23/8" cable travel positions. Dual trip levers provide
shutoff of emergency valves from two locations.
Figure 507AO
SPECIFICATION OPTIONS:
I.D. NUMBER A B C D E F WT.

507---0100 AO 1 N P 16 3/4 4 13/16 12 1/8 6 CHART KEY:
507---0200 AO 2 N P 16 3/4 4 13/16 12 1/8 8 A—Compartment: 1, 2, 3, 4, 5
507---0300 AO 3 N P 16 3/4 8 3/8 12 1/8 11.5 B—Air Operated: Y for Yes, N for No
507---0400 AO 4 N P 16 3/4 8 3/8 12 1/8 13.25 C—Material/Coating: P for Powder
507---0500 AO 5 N P 16 3/4 8 3/8 12 1/8 15
Coated.
507AO-0100 AO 1 Y P 20 1/2 6 3/16 12 1/8 7
D—Length
507AO-0200 AO 2 Y P 20 1/2 6 3/16 12 1/8 10
507AO-0300 AO 3 Y P 20 1/2 9 3/4 12 1/8 13
E—Width
507AO-0400 AO 4 Y P 20 1/2 9 3/4 12 1/8 15 F—Height
507AO-0500 AO 5 Y P 20 1/2 9 3/4 12 1/8 17 Weight—Shipping Weight
P.O. Box 238 • Dubuque, Iowa 52004-0238

563.583.5701 (tel) • 800.553.4840 • 563.583.5028 (fax)
w w w . m o r b r o s . c o m
AIR ELIMINATOR
FROM PUMP
TO PIPING
HEATER
JUNCTION
BOX
SENSOR
FILTERS
R
20” PAF 406-98 OFFSET MANHOLE

With Integral Relief Valve/10” Fill
INTEGRAL RELIEF VALVE/10” FILL
TEST PRESSURE 36 PSIG
BETTS INDUSTRIES, INC.

MEETS DOT 178.345-5
WARREN, PA. U.S.A.

COVERED BY PATENTS
ISSUED AND PENDING
CT-0040
LESS THAN 1 LITER LEAKAGE
INCREASED FLOW RATE
SECONDARY SAFETY LATCH
Pressure Relief Valve setting 3.63 psig

Rated Pressure Actuated Emergency Venting:
494,084 cu. ft. free air per hour @ 6.25 psig
Rated Liquid Flow Capacity 1335 gpm @ 5.0 psig
PAF manholes with integral latch style surge suppression relief valves are designed for use on DOT406 and replacement on
MC306 specification cargo tanks. Manholes are certified and marked in accordance with 49CFR178.345-5 with a test
pressure of 36 psig. Manhole covers are 7 gage steel or stainless and are secured to the tank weld collar with a clamp ring
and bolt which can be easily removed to provide access into the tank.
The integral 10” relief valve provides emergency pressure relief and meets the 1 liter surge leakage limit imposed by
49CFR178.345-10(b)(3)(ii). The relief valve also serves as a 10” latch style fill which can be easily opened to provide access
for filling the tank or for inspection. Relief valves contain an adjustment feature to allow for fine-tuning of set pressure in the
field. Other standard features include a heavy duty clamp ring, secondary safety latch and model 6496ALB pressure-vacuum
vent mounted in the 10” relief valve cover.
Manholes are available with a self-latching feature that allows the 10” relief valve/fill cover to drop and securely latch upon
movement of the tank if the cover is inadvertently left open. For self-latching model substitute L863 for L820 in assembly
number.
1
Note: 3 /2” Vent and Liquid Level Switch not included in assembly.
Clamping Ring,
Cover Relief Clamping Ring Wt.
Bolt, Washer, Normal Vent Assembly No.
Plate Valve Nut (lb.)
Strongback, & Latch
Steel Zinc Plt. Alum. Steel Zinc Plt. Brass Alum. 29.7 PPVL820BXB
Stnls 304 Alum. Stnls 304 Stnls 304 Alum. 30.2 PPVL820CXB
Stnls 316 Alum. Stnls 304 Stnls 304 Alum. 30.2 PPVL820DXB
Note: Manhole assemblies, as listed above, have Buna-N gaskets (suffix “B”). For variation in gasketing change last letter of
assembly number as follows.
Suffix “V” indicates Viton collar gasket & Viton 10” fill gasket
Suffix “W” indicates White Hypalon collar gasket & White Hypalon 10” fill gasket
Suffix “T” indicates Teflon envelope collar gasket & Tef-Sil 10” fill o-ring
Manhole collars are available in aluminum, steel, and stainless steel. Please see parts page for correct numbers.
When welding collars to tank, care should be exercised to insure collar remains flat and round.
TM
INDUSTRIES, INC. Sept 1999 Section 86 Page 19A

WARREN, PA.
PLAN VIEW DIMENSIONS
1
PARTS LIST A 4 /4” Dia. (107.95mm)
7
B 8 Holes-.390 Dia. (9.90mm) on 4 /8” (123.83mm) B.C.
3
C 2 /8” Dia. (60.325mm) Hole
20” PAF 406-98 MANHOLE D
1
/4” N.P.T. Coupling
Self-Latching Model Illustrated E 7” Rad. (177.8mm)
3
F 6 /8” (161.93mm)
3
G 4 /4” (120.65mm)
1
H 3 /4” (82.55mm)
No. Description Material Part No. No. Description Material Part No.
1 Fill Cover Alum/E-Coated 8297ALEY 9 Vent Assembly Aluminum 6496ALB
1a Fill Cover (O-Ring Grvd.) Alum/E-Coated 8297ALEY389 10 Gasket Buna-N 3716BN
Buna-N 3119BN 11 Cylinder Assembly Aluminum 6657AL
Gasket -
2 Viton 3119VT 12 Piston Aluminum 6654AL
Integral Relief Valve
Wh. Hypalon 3119WH 13 Stem Stnls 304 6688SL
2a O-Ring Tef-Sil 3902TS 14 Spring Steel 4122MS
1
Steel Zinc Plt. 3029ZC 15 /2” NPT Plug Zinc Plt. Steel Zinc Plt. 9V4907
3 Bolt-Clamp Ring
Stnls 304 3029SL 17 Stem O-Ring -112 Buna-N 4118BN
Brass 3030BR 18 Cylinder O-Ring –137 Buna-N 4015BN
4 Nut-Clamp Ring
Stnls 304 9Q5809 19 Piston O-Ring –137 Tef-Sil 4015TS
Steel Zinc Plt. 3031ZC 20 O-Ring Retainer Alum/E-Coated 4117ALEY
5 Washer-Clamp Ring
Stnls 304 3031SL 21 Retainer Ring Stnls 304 9Q4961
Steel 3036MS 22 Bellows EPDM 4020EPDM
7
6 Clamping Ring Steel Zinc Plt. 3036ZC 23 Lockwasher Ext. Tooth /16” Stnls 304 9Q5961
7
Stnls 304 3036SL 24 Nut Hex /16x20 Stnls 304 9Q5960
Buna-N 3560BN 25 Plastic Plug Polyethylene 9Z6163
3
Viton 3560VT 26 /8-16 Hex Nut w/ Insert Steel Zinc Plt. 9Q5896
Manhole Gasket
7 Wh. Hypalon 3560WH
Channel Type
Teflon Env. Gasket Maximum Temperature
3033TF Buna-N (Nitrile) 250°F
w/ Wh. Hypalon
Steel 3176MS Viton 400°F
Manhole Collar Aluminum 3176AE White Hypalon 250°F
8 Teflon-Silicone 400°F
Channel Type Stnls 304 3176SL
Stnls 316 3176SS Teflon Envelope w/ White Hypalon Insert 250°F
Replace oil cylinder using Automatic Transmission Fluid Dexron III/Mercon, SAE 5W-20 with viscosity of 177 SUS at
100°F and a pour point of no greater than –45°F.
MAINTENANCE: Manhole assemblies should be inspected with sufficient frequency to insure 10” Integral Relief Valve
functions properly. Any worn, damaged or missing parts must be replaced. Gaskets should be replaced if their
effectiveness to insure a liquid tight seal is impaired in any way. Replacement gaskets must be compatible with
products carried.
WARNING Consult PAF406-98 maintenance manual prior to disassembly of this relief valve.
Use only genuine Betts Industries Inc. replacement parts. Use of substitute parts can impair the proper
functioning of this product.
TM
INDUSTRIES, INC. Sept 1999 Section 86 Page 19B

WARREN, PA.
Warren, PA 16365
Phone: 814-723-1250
MAINTENANCE MANUAL
FOR
PAF 406-96 & 406-98
SURGE
RELIEF VALVE
Section 1: Identification of Adjustable PAF 406-96 & 98
Section 2: Maintenance and Testing for PAF 406-96 & 98
Section 3: Set Pressure Adjustment of PAF 406-96 & 98
Section 4: Removal of PAF 406-96 & 98 from Closure Assembly
Section 5: Disassembly of PAF 406-96 & 98
Section 6: Assembly of PAF 406-96 & 98
9/16/99
Warren, PA 16365
Phone: 814-723-1250
SECTION 1:
IDENTIFICATION OF ADJUSTABLE
PAF S URGE RELIEF VALVE (PAF 406-96 & 98)
Betts PAF Surge Relief Valves (PAF 406-96 and PAF 406-98) meet or exceed all U.S. DOT
requirements for primary pressure relief valves on DOT406 cargo tanks as contained in
49CFR178.345-10 and 49CFR178.346-3 of the Code of Federal Regulations. The Betts PAF
Surge Relief Valve is able to withstand a brief pressure surge and contain lading (liquid cargo)
leakage to less than one liter (per TTMA RP NO 81).
Betts PAF Surge Relief Valve (PAF 406-96 & 406-98) protects the cargo tank from rupture due to
over-pressurization caused by overfilling or fire and is, therefore, crucial to the safe operation of
the tank. In order to maintain your Betts PAF Surge Relief Valve in proper working condition, the
following procedures must be followed.
All PAF 406-96’s are cast with

“MODEL PAF 406-96 ”
And PAF 406-98’s are cast with
“MODEL PAF 406-98”
HEX
PLASTIC CAP
The adjustable PAF
DETAIL 406-96 & 98 have an
internal hex at the top
of the stem under the
plastic yellow cap, as
well as, a Black E-
coated cover.
BLACK E-COATED
COVER
Warren, PA 16365
Phone: 814-723-1250
SECTION 2:
MAINTENANCE AND TESTING
FOR PAF S URGE RELIEF VALVE 406-96 & 98
A. U.S. DOT Requirements: This portion of the manual refers to the DOT regulations and is intended to
serve as an interface to relate the manual to the code. This manual does not take the place of the Code
of Federal Regulations. A current copy of the Code of Federal Regulations should be reviewed and
followed to insure the requirements are met for each individual case.
There are three basic tests/inspections mandated by 49CFR Part 180 for MC306 and DOT406 cargo tanks.
Test/Inspection Interval Period Code Paragraph

External Visual Inspection 1 year 49CFR180.407(d)
Leakage Test 1 year 49CFR180.407(h)
Pressure Retest 5 year 49CFR180.407(g)
1. External Visual Inspection: As part of the annual external visual inspection, 49CFR180.407(d)(3)
requires that all pressure relief valves, be visually inspected for any corrosion or damage which might
prevent the valve from functioning. If the cargo tank is used to haul product that is corrosive to the
relief valve, the valve must be removed from the cargo tank for inspection and bench testing.
Note: Betts recommends that the external visual inspection of vents be performed monthly.
1.1. Visually inspect all external surfaces of the manhole and PAF, which includes opening the
Latch (1) and Strongback (5).
NOTE: If any corrosion or damage to the PAF or manhole is observed, it must be repaired and
successfully bench tested prior to returning to service. Refer to 3.5 for PAF bench test procedure.
1.1.1. Clean and inspect the bottom side of the PAF for signs of damage, corrosion, or product
gumming that could effect the operation of the Relief Valve.
1.1.2. Closely inspect the Cylinder (10) for any damage or dents. Also, insure Cylinder (10) is
threaded tightly to the Cover (9). See figure 1.
1.1.3. Inspect and clean the Normal Vent (8).
1.1.4. Inspect the 10” Seat (25) for damage or corrosion. Build-up or grim on the seat should be
removed. Nicks on the 10” seat may cause the gasket not to seal.
1.1.5. Inspect the 10” Fill Gasket (24) for signs of wear or degradation. Replace gasket if required.
1.1.6. Inspect the Clamp Ring Gasket (26) for evidence of product seepage. Replace any gaskets
where seepage is detected.
COVER (9) Inspect & clean

Inspect CYLINDER (10) GASKET (24)
Inspect & clean

NORMAL VENT (8)
STRONGBACK (5)
Inspect SEAT (25)
Inspect GASKET (26)

for leakage
Figure 1
Warren, PA 16365
Phone: 814-723-1250
2. Leakage Test: 49CFR180.407(h) requires tanks to be tested annually at 80 % of the tank design
pressure or MAWP, whichever is marked on the tank certification or specification plate. All tank
components must remain in place during this test, except any re-closing pressure relief valve with a set
pressure less than the leakage test pressure must be removed or rendered inoperative during the test.
Betts Normal Vents, therefore, must be removed during the leakage test.
2.1. Remove Normal Vent from manhole cover and plug opening with Betts Plug No. 3013.
2.2. Apply test pressure in accordance with 49CFR180.407(h)
2.3. Inspect all gasket joints on PAF and manhole for leaks. If PAF leaks, adjust in accordance with
Set Pressure Adjustment instructions (Section 3 of this manual) and retest the unit. Replace
damaged or worn gaskets as required.
3. Pressure Retest: As part of the pressure retest, 49CFR180.407(g)(ii)(A) requires that all re-closing
pressure relief valves be removed from the tank for inspection and bench tested to verify that the
relief valve is functioning properly. The pressure retest and the relief valve bench test must be
performed at least every five years.
Note: Betts recommends that the PAF 406-96 and PAF 406-98 be bench tested annually.
3.1. Pressure Retest Procedures:

3.1.1. 49CFR180.407(g)(1)(vii) requires that all closures except pressure relief devices must be in
place during the test.
3.1.2. Manholes must remain in place during pressure test.
3.1.3. Open 10” PAF Relief Valve.
3.1.4. Install Betts Retest Fixture (part no. 6556LCB) to seal the 10” opening. See figure 2.
3.2. Betts Push and Air Operated Vapor Recovery Valves remain in place during the test.
NOTE: If vapor recovery valves from other manufactures are installed, refer to the
manufacturers’ instructions to see if they should be removed.
3.3. After preparing the rest of the tank, perform the pressure test in accordance with the regulations.
Inspect all parts of manhole assembly for leakage. Repair or replace parts as required.
3.4. Remove all clamps or plugs from relief valve immediately after test is completed.
Retest Fixture
(Part No. 6556LCB)
Inspect for Clamp Channel

Leakage Here Inside of 10” Fill
Figure 2
Warren, PA 16365
Phone: 814-723-1250
3.5. Bench Test Procedure for PAF Surge 406-96 & 98
3.5.1. Remove manhole assembly from tank by removing the clamp ring bolt and clamp ring.
3.5.2. Remove Normal Vent (8) and plug port with Betts Plug (No. 3013)
3.5.3. Attach manhole assembly to appropriate Betts PAF 406-96 Test Fixture (No. 6685SL.)
3.5.4. Apply a soap solution around the perimeter of the DoveTail 10” Gasket.
3.5.5. Gradually apply pressure to the tank and observe the pressure at which bubbles first appear.
3.5.6. Per 49CFR178.346-3(c) the set pressure must not be less than 3.63 psig and not more than
4.55 psig for a tank with a MAWP of 3.3 psig.
3.5.7. Slowly release the pressure from the test fixture and verify the PAF reseals not less than the
MAWP of the tank.
3.5.8. Replace or adjust any relief valve that fails the set pressure test requirements. Refer to
instructions for Set Pressure Adjustment (Section 3 of this manual) to adjust the set
pressure, and retest the unit.
4. Model 6496AL (Normal vent for DOT 406) Test Procedure:

A Normal Vent Test Tank (Part No. 6687AL) must be used to test the Normal Vents.
Note: A regulator must be used to slowly apply pressure to the tank.
4.1. Pressure Test: 49CFR 178.346-3(b)(2) states that the normal vent for a DOT 406 must be set to
open at not less than 1 psig.
4.1.1. Screw the Normal Vent into the lid of the test tank as shown in figure 3 A. In order to
detect leakage, attach the reducer bushing, compression fitting, and tubing. Place the end of
the tubing in a water jar. The water jar is not included with the test tank.
4.1.2. Slowly apply pressure to the tank. Bubbles will indicate the opening pressure of the vent.
4.1.3. A properly functioning 6496AL Normal Vent should open between 1.0 to 1.5 psig, but in no
case open less than 1 psig.
4.2. Vacuum Test: 178.346-3(c)(2) states that the normal vent for a DOT 406 must be set to open at
no more than 6 ounces vacuum (.375 psig).
4.2.1. Screw the Normal Vent into the lid of the test tank as shown in figure 3 B.
4.2.2. Slowly apply pressure to the tank and inspect the top opening for pressure release. Apply
soapy water to the top of the vent in order to detect the point at which the vent opens.
4.2.3. A properly functioning 6496AL Normal Vent should vacuum relieve between 0.25 to 0.375
psig, but in no case more than 0.375 psig.
4.3. Repair or replace any Normal Vent that does not meet the specifications.
Tubing
Pressure Release
Pressure Release
Reducer Bushing
Test Tank
6687AL
Seal
Air out to Air out to

Air in from manometer Air in from manometer
regulator or gage. regulator or gage.
Water Jar Bubbles

Indicate
Leakage
PRESSURE TEST VACUUM TEST

Figure 3A Figure 3B
Warren, PA 16365
Phone: 814-723-1250
SECTION 3:
OF PAF S URGE RELIEF VALVE
NOTE: THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL 306-98, 406-98 AND PAF

death may result.
2. Open Latch (1) to expose yellow Plastic Plug (2) as shown in figure 4.
4. Place an 11/16 box end wrench over Hex Nut (3).
5. Place a 7/32 allen wrench into the hex socket of the Stem (4).
6. Hold the allen wrench stationary and rotate the box end wrench counterclockwise to
loosen the Hex Nut (3) two full turns.
7. At this point, the PAF can be adjusted by rotating the Stem (4) with the allen wrench.
8. To increase the set pressure, turn the Stem (4) clockwise.
Note: The Stem (4) must fully engage threads of Hex Nut (3) when nut is tightened.
Loosen
Nut
Increase Set
Pressure
Warren, PA 16365
Phone: 814-723-1250
9. To decrease the set pressure, turn the Stem (4) counter-clockwise.

Note: The amount of adjustment in the counter-clockwise direction is limited by
a shoulder stop on the Stem (4).
10. The adjustment feature is sensitive, so that, one turn of the stem may increase the set
pressure significantly. Adjust stem ¼ turn at a time, until the desired setting is
achieved.
Never adjust the relief valve so that a person must stand on

the Strongback (5) to operate the Latch (1). This could cause
a person to loose their balance and fall, if there is any
residual pressure in the tank when the relief valve is opened.
11. After adjusting the PAF surge relief valve, use the box wrench to tighten the Hex Nut
(3), while using the allen wrench to hold the stem stationary.
12. Replace the Plastic Plug (2).
13. After adjustment, test the set pressure to verify that it falls within the required range.
13.1. Per 49CFR178.346-3(c) the set pressure for models PAF406-96 & 406-98
must not be less than 3.63 psig and not more than 4.55 psig for a tank with
a MAWP of 3.3 psig.
13.2. Per 49CFR178.341(d)(2) the set pressure of model PAF306-98 must not be
less than 3.0 psi for a MC306 tank
14. If the adjustment does not achieve the desired pressure setting, check the following:
14.1. Inspect the 10” metal seat. Remove any build up and repair any nicks.
14.2. Replace the 10” gasket.
14.3. Insure strongback is not bent or damaged.
14.4. Insure the collar that is welded to the tank is not excessively warped.
14.5. Insure closure assembly was mounted correctly to manhole collar.
14.5.1. Unbolt clamp-ring and loosen closure assembly from collar seat.
14.5.2. Release latch to relieve force on 10” fill cover.
14.5.3. While the 10” fill is opened, tighten clamp-ring bolt while
tapping circumference of clamp-ring with a hammer.
14.5.4. Close 10” fill and latch.
Warren, PA 16365
Phone: 814-723-1250
SECTION 4:
REMOVAL OF PAF S URGE RELIEF VALVE
FROM CLOSURE ASSEMBLY
NOTE: THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL PAF 406-96 & 98 WITH
BLACK E-COATED COVER AND STEM WITH INTERNAL HEX AT THE TOP.

death may result.
2. Open latch to expose Yellow Plug (2) as shown in figure 5.
4. Use an 11/16 socket or box end wrench to remove Hex Nut (3).
5. Remove Star Washer (6).
6. Open fill assembly as shown in figure 6.
7. Place a 7/32 allen wrench in the hex socket of the Stem (4).
8. By rotating the stem clockwise, the PAF assembly can be unscrewed from the closure
assembly. NOTE: During removal, care should be taken not to damage the last
threads on the stem, by supporting the PAF with a hand under the cylinder.
9. Remove the Bellow (7).
10. At this point, further disassembly should be conducted at a workbench. Follow the
procedure “Disassembly of PAF Surge Relief Valve” if disassembly of the cylinder is
required.
DISASSEMBLE
DISASSEMBLE
SUPPORT HERE
Warren, PA 16365
Phone: 814-723-1250
SECTION 5:
DISASSEMBLY OF PAF S URGE RELIEF VALVE
NOTES:
Ø THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL PAF 406-96 & PAF
406-98 WITH BLACK E-COATED COVER AND STEM WITH INTERNAL HEX AT THE TOP.
Ø UNDER NORMAL CIRCUMSTANCES, THE DISASSEMBLY OF THE SPRING CYLINDER IS

NOT REQUIRED NOR RECOMMENDED, UNLESS ALL OTHER ATTEMPTS TO REPAIR THE
RELIEF VALVE HAVE FAILED. IT IS RECOMMENDED THAT THE VALVE BE RETURNED TO
BETTS INDUSTRIES FOR REPAIR.
Ø A PAF SURGE DISASSEMBLY TOOL (PART # 6684MS) IS REQUIRED TO DISASSEMBLE

THE SPRING CYLINDER.
1. Remove the PAF surge relief valve assembly from the closure assembly by following
the steps outlined in the procedure “Removal of PAF Surge Relief Valve from Closure
Assembly”.
2. Remove Normal Vent (8) by griping with slip joint pliers and unscrewing from Cover (9).
See figure 7.
The cylinder contains a compressed spring, which could cause

injury, if the cylinder is removed improperly. Review the following
section carefully before attempting to remove cylinder.
3. The Cylinder (10) contains Hydraulic Oil (11) that must be drained.
4. Use a 3/8 allen wrench to remove the ½ in. NPT Plug (12) while holding the Cylinder
(10) stationary by gripping with slip joint pliers within one inch from the bottom. It is
very important that the cylinder does not unscrew from the cover at this time.
5. If the unit has a 1/8 in. NPT Plug (13) remove it at this time.
6. Drain the oil that is on the top and bottom of the Piston (14).
Insure CYLINDER
Does NOT Unscrew
Grip Here to Remove
Grip With Slip-Joint

Pliers Here.
Warren, PA 16365
Phone: 814-723-1250
7. Insert the 3/8 female thread end of the Disassembly Tool (15) (part # 6684MS) into the
½ in. NPT opening as shown in figure 8.
8. Thread the Disassembly Tool (15) onto the 3/8 male thread of the Stem (4) that extends
from the Lock Nut (16). See figure 8. The tool should engage at least four threads.
Note: Use a 7/32 allen wrench on the bottom of the tool and one at the top
of the stem to tighten tool completely down.
Screw Tool to
End of STEM (4)
3/8 Female
Thread of Tool

Than Actual Length
9. At this point, a 7/32 allen wrench must be used to hold the shaft of the tool stationary
with respect to the cylinder, while an 11/16 wrench is used to turn the Tool Nut (17)
clockwise. Once the nut has made contact with the cylinder, turn the nut two complete
turns to compress the Spring (18). See figure 9.
Tool Must Thread

Completely to Nut
Two Turns Clockwise

To Compress Spring
Hold Shaft
Stationary
Warren, PA 16365
Phone: 814-723-1250
10. The Cover (9) can now be unscrewed from the Cylinder (10). Do NOT unscrew the
stem from the tool. If slip joint pliers are required to grip the cylinder, only grip
within one inch from the end. See figure 10.
After the cover is removed, the spring is still under load

in the cylinder. Do NOT point the open end of the tube
toward yourself or a bystander.

Than Actual Length Unscrew Nut
Grip Cylinder Hold Shaft

On This End Stationary
11. To release the spring, hold the allen wrench stationary with respect to the
cylinder, and turn the Tool Nut (17) counter-clockwise. It is imperative that the
shaft of the tool does not unscrew from the Stem (4) during disassembly process.
Continue to back off the Tool Nut (17) until the piston is extended beyond the
length of the spring. See figure 11.
12. At this point insure the spring tension is released, and the Tool (15) can be
unscrewed from the Stem (4).
Warren, PA 16365
Phone: 814-723-1250
13. Disassemble the stem/piston assembly by inserting a 7/32

allen wrench into the top of the Stem (4) and unscrew the
LockNut (16) using a 9/16 socket. See Figure 12. Note: The
piston may appear different than shown depending on the
model you may have.
Apply petroleum
14. If the Piston O-ring (19) requires removal, cut the o-ring with jelly here during
a razor blade, being careful not to damage the piston groove. re-assembly.
15. The Stem O-ring (22) and O-ring Retainer (21) are removed
by using a snap ring tool to remove Snap Ring (20). See
figure 13.
16. If the Cylinder O-ring (23) requires removal, cut the o-ring
with a razor blade being careful not to damage the o-ring
groove.
17. If the 10” Fill Gasket (24) requires removal, cut a small slot
in the center of the gasket and use a screwdriver to pry gasket
out of dovetail groove, being careful not to damage groove.
See figure 13.
Slice Gasket as Shown &

Pry Out with Screwdriver.
For maintenance or assembly instructions consult appropriate procedures.

Warren, PA 16365
Phone: 814-723-1250
SECTION 6:
ASSEMBLY OF
PAF S URGE RELIEF VALVE
NOTE: THESE INSTRUCTIONS APPLY ONLY TO ADJUSTABLE MODEL PAF 406-96 & PAF
1. Preparation of O-Rings and Components:

1.1. All parts should be cle aned and degreased to insure the removal of all product build up.
1.2. All components should be inspected for damage or wear.
1.3. To insure integrity of the seals, all o-rings and gaskets should be replaced using Betts’
replacement parts.
1.4. Inspect all o-ring grooves for damage (nicks, scratches, or burrs).
2. Cover sub-assembly: Refer to figure 14.

2.1. Insert Stem O-ring (22) into Cover (9).
2.2. Insert O-ring Retainer (21) and use a snap ring tool to insert the Snap Ring (20) into
groove.
2.3. Place black Buna Cylinder O-ring (23) into o-ring groove on Cover (9).
2.4. Use Betts’ Dove Tail Gasket Tool (26) (part # 6504AL) to place 10” Fill Gasket (24)
into Cover (9). See figure 14.
2.4.1. Lubricate the gasket and dovetail groove with a soap solution.
2.4.2. Using fingers, pinch the back side of the gasket together and insert a small section
of the gasket into the groove.
2.4.3. Use short strokes with the Dove Tail Gasket Tool (26) to insert the gasket.
2.4.4. The last portion of the gasket will need to be pushed in with fingers.
Note: The gasket can also be installed by hand. A 10” o-ring (4100BN) is also available
for use as a replacement for the dovetail gasket and can be installed in the groove.
Apply petroleum
jelly here.
Apply never-seize here.

Warren, PA 16365
Phone: 814-723-1250
3. Piston/Stem sub-assembly: Refer to figure 12 of section 5.

3.1. Inspect Stem (4) for signs of wear or corrosion. Replace as required.
3.2. Insert 3/8 end of Stem (4) into counter sunk hole of Piston (14). Note: The piston may
appear different depending on which model you have.
3.3. Insert a 7/32 allen wrench into the top of the Stem (4) and tighten the Lock Nut (16)
completely down using a 9/16 socket. Note: The Stem (4) MUST turn freely in the
Piston (14) after the nut is tightened.
3.4. Pre-heat the orange Tef-Sil Piston O-ring (19) in warm water and immediately slide the
o-ring over the Piston (14) and position it into groove.
3.5. Smear a thin layer of petroleum jelly around the Piston O-ring (19) to facilitate ease of
installing the piston into the cylinder.
4. Loading the Spring: Refer to figure 11 of section 5.

4.1. Inspect the inside of the Cylinder (10) for damage (dents, scratches, or corrosion). If the
cylinder is damaged it must be replaced.
4.2. Insert the 3/8 female thread end of the Disassembly Tool (15) (part # 6684MS) into the
½ “ NPT opening of the Cylinder (10).
4.3. Place the Spring (18) into the Cylinder (10).
4.4. Thread the 3/8 stub that extends from the Piston/Stem assembly into the Disassembly
Tool (15) and tighten with two allen wrenches. NOTE: Ensure the end of tool is tight
against the Lock Nut (16) as shown in figure 11 of section 5.
4.5. Compress the Spring (18) by using a 7/32 allen wrench to hold the shaft of the tool
stationary with respect to the cylinder, while an 11/16 wrench is used to turn the Tool
Nut (17) clockwise. (See figure 11 of section 5.) Insure the threads are not damaged on
the cylinder when the piston is pulled into the top of the cylinder.
After the spring is compressed in the cylinder, do NOT

point the open end of the tube toward yourself or a
bystander.
4.6. Continue to turn the Tool Nut (17) until the top of the piston is at least 7/8“ below the
top of the Cylinder (10). See figure 10 of section 5.
5. Installing the Cover (9):

5.1. Smear a thin amount of never-seize compound on the threads of the Cover (9) as shown
in figure 14.
5.2. Smear petroleum jelly around Cylinder O-ring (23) as shown in figure 14 and the top of
the Stem (4) as shown in figure 12 of section 5.
5.3. Position the Cover (9) over the Stem (4) as shown in figure 12 of section 5.
5.4. Slowly screw the Cover (9) onto the Cylinder (10). Care should be taken not to damage
the threads of the cylinder or cover. Beware of cross threading. Ensure that the cover is
screwed completely down to the cylinder so there is NO gap. See figure 15.
The Cylinder must be threaded completely on the Cover

prior to the Disassembly Tool being removed.
5.5. The Spring (18) can now be released by holding the allen wrench stationary with respect
to the Cylinder (10) and turning the Tool Nut (17) counter-clockwise.
5.6. Once the Tool Nut (17) has released the spring pressure, the tool can be unscrewed and
removed from the Cylinder (10).
Warren, PA 16365
Phone: 814-723-1250
6. Re-filling the hydraulic oil: Refer to figure 15.

Note: Replace the oil in the cylinder with Automatic Transmission Fluid
DexronIII/Mercon SAE 5W-20 with a viscosity of 177 SUS at 100°F and a pour
point of no greater than –45°F.
6.1. If this unit has a 1/8” NPT, place thread sealant on the 1/8” NPT Plug (13) and insert it
in the Cover (9).
6.2. Turn the PAF upside down and pour ATF fluid through the ½” NPT opening at the
bottom of the Cylinder (10).
6.3. It is very important that this lower chamber is completely full of oil, with NO air
pockets.
6.4. Place thread sealant on the ½” NPT Plug (12) and insert it into the bottom of the
Cylinder (10). Tighten the plug using a 3/8 allen wrench.
7. Smear a small amount of never-seize compound on the threads of the Normal Vent (8) and
screw it into the opening of the Cover (9).
NO Oil in this
Chamber
Ensure
NO Gap
Fill the Bottom

Chamber Completely
8. To attach the PAF Relief Valve to the closure assembly, refer to figure 6 of section 4.
8.1. Place the Bellow (7) over the Stem (4).
8.2. Thread Stem (4) into Wobble Support (27) on Strongback (5). NOTE: Use an 7/32 allen
wrench inserted from the top of the Wobble Support (27) and turn counterclockwise to
screw in the stem.
8.3. Insure the first thread is not damaged as the stem is started into the wobble support.
8.4. As the stem is threaded in, insure the Locating Ears (28) are aligned at the hinge side of
the Strongback (5) and straddle the strongback as shown in figure 4 of section 3.
Tighten the stem all the way in.
8.5. Insert Lock Washer (6) and thread Hex Nut (3) onto Stem (4) as shown in figure 6 of
section 4.
8.6. To adjust the set pressure and tighten down the stem, refer to Section 3 of this manual.
Installation & Part
Installation s Manual
Parts
M/MA Meters
Installation: M100-10
Table of Contents and Safety Procedures
Contents
Safety Procedures
Description Page Number
How LC Meters Work ........................................... 3 ! WARNING
WARNING
Owner’s Information Packet ................................. 4
Installation Requirements ..................................... 6 All internal pressures must be relieved before
Operation Requirements ....................................... 7 disassembly or inspection of the strainer, air eliminator,
Meter Start Up and Operation .............................. 8 any valves in the system, the packing gland, and the
Reversing the Meter Registration ......................... 9 front or rear covers. See “Relieving Internal Pressure”
Setting the Standard Adjuster .............................. 10 (page 11).
Meter Maintenance ............................................... 10
Relieving Internal Pressure ................................... 11 Be Prep ared
Prepared
Servicing the Drive Components ........................... 12 Make sure that all necessary safety precautions have been
Removing the Dust Cover ..................................... 12 taken. Provide for proper ventilation, temperature control,
Removing the Adjuster and fire prevention, evacuation and fire management.
Adjuster Drive Assembly ...................................... 12
Buna/Viton/Teflon Packing Gland ......................... 15 Provide easy access to the appropriate fire extinguishers
The Retaining Plate .............................................. 15 for your product. Consult with your local fire department
Disassembling the Meter ...................................... 16 and state and local codes to make sure that you are
Removing the Non-Corroded adequately prepared.
Rotor Gears .......................................................... 18
Removing Corroded Rotor Gears .......................... 18 Read this manual as well as all the literature provided in
Reassembling the Meter ...................................... 20 your owner’s packet.
Timing the Rotor Gears ........................................ 21
Torque Chart ......................................................... 22
Wrench and Socket Size Chart ........................... 23
In the Event of a Gas Leak
In the event of a large gas leak: Evacuate the area and
Troubleshooting .................................................... 24
notify the fire department.
How to Order Replacement Parts ........................ 26
Illustrated Parts Breakdown ................................. 27-30
In the event of a small, contained gas leak:
Quality Statement ................................................ 31
1. Stop the leak and prevent accidental ignition.
Please have the following information available when you 2. Prevent the entrance of gas into other portions of the
make inquires, order replacement parts, or schedule buildings. Some gases, such as LPG, seek lower
service. If a specific meter accessory is involved, please levels, while other gases seek higher levels.
provide the model and serial number of the accessory in
question (see page 4). 3. Evacuate all people from the danger zone.
Your Meter’s Serial Number: ________________________ 4. See that the gas is dispersed before resuming business
and operating motors. If in doubt, notify your local fire
Your Full-Service Distributor: _______________________ department.
Your Full-Service Distributor’s In the Event of a Gas Fire

Telephone Number: _______________________________ In the event of large fires or fires that are spreading:
Evacuate the building and notify your local fire department.
NOTICE Stop the leakage only if you can safely reach the equipment.
In the event of small, contained fires that you can

This manual provides warnings and procedures that are
safely control: Stop the leakage if you can safely reach
intended to inform the owner and/or operator of the
the equipment. Then use the appropriate extinguisher:
hazards present when using the Liquid Controls Meter
Class B fire extinguisher, water, fog, etc., depending on
on LP-Gas and other products. The reading of these
the materials. If in doubt, call your local fire department.
warnings and the avoidance of such hazards is strictly
in the hands of the owner-operators of the equipment.
Neglect of that responsibility is not within the control of
the manufacturer of the meter.
2
How LC Meters Work
Liquid Controls meters are positive displacement meters.

They are designed for liquid measurement in both custody
transfer and process control applications. They can be
installed in pump or gravity flow systems. Because of
their simple design, they are easy to maintain, and easy
to adapt to a variety of systems.
The meter housing (1) is designed with three cylindrical

bores (2). Three rotors, the blocking rotor (3) and two
displacement rotors (4, 5), turn in synchronized Meter Element Exploded Line Drawing
relationship within the bores. The three rotors are
supported by bearing plates (6, 7). The ends of the rotors Capillary seals mean no metal-to-metal contact within
protrude through the bearing plates. Blocking rotor gear the metering element. This means no wear. No wear
(8) is placed on the end of the blocking rotor. Displacement means no increase in slippage, and no increase in slippage
rotor gears (9, 10) are placed on the ends of the means no deterioration in accuracy.
displacement rotors. These gears create the synchronized
timed relationship between the three rotors. Throughout the metering element, the mating surfaces are
either flat surfaces or cylindrical faces and sections that
As fluid moves through the meter housing, the rotor are accurately machined. These relatively simple
assembly turns. The liquid is broken into uniform sections machining operations, plus the fact that there is no
by the turning rotors. Fluid displacement happens oscillating or reciprocating motion within the device,
simultaneously. As fluid enters, another portion of the permits extremely close and consistent tolerances within
fluid is being partitioned and measured. At the same time, the LC meter.
the fluid ahead of it is being displaced out of the meter and
into the discharge line. Since the volume of the bores is The product flowing through the meter exerts a dynamic
known, and the same amount of fluid passes through the force that is at right angles to the faces of the displacement
meter during each revolution of the blocking rotor, the exact rotors. The meter is designed so that the rotor shafts are
volume of liquid that has passed through the meter can be always in a horizontal plane. These two facts result in no
accurately determined. axial thrust. Therefore, with no need for thrust washers or
thrust bearings, the rotors automatically seek the center
This true rotary motion is transmitted through the packing of the stream between the two bearing plates eliminating
gland, the face gear, the adjuster drive shaft, and the wear between the ends of the rotors and the bearing plates.
adjuster to the register stack and counter. True rotary Once again, no wear results in no metal fatigue and no
motion output means consistent accuracy since the friction.
register indication is in precise agreement with the actual
volume throughput at any given instant. The Liquid Controls meters are made of a variety of materials
to suit a variety of products. Because of our no-wear
At any position in the cycle, the meter body, the blocking design, capillary seals, and unique rotary metering, LC
rotor, and at least one of the displacement rotors form a meters provide unequalled accuracy, long operating life,
continuous capillary seal between the un-metered upstream and unusual dependability.
product and the metered downstream product.
3
Owner
Owner’’s Information Packet
1. Is all your documentation included with your 2. Record your meter serial number in the space
meter? LC meters come in many variations. The provided on the inside cover of this manual. The inside
information sent to you depends on the accessories cover also provides a space for your full-service
you have ordered with your meter. Make an inventory distributor’s name and telephone number. Fill in this
of your owner’s information packet. First, find your information and keep it handy. You will always need
LC packing slip with the computer printout. Locate your meter serial number and model number when
the serial number and the meter model number on calling for service or parts! See ‘How to Order
this printout. Cross reference the packing slip number Replacement Parts’ in this manual.
with the actual meter numbers. The illustration on
this page will help you locate the Specification and
Serial Number Plates on the meter and its accessories.
4
Owner
3. Identify your meter

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

chart shown above to make sure that all the
documentation needed for your meter and accessories
is in your red information packet. If documentation is
missing, call your full-service distributor or Liquid
Controls for replacement materials.
5
Inst allation Requirement
Installation Requirementss
Make sure that all necessary safety precautions have been Position the meter with service in mind. Provide ample
taken. Provide for proper ventilation, temperature control, work space. Removing covers can be difficult when work
fire prevention, evacuation and fire management. space is not available. Always supply a platform or support
for the meter mounting.
Provide easy access to the appropriate fire extinguishers
for your product. Consult with your local fire department A meter is metallurgically designed to be physically
and state and local codes to make sure that you are compatible with a given type of liquid, as originally specified
adequately prepared. by the customer, and as indicated on the Serial Number
Plate. A meter should not be used with a liquid different
Read this manual as well as all the literature provided in from the liquid originally specified, unless the physical
your owner’s manual. If you have any questions, consult characteristics and pH rating are similar and the application
with your full-service distributor or call the Service has been checked with LC Sales and Engineering through
Department at Liquid Controls. your full-service distributor.
Install the meter and accessories in conformance with Install a strainer on the meter inlet to avoid damage from
applicable state and federal construction, electrical and foreign matter, such as weld slag, from entering the system.
safety codes. The strainer must always be located on the inlet side.
NOTE: Class 10 LPG meters must be installed in All meters are tagged identifying their direction of flow.
accordance with the requirements of ANSI-NFPA 58 in Meters are set with a flow direction of left to right as
addition to all other state and local codes. standard. However, when a meter is ordered, the customer
can specify that the flow be set from either direction. If the
WARNING: Under normal operation, do not expose any meter register counts in reverse, the meter is reading the
portion of the LP-Gas system to pressures in excess of direction of flow in reverse. If this occurs, the meter
rated working pressures without an automatic safety valve registration must be reset. See ‘Reversing the Meter
to vent the over pressure discharge to a place of safety Registration’ in this manual for mechanical output meters.
away from the operator and other people. Failure to provide Refer to your accessory manual for electrical output meters
such a safety relief may result in leakage or rupture of one (such as meters equipped with a pulser).
or more of the components in the system. This can result
in injury of death from the gas, a fire, or pieces of flying
debris from the rupture.
Before shipment, protective thread caps were placed in all

meter and accessory openings. They should remain in
place until you are ready to attach piping.
Prior to meter installation, the entire piping system should NOTE

be thoroughly flushed of all debris, with a liquid that is
compatible with the construction of the meter. Always request up-to-date, engineering approved,
dimensional drawings before starting any construction.
Keep external surfaces of the meter clean. Do not rely on catalog pictures or drawings which are
for reference only. After receiving prints, check to see
The meter must always be securely bolted to a platform or that all equipment ordered is shown and that any extra
supporting member, regardless of the mounting position pressure taps, plugs, etc. are noted and their size
of the meter. Never ‘hang’ a meter on the connecting piping. specified.
Install meter only on the discharge side (downstream) of

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

calibration purposes.
7
Meter S
Sttart Up and Operation
Prior to meter start up,

up use extreme caution. Make Filling the system with a pump - Consult the pump
sure that: manufacturer for proper pump priming. Once the pump is
primed with product, proceed as follows:
1. The meter is properly secured
2. All connections are tight • Follow steps one through four above for proper meter
3. All valves are in the closed position start-up.
Placing your meter in operation: When placing your NOTE

meter in operation, the meter and system must be filled
slowly with liquid and be free of air prior to start-up. Extreme
Make sure that your pump can operate against a
care must be taken to avoid damaging the meter during
dead head pressure. If NOT
NOT,, consult the factory
this time. The system may be filled by gravity (preferred)
for assistance.
or by use of the pump (if required) when filling the system
with liquid for the first time.
Never operate the meter or system when partially
Gravity filling - systems with positive head pressure filled with liquid, or with pockets of compressed air
from product storage above the inlet port of the meter. or vapor present. If these conditions cannot be
avoided, air and vapor elimination systems may be
1. Make sure all valves (up stream and down stream of required. If you cannot fill the meter slowly by
the meter) in the system are closed. gravity or by using a valve to throttle back the flow,
consult the factory
factory..
2. Crack open the valve located at the storage tank. The
meter’s register/counter will start to move and then Do not operate the meter at a pressure exceeding that
stop, provided there is not a valve between the tank marked on the Serial Number Plate. Under any and all
and the meter inlet. If there is another valve between pressure producing circumstances, for instance, thermal
the tank and meter, repeat this process with each valve expansion and hydraulic shock, the working pressure
until the meter is exposed to the liquid. must not exceed the indicated maximum.
3. Once you are assured that the meter has registered If the meter is operated at a rate greater than the
some volume and stopped, continue to fully open the maximum recommended GPM, excessive wear and
tank valve. premature failure may occur.
4. With the valve(s) open between the tank and the meter, The meter can be calibrated for flows below minimum
now go to the valve located down stream of the meter. ratings if the flow remains constant and varies within
Open the down stream valve slowly until the meter’s narrow limits or if the product is viscous. A meter should
register/counter starts to move. Do not run the meter never be run beyond the maximum flow rate determined
any faster than 25% of its rated flow during start-up. for that class meter and/or liquid measured.
Once the product is flowing out the end of your system,
the outlet valve can be opened all the way provided
that the system is designed not to exceed the flow ! WARNING
WARNING
rate marked on the meter.
All internal pressures must be relieved before
NOTE
NOTE: If the valves are not manual, consult the valve disassembly or inspection of the strainer, air eliminator,
manufacturer for slow flow start-up. any valves in the system, the packing gland, and the
front or rear covers. See “Relieving Internal Pressure”
(page 11).
8
Reversing the Meter Registration
The direction of flow is specified by the customer when

the meter is ordered. The standard direction of flow is
from left to right when facing the front of the meter. A red
pressure sensitive label indicating inlet is affixed to the
meter at time of shipment.
If the meter is equipped with a strainer and/or valve, the

strainer (and/or valve) MUST be moved when reversing the
direction of flow through the meter. The strainer should
always be located on the inlet side of the meter
meter.. When
the meter is equipped with a valve, it is moved to the outlet Adjuster drive gear
side of the meter. Some repositioning of the valve engaged from the top.
components may be required. See the Valve Manual in Adjuster drive gear
the Owner’s Information Packet. engaged from the
bottom.
When the meter is first installed, check the register. If the
register counts DOWN, meaning that the register numbers
decrease rather than increase, you must reverse the
direction of registration by reversing the position of the
adjuster drive gear.
7. Reassemble the parts in reverse order. Make sure
that the adjuster drive gear meshes with the packing
Reversing the drive to the register is accomplished by
gland’s pinion gear (6) without being too tight. Make
reversing the position of the adjuster drive gear relative to
sure there is a little play in the gear teeth. The retaining
the pinion gear of the packing gland, as shown to the left.
ring (4) should be placed in the groove provided on the
See below for step-by-step instructions.
drive shaft (3), regardless of the adjuster drive gear
position. The packing gland pinion gear to adjuster
drive gear ratio is either 1:1 or 2:1. In the 2:1 ratio, the
1. Refer to “Servicing the Drive Components”, Step 1 to
pinion of the packing gland is smaller in diameter.
remove the dust cover (page 12).
2. Remove the retaining ring (4) with a screwdriver or

pliers.
3. Remove the two retaining spring screws (1) with a

standard screwdriver. Note: For M-15, M-25, M-30,
and M-40 models loosen the single set screw.
4. Remove the retaining spring (2).
5. Remove the drive shaft (3) mounted with the adjuster

drive gear assembly including (4) Retaining Ring and
(5) Adjuster Drive Gear.
6. Remove the adjuster drive gear (5) and turn it 180° so

that it is upside down from the original installation
position. The bushing (7) supports the adjuster drive
gear in the lower position. The retaining ring (4)
supports the adjuster drive gear in the upper position.
Packing Gland
9
Setting the S
Sttandard Adjuster
NOTE: These instructions apply to meters equipped with

mechanical output accessories only. If your meter is
equipped with an electrical output (i.e., electronic pulser)
refer to your accessory manual, such as the Pulser Manual
supplied in your owner’s information packet.

2. Check meter registration by delivering product to a

reliable, accurate prover. Perform multiple delivery tests
to verify the meter repeatability.
3. Record the setting indicated on the adjuster:
4. Note the difference between the volume of the prover

and the volume indicated on the meter counter.
Calculate the % correction required, as follows:
Volume in prover - volume on meter counter

% correction = X 100
volume in prover
5. Loosen the adjuster clamp screw.
6. When the prover volume is less than the meter counter

volume, add the percentage to the original adjuster
setting by turning the thimble towards the arrow marked
larger (volume). Correct the original setting by
approaching the number desired from the next larger
number. For example, if the desired adjuster setting
is 2.4, turn the adjuster thimble to the left to number
5, then to the right to obtain the 2.4 setting. Adjuster
is currently set at 2.3 in the illustration to the right.
7. When the prover volume is more than the meter

counter volume, subtract the percentage from the
original adjuster setting by turning the thimble in the
direction of the arrow marked smaller volume percent.
8. Retighten the adjuster clamp screw. Run product

through the meter to allow the adjuster to take a set.
Then make several prover runs to check for accuracy
Meter Maintenance and Seasonal meter storage If the meter is used for seasonal
work, at the end of each season the meter should be
repeat ability
ability..
repeatability removed from the system and thoroughly flushed with a
Prevent pipe strain or stress from occurring when making compatible liquid. This includes removing the drain on the
meter or accessory repairs. Pipe strain and stress occurs front and rear covers. Then flush the product from the front
when the pipes are not supported or are not aligned and rear covers. If flushing with water is preferred, extra
correctly to the meter. The weight of the pipes must always care should be taken to drain the meter completely and
be supported independent of the meter. This means that dry all internal parts. Immediate refilling with a compatible
the meter and accessories can be easily removed without liquid (or oil misting) is essential to prevent corrosion as
affecting the pipes or the pipe alignment. Never leave any well as ice damage to parts from moisture that was
of the pipes hanging. overlooked after flushing and drying.
10
Meter Maintenance
Do not mar or scratch any of the precision machined appear evenly placed. If the bolts are bent, check the
surfaces by prying or sanding parts. housing and cover for flatness. Use a straight edge to
determine flatness.
Torque all fasteners such as screws and bolts in
accordance with specifications listed in the ‘Torque Chart’ Look for gap
gaps s when disassembling a meter. Use a feeler
in this manual (page 22). gauge to check for gaps between the bearing plate and
housing. If you do find gaps, check the bearing plates for
Stone the machined surfaces when reassembling the flatness with a straight edge. Gaps can be caused by
meter to assure that the machined surfaces are free of shock problems that must be resolved. Contact your full-
burrs and mars. service distributor for assistance if this occurs.
Repair pulled threads with threaded insert fasteners. Check the O-rings for damage. Cracked, rough, or worn
These can be used in many instances. Contact your full- O-rings should be replaced. However, a more serious
service distributor for advice if this occurs. problem of shock may be indicated if the O-rings look
nibbled. Shock problems must be verified and resolved.
Coat threads with anti-seize when removing and replacing Contact your full-service distributor for assistance if this
bolts and castings in a meter. occurs.
Removing flange gaskets When removing the flange Check the bearing plates for flatness. Use a straight
assembly, always carefully scrape off the flange gaskets. edge. Warped bearing plates can be caused by shock
Make sure that the flange surface has been scraped clean. problems that must be resolved. Contact your full-service
Discard the old flange gasket and install a new flange distributor for assistance if this occurs.
gasket. Never reuse old flange gaskets.
Check with regulatory agency that governs Weights &
Examine all fasteners to make sure they are not bent, Measures in your area. Removing the dust cover seal
rusted, or have pulled threads. The threads should all wire or other maintenance procedures may require Weights
& Measures recalibration.
! WARNING
WARNING
Relieving Internal Pressure

All internal pressure must be relieved to zero pressure
before disassembly or inspection of the strainer, air eliminator any valves in the system,
the packing gland, and the front or rear covers.
Serious injury or death from fire or explosion could result from maintenance of an
WARNING
improperly depressurized and evacuated system.
Procedure for Non-LPG Meters 4. Slowly open the valve/nozzle at the end of the supply
1. Turn off pump pressure to the system. line.
2. Close valves before and after the meter. 5. After product has bled off, close the valve/nozzle at
3. Remove pressure by removing the drain plugs and the end of the supply line.
draining the meter. 6. Slowly crack the fitting on top of the differential valve
to relieve product pressure in the system. Product
Procedure for LPG Meters will drain from the meter system.
1. Close the belly valve of the supply tank. 7. As product is bleeding from the differential valve, slowly
2. Close the valve on the vapor return line. reopen and close the valve/nozzle on the discharge
3. Close the manual valve in the supply line on the inlet line. Repeat this step until the product stops draining
side of the meter. If no manual valve exists on the from the differential valve and discharge line valve/
inlet side, consult the truck manufacturer for nozzle.
procedures to depressurize the system. 8. Leave the discharge line valve/nozzle open while
working on the system.
11
Servicing the Drive Component
Componentss
Removing the Dust Cover
1. Cut the dust cover seal wire with a side cutters.
Remove the dust cover screws with a 5/16’ wrench or
slotted screwdriver and then remove the dust cover.
See “Relieving Internal Pressure” and “Regulatory
Agency” in the ‘Meter Maintenance’ section (page
11) of this manual.
Removing the Adjuster and Adjuster Drive Assembly
1. Record the adjuster micrometer setting.
2. Carefully note the adjuster drive gear position. The

gear engages the packing gland pinion from below or
above. This gear must be reinstalled in its original
position or the meter counter will run backwards.
12
Componentss
3. Use a standard screwdriver to loosen (or remove) the

two retaining spring screws.
4. Swing the retaining spring off the adjuster drive bushing.
5. Loosen the adjuster mounting clamp screw with a

phillips head screwdriver.
Removing the adjuster from the top of the meter when top
access is easiest. Front access instructions are on the
next page.
6. Remove screws that secure adjuster mounting plate

to counter adapter.
7. Lift adjuster mounting bracket with adjuster out of the

counter adapter.
8. Remove the adjuster drive assembly from the housing.
13
Componentss
Removing the adjuster from the front of the meter when

front access is easiest. Top access instructions are on
the previous page.
10. Remove the slotted head screw that secures the

adjuster to the mounting plate.
11. Bring the adjuster out through the front of the meter
by rotating it from left to right to clear the adjuster
mounting plate and then pull down to remove from the
meter.
! WARNING
WARNING
disassembly or inspection of the strainer, air eliminator,
any valves in the system, the packing gland, and the
(page 11).
Servicing the Packing Gland

The packing gland is affected by the liquid being metered,
the operating temperature, and other system conditions.
After prolonged use, the gland may show leakage from
the metering chamber. This is a sign of wear. The gland
should be replaced or repaired if this occurs. It can be
serviced in the field.
1. Remove the two packing gland retaining plate screws

with a 5/16” socket and ratchet drive extension or
5/16” nut driver.
2. Pull out the packing gland.
3. Take apart the packing gland by gently prying off the

retaining ring with a standard screwdriver.
4. Pull the driver out from the assembly.
14
Buna/V iton/T
Buna/Viton/T eflon Packing Gland
iton/Teflon
Packing Gland Component

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

Retaining
The retaining plate has four holes: two that are drilled 1-1/
2” on center and two that are drilled 1-5/8” on center. If
your meter has a counter adapter dust cover (Item #0366)
shaped like the illustration shown below, use the holes
drilled 1- 5/8” on center to mount the packing gland retaining
plate.
If your meter does not have the counter adapter dust cover
shaped like the illustration shown on the right, use the two
holes drilled 1-1/2” on center to mount the packing gland
retaining plate.
Item 11 (above)
Adapter Dust Cover for holes

drilled 1-5/8” on center
15
Disassembling the Meter
Mechanical Output Meters*
! WARNING
WARNING
(page 11).
* For electrical output meters refer to the Pulser Manual

1. Remove the counter bracket screws with a box wrench

or socket driver. The counter bracket can be removed
with or without removing the adjuster assembly.
NOTE: For Aluminum M-30 and M-40 models the counter

bracket and front cover are one piece. Go to step 2.
2. Turn the meter on either the inlet or outlet side. Let it

stand to allow the product to drain from the meter
chamber.
3. Locate the drain plugs on the front and rear covers.

Remove the drain plugs using an allen wrench. Let the
meter stand to allow product to drain from the front
and rear covers.
16
4. Use a socket wrench or box end wrench to remove

the screws securing the front cover. Remove the
screws that hold the rear cover. The number of screws
will vary depending on meter size.
5. Remove the front and rear covers. MA-4, M-5, and

MA-5 old style models, M-60 and M-80 current
models have a driven reduction gear attached with a
shoulder bolt to the center of the front bearing plate.
6. Carefully remove the O-rings / flat gaskets from front

and rear of the housing. Undamaged Buna or Viton O-
rings may be reused. Flat gaskets and Teflon O-rings
should always be replaced and never reused.
7. Hold a spare displacement rotor gear between the right

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

Rotor gears are on the front.
8. Hold the spare gear between the left displacement

rotor gear and blocking rotor gear. Use the rotor gear
wrench or socket to remove the screw and the packing
gland driver held by the screw.
9. Hold the spare gear between the right displacement

rotor gear and the blocking rotor gear. Use the rotor
gear wrench or socket to remove the left displacement
rotor gear screw and washer.
17
Removing Non-Corroded Rotor Gears
1. Insert two standard screwdrivers behind the blocking
rotor gear: Gently pry the gear off its rotor tapered
end. If the gears show signs of corrosion, or do not
pry off easily, use the alternative method described in
steps 5-8.
2. Use the same method to remove the left rotor gear

and the right rotor gear. Remember, if the gear does
not pry off easily, or feels stuck, use the alternative
method described in steps 5-8.
3. As each gear comes off the rotor remove the key (1)
from the rotor keyway (2). Save the key to use when
reassembling the meter.
4. Use the bearing plate wrench to remove the screws

that hold the front bearing plate to the meter housing.
On the back of the meter housing, remove the screws
that hold the rear bearing plate to the housing. Go to
step 1, Removing the Bearing Plates.
Removing Corroded Rotor Gears

5. Replace all three rotor gear screws, without washers,
halfway onto each of the rotor ends.
6. On the back of the meter housing, remove the screws

that hold the rear bearing plate to the housing using
the bearing plate wrench or socket. The number of
screws varies with the size of meter.
18
7. With a plastic or non-metallic mallet, tap on the heads

of the screws lightly and equally. As you tap on the
screw heads, the gears are driven off the rotors. As
the rotors are driven in, the rear bearing plate and the
rotor assembly are pushed away from the housing.
NOTE
NOTE: For carbon insert bearing plates, remove the
rear plate first and then each rotor as it is hand
supported.
8. Use the bearing plate wrench or socket to remove the

screws that hold the front bearing plate to the meter
housing. The number of screws varies between different
meter sizes.
Removing the Bearing Plates

and Rotors
1. Insert a screwdriver into each of the two notches near
the dowel pins. Be careful not to mar any of the
surfaces. Gently pry the front bearing plate off the dowel
pins.
2. Remove the front bearing plate and rotor assembly by

pulling a rotor straight out from the housing. Be careful
not to mar any of the surfaces. MA-4, M-5, and MA-5
old style models, M-60 and M-80 current models:
Pull the rotor from the rear bearing plate. This will also
remove the drive reduction gear which is attached to
the blocking rotor.
3. Remove the remaining bearing plate from the other

side by inserting a screwdriver into each of the two
notches near the dowel pins. Be careful not to mar
any surfaces. Gently pry the front bearing plate off the
dowel pins. NOTE: MA-4, M-5, and MA-5 old style
models, M-60 and M-80 current models have a
driven reduction gear in attached with a shoulder bolt
to the center of the front bearing plate.
4. Inspect and clean all critical surfaces like gear teeth,

rotors and internal housing faces. Remove any
crystalline formations using fine emery cloth or a fine
wire brush. Be careful not to mar or alter the shape of
any of the parts. Changing the shape of the parts may
interfere with their operation. Remove nicks and burrs
on metal parts with a stone. Remove all grit and other
foreign particles. These may also damage parts and
interfere with proper operation. Replace all parts that
appear worn or damaged.
19
Reassembling the Meter
1. MA-4, M-5, and MA-5 old style models, M-60 and

M-80 current models: Rotor gears are on the rear
bearing plate. All other models: Rotor gears are on
the front bearing plate. Install the non-rotor gear bearing
plate using the bearing plate screws and wrench.
2. Insert the non-tapered ends on the three rotors into

the housing. Place each rotor into its respective bore
in the installed bearing plate. MA-4, M-5, and MA-5
Make sure that the teeth of the driving reduction gear
mesh with the teeth of the driven reduction gear.
3. Place the remaining bearing plate over the three tapered

rotor ends and fasten it with the bearing plate screws.
Use the bearing plate wrench. The number of screws
varies with meter size.
4. The rotors should have a small amount of end-play

and be easy to turn. Test each rotor, one at a time.
Turn the rotors to make sure that they revolve freely.
Jog the rotors from end to end to check for end-play.
If they do not move easily in both tests, remove the
rotors and check for burrs and corrosion deposits.
Clean them thoroughly.
Repeat Steps 2, 3 and 4.
5. The rotor key is a small wedge of metal. Each rotor

has a notch, or “keyway”, to hold a key. Position a
key into each one of the three rotors. Press the keys
into the rotor keyways with your thumb and forefinger.
6. Slide the blocking rotor gear on its tapered rotor end.

Slide the right displacement rotor gear on its tapered
rotor end so that the timing marks line up between the
two gears. See ‘Timing the Rotor Gears’ on the next
page. Hint: Before you place the right displacement
rotor gear on its tapered end, hold the right rotor gear
in position. Turn the blocking rotor gear. Try to line up
the timing marks before you place the right
displacement rotor gear on its tapered rotor end.
7. Position the left displacement rotor gear on its tapered

rotor end so that its timing mark lines up with the
blocking rotor gear. See ‘Timing the Rotor Gears’.
20
Timing the Rotor Gears
Rotor gears are timed by lining up the timing marks. The
blocking rotor gear has a tooth directly in front of its
timing mark. On the displacement rotor gears, the timing
mark falls in front of the space between two gear
teeth. Make sure that the tooth in front of the timing mark
on the blocking rotor gear connects with the space in
front of the timing mark on the displacement rotor gear.
You may need to remove the gears and reposition them
several times on their rotor ends in order to get the timing
marks to line up correctly. For more information, See
‘Troubleshooting’.
1. Position the spare displacement rotor gear between 7. Install the front drain plug (6) in the front drain plug
the left displacement rotor gear and the blocking rotor hole (7) using the drain plug allen wrench.
gear to prevent the gears from moving. Attach the right
displacement gear washer and screw using the rotor 8. Install an O-ring (8) into the groove (9) on the rear of
gear wrench. Tighten the screw to the torque the meter housing. The M-60 and M-80 models use
specification listed in the Torque Chart (page 22). a flat gasket.
2. Keep the spare displacement rotor gear positioned by 9. Fasten the rear cover (10) with the cover screws (11)
the left displacement rotor gear. Attach the left using the cover socket or open end/box end wrench.
displacement gear washer and screw using the rotor NOTE: 9A.
9A LC recommends tightening the rear cover
gear wrench. Tighten the screw to the torque screws in a criss-cross or “star” pattern with a minimum
specification listed in the Torque Chart. of two passes. First pass should be at half torque,
with final pass(es) at full torque. This will ensure
3. Position the spare displacement rotor gear between uniform seal compression on cover O-ring or gasket.
the right displacement rotor gear and the blocking rotor See M-7 pattern on page 22 reference.
gear. Attach the blocking rotor gear with the packing
gland driver and screw using the rotor gear wrench. 10. Install the rear drain plug (12) in the rear drain plug
Tighten the screw to the torque specification listed in hole (13) using the drain plug allen wrench.
the Torque Chart.
4. Rotate the gears to make sure that the rotors turn 11. If your meter is equipped with an electrical output
freely. Burrs, foreign material, or marred surfaces can accessory, such as a digital pulser, reinstall it according
restrict the rotor movements. It may be necessary to to the instructions outlined under ‘Reinstalling...’ in
remove the gears and rotors and deburr and clean the your accessory manual, such as the Pulser
surfaces again. Installation, Operation and Maintenance Manual
supplied in your owner’s information packet. Install
5. Install an O-ring (1) into the groove (2) on the front of the front drain plug (6) in the front drain plug hole (7)
the meter housing. The M-60 and M-80 models use a using the drain plug allen wrench.
flat gasket.
6. Fasten the front cover (3) with the cover screws (4)
using the cover socket or open end/box end wrench.
NOTE: 6A. LC recommends tightening the front cover
screws in a criss-cross or “star” pattern with a minimum
of two passes. First pass should be at half-torque,
uniform seal compression on cover O-ring or gasket.
See M-7 pattern on page 22 for reference.
Meter Assembly Exploded View
21
Torque Chart
TORQUE PATTERN M-7 COVERS
PA
Torque Chart
*Torque Tolerance is ± 10%
22
Wrench and Socket Size Chart
NOTE: FOR ROTOR GEAR SCREWS
Please apply these techniques when repairing meters in the field.
1. Prior to installation, apply a small amount of Locquic Primer N764 to each screw.
2. Apply a light coat of Loctite 242 in three even strokes to each screw. The Loctite and Locquic primer are not
to be applied to the female connection in the rotor.
23
Troubleshooting
! WARNING
WARNING
All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in the
system, the packing gland, and the front or rear covers. See “Relieving Internal Pressure” (page 11).
PROBLEM:
Leakage past packing gland drive shaft housing from internal metering chamber.
PROBABLE CAUSE AND SOLUTION:

Internal seal of packing gland assembly is worn. Replace packing gland and O-ring seal.
OPERATING NOTE:
OPERATING
Two common causes of packing gland leakage are thermal expansion and hydraulic shock. If two valves in a
piping system (on either side of the meter) are closed at one time, and if the temperature rises as little as 1°F in
the system, it could result in a rise in pressure within the system that would exceed the working pressure rating
of the meter. To avoid this hazard caused by thermal expansion, a pressure-relief valve of some kind must be
installed in the system. Hydraulic shock occurs when a large volume (mass) of liquid is moving through a pipe line
at some flow rate and a valve is suddenly closed. When the flow is stopped, the entire mass of the liquid in the
piping system acts as a battering ram causing a shock effect within the meter. The greater the mass length of line
and/or velocity, the greater the hydraulic shock. Since the valve is usually located at the meter outlet, the meter
housing, packing gland and the meter internal members receive the full impact of such hydraulic shock. To prevent
this hazard a slow closing two-stage valve should be used with the meter. On those systems where mass length
of line, etc. are of such magnitude as to preclude the elimination of hydraulic shock with the use of a two-stage
slow closing valve, an impact-absorbing air cushioning device should be used.
PROBLEM:
Leakage from the cover gasket.

Gasket has been damaged due to shock pressure or cover bolts have not been tightened sufficiently.
PROBLEM:
Product flows through meter but the register does not operate.

A. Check packing gland, and gear train.
B. If all meter parts are moving then problem is in register. Faulty register should be checked and repaired by
trained mechanic.
C. Remove register from meter. If all meter parts are moving but output shaft of adjuster assembly is not, adjuster
is worn and must be replaced.
D. If totalizer numerals (small numbers) on register are recording, but the big numerals are not moving, register
needs repair.
E. Packing gland gear not turning. For M-60 and M-80 meters, the drive blade may be sheared. Replace the
packing gland. This may be caused by starting the flow too rapidly.
24
Troubleshooting
PROBLEM:
Breaking teeth on timing gears.

A. Starting or stopping flow in meter too rapidly.
B. Pump bypass not adjusted properly.
PROBLEM:
Product flows through meter but register does not record correctly.

A. Adjuster not properly calibrated.
B. Incorrect gear plate or gear ratio has been installed.
C. Air is in the system.
PROBLEM:
No flow through meter.

A. Faulty non-functioning pump.
B. Valve not open or not functioning.
C. Meter “frozen” due to build-up of chemical “salts” or foreign material inside metering chamber. To correct,
clean the meter and inspect for damage.
PROBLEM:
Meter runs too slowly.

A. Valve internal mechanism faulty. Valve does not open fully.
B. Meter gears or rotors partially “salted” enough to slow up rotation of parts. To correct, clean the meter.
C. Downstream restriction.
D. Clogged strainer basket.
PROBLEM:
The meter counts down in reverse (the meter numbers decrease).

It is necessary to reverse the direction of flow by reversing the adjuster drive gear. See ‘M-7/MA-7 Meter Start Up
and Operation: Reversing the Meter Registration’ in this manual.
25
How to Order Replacement Parts
Parts
1. Refer to the exploded view drawings on Pages 27-31. The Bills of Material for most meter classes are on
Find the four digit item number for the part you want to the LC public website. Always check the website for
order. The item numbers are listed on the exploded the most current BOM.
drawings.
2. Find the computer printout titled Parts List that has

been inserted in the Owner’s Information Packet which
was shipped with your order. Look up the item number
on the Parts List. The Parts List shows each item
number with a corresponding part number. Find the
corresponding five digit part number for the item you
want to order. The part number represents an individual
piece, a kit, or a complete assembly.
3. Inform your distributor of the part number that you need.

The part number is the only number that allows the
distributor to find the correct component for your meter.
26
Illustrated Part
Partss Breakdown
M5 through M25 Meters (including MA Meters)
NOTE
NOTE: Numbers shown are ITEM numbers, not Part Numbers. Refer to the Bill of Materials supplied in the red Owner’s
Information Packet to locate the PART NUMBER associated with these ITEM NUMBERS
ART NUMBERS.
NOTE
NOTE: Meter components may appear different between models.
27
Illustrated Part
Partss Breakdown
M30, M40 Meters
NOTE
ART NUMBERS.
NOTE
28
Illustrated Part
Partss Breakdown
M60, M80 Meter Cover
NOTE
ART NUMBERS.
NOTE
29
Illustrated Part
Partss Breakdown
M60, M80 Meter Element
NOTE
ART NUMBERS.
NOTE
30
Quality S
Sttatement
At Liquid Controls, we are dedicated to being the world leader in the field of liquid measurement.
Everyone associated with the enterprise must be committed to our quality effort and pursuing perfection.
To gain satisfaction in the eyes of our customers, we must accurately define and fulfill the customers’ present and
continuing needs.
We will strive to minimize the users’ cost by providing products of high reliability, maintainability, serviceability, and no of
no planned obsolescence, which combine to give the customer superior value.
Our people are our greatest resource. We will create a positive, team-oriented environment which every person has trust
and respect for one another, is recognized for achievement, and motivated toward excellence.
Absolute accountability for our efforts is determined by significant measures: our customers’ level of satisfaction, the
development of our people, and our contribution to the community.
Our goal is to be Simply the Best

Best.
31
A Unit of IDEX Corporation
105 Albrecht Drive
Lake Bluff, IL 60044-2242
1.800.458.5262 • 847.295.1050 © 2004 Liquid Controls
Fax: 847.295.1057 Pub. No. 48683
www.lcmeter.com (05/04)
PARTS MANUAL
LIQUID
® ® ® CONTROLS
M-7, MA-7, M-10 Meters A Unit of IDEX Corporation
Exploded View: M-7/MA-7/M-10 Meter Covers
CAUTION
T
SHA F LO
T WITH S E
AL RIV
IGN COUNTER D
0
2
1 0202 Adjuster
6
0
1
2 4
5 assembly
3
0609 Screw, mounting

plate (2)
0364 Plate, adjuster mounting
0613 Screw, adjuster 0126 Bracket, counter adapter
0366 Plate, 0382 Shaft,

dust cover adjuster
0336 Gear
0574 Ring,
retaining
LIQUID
CONTRO
LAKE BL LS CO
UFF, IL, RP.
MODEL USA
NO.
SERIAL
NO.
®
VOL/REV
ACCURA
CY
TEMP ER
FLOW ATURE
RATE
MAX PRES
PRODUC SURE
T
UK81
1783
0165 Gear,
packing gland
0250 Packing 0705 Washer,
Gland Assy. flat (4)
0673 Screw (4)
0780 Seal
wire
Driveshaft bushing (2)
0630 Screw (2)
0603 Screw (2)
How to Order
Replacement Parts 0566 Plug,
pipe-hex socket
(2, one for each cover)
1. Find the item number listed on the exploded
drawing. The 4 digit item numbers are listed
with a word description. 0125 Cover, rear
2. Find the computer printout titled Parts List that
has been inserted in this manual. Look up the item 0627 Hex washer head screw
number on the Parts List. The Parts List shows each (20, for both covers)
item number with a corresponding part number.

Find the corresponding 5 digit part number for the
item you want to order. The part number represents
an individual piece, a kit or a complete assembly.
3. Inform your distributor of the part number that you
need. The part number is the only number that
allows the distributor to find the correct component
for your meter.
When placing order for replacement parts please
reference the meter's serial number.
®
Front cover Rear cover

0570 Pipe plug (optional)
0153 Rotor, blocking

0611 Screw, hex head
w/lockwasher (64 per plate)
0528 Key (3)
0161 Gear, (1 per rotor)
blocking rotor
0326 Driver,
packing gland
*0675 Screw,
cap socket head .
CORP
ROLS A
CONT US
LIQUID BLUFF, IL,
LAKE L NO.
MODE
NO.
SERIAL
0765 Washer, Lock
0673 Screw, 0318 Pin, dowel (4)

0163 Gear,
hex washer head (2)
displacement pinion (2) 0372 Plate, serial number
0771 Bellevue washer, 0144 Plate, bearing (2) 0155 Rotor, displacement (2)
0110 Housing
rotor gear (2)
0430 O-Ring (2)

Exploded View: M-7/MA-7/M-10 Meter Housing
*For M-10 Meter Blocking Rotor,

#0672 Shown HereReplaces #0675
0672 Screw, blocking rotor
SOLD AND SERVICED BY
A NETWORK OF HIGHLY TRAINED
FULL SERVICE DISTRIBUTORS
Backed By Our Worldwide Reputation For

Quality, Accuracy and Advanced Design.
WARRANTY: charge, ex-works factory. In no event shall Seller be liable of installation, start-up and servicing of Electronic Products
Liquid Controls (“Seller”) products are warranted against for any special, consequential, incidental, indirect or by Seller trained service representatives, this warranty is
defects in material or workmanship for a period of one (1) exemplary damages arising out of warranty, contract, tort null and void. Seller’s obligations as set forth above shall
year from date of installation, provided that the (including negligence) or otherwise, including but not lim- not apply to any product, or, or any component or part
warranty shall not extend beyond twenty-four (24) months ited to, loss of profit or revenue, loss of use of the product or thereof, which is not properly installed, used, maintained
from the date of original shipment from Seller. Seller’s any associated products and/orequipment, cost of substitute or repaired, or which is modified other than pursuant to
obligations, set forth below, shall apply only to failure(s) to goods or services, downtime costs or claims of or by Seller’s instructions or approval. NOTE: The above
meet the foregoing obligations provided that Seller is given Purchaser’s clients or customers. In any event, the total warranty applies only to products manufactured by Liquid
written notice within thirty (30) days of any occurrence liability of Seller for any and all claims arising out of or Controls, Lake Bluff, Illinois. Private label, OEM, and/or
from which a claim of defect arises. If a warranty dispute resulting from the performance, non-performance or use of products manufactured by Liquid Controls licensee(s) are
occurs, the Purchaser shall be required to provide Seller the product shall not exceed the purchase price of the indi- specifically excluded from the above warranty. Consult
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In the event that a factory inspection by Seller or its implied, whether arising under any statute, common law, OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
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A Unit of IDEX Corporation Distributed By:
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© 2001 Liquid Controls Printed in U.S.A.(03/01) Bulletin #48496B $1

VALUE 90 11/2"
AUTOMATIC BULK FUELING NOZZLE
Catlow’s Value 90 Nozzle is an extra heavy duty, high flow, bulk fueling nozzle for marine, truck and bus or home fuel
oil delivery.
The Value 90 has been designed for durability and yet economically priced. This rebuildable nozzle comes complete
with automatic venturi shut-off and a dual position, hold-open mechanism.
Features:
• Curved lever design for easier gripping
• Dual Poppet Assembly makes nozzle easier to open against high inlet pressure
• Dash Pot minimizes line shock
• Dual position hold-open mechanism for user friendly operation
• BSPP and BSPT threads available upon request
Benefits:
• Strong body casting resists cracking
• Venturi type automatic shut-off prevents accidental spillage
• Spout assembly easily replaced
• Nozzle design allows easy access to awkward fueling
positions
• Lighter in weight
Materials:
• Body.......Aluminum
• Weight....5.3 lbs.
• Inlet........11/2" NPT
• Spout.....Aluminum 1 3/8" OD
• Seals......Viton and Buna
Ordering Specifications:
• CV90-001 11/2" Bulk Fueling Nozzle, New
• CV90-002 11/2" Bulk Fueling Nozzle, New (ULC)
• RV90 11/2" Bulk Fueling Nozzle, Rebuilt
Accessories:
• V90S Replacement spout assembly
• V90SW 1 1/2" x 1 1/2" Swivel
CATLOW Inc. Sales Desk (800) 222-8569

Sales Fax (937) 898-8631 Phone (937) 898-3236
2750 US RT 40, Tipp City, OH 45371
© 2006 CATLOW Inc. All Rights Reserved CV900306
BLACKMER TRUCK PUMPS 960280
INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS INSTRUCTIONS NO. 201-A00
Page 1 of 12
MODELS: TX, TXS, TXD, TXSD 1.5, 2A, 2.5A, 3E, 4A Section 200
TXV 2.5B, 3B Effective March 2003
Replaces June 2001
and Discontinued TX(S) 2, 21/2, 3; TXV 2(A)(B), 21/2(A), 3(A) Models
SAFETY DATA
This is a SAFETY ALERT SYMBOL.

When you see this symbol on the product, or in the manual, look for
one of the following signal words and be alert to the potential for
personal injury, death or major proper ty damage.
Warns of hazards that WILL cause serious personal injury,

death or major proper ty damage.
TABLE OF CONTENTS Page
SAFETY DATA .................................................................1-2 Warns of hazards that CAN cause serious personal injury,
PUMP DATA .........................................................................2 death or major property damage.
Technical Data.......................................................2
Initial Start Up Information .....................................2
Warns of hazards that CAN cause personal injury
INSTALLATION ...............................................................2-3 or property damage.
Pre-Installation Cleaning .......................................2
Location and Piping...............................................2 NOTICE:
Truck Mounting......................................................3 Indicates special instructions which are very
Pump Drive............................................................3 impor tant and must be followed.
Pump Rotation.......................................................3
To Change Pump Rotation ....................................3
OPERATION .....................................................................4-5
NOTICE:
Pre-Start Up Check List.........................................4
Blackmer truck pumps MUST only be installed in
Start Up Procedures ..............................................4
systems which have been designed by qualified
Pump Speed..........................................................4 engineering personnel. The system MUST conform to
Reverse Rotation...................................................4 all applicable local and national regulations and safety
Flushing the Pump ................................................4 standards.
Relief Valve ...........................................................4
Relief Valve Setting and Adjustment .....................5 This manual is intended to assist in the installation
and operation of the Blackmer truck pumps, and
MAINTENANCE ...............................................................5-8 MUST be kept with the pump.
Lubrication.............................................................5
Vane Replacement ................................................5 Blackmer truck pump service shall be performed by
Pump Disassembly................................................6 qualified technicians ONLY. Service shall conform to
Pump Assembly ....................................................6 all applicable local and national regulations and safety
standards.
GENERAL PUMP TROUBLESHOOTING .................9-10
Thoroughly review this manual, all instructions and
hazard warnings, BEFORE performing any work on
the Blackmer truck pumps.
NOTE: Numbers in parentheses following individual
parts indicate reference numbers on the Maintain ALL system and Blackmer truck pump
operation and hazard warning decals.
corresponding Blackmer Parts Lists.
SAFETY DATA
FAILURE TO SET THE VEHICLE DISCONNECTING FLUID OR
EMERGENCY BRAKE AND CHOCK PRESSURE CONTAINMENT
WHEELS BEFORE PERFORMING COMPONENTS DURING PUMP
SERVICE CAN CAUSE SEVERE OPERATION CAN CAUSE SERIOUS
Hazardous machinery Hazardous pressure PERSONAL INJURY, DEATH OR MAJOR
can cause severe PERSONAL INJURY OR PROPERTY can cause
personal injury or personal injury or PROPERTY DAMAGE.
property damage. DAMAGE. property damage.
FAILURE TO RELIEVE SYSTEM IF PUMPING HAZARDOUS FLUIDS

PRESSURE PRIOR TO PERFORMING SYSTEM MUST BE FLUSHED PRIOR
PUMP SERVICE OR MAINTENANCE TO PERFORMING SERVICE.
CAN CAUSE PERSONAL INJURY OR
Hazardous pressure
can cause PROPERTY DAMAGE. Hazardous or toxic
personal injury or fluids can cause
property damage. serious injury.
PUMP DATA
TECHNICAL DATA INITIAL START UP INFORMATION
TX(S)(D) TXV
Models Models Model No.
Maximum Temperature* 300oF (149oC) 375oF (190oC)
Serial No.
Maximum Pump Speed 640 RPM1
Maximum Viscosity* 50,000 SSU (10,800 cSt) Date of Installation:

Maximum Differential Pressure 125 psi (8.6 bar)
Pressure Gauge Reading:
Maximum Working Pressure 175 psi (12.1 bar)
(Inlet Pressure + Differential Pressure)
Vacuum Gauge Reading:
* Optional materials of construction may be required to meet the
operating limits listed above. Refer to Blackmer Material Specs Flow Rate:
201/91-92 for TX(S)(D) models or 202/91-92 for TXV models.
1 780 RPM maximum pump speed for TX(S)(D)1.5, 2 and 2.5 models.
500 RPM maximum pump speed for TX4A pump models.
INSTALLATION
NOTICE: PRE-INSTALLATION CLEANING
BLACKMER TRUCK PUMPS MUST ONLY BE Foreign matter entering the pump WILL cause extensive
INSTALLED IN SYSTEMS DESIGNED BY QUALIFIED damage. The supply tank and intake piping MUST be cleaned
ENGINEERING PERSONNEL. SYSTEM DESIGN MUST and flushed prior to pump installation and operation.
CONFORM WITH ALL APPLICABLE REGULATIONS
AND CODES AND PROVIDE WARNING OF ALL LOCATION AND PIPING
SYSTEM HAZARDS. An improperly designed piping system or unit installation WILL
significantly reduce pump performance and life. Blackmer
recommends the following piping system layout and unit
FAILURE TO SET THE VEHICLE installation.
EMERGENCY BRAKE AND CHOCK 1. To minimize intake losses, locate the pump as close as
WHEELS BEFORE PERFORMING possible to the source of supply.
SERVICE CAN CAUSE SEVERE 2. Piping MUST be properly supported to prevent any piping
Hazardous machinery
PERSONAL INJURY OR PROPERTY loads from being placed on the pump.
can cause severe
personal injury or
property damage. DAMAGE. 3. Intake piping and fittings MUST be at least as large in
diameter as the pump intake connection.
2
INSTALLATION
4. Minimize the number of intake line fittings (valves, elbows, long as the pump is shimmed to have its shaft parallel in all
etc.) and piping turns or bends. respects to the PTO shaft.
5. Temporarily install vacuum and pressure gauges in the 1/4" 5. The yokes of the universals at both ends of the jack shaft
NPT intake and discharge ports located on the pump must be parallel and in phase.
cylinder to check pump performance at start-up. 6. The maximum recommended angle between the jack shaft
and the pump shaft is 15 degrees. Refer to Table 1.
6. Install a strainer in the inlet line to protect the pump from
foreign matter. Placement of intake strainers should
Failure to follow any of these guidelines may result in a gallop
facilitate frequent cleaning.
or uneven turning of the pump rotor, which will in turn cause a
7. Intake and discharge piping MUST be free of all leaks. surging vibration to the liquid stream and piping system.
Contact the supplier of the drive line components for specific
TRUCK MOUNTING design assistance.
The pump will operate satisfactorily in any position. Consult

Blackmer factory for vertical shaft mounts. The pump can be Hydraulic Drive
bolted to the truck frame or on a saddle hung below the frame, The pump may also be driven hydraulically. Hydraulic motors
and MUST be adequately supported. Mounting the pump with must be well supported with their shafts parallel to the pump
the cylinder feet down, or with the intake port up, is shaft in all respects. Blackmer provides an optional close-
recommended for thorough draining of the pump. coupled hydraulic motor adapter. The adapter provides for
straight alignment of a hydraulic motor drive through a solid
coupling connected to a straight key pump shaft. This
PUMP DRIVE
coupling connection requires grease lubrication every three
The pump may be driven by a power take-off through universal months at minimum. Refer to the "Lubrication" section of this
joints. When using universal joints, a splined slip joint, manual.
properly lubricated, must be used on the connecting jack shaft
to prevent end thrust on the pump shaft. PUMP ROTATION
It is very important to install a proper drive line to avoid NOTICE:
excessive wear, vibration and noise (see Fig. 1 and Table 1). CONFIRM CORRECT PUMP ROTATION BY CHECKING
THE PUMP ROTATION ARROWS RESPECTIVE TO PUMP
DRIVER ROTATION.
TO CHANGE PUMP ROTATION

TX(S)D and TXV Models
The TX(S)D and TXV pump models are equipped with a
double ended rotor and shaft, enabling them to be driven from
either shaft end. To change rotation, rotate the pump 180
degrees so that the opposite shaft becomes the driven shaft.
(Yokes must be in phase) On TX(S)D pump models, the shaft protector (186) MUST be
mounted over the non-driven shaft end. On TXV pump
Figure 1 - Pump Drive models, the outboard bearing cover (27) MUST be mounted
over the non-driven shaft end.
Angle of Drive Shaft OPERATION WITHOUT SHAFT

PROTECTOR CAN CAUSE SERIOUS
1o through 5o 6o through 10o 11o through 15o
PERSONAL INJURY, MAJOR
Very Good Good Fair
PROPERTY DAMAGE, OR DEATH.
Table 1 Do not operate
without guard
in place.
General guidelines to follow for proper pump drive:
1. Do not use square slip joints. TX1.5, TX4 Models and Discontinued TX(S) Models
2. Use the least number of jack shafts as is practical. To reverse the pump rotation, remove the bearing covers,
3. Use an even number of universal joints. locknuts/lockwashers or lock collars (if equipped), from both
4. The pump shaft and power take-off shaft should be parallel inboard and outboard heads. Remove the inboard head
in all respects. Use an angular level measuring device to assembly and reverse the rotor and shaft, so that the driven
ensure the PTO and pump shaft are parallel to each other. end of the shaft protrudes from the outboard head. Remove
If necessary, the pump can be shimmed to correct any and replace the vanes so that the relief grooves face in the
misalignment. The PTO shaft coming off at the direction of pump rotation. Refer to the "Maintenance" Section
transmission does not need to be perfectly horizontal as of this manual for pump disassembly and assembly.
3
OPERATION
PRE-START UP CHECK LIST REVERSE ROTATION
1. Check the alignment of the pipes to the pump. Pipes must
NOTICE:
be supported so that they do not spring away or drop down
when the pump flanges or union joints are disconnected. PUMPS OPERATED IN REVERSE MUST HAVE A
SEPARATE PRESSURE RELIEF VALVE INSTALLED TO
2. Temporarily install vacuum and pressure gauges in the 1/4" PROTECT THE PUMP FROM EXCESSIVE PRESSURE.
NPT ports located on the pump cylinder. These can be
used to check the actual suction and discharge conditions It may be desirable to run the pump in reverse rotation for
after pump start-up. system maintenance. The pump will operate satisfactorily in
reverse rotation to strip lines, at a reduced performance level.
3. Inspect complete piping system to ensure that no piping
When operating the pump in reverse, a separate bypass valve
loads are being placed on the pump.
MUST be installed to protect the pump from excessive
4. Secure appropriate hose connections. pressure.
START UP PROCEDURES FLUSHING THE PUMP
NOTICE:
PUMP OPERATING AGAINST A IF FLUSHING FLUID IS TO BE LEFT IN THE PUMP FOR
CLOSED VALVE CAN CAUSE AN EXTENDED TIME, IT MUST BE A LUBRICATING,
NON-CORROSIVE FLUID. IF A CORROSIVE, NON-
SYSTEM COMPONENT FAILURE,
LUBRICATING FLUID IS USED, IT MUST BE FLUSHED
PERSONAL INJURY AND PROPERTY
Hazardous pressure
FROM THE PUMP IMMEDIATELY.
can cause DAMAGE.
personal injury or
property damage.
To flush the pump, use the following procedure:
1. Allow the pump to evacuate as much fluid as possible.

2. Run cleaning fluid through the pump intake. The cleaning
NOTICE:
fluid must be compatible with the pump O-rings and vane
CONSULT THE "GENERAL PUMP TROUBLESHOOTING" material. When handling "sticky" fluids that solidify within
SECTION OF THIS MANUAL IF DIFFICULTIES DURING the pump (i.e., waxes, adhesives, resins, asphalts, etc.),
START UP ARE EXPERIENCED. use a fluid that will prevent solidification of the fluid being
transferred and facilitate flushing.
1. Start the pump. Priming should occur within one minute. 3. Operate the pump against a closed discharge for 15
seconds to allow the cleaning fluid to recirculate through
2. Check the vacuum and pressure gauges to ensure the
the internal relief valve.
system is operating within expected parameters. Record
the gauge readings in the "Initial Start Up Information"
section of this manual for future reference. RELIEF VALVE
3. Inspect piping, fittings, and associated system equipment NOTICE:
for leaks, noise, vibration and overheating. THE PUMP INTERNAL RELIEF VALVE IS DESIGNED TO
4. Check the flow rate to ensure the pump is operating within PROTECT THE PUMP FROM EXCESSIVE PRESSURE
the expected parameters. AND MUST NOT BE USED AS A SYSTEM PRESSURE
CONTROL VALVE.
5. Check the pressure setting of the relief valve by
momentarily closing a valve in the discharge line and Pumping volatile liquids under suction lift may cause
reading the pressure gauge. This pressure should be 15 - cavitation. Partial closing of the discharge valve WILL result in
20 psi (1.0 - 1.4 bar) higher than the maximum system internal relief valve chatter and must not be done. For these
operating pressure, or the external bypass valve setting (if applications, install an external bypass valve, and any
equipped). DO NOT operate the pump against a closed necessary piping, back to the storage tank. This bypass
discharge valve for more than 15 seconds. If system must be used when operating for extended periods
adjustments need to be made, refer to the "Relief Valve (more than 1 minute) against a closed discharge valve.
Setting and Adjustment" section of this manual.
PUMP SPEED RELIEF VALVE SETTING AND ADJUSTMENT

PTO and hydraulically driven units MUST contain speed The relief valve pressure setting is marked on a metal tag
control devices to prevent pump speeds above the maximum attached to the valve cover. Generally, the relief valve should
RPM specifications, regardless of the truck engine unloading be set at least 15 - 20 psi (1.0 - 1.4 bar) higher than the
speeds. Should fluid delivery be appreciably less than operating pressure, or the external bypass valve setting (if
expected, see the "General Pump Troubleshooting" section. equipped).
4
OPERATION
Relief Valve Adjustment Procedure: NOTICE:
1. To INCREASE the pressure setting , remove the relief WHERE REGULATIONS REQUIRE, HOLES IN R/V CAP (1) AND
valve cap, loosen the locknut, and turn the adjusting screw CAPSCREW W / HOLE (5C) ARE USED BY THE WEIGHTS AND
inward, or clockwise. Replace the valve cap. MEASURES OFFICIAL (S) TO APPLY A SECURITY SEAL OR TAG.
2. To DECREASE the pressure setting, remove the relief
valve cap, loosen the locknut, and turn the adjusting screw
outward, or counterclockwise. Replace the valve cap. INCORRECT SETTINGS OF THE
PRESSURE RELIEF VALVE CAN
Refer to the individual Blackmer pump parts lists for various
spring pressure ranges. The pumps are supplied from the CAUSE SYSTEM COMPONENT
factory with the relief valve adjusted to the mid-point of the FAILURE, PERSONAL INJURY AND
spring range. If the pump is equipped with a Blackmer air Hazardous pressure
can cause PROPERTY DAMAGE.
valve, refer to setting and adjustment procedures covered in personal injury or
property damage.
Blackmer Air Valve Instructions and Parts List No. 201-F00,
286/F or 201-B00.
MAINTENANCE
NOTICE: LUBRICATION
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED Ball bearings and hydraulic motor couplings (if equipped) must
TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE be lubricated every three months at a minimum. More frequent
PROCEDURES AND WARNINGS AS PRESENTED IN lubrication may be required, depending on the application and
the operating conditions. TXV pump model bearings MUST
THIS MANUAL.
be replaced after each 1000 hours of service if fluid
temperature is greater than 250oF (120oC).
FAILURE TO SET THE VEHICLE
Recommended Grease:
EMERGENCY BRAKE AND CHOCK
WHEELS BEFORE PERFORMING TX(S)(D) Models - Exxon (Esso) - Ronex MP or Mobile -
Mobilith AW-2, or equivalent Lithium grease.
SERVICE CAN CAUSE SEVERE
Hazardous machinery TXV Models - Exxon (Esso) - Polyres or Mobile - Mobile Poly
can cause severe PERSONAL INJURY OR PROPERTY
372, or equivalent Polyurea grease.
personal injury or
property damage. DAMAGE.
Greasing Procedure:
1. Remove the grease relief fittings (76A) from the bearing
FAILURE TO RELIEVE SYSTEM covers (27 and 27A) or hydraulic motor adapter (135).
PRESSURE PRIOR TO PERFORMING 2. SLOWLY apply grease with a hand gun until grease begins
PUMP SERVICE OR MAINTENANCE to escape from the grease relief fitting port. Discard
excess grease in accordance with the proper codes and
regulations.
Hazardous pressure PROPERTY DAMAGE.
can cause 3. Replace the grease relief fittings (76A).
personal injury or
property damage.
DO NOT overgrease pump bearings. While it is normal for
some grease to escape from the grease tell-tale hole after
DISCONNECTING FLUID OR lubrication, excessive grease on pumps equipped with
PRESSURE CONTAINMENT mechanical seals can cause seal failure.
COMPONENTS DURING PUMP

OPERATION CAN CAUSE SERIOUS VANE REPLACEMENT
PERSONAL INJURY, DEATH OR MAJOR
Hazardous pressure
can cause
NOTICE:
personal injury or PROPERTY DAMAGE. MAINTENANCE SHALL BE PERFORMED BY QUALIFIED
property damage.
TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE
PROCEDURES AND WARNINGS AS PRESENTED IN
IF PUMPING HAZARDOUS FLUIDS THIS MANUAL.
SYSTEM MUST BE FLUSHED PRIOR 1. Remove the head assembly from the outboard (non-
driven) side of the pump according to steps 2 - 6 in the
TO PERFORMING SERVICE.
"Pump Disassembly" section of this manual.
2. Turn the shaft by hand until a vane comes to the top (12
Hazardous or toxic
fluids can cause o'clock) position of the rotor. Remove the vane.
serious injury.
3. Install a new vane, ensuring that the rounded edge is UP,
5
MAINTENANCE
and the relief grooves are facing towards the direction of a. Bend up the engaged lockwasher tang and rotate the
rotation. See Figures 2 and 3. locknut counterclockwise to remove it from the shaft
4. Repeat steps 2 and 3 until all vanes have been replaced. b. Slide the lockwasher off the shaft. Inspect the
lockwasher for damage and replace as required.
5. Reassemble the pump according to steps 2 - 7 and 12 - 17
of the "Pump Assembly." section of this manual. c. Repeat steps a and b on the opposite shaft end.
5. The TX(S)4-inch pump model is equipped with bearing lock
collars (24A). To remove:
a. Remove the jam nuts (24C) and loosen the two set
screws (24B).
b. Slide the lock collar off the shaft.
c. Repeat steps a and b on the opposite shaft end.
6. Remove the head capscrews (21) and carefully pry the
head (20) away from the cylinder (12).
7. Slide the head off the shaft. The head O-ring (72), bearing
(24), and mechanical seal (153) or lip seal (152) will come
off with the head assembly. Remove and discard the head
Figure 2 - Vane Installation - TX(S)(D) Models* O-ring.
*NOTE: 1.5 and 2-inch pump models have four (4) vanes.
a. Pull the bearing (24) from the housing in the head (20).
b.To remove the mechanical seal (153), use two screw
drivers to gently push the backside of the seal jacket to
push the seal from the head (see Figure 4). Use care
when placing the screw drivers to prevent damage to
the seal faces. Remove and discard mechanical seal
O-rings.
Figure 3 - Vane Installation - TXV Models*

Figure 4 - Mechanical Seal Removal
*NOTE: 2-inch pump models have four (4) vanes.
PUMP DISASSEMBLY c. To remove the lip seal assembly (152), use a thin pry
bar against the lip seal retaining ring to gently push the
NOTICE: housing (152B) out of the head (20). Use care not to
FOLLOW ALL HAZARD WARNINGS AND damage the lip seal (152A). To remove the lip seal
INSTRUCTIONS PROVIDED IN THE "MAINTENANCE" (152A), remove the retaining ring (152D) from the
SECTION OF THIS MANUAL. housing, and gently pry the lip seal from the housing.
Remove and discard the housing O-ring(s) (152C and
1. Starting on the inboard (driven) end of the pump, clean the 152E).
pump shaft thoroughly, making sure the shaft is free of
8. Pull the rotor and shaft (13) from the cylinder (12). While
nicks and burrs. This will prevent damage to the
one hand is pulling the shaft, the other hand should be
mechanical seal or lip seal when the inboard head
cupped underneath the rotor to prevent the vanes (14) and
assembly is removed.
push rods (77) from falling out. Carefully set the rotor and
2. Remove the inboard bearing cover capscrews (28) and shaft aside for future vane replacement and reassembly.
slide the inboard bearing cover (27A) and gasket (26) off
9. Remove the remaining components from the outboard side
the shaft. Discard the bearing cover gasket. On the 1.5, 2,
of the pump, as instructed in steps 6 and 7 above.
2.5, and 3-inch pump models, the dirt shield (123A) will
come off with the bearing cover.
PUMP ASSEMBLY
3. Remove the outboard bearing cover capscrews (28) and
slide the outboard bearing cover (27) and gasket (26) off Before reassembling the pump, inspect all component
parts for wear or damage, and replace as required. Wash
the shaft. Discard the bearing cover gasket.
out the bearing /seal recess of the head and remove any
4. If equipped with locknuts and lockwashers (24A and 24B): burrs or nicks from the rotor and shaft.
6
MAINTENANCE
e. Install new housing O-ring(s) (152C and 152E) in the
1. Reassemble the OUTBOARD side of the pump first:
groove(s) of the housing. Lightly grease the housing O-
a. For a CLOCKWISE rotation pump, position the pump ring(s) and push the lip seal and housing assembly into
cylinder with the INTAKE port to the left. the head recess with the lip seal inward. The lips of the
lip seal will face the rotor when the housing is installed.
b. For a COUNTERCLOCKWISE rotation pump, position
Make sure the housing is bottomed out in the back of
the pump cylinder with the INTAKE port to the right.
the head (20).
2. Install a new head O-ring (72) in the groove on the inside
face of the head (20). Lay the O-ring flat and start in on
one side of the groove, stretching ahead with the fingers,
as shown in Figure 5.
Figure 6 - Lip Seal - TXV “B” Models
Figure 5 - Head O-ring Installation
3. Install the head (20) on the outboard side of the cylinder

(12). Install and uniformly tighten four head capscrews
(21) 90o apart, torquing to 25 lbs ft (34 Nm).
4. MECHANICAL SEAL (If equipped)

Apply a small amount of motor oil in the head recess. Push
the mechanical seal assembly (153) into the recess of the
head with seal jacket drive tangs inward. The pin in the
stationary seat must be between the lugs in the back of the
head recess.
5. LIP SEAL ASSEMBLY (if equipped) Figure 7 - Lip Seal - Discontinued TXV “A” Models
The lip seal assembly (152) consists of a metal housing
with elastomer(s) around its outer diameter(s), and a teflon
6. Hand pack the ball bearing (24) with grease. Refer to the
lip seal in its inner diameter. TXV “A” model pumps are
"Lubrication" section for the recommended grease.
equipped with spacer washers. Refer to Figures 6 and 7.
7. Install the bearing (24) into the head recess. The bearing
a. Apply a small amount of light motor oil on the inner
balls must face outward, with the grease shield inward.
diameter of the lip seal housing (152B) to facilitate lip
Ensure the bearing is fully and squarely seated against the
seal (152A) installation.
lip seal housing (152B) or mechanical seal (153). On TXV
Note: When installing the lip seal, be careful not to pump models, install two 3/8" (10 mm) washers and two
damage the lip seal O-ring. bearing cover capscrews (28) to clamp the bearing and
b. On TXV “B” model pumps, push the lip seal (152A) compress the lip seal housing inner O-ring (152E) for
squarely into the housing (152B) with the pin in the lip proper bearing locknut adjustment (see Figure 8). The
seal aligned with the hole in the back of the housing. washers and capscrews will be removed after the locknuts
The lip seal should seat flush or slightly recessed in the are adjusted.
housing, around its entire diameter.
c. On TXV “A” model pumps, insert the spacer washers
(152F) into the housing, then push the lip seal (152A)
squarely into the housing (152B) with flat side of the lip
seal against the spacer washers. The lip seal should
seat flush or slightly recessed in the housing, around its
entire diameter. Note: If necessary, the spacer
washers can also be located after the lip seal, as shown
in Figure 7, to re-position the lip seal on the pump shaft.
d. Insert the retaining ring (152D) into the groove in the
housing. Figure 8 - Clamping the Bearing
7
MAINTENANCE
8. Turn the pump cylinder (12) around and begin assembly on c. Loosen both locknuts (24A) one complete turn.
the opposite, inboard end. d. Tighten one locknut (24A) until a slight rotor drag is felt
9. Remove the vanes (14) and push rods (77) from the rotor when turning the shaft by hand.
and shaft assembly (13). Inspect for wear and damage, e. Back off the nut the width of one lockwasher tang "B".
and replace as follows: Secure the nut by bending the closest aligned
a. Partially install the non-driven end of the rotor and shaft lockwasher tang into the slot in the locknut. The pump
(13) into the open side of the pump cylinder (12). should turn freely when rotated by hand.
b. Leave part of the rotor outside of the cylinder so that the f. Tighten the opposite locknut (24A) by hand until it is
bottom vanes (14) can be installed and held in place as snug against the bearing (24). Then, using a spanner
the push rods (77) are installed in the push rod holes of wrench, tighten the nut the width of one lockwasher
the rotor. Insert the new vanes into the rotor slots with tang. Tighten just past the desired tang, then back off
the rounded edges outward, and the vane relief the nut to align the tang with the locknut slot. Secure
grooves facing TOWARDS the direction of rotation. the nut by bending the aligned lockwasher tang into the
Refer to Figures 2 and 3. slot in the locknut. The pump should continue to turn
freely when rotated by hand.
c. After the bottom vanes (14) and push rods (77) are
installed, insert the rotor and shaft (13) fully into the g. To check adjustment, grasp the nut and washer with
fingers and rotate back and forth. If this cannot be
cylinder (12).
done, one or both locknuts (24A) are too tight and
d. Install the remaining vanes (14) into the top positions of should be alternately loosened one stop at a time
the rotor. If equipped with a mechanical seal (153), (.001") (25 microns). Begin by loosening the locknut
rotate the shaft by hand to engage the drive tangs adjusted last.
of the seal jacket in the rotor slots.
h. On TXV pumps, after adjustment is complete, remove
10. Install the inboard head (20), mechanical seal (153) or lip the bearing cover capscrews (28) and 3/8" washers from
seal (152), and bearing (24) as instructed in steps 2 both ends of the pump.
through 7. Apply a thin coating of motor oil on the inboard
shaft to aid installation. 13. LOCK COLLAR INSTALLATION - TX(S)4 Pump Models
a. Slide the lock collar (24A) over the shaft and against the
11. Rotate the shaft by hand to engage the mechanical seal
drive tangs (if equipped), and to test for binding or tight bearing (24), with the counterbored side towards the
spots. If the rotor does not turn freely, lightly tap the rims of bearing.
the heads (20) with a soft faced mallet until the correct b. Push the collar (24A) forcibly against the bearing (24)
position is found. Install all of the remaining head by hand, while tightening the two setscrews (24B).
capscrews (21) for each head (20) and uniformly torque to Install and tighten the two jam nuts (24C) against the
25 lbs ft (34 Nm). collar.
12. LOCKNUT INSTALLATION (if equipped) c. Repeat this procedure on the opposite pump end. After
installing both lock collars, verify the shaft turns freely
It is important that the bearing locknuts (24A) and when rotated by hand.
lockwashers (24B) be installed and adjusted properly.
14. Inspect the grease seal (104) for wear or damage and
Overtightening locknuts can cause bearing (24) failure or a
replace as required. Grease the outside diameter of the
broken lockwasher tang. Loose locknuts will allow the rotor grease seal and push it into the bearing cover (27 or 27A)
(13) to shift against the heads, causing wear. See Figure 9. with the lip of the seal inward. The lip will face outward
when the bearing cover is installed on the head.
15. Attach a new bearing cover gasket (26) and the bearing
cover (27 or 27A) to the head (20). Install and torque the
bearing cover capscrews (28) to 15 lbs ft (20 Nm).
16. Follow steps 14 and 15 to install the grease seal (104) and
bearing cover (27 or 27A ) on the opposite side of the
pump. On TXV pump models, the outboard bearing cover
(27) is also a shaft protector and must be installed on the
non-driven shaft end.
17. On 1.5, 2 and 2.5-inch pump models, push the dirt shield
(123A) over the inboard shaft and firmly against the
bearing cover (27).
Figure 9 - Locknut Adjustment 18. On TX(S)D pump models, attach the shaft protector (186)
on the non-driven shaft end.
a. On both ends of the pump shaft, Install a lockwasher
(24B) with the tangs facing outward, followed by a OPERATION WITHOUT SHAFT
locknut (24A) with the tapered end inward. Ensure the PROTECTOR CAN CAUSE SERIOUS
inner tang "A" of the lockwasher is located in the slot in
the shaft threads, bending it slightly, if necessary.
b. Tighten both locknuts (24A) to ensure that the bearings
(24) are bottomed in the head recess. DO NOT Do not operate
without guard
overtighten and bend or shear the lockwasher inner in place.
tang.
8
GENERAL PUMP TROUBLESHOOTING
NOTICE:
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANS
ONLY, FOLLOWING THE APPROPRIATE PROCEDURES AND
WARNINGS AS PRESENTED IN THIS MANUAL.
SYMPTOM PROBABLE CAUSE
Pump Not Priming 1. Pump not wetted.

2. Worn vanes.
3. Suction valve closed.
4. Leaks in the suction line.
5. Strainer clogged.
6. Suction line or valves clogged or too restrictive.
7. Broken drive train.
8. Pump vapor-locked.
9. Pump speed too low for priming.
10. Relief valve partially open, worn or not seating properly.
Reduced Capacity 1. Pump speed too low.

2. Suction valves not fully open.
4. Excessive restriction in the suction line (i.e.: undersized piping, too many elbows
& fittings, clogged strainer, etc.).
5. Damaged or worn parts.
6. Excessive restriction in discharge line causing partial flow through the relief valve.
7. Relief Valve worn, set too low, or not seating properly.
8. Vanes installed incorrectly (see "Vane Replacement").
Noise 1. Excessive vacuum on the pump due to:

a. Undersized or restricted fittings in the suction line.
b. Pump speed too fast for the viscosity or volatility of the liquid.
c. Pump too far from fluid source.
2. Running the pump with a closed discharge line.
3. Pump not securely mounted.
4. Improper drive line (see "Pump Drive").
5. Bearings worn or damaged.
6. Vibration from improperly anchored piping.
7. Bent shaft, or drive coupling misaligned.
8. Excessively worn rotor.
9. Malfunctioning valve in the system.
10. Relief valve setting too low.
11. Damaged vanes (see following category).
Damaged Vanes 1. Foreign objects entering the pump.

2. Running the pump dry.
3. Cavitation.
4. Viscosity too high for the vanes and /or the pump speed.
5. Incompatibility with the liquids pumped.
6. Excessive heat.
7. Worn or bent push rods, or worn push rod holes.
8. Settled or solidified material in the pump at start-up.
9. Hydraulic hammer - pressure spikes.
10. Vanes installed incorrectly (see"Vane Replacement").
Troubleshooting continued on page 10.
9

Broken Shaft 1. Foreign objects entering the pump.
2. Viscosity too high for the pump speed.
3. Relief valve not opening.
5. Pump/driver misalignment.
6. Excessively worn vanes or vane slots.
Lip Seal / Mechanical Seal Leakage 1. O-rings not compatible with the liquids pumped.
2. O-rings nicked, cut or twisted.
3. Shaft at seal area damaged, worn or dirty.
4. Ball bearings overgreased.
5. Excessive cavitation.
6. Lip seal not seated properly.
7. Corrosion on lip seal housing.
8. Mechanical seal faces cracked, scratched, pitted or dirty.
10
NOTES
11
1809 Century Avenue, Grand Rapids, Michigan 49509-1595, U.S.A.
Telephone: (616) 241-1611 • Fax: (616) 241-3752
E-mail: blackmer@blackmer.com • Internet Address: www.blackmer.com Litho in U.S.A • © Copyright 2003
INSTALLATION INSTRUCTIONS
The RCI Technologies water sensor and indicator have been designed to operate when the RCI Technologies Fuel
Purifier is in need of purging. A buzzer followed by a red indicator light will come on when the water level in the
purifier reaches the sensor level. The buzzer will last 10 seconds. The light will stay on until the unit is purged.
466 W. Arrow Hwy, Ste D

San Dimas, CA 91773
Tel: 800-868-2088
Fax: 909-305-1245
Email: rrandle@rcipurifier.com
International Email: rrandle@az.uia.net
INSTALLATION AND WIRING INSTRUCTIONS
NOTE: First determine power supply – 12 volt or 24 volt.
Installation:
Remove heater from package. Apply Teflon tape (or other approved thread
sealant) to the threads of the heater. Insert heater into the heater coupling and
tighten into the body of the purifier.
Wiring 12 VDC Heater
1. Connect the two black leads together and attach to the negative
side of a switch controlled fused circuit (using appropriate wire
connectors).
2. Connect the common lead (white with black tracer) to the positive
side of the switch controlled fused circuit (again using the
appropriate wire connectors).
1. Remove excess wire from the common lead (white with black
tracer) leaving 1 to 2 inches of wire. Cap common lead with
appropriate wire cap and crimp.
2. Connect the two black leads to the 24-volt switched fused power 12 Volt – 6 amps
supply (using the appropriate connectors). 24 Volt – 3 amps
For Assistance or Technical support call:

(800) 868-2088
Operator Accessories
1.00
2.75
.75 .75
1.97
1.91
7.26
1.64
1.07
Ø.56 HOLE (5) Ø.28 HOLES

Description Part No. Material Weight (lb)
Remote Control Assy. 35603SL 1.10
Stainless
Cable Clamp only 9Q1660 .10
New design provides greater stroke (2-1/8”) and leverage. Stainless steel to resist corrosion. Remote attaches to trip
lever on operator using cable. Pulling remote lever rotates operator trip lever and bar assembly, causing all open
emergency valves to close. Per 49CFR178.345-11, remote must be located at least 10 feet away from
loading/unloading outlet (where vehicle length allows) or on the end of the cargo tank farthest from the
loading/unloading outlet. Test cable remote controls and operators at least once a day to insure proper functioning.
3.86 .40
Ø.31 x .75
Fusible Link
CLEVIS PIN .60
.28
1.71
7
.47 16-20 UNF
COTTER PIN HEX NUT Part No. Material Weight (lb)
21050A Steel .17
Heavy duty fusible cable links are designed to attach the cable to the emergency valve cable lever arm and to provide
thermal activation at the emergency valve. Fusible element melts at not more than 250°F, releasing the cable tension
and allowing the emergency valve to close. Uses same non-slip, adjustable cable attachment as on Betts operators.
TM
May 1999 Section 29 Page 1A
INDUSTRIES, INC.
WARREN, PA.
VEEDER-ROOT
INSTALLATION, OPERATION
AND SERVICE INSTRUCTIONS
SERIES 7886
HIGH-
HIGH-CAPACITY
CAPACITY
& SERIES 7887
METER REGISTERS
Manual No. 251325 (REV. B)
VEEDER-ROOT
Petroleum Products
Installation, Operation and Service Manual
Series 7886 High-Capacity & 7887 Meter Registers
TABLE OF CONTENTS
SECTION 1. INTRODUCTION
A. General ..................................... I
SECTION 2. SERIES 7887 DESCRIPTION
A. General ..................................... I
B. Specifications ................................ 2
A. General ..................................... 3
SECTION 4. PERIODIC INSPECTION
A. General ..................................... 5
B. Disassembly Prior to Cleaning ............... 5
C. Cleaning .................................... 5
D. Inspection ................................... 5
E. Lubrication .................................. 5
F. Troubleshooting .............................. 7
SECTION 5. DISASSEMBLY AND ASSEMBLY
A. General ..................................... 8
B. Removal of Major Groups ...................... 8
C. Individual Parts Replacement .................. 10
D. Installation of Major Groups .................... 10
E. Final Checks and Adjustments ............. 15
F. Operational Check ............................ 16
SECTION 6. DAMAGE CLAIMS AND WARRANTY
A. Damage Claims ............................... 16

B. Return Shipping .............................. 16
C. Warranty and Conditions ...................... 16
Where manufacturer's replacement stocks are available, it is important
A. GENERAL. These instructions are for servicing that no attempt be made to repair any meter register defective within
the Series 7886 High-Capacity and Series 7887 Meter the terms of the warranty as by doing so, the warranty is void and the
Registers user is deprived of the protection provided by the warranty. It is
designed and manufactured by the Veeder-Root Company, recommended that, when possible, meter registers be replaced and
6th Avenue at Burns Crossing. P.O@ Box 1673, Altoona, PA the defective unit returned to the meter manufacturer.
16603. Phone: (814) 695-4476. Note: See Section 6 for complete Damage Claims and Warranty.
When a vertical bar I appears adjacent to text orILlu strations,
information has been added or changed at the last issue IMPORTANT!
date. The instructions, photographs and drawings in Sec tions 4 and
Note- Consult Veeder-Root on any unusual application,
installation or possible modification of this basic design.
5 are based on the Series 7887 Meter Register. With the
Every Meter Register is thoroughly tested at the Veeder-Root exception of an additional counting wheel, the Series 7886
factory and by the meter manufacturer when installed on the High-Capacity Meter Register is physically similar and the
meter. However, like any precision mechanism, it requires same procedures should be followed.
periodic care to ensure maximum service. This manual is for
use in areas where factory rebuilding facilities and adequate
exchange stocks are not readily accessible.
SECTION 2. SERIES 7887 DESCRIPTION clutch assembly which in turn drives a gear on the right (unit)
wheel assembly. Revolutions are then accumulated on the
A. GENERAL. 1. Physical. The Series 7887 Meter Register, wheels. In addition, this rotating shaft drives the bracket
Figure 1, displays a running account, final total and accumulated group connected to the accumulative totalizer shaft, thus both
total of the quantity of liquid product delivery. Contained in a 4'x I displays are driven from the same source, assuring accurate
O'diecast enclosure, individual delivery data is displayed on five recording of information. During the reset operation, the
3/4' high flgures while totalizer information is recorded on eight clutch is disconnected from the drive shaft, a shutter moves
1/8' high figures. Reset of the Meter Register is accomplished into place covering the display wheels and reset fingers
through a reset knob on the right-hand side of the unit. engage heart-shaped cams on the individual wheels to move
them back to a zero position. In addition, a set of anti-topping
2. Operational. The Meter Register is operated by a drive shaft fingers engages the wheels to preventjamming. At the
connected to a group of gears on the gear plate which converts completion of reset, the display wheels will read all zeros,
the drive revolutions to the appropriate ratio. The output bevel and the shutter will rise to the normal operating position. The
gear of the group drives a bevel gear, Figure 5, which is clutch will engage the drive shaft to transfer the information
connected to the drive shaft and clutch assembly. In rotating, this from the next delivery. The totalizer wheels will be unaffected
shaft drives a gear on the by this reset operation, thus displaying an accurate measure
of the accumulated totals of many deliveries.
B. SPECIFICATIONS.
Specifications listed are standard unless otherwise noted. Optional Style of Figures: Veeder-Root/Cornell for optimum read- ability.
features are available at additional cost.
Character Configuration: 0 to 9 (options available).
Speed: 250 rpm.
Reset: Single handle on register. Designed for one-handed
Torque: Average running torque at room temperature with 1: I input: operation.
4 oz-in. During display wheel transfer from all 9's to all O's, the
instantaneous peak torque may reach 40 oz-in. Mounting: Eight 1/4 x 28 tapped holes with steel inserts on a 6.625'
(168.28 mm) diameter. Special adaptors are available for nearly all
Operating Temperature Range: -40' to +710C (-400 to + I 60'F). meters.
Number of Figures: Meter Register: 5. Accumulative Totalizer: 8 Construction: Cover: cast aluminum. Case and sub frame: cast
Zamak. Wheels, pinions, and clutch: acetal resin.
Size of Figures: Meter Register: 0.750' high x 0.400' wide
(I 9.05 x 10. 16 mm). Totalizer: 0. 1 25' high x 0.078' wide (3.175 x Gearing: 1:1 is standard. 1:1 through 42:1 are available.
1.98 mm). Lubrication: Periodic.
Color of Figures: White on black, except right-hand totalizer OPTIONS

wheel which is black on white when recording tenths of units, and
white on black when recording whole units. Nonreset Pulser: Meter Register with Series 1871 or 7671 Pulse
Transmitter.
SECTION 3. SERIES 7886 DESCRIPTION B. SPECIFICATIONS.
Specifications listed are standard unless otherwise
A. GENERAL. noted. Optional features are available at additional cost.
1. Physical. The Series 7886 High-Capacity Meter Register, Speed: 250 rpm.
Figure 3, displays a running account, final total and Torque: Average running torque at room temperature
accumulated total of the quantity of liquid product delivery. with
Contained in a 4' x 10' die cast enclosure, individual delivery 1:1 input: 4oz-in. During displaywheeltransfer from all 9s
data is displayed on six 5/8' high figures while totalizer to all O's, the instantaneous peak torque may reach 40
information is recorded on eight 1/8' high figures. Reset of the oz-in.
Meter Register is accomplished through a reset knob on the Operating Temperature Range: -40' to +71'C (-40' to +
right-hand side of the unit. 160'F).
Number of Figures: Meter Register: 6. Accumulative
2. Operational. The Meter Register is operated by a drive Totalizer: 8
shaft connected to a group of gears on the gear plate which Size of Figures: Meter Register: 0.625' high x 0.300'
converts the drive revolutions to the appropriate ratio. The wide (15.87 x 7.62 mm). Totalizer: 0.125' high x 0.078'
output bevel gear of the group drives a bevel gear, Figure 5, wide (3.175 x 1.98 mm).
which is connected to the drive shaft and clutch assembly. In Colorof Figures: White on black, except right-hand
rotating, this shaft drives a gear on the clutch assembly which totalizer wheel which is black on white when recording
in turn drives a gear on the right (unit) wheel assembly. tenths of units, and white on black when recording whole
Revolutions are then accumulated on the wheels. In addition, units.
this rotating shaft also drives the bracket group connected to Style of Figures: Veeder-Hoot/Cornell for optimum
the accumulative totalizer shaft, thus both displays are driven read- ability.
from the same source, assuring accurate recording of Character Configuration: 0 to 9 (options available).
information. During the reset operation, the clutch is Reset: Single handle on register. Designed for one-
disconnected from the drive shaft, a shutter moves into place handed operation.
covering the display wheels and reset fingers engage heart- Mounting: Eight 1/4 x 28 tapped holes with steel inserts
shaped cams on the individual wheels to move them back to on a 6.625' (168.28 mm) diameter. Special adaptors are
a zero position. In addition, a set of anti-topping fingers available for nearly all meters.
engages the wheels to prevent jamming. At the completion of Construction: Cover: cast aluminum. Case and sub
reset, the display wheels will read all zeros, and the shutter frame: cast Zarnak. Wheels, pinions, and clutch: acetal
will rise to the normal operating position. The clutch will resin.
engage the drive shaft to transfer the information from the Gearing: 1:1 is standard. 1:1 through 42:1 are available.
next delivery. The totalizer wheels will be unaffected by this Lubrication: Periodic.
reset operation, thus displaying an accurate measure of the OPTIONS
accumulated totals of many deliveries. Nonreset Pulser: Meter Register with Series 1871 or
7671 Pulse Transmitter.
SECTION 4. PERIODIC INSPECTION c. 57 tooth gear on clutch assembly with gear on right wheel
(For Series 7886 High-Capacity and Series 7887 Meter assembly.
Registers) d. Gear drive shaft with gear train that operates the totalizer,
and gear connecting the drive train to the totalizer.
A. GENERAL The Meter Register is fully lubricated and property
adjusted at manufacture. However, periodic cleaning and lubrication 3. Rotate drive shaft by hand to see that unit operates freely
are required. and then reset, checking for proper reset and shutter action.
Adjust pointer after reset as required.
Judgment of the intervals at which the meter register requires such
service must necessarily be left to the individual user due to varying 4. Check all screws, retaining rings and groove pins to see that
conditions of service. Under normal conditions, this will be at least they are tight and seated properly.
once a year, or after each 2-1/2 million units of measure delivered,
whichever comes first. E. LUBRICATION.
1. Recommended Lubricants
B. DISASSEMBLY PRIOR TO CLEANING. Remove the meter Note: Chelae and Vischem products are manufactured
register from its housing as follows: by Ultrachem Inc.,
1400 N. Walnut St., P.O. Box 2053 Wilmington, DE 19899
I .Remove the bolts securing the cover (if present) to the top of the
housing. These bolts are hex head and are located at the four Oil: Chemlube 201 or equivalent with a temperature range of -
corners of the bottom of the housing. Remove the cover. 65F to + 275F (-54'C to + 135'C).
Grease: Vischem 352 or equivalent with a temperature range of
2. Remove the three button-head bolts securing the meter register -65'F to +300'F (-54'C to + 149'C).
to the housing. Remove the meter register. Note: All lubricants used in the register must be of a type
which remains fluid over the full temperature range
3. Remove the screws securing the gear plate to the bottom of the to which the register will be subjected. Also, they
housing. Remove the gear plate. should not oxidize or dry out leaving a gummy or
perceptible residue.
C. CLEANING. If the Chemlube 201 oil lubricant is not available, a substitute
with equivalent properties may be used. To assist field
CAUTION: DO NOT USE A WIRE BRUSH. personnel in obtaining suitable lubricants for the meter register
and ticket printers, the following list showing equivalent
1. Wipe bezel crystal with a clean lint-free rag. lubricants has been prepared:
OIL
2. If the wheel faces are dirty, gently clean with a clean AEROSHELL FLUID NO. 3
lint-free rag dipped in mild soapy water. REGENT SPINTEX OIL 60
GARGOYLE ARCTIC OIL LIGHT
3. Clean the gears on the base plate by flushing or with a brush CASTROL HYSPIN 40
dipped in solvent. Blow dry with compressed air. ANDEROL 401D
GREASE
4. Clean housing by dipping, flushing or brushing with solvent. Blow AEROSHELL 14
dry with compressed air. ESSO BEACON 325
ANDEROL 795
D. INSPECTION. A periodic inspection of the entire meter register,
housing and gear plate is required to make sure that they function 2. Points to Lubricate
property, parts are in place, and no binding or excessive side-to-side
motion of shafts occurs. A checklist on such procedures follows: Oil: All points indicated as "Oil" on Figure 6 should be lubricated
with oil as described above. This includes all shafts, studs, and
1. Check the following shafts for perceptible side-to-side motion. bosses on which a moving part bears.
Note: Remove the meter register from the housing before checking Grease: Grease should be applied to all points indicated as
shaft freedom. "Grease' on Figure 6. This includes gears and the no-back
a. Wheel Shaft ratchet and pinion.
b. Anti-Topping Finger Group Shaft
c. Reset Finger Group Shaft Note: The oil and grease should be applied with a small
d. Clutch Group Shaft brush to make certain that all areas will he properly
e. Pinion Shaft lubricated. In this manner, the amount of lubrican
t being used will be more easily controlled.
2. Temporarily install the base plate and meter register in
the housing and check for proper engagement and freedom of
movement of: a. All gears on gear plate.
b. Output bevel gear on gear plate with the bevel drive gear on drive
shaft.
F. TROUBLESHOOTING. Tabel 1 is used to assist in
locating problems and making repairs and corrections. In
some problems, similar defects can be produced by several
causes of an entirely different nature. Cause of trouble must
be determined and the correction made.
Table 1. Troubleshooting
TROUBLE POSSIBLE CAUSE CORRECTION

1. Drive shaft hard to turn. Pointer or brake rubbing on first wheel Check pointer and break positioning.
Adjust as required.
Dirt or pieces of foreign material in teeth Remove case. Check all gears, clean and
of drive gears, gear plate, totalizer or lubricate as necessary. See Sect 4.
bevel gear train driving totalizer.
2. Binding occurs during reset cycle Missing washers on outside of clutch Check end play and washer as required.
shaft.
Pinion jam, anti-topping finger(s) broken Check end play of wheel shaft. Replace
or spring(s) missing broken anti-topping finger(s) or missing
spring(s)
3. Reset knob turns hard Reset knob flange on the case binds on Remove reset knob. Loosen flange
reset shaft. screws, center the flange on the shaft
and tighten the screws.
Wheel shaft group is bent. Replace wheel shaft.
Reset fingers rubbing on wheel or Check for missing retaining rings on reset
retaining rings. finger and wheel shafts. Replace as
required.
4. Any one wheel will not reset to zero Broken reset finger. Replace reset fingers as required.
Locking disc pin out of wheel groove. Disassemble wheel group and insert
locking disc pin into groove in wheel.
5. Incomplete reset cycle. Knob turns but Key in large multiple cam broken. Replace cam with new cam and key.
reset does not occur. Reset actuating lever not engaged in cam Remove cam, inspect and replace parts
or reset arm broken. as required, and assemble properly.
6. Shutter partially obscured wheels at Shutter disconnected from reset lever. Connect shutter to reset lever.
completion of reset cycle or completely
covers wheels at reset cycle.
7. Shutter will not drop into place or loss Detent lever spring missing or broken. Install new spring.
of detent action during reset.
8. Pointer not aligned with unit wheel. Improper adjustment of brake or pointer. Adjust brake to proper clearance.
Adjust pointer to center mark.
9. Unit wheel can be turned in reverse by Dirty drive shaft clutch assembly. Clean clutch group and lubricate. See
hand. Section 4.
10. Cannot drive meter register. Pinion jam, reset fingers are engaged, Check washers on pinion shaft. Check
heart cams hit on detent lever shutter and play of shafts. Clean and lubricate
stud, clutch not engaged. clutch.
SECTION 5. DISASSEMBLY AND ASSEMBLY (For Series 1. If present, remove the retaining ring securing the reset idler
7886 High-Capacity gear to the reset idler gear shaft.
and Series 7887 Meter Registers) 2. Remove retaining rings and washers securing the pinion,
reset, anti-topping and clutch shafts to the right-hand side plate
A. GENERAL. When disassembling the meter register, be (Figure 7). Remove screws and lockwasher securing the
extremely careful not to lose or intermix any of the washers found totalizer group and rear mounting bar from right-hand side plate.
on the shafts. By doing so, potential problems with end-play and 3. Remove side plate.
backlash adjustments will be greatly lessened. When removing
retaining rings or other parts from shafts, do not hold the shaft CAUTION: DO NOT LOSE OR INTERMIX WASHERS FROM
with any tool that might gouge or create burrs on the shaft. EACH SHAFT.
B. REMOVAL OF MAJOR GROUPS. Instructions for removal of Note: Remove only those shaft groups necessary to gain
all shaft groups are provided. access to parts being replaced.
4. Clutch Shaft Group Removal. Note: If the inoperable totalizer has a small bevel gear
a. Remove retaining ring and washers securing the clutch (approx. 11/32 inch dia.) on the drive shaft, replace the
shaft group to the left-hand side plate. See Figure 8. bracket group on the left side frame as well as the totalizer
b. Move clutch lever group so clutch is free. See Figure 9. group (see Figure 31 and Paragraph D, 7 and E, 5).
Remove clutch shaft group. See Paragraph C, 1 for Remove the screw holding the pointer onto the old totalizer
parts replacement. and save for installation on new totalizer.
5. Reset Finger Group Removal.
a. Remove retaining ring and washer securing the reset 9. Pinion Removal.
group to the left-hand side plate. See Figure 8. a. Remove retaining ring securing pinion shaft to the left-
b. Disengage the reset fingers and no-back pawl from th hand side plate. See Figure 8.
wheels. SeeFigure 10. Rernovethegroup. See Paragraph C, b. Rotate the detent lever group so it will clear the reset
2 for parts replacement. cam. Remove shaft. c. Remove pinions, detent lever group
washers and retaining rings from shaft.
6. Stop Shaft Removal.
a. Remove the springs from between the anti-topping 10. Wheel Group Removal.
fingers and the stop shaft. a. Mark relationship of reset gear to wheel group shaft to
b. Remove the spring from between the detent lever group assure proper positioning during assembly.
and the stop shaft. b. Remove pin securing reset gear to the wheel group shaft.
c. Remove the stop shaft. c. Remove gear, retaining ring and washer. Remove shaft.
See Paragraph C, 4 for parts replacement.
7. Anti-Topping Finger Group Removal.
a. Remove the retaining ring and washers securing the anti-
topping finger group shaft to the left-hand side plate. See
Figure 8.
b. Disengage the anti-topping fingers and the clutch lever
group from the wheels. See Figure I 1.
c. Remove the group from the side plate. See Paragraph C,
3 for parts replacement.
8. Totalizer Group Removal.

a. Remove the screws securing the totalizer group to the
left-hand and right-hand side plates. See Figures 7 and 8.
b. Remove the totalizer group.
c. No additional disassembly of the totalizer is possible. If the
totalizer is inoperable, replace the group.
C. INDIVIDUAL PARTS REPIACEMENT
1. Clutch Shaft Parts Replacement. See Figure 12.

a. Totalizer and Drive Bevel Gears.
(1) Drift out pin securing gear to shaft.
(2) Remove gear.
(3) Remove retaining rings and washers that position drive
gear. Do not change the order of the rings and
washers.
(4) Drift out pin holding drive gear and remove gear.
(5) Install new gear, pin, retaining rings and washers.
Use new pin if required.
(6) Install totalizer bevel gear and secure with pin.
CAUTION: CHECK SHAFT FOR STRAIGHTNESS AFFER

PINNING. A BENT SHAFT WILL CAUSE BINDING DURING
DRIVING OF METER REGISTER. CLUTCH MUST NOT BE
DISASSEMBLED OR REPLACED AS AN INDIVIDUAL
GROUP. IF CLUTCH IS BROKEN OR MALFUNCTIONS,
REPLACE COMPLETE SHAFT AND CLUTCH AS AN
ASSEMBLY.
2. Reset Finger Group Parts Replacement. See Figure 13. Individual

reset fingers, reset arm, no-back pawl and pawl spring may be
replaced as required.
a. Remove retaining rings and appropriate washer to reach
particular part.
b. Replace defective items with new part. Assemble remaining parts
on shaft. Install retaining rings and washers. Check end play per
Figure 28.
3. Anti-ToppingFingerGroupPartsReplacement.SeeFigure 14.
Individual anti-topping fingers, reset lever and clutch lever may be
a. Remove retaining rings, washers and parts as required to get to
part that is to be replaced.
b. Install parts, retaining rings and washers in the sequence shown
in Figure 14. Be sure to install parts so they are in the proper
direction. Check end play per Figure 28.
4. Wheel Group Parts Replacement. See Figures 15, 16, 17 and 18.
The reset cam, individual wheels, locking discs and eccentrics may
be replaced as required.
a. Remove retaining rings, washers and key as required to remove
reset cam, wheels, locking discs and eccentrics.
b. Install parts, retaining rings, washers and key in the sequence
shown in Figure 17. When installing wheels, be sure the pin on the
locking disc engages the groove in the wheel as shown in Figure 18.
Check end play per Figure 28.
D. INSTALLATION OF MAJOR GROUPS
Prior to installing each shaft, lubricate per Paragraph E in Section 4.
During assembly, do not intermix washers from one shaft to another.
1. Wheel Group Installation.
a. lfnotpresent,installaO.030inchthickwasheroverthe end of the
wheel group shaft opposite the cam.
b. Install the shaft into the proper hole in the left-hand side plate.
See Figure S.
2. Anti-Topping Finger Group Installation. See Figure 19.
a. Hold wheel and side plate assembly upside down.
b. Install anti-topping finger group in proper hole in left- hand side
plate (see Figure 8). Be sure all fingers and clutch lever are free of
wheels and the pin on the reset ievel, engages the track on the cam.
c. Seat the shaft, install washers and retaining ring to
secure shaft to left-hand side plate.
d. See that all fingers are free to engage wheels.
3. Stop Shaft Installation.
a. Install retaining rings on ends of shaft.
b. Insert stop shaft into proper hole in left-hand side
plate. See Figure 8.
4. Reset Finger Shaft Group Installation.
a. Rotate no-back pawl so that spring puts pawl under
tension. Slip an elastic band over the reset fingers
and pawl to hold pawl in position. See Figure 20.
b. Install shaft into left-hand side plate and secure
with retaining ring and washers. See Figure 8.
c. Engage pin on reset lever group with slot in reset
arm. See Figure 22.
5. Clutch Shaft Group Installation.
a. Install shaft in proper hole in left-hand side plate.
Add washers and secure with retaining ring. See Figure 8.
b. Make sure that bevel gears that drive the totalizer
are free to turn.
6. Right-Hand Side Plate Installation 8. Spring Installation.
a. Hold meter register assembly as shown in Figure 22 and a. See Figure 23 for identification of springs.
place a rubber band around the assembly to hold it together. Be b. Install the five anti-topping finger springs between the anti-
sure the pin in the reset lever group remains engaged in the slot topping fingers and the stop shaft. See Figure 24.
in the reset arm. c. Install the reset spring between the reset lever and the pinion
b. Install side plate over wheel shaft first, then engage the other shaft.
shafts. d. Install the detent spring between the detent lever group and
c. Temporarilysecure the side plate to the rear mounting bar the stop shaft.
with screws. e. Install the clutch spring between the clutch lever group and
7. Bracket Group (if required) and Totalizer Installation. the pinion shaft.
a. If required, install new bracket group to inside of left side
frame and secure with two screws and lockwashers. See 9. Pinion Shaft Assembly Installation
Figure 31. a. If not previously accomplished, remove all parts from pinion
b. Install pointer with screw (saved from old totalizer) onto new shaft.
totalizer group but do not tighten screw securely. Pointer b. Rotate wheel shaft so reset fingers are fully engaged in the
position must be adjusted after totalizer group is installed. See heart-shaped cams on each wheel.
Paragraph F, 2. c. Place pinions, with short finger up, in between each wheel as
c. Install the totalizer group so that the bevel gear is in mesh shown in Figure 25.
with the top bevel gear on the bracket group and secure with d. Install the end of the shaft closest to the two retaining ring
retaining screws. For adjustment of bevel gear drive, see slots into the left-hand side plate and through each pinion.
Paragraph E, 5.
e. Install washers and detent lever group onto shaft and engage
shutter with tab on detent lever.
f. Push shaft through the right-hand side plate and secure with
washer and retaining ring.
g. Secure detent lever group into position with retaining rings.
h. After assembly, rotate wheel shaft to make sure all pinions
have been positioned properly. If binding occurs, reposition
pinions per step c.
10. Reset Gear Installation.

a. Install reset gear on wheel shaft, aligning orientation mark
made at disassembly.
b. Secure gear to shaft with pin. II. Reset Idler Gear Installation.
a. If present, install reset idler gear on the reset idler gear shaft.
See Figure 8.
b. Secure with retaining ring.
Note: This gear will be tirned when the meter duplicator and
meter register are assembled together.
E. FINAL CHECKS AND ADJUSTMENTS.
1. End Play Check: Check end play (back and forth motion) of
shafts and parts as follows:
a. For proper measurement, the meter register must be installed in

the TD-42383 mounting fixture, Figure 26, to constrain the frame
into the same position that it is when installed in the housing.
b. Secure the meter register to the fixture with two 1/4-28 button-
head bolts. See Figure 27.
c. Take end play measurements of each shaft. Add or subtract
washers as necessary to obtain correct end play.
2. Input Drive Bevel Gear Engagement Adjustment.
a. Install the gear plate onto the fixture using the

appropriate hardware.
b. Remove the retaining ring behind the bevel gear and add or
subtract washers as required for proper rnesh between the bevel
gear on the gear plate and the drive bevel gear on the clutch shaft.
The shaft end play must be maintained as specified in Figure 28.
c. Replace the retaining ring after adjustment.
3. Clutch Lever
Positioning Adjustment.
a. Rotate the reset gear until the clutch is fully disengaged.
b. Measure the clearances as shown in Figure 29.
c. If the dimensions cannot be obtained, add or remove washers as
required, or replace the clutch and shaft.
d. The amount of face engagement between the spur gear on the
input clutch and the first wheel should be 75% + 20%.
4. Wheel Brake Adjustment.
a. Rotate reset gear to position earn as shown in Figure 30.

b. Measure clearance between brake and first wheel. If
clearance is not within the dimensions given, adjust brake by
loosening screw and moving brake into position.
c. Remove the meter register from the fixture by removing the two
button-head screws. Remove the gear plate from the fixture.
5. Gearing Adjustment for Totalizer. See Figure 31.
Loosen set screw on bottom bevel gear. Mesh the top bevel
gear tightly with the totalizer bevel gear. Press the register clutch
shaft toward the left side frame. Adjust the bottom bevel gear such
that it has 0.012 - 0.015 end play when meshing with the clutch
shaft bevel gear. Tighten set screw and secure with a sealant
(Loctite 222 or equivalent) to prevent loosening.
6. ApplyAnderoIL-795orequivalentgreaseonteethofbevel gears.
7. Backlash Compensating Mechanism Adjustment for

EEC UNITS ONLY.
While unit is running at 100-200 RPM, adjust screw so that pawl is
approximately in the middle of clip as shown in Figure 32 (on Page
16). Oscillation of pawl is permissible.
To check for proper operation, use a 1: I gear plate and operate

register at 100-200 RPM. Stop counting, hold input shaft of gear
plate and reset register. Wheel should reset so that some part of
graduation at zero always aligns with pointer.
B. RETURN SHIPPING. All shipments of Veeder-Root
products must be prepaid. Equipment must be packed in a
strong exterior container and surrounded by shock absorb-
ing material. Veeder-Root will accept no liability foi- damage
caused by improper packing. It is suggested that the original
shipping containei- be used if it is available. Address
shipment to Veeder-Root Co., 6t]i Avenue at Burns Crossing,
11.0. liox 1673, Altoona, I'A 16603.
C. WARRANTY AND CONDITIONS

1. WARRANTY. We warrant that our products shall he free
from defects in material and workmanship for a period of one
year from the date of shipment thereof or the product's total
rated life, whichever first occurs. Within the warranty period
we shall repair or replace such products which are returned
to us with shipping charges prepaid and which are deter-
inined by us to be defective. This warranty will not apply to
any product which has been subjected to misuse, negligence,
or accident; or misapplied; or used in violation of product
manuals, instructions, or warnings; or modified or repaired by
unauthorized persons; or improperly installed.
2. INSPECTION. You shall inspect the produ(-t promptly after

i-eceipt and shall notify us at oui- Altoona office, in wi-
F. OPERATIONAL CHECK. Before returning the meter register iting,ofanyclaims,includingclaii-nsofbreactiofwarraiity, within
to normal service, check that it operates properly as follows: thirty days aftei- you discover or should have dis- (-ovei-
edtliefactsuponwliielitlieclaimishased.Yourfailtire to give
1. Rotate the input bevel gear and see that the totalizer and written notice of a (-Iaiin within the time period shall be
individual delivery wheels are driven and that they record the deeiiie(i to be a waivei- of sii(-Ii claim.
same amount. There should be no binding or drag.
3. LIMITATION OF REMEDY AND WARRANTY. The
2. Rotate the reset gear and see that the shutter drops into provisions of Paragraph I are our sole obligation and exclude
place, the wheels all reset and that there is no binding or drag. all other remedies or warranties, express or implied, including
At the completion of reset, the zeros should align with the warranties of MERCHANTA-BILITY and FITNESS FOR A
pointer. PARTICULAR PURPOSE, whether or not purposes or
specifications are described herein. We further disclaim any
3. See Troubleshooting, Table 1. Page 5, if there are any responsibility whatsoever to you or to any other person for
problems. injury to person or damage to or loss of property or value
caused by any product which has been subjected to misuse,
negligence, or accident; or misapplied; or used in violation of
SECTION 6. DAMAGE CLAIMS AND WARRANTY product manuals, instructions, or warnings; or modified or
repaired by unauthorized persons; or improperly installed.
A. DAMAGE CLAIMS
1. Thoroughly examine the enclosure as soon as it is received. 4. LIMITATION OF DAMAGES. Under no circumstances
If damaged, write on the face of the freight bill a complete and
shall we be liable for any incidental, consequential or special
detailed description of the damage. Have the carrier's agent damages, losses or expenses arising from this contract or its
sign the description. performance or in connection with the use of, or inability to
use, our product for any purpose whatsoever.
Note: Insist that the carrier's agent verify the inspection
and sign the description. 5. LIMITATION OF ACTIONS. No action regardless of form
arising out of this contract may be commenced more than
2. Immediately notify the delivering carrier of damage or loss. one year after- the cause of action has accrued, except an
This notification may be given either in person or by telephone. action for nonpayment.
Written confirmation must be mailed within 48 hours. Railroads
and motor carriers are understandably reluctant to make 6. COLLATERAL PROMISES. There are no representations,
adjustments for damaged merchandise unless inspected and warranties, or conditions express or implied, statutory or
reported promptly. otherwise except those herein contained, and no agreements
or waivers collateral hereto shall be binding on either party
3. Riskoflossofordamagetomerchandiseremainswiththe liuyer. It unless in writing and signed by you and accepted by us at our
is the liuyer's responsibility to file a claim with,,the carrier Altoona office.
involved.
7. INTERPRETATION. Rights and liabilities arising out of any
4. Imniediately advise your Veeder-Root representative,
contract with us shall be determined under the Uniform
distributor, oi, the factory so that we may assist you. Commercial Code as enacted in Connecticut.
VEEDER-
VEEDER-ROOT
Petroleum Products
6th Avenue at Burns Crossing

P.O. Box 1673
Altoona, PA 16603-1673
Phone (800) 873-3313
Fax (800) 234-5350
or
Phone (814) 695-4476
Fax (814) 695-7605
Copied from
Veeder-Root Technical Manual
8-014
Issued:12/95
Supersedes: 5/93
Compiled by:
Michael Leffew,
Isometrics, Inc.
Reidsville, NC
Wet-R-Dri Valve TTMA STYLE
LIGHTWEIGHT
COMPACT
VERSATILE
I.D.
O.D.
Standard Model Detent Model Standard Material Max. Working Temperature

Size Wt. Wt.
Assembly No. Assembly No. Body Disc Pressure Range
WD200 AL B 2.4 WD201 AL B 2.4 Aluminum
2” Buna-N 75 PSI
WD200 GI B 4.6 WD201 GI B 4.6 Grey Iron
See Chart Below

3” Buna-N 75 PSI
WD400 AL V 4.5 WD401 AL V 4.5 Aluminum
4” Viton 75 PSI
WD400 GI V 8.3 WD401 GI V 8.3 Grey Iron
5” WD500 AL V 7.9 WD501 AL V 7.9 Aluminum Viton 50 PSI
6” WD600 AL U 11.8 WD601 AL U 11.8 Aluminum Urethane 50 PSI
NOTE: Standard drilling fits TTMA recommended standards.
Valves are available with the following options: Stainless steel liners and shafts, grease fittings installed in the drive and
bearing shafts, and “E” Coating of aluminum valves (recommended for aluminum valves used in water service).
For repair kit, see Section 20, Page 5B.
Dimensions Suffix for Disc Material

Buna-N Urethane
Size A B C I.D. O.D. B.C. Holes Viton EPDM
Black White Black White
3 1 1 1 3 3 7
2” 6 /4 4 /4 1 /8 2 /4 3 /4 3 /4 6- /16 B WB V U WU E
3 5 1 3 5 7 7
3” 6 /4 4 /8 1 /8 3 /8 5 /8 4 /8 8- /16 -40°F -40°F -0°F -40°F -40°F -50°F
3 1 1 3 5 7 7
4” 6 /4 5 /8 1 /8 4 /8 6 /8 5 /8 8- /16 +200°F +200°F +400°F +200°F +200°F +300°F
3 3 1 7 5 7
5” 6 /4 6 /8 2 /8 5 /16 7 /8 7 12- /16 NOTE: Temperature ranges based on
1 1 5 1 7
6” 12 7 2 /8 6 /8 8 /8 8 /8 12- /16 published information and may vary
1 7 1 7
8” 12 8 2 /2 8 10 /8 10 /8 16- /16 due to actual operating conditions.
INSTALLATION:
The Wet-R-Dri Valve may be mounted in any position with handle located for easy operation. Valve, as assembled, opens by
1
turning handle /4 turn counter clockwise (right hand operation). If clockwise rotation is desired (left hand operation) please
specify. Care should be taken when mounting valve to be sure the I.D. of adjoining flanges or pipe is large enough to allow
disc of valve to open freely. We suggest using our accompanying flanges and adapters shown in Section 20, Page 5A.
TM
INDUSTRIES, INC. Feb 1995 Section 20 Page 1A

WARREN, PA.
PARTS LIST
Wet-R-Dri VALVE
2 2
6
4 5 6
10
12
11
9 WD101-3 BU
1 9 WD101-3 BU
1
92 92
7 7
8 8
STANDARD MODEL DETENT MODEL
2” Size 3” Size 4” Size 5” Size 6” Size 8” Size

No. Description Material
Part No. Part No. Part No. Part No. Part No. Part No.
Buna-N WD101-2 BN WD101-3 BN WD101-4 BN WD101-5 BN WD101-6 BN WD101-8 BN
Viton WD101-2 VT WD101-3 VT WD101-4 VT WD101-5 VT WD101-6 VT WD101-8 VT
1 Disc
Urethane WD101-2 PY WD101-3 PY WD101-4 PY WD101-5 PY WD101-6 PY WD101-8 PY
EPDM WD101-2 EP WD101-3 EP WD101-4 EP WD101-5 EP WD101-6 EP WD101-8 EP
Handle Mall. “E” Coated 25884EY 25884EY 25884EY 25884EY 25933AL 25933AL
2 Cap Screw Steel Zinc Plt. 9Q5813 9Q5813 9Q5813 9Q5813 9Q5898 9Q5898
Hex. Nut Steel Zinc Plt. 9Q5808 9Q5808 9Q5808 9Q5808 9Q5808 9Q5808
4 Drive Shaft Steel 27053MS 27050MS 27050MS 27051MS 16229MS 16229MS002
5 Drive Shaft Steel 27053MS001 27050MS001 27050MS001 27051MS001 16229MS 16229MS002
6 O-Ring To Match Disc Mat’l. 17889** 17889** 17889** 17889** 18831** 18831**
7 Bearing Shaft Steel 16006MS 15913MS 15913MS 15913MS 16230MS 16230MS002
9 Driv-Lok-Pin Steel Zinc Plt. 9Q4893 9Q4893 9Q4893 9Q4925 9Q4926 9Q4938
10 Detent Ball 440 Stnls 9Z4856 9Z4856 9Z4856 9Z4856 9Z4856 9Z4856
11 Detent Spring 304 Stnls 15229SL 15229SL 15229SL 15229SL 15229SL 15229SL
12 Ret. Screw 304 Stnls 9Q5838 9Q5838 9Q5838 9Q5838 9Q5838 9Q5838
** O-Ring material suffix to match Disc suffix (i.e.-17889VT)
WARNING Use only genuine Betts Industries Inc. replacement parts. Use of substitute parts can impair the proper
functioning of the Wet-R-Dri Valve.
TM
INDUSTRIES, INC. Jan 1993 Section 20 Page 1B

WARREN, PA.
Installation & Part
Installation s Manual
Parts
M/MA Meters
Installation: M100-10
Table of Contents and Safety Procedures
Contents
Safety Procedures
Description Page Number
How LC Meters Work ........................................... 3 ! WARNING
WARNING
Owner’s Information Packet ................................. 4
Installation Requirements ..................................... 6 All internal pressures must be relieved before
Operation Requirements ....................................... 7 disassembly or inspection of the strainer, air eliminator,
Meter Start Up and Operation .............................. 8 any valves in the system, the packing gland, and the
Reversing the Meter Registration ......................... 9 front or rear covers. See “Relieving Internal Pressure”
Setting the Standard Adjuster .............................. 10 (page 11).
Meter Maintenance ............................................... 10
Relieving Internal Pressure ................................... 11 Be Prep ared
Prepared
Servicing the Drive Components ........................... 12 Make sure that all necessary safety precautions have been
Removing the Dust Cover ..................................... 12 taken. Provide for proper ventilation, temperature control,
Removing the Adjuster and fire prevention, evacuation and fire management.
Adjuster Drive Assembly ...................................... 12
Buna/Viton/Teflon Packing Gland ......................... 15 Provide easy access to the appropriate fire extinguishers
The Retaining Plate .............................................. 15 for your product. Consult with your local fire department
Disassembling the Meter ...................................... 16 and state and local codes to make sure that you are
Removing the Non-Corroded adequately prepared.
Rotor Gears .......................................................... 18
Removing Corroded Rotor Gears .......................... 18 Read this manual as well as all the literature provided in
Reassembling the Meter ...................................... 20 your owner’s packet.
Timing the Rotor Gears ........................................ 21
Torque Chart ......................................................... 22
Wrench and Socket Size Chart ........................... 23
In the Event of a Gas Leak
In the event of a large gas leak: Evacuate the area and
Troubleshooting .................................................... 24
notify the fire department.
How to Order Replacement Parts ........................ 26
Illustrated Parts Breakdown ................................. 27-30
In the event of a small, contained gas leak:
Quality Statement ................................................ 31
1. Stop the leak and prevent accidental ignition.
Please have the following information available when you 2. Prevent the entrance of gas into other portions of the
make inquires, order replacement parts, or schedule buildings. Some gases, such as LPG, seek lower
service. If a specific meter accessory is involved, please levels, while other gases seek higher levels.
provide the model and serial number of the accessory in
question (see page 4). 3. Evacuate all people from the danger zone.
Your Meter’s Serial Number: ________________________ 4. See that the gas is dispersed before resuming business
and operating motors. If in doubt, notify your local fire
Your Full-Service Distributor: _______________________ department.
Your Full-Service Distributor’s In the Event of a Gas Fire

Telephone Number: _______________________________ In the event of large fires or fires that are spreading:
Evacuate the building and notify your local fire department.
NOTICE Stop the leakage only if you can safely reach the equipment.
In the event of small, contained fires that you can

This manual provides warnings and procedures that are
safely control: Stop the leakage if you can safely reach
intended to inform the owner and/or operator of the
the equipment. Then use the appropriate extinguisher:
hazards present when using the Liquid Controls Meter
Class B fire extinguisher, water, fog, etc., depending on
on LP-Gas and other products. The reading of these
the materials. If in doubt, call your local fire department.
warnings and the avoidance of such hazards is strictly
in the hands of the owner-operators of the equipment.
Neglect of that responsibility is not within the control of
the manufacturer of the meter.
2
How LC Meters Work
Liquid Controls meters are positive displacement meters.

They are designed for liquid measurement in both custody
transfer and process control applications. They can be
installed in pump or gravity flow systems. Because of
their simple design, they are easy to maintain, and easy
to adapt to a variety of systems.
The meter housing (1) is designed with three cylindrical

bores (2). Three rotors, the blocking rotor (3) and two
displacement rotors (4, 5), turn in synchronized Meter Element Exploded Line Drawing
relationship within the bores. The three rotors are
supported by bearing plates (6, 7). The ends of the rotors Capillary seals mean no metal-to-metal contact within
protrude through the bearing plates. Blocking rotor gear the metering element. This means no wear. No wear
(8) is placed on the end of the blocking rotor. Displacement means no increase in slippage, and no increase in slippage
rotor gears (9, 10) are placed on the ends of the means no deterioration in accuracy.
displacement rotors. These gears create the synchronized
timed relationship between the three rotors. Throughout the metering element, the mating surfaces are
either flat surfaces or cylindrical faces and sections that
As fluid moves through the meter housing, the rotor are accurately machined. These relatively simple
assembly turns. The liquid is broken into uniform sections machining operations, plus the fact that there is no
by the turning rotors. Fluid displacement happens oscillating or reciprocating motion within the device,
simultaneously. As fluid enters, another portion of the permits extremely close and consistent tolerances within
fluid is being partitioned and measured. At the same time, the LC meter.
the fluid ahead of it is being displaced out of the meter and
into the discharge line. Since the volume of the bores is The product flowing through the meter exerts a dynamic
known, and the same amount of fluid passes through the force that is at right angles to the faces of the displacement
meter during each revolution of the blocking rotor, the exact rotors. The meter is designed so that the rotor shafts are
volume of liquid that has passed through the meter can be always in a horizontal plane. These two facts result in no
accurately determined. axial thrust. Therefore, with no need for thrust washers or
thrust bearings, the rotors automatically seek the center
This true rotary motion is transmitted through the packing of the stream between the two bearing plates eliminating
gland, the face gear, the adjuster drive shaft, and the wear between the ends of the rotors and the bearing plates.
adjuster to the register stack and counter. True rotary Once again, no wear results in no metal fatigue and no
motion output means consistent accuracy since the friction.
register indication is in precise agreement with the actual
volume throughput at any given instant. The Liquid Controls meters are made of a variety of materials
to suit a variety of products. Because of our no-wear
At any position in the cycle, the meter body, the blocking design, capillary seals, and unique rotary metering, LC
rotor, and at least one of the displacement rotors form a meters provide unequalled accuracy, long operating life,
continuous capillary seal between the un-metered upstream and unusual dependability.
product and the metered downstream product.
3
Owner
1. Is all your documentation included with your 2. Record your meter serial number in the space
meter? LC meters come in many variations. The provided on the inside cover of this manual. The inside
information sent to you depends on the accessories cover also provides a space for your full-service
you have ordered with your meter. Make an inventory distributor’s name and telephone number. Fill in this
of your owner’s information packet. First, find your information and keep it handy. You will always need
LC packing slip with the computer printout. Locate your meter serial number and model number when
the serial number and the meter model number on calling for service or parts! See ‘How to Order
this printout. Cross reference the packing slip number Replacement Parts’ in this manual.
with the actual meter numbers. The illustration on
this page will help you locate the Specification and
Serial Number Plates on the meter and its accessories.
4
Owner
3. Identify your meter

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

chart shown above to make sure that all the
documentation needed for your meter and accessories
is in your red information packet. If documentation is
missing, call your full-service distributor or Liquid
Controls for replacement materials.
5
Inst allation Requirement
Installation Requirementss
Make sure that all necessary safety precautions have been Position the meter with service in mind. Provide ample
taken. Provide for proper ventilation, temperature control, work space. Removing covers can be difficult when work
fire prevention, evacuation and fire management. space is not available. Always supply a platform or support
for the meter mounting.
Provide easy access to the appropriate fire extinguishers
for your product. Consult with your local fire department A meter is metallurgically designed to be physically
and state and local codes to make sure that you are compatible with a given type of liquid, as originally specified
adequately prepared. by the customer, and as indicated on the Serial Number
Plate. A meter should not be used with a liquid different
Read this manual as well as all the literature provided in from the liquid originally specified, unless the physical
your owner’s manual. If you have any questions, consult characteristics and pH rating are similar and the application
with your full-service distributor or call the Service has been checked with LC Sales and Engineering through
Department at Liquid Controls. your full-service distributor.
Install the meter and accessories in conformance with Install a strainer on the meter inlet to avoid damage from
applicable state and federal construction, electrical and foreign matter, such as weld slag, from entering the system.
safety codes. The strainer must always be located on the inlet side.
NOTE: Class 10 LPG meters must be installed in All meters are tagged identifying their direction of flow.
accordance with the requirements of ANSI-NFPA 58 in Meters are set with a flow direction of left to right as
addition to all other state and local codes. standard. However, when a meter is ordered, the customer
can specify that the flow be set from either direction. If the
WARNING: Under normal operation, do not expose any meter register counts in reverse, the meter is reading the
portion of the LP-Gas system to pressures in excess of direction of flow in reverse. If this occurs, the meter
rated working pressures without an automatic safety valve registration must be reset. See ‘Reversing the Meter
to vent the over pressure discharge to a place of safety Registration’ in this manual for mechanical output meters.
away from the operator and other people. Failure to provide Refer to your accessory manual for electrical output meters
such a safety relief may result in leakage or rupture of one (such as meters equipped with a pulser).
or more of the components in the system. This can result
in injury of death from the gas, a fire, or pieces of flying
debris from the rupture.
Before shipment, protective thread caps were placed in all

meter and accessory openings. They should remain in
place until you are ready to attach piping.
Prior to meter installation, the entire piping system should NOTE

be thoroughly flushed of all debris, with a liquid that is
compatible with the construction of the meter. Always request up-to-date, engineering approved,
dimensional drawings before starting any construction.
Keep external surfaces of the meter clean. Do not rely on catalog pictures or drawings which are
for reference only. After receiving prints, check to see
The meter must always be securely bolted to a platform or that all equipment ordered is shown and that any extra
supporting member, regardless of the mounting position pressure taps, plugs, etc. are noted and their size
of the meter. Never ‘hang’ a meter on the connecting piping. specified.
Install meter only on the discharge side (downstream) of

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

calibration purposes.
7
Meter S
Sttart Up and Operation
Prior to meter start up,

up use extreme caution. Make Filling the system with a pump - Consult the pump
sure that: manufacturer for proper pump priming. Once the pump is
primed with product, proceed as follows:
1. The meter is properly secured
2. All connections are tight • Follow steps one through four above for proper meter
3. All valves are in the closed position start-up.
Placing your meter in operation: When placing your NOTE

meter in operation, the meter and system must be filled
slowly with liquid and be free of air prior to start-up. Extreme
Make sure that your pump can operate against a
care must be taken to avoid damaging the meter during
dead head pressure. If NOT
NOT,, consult the factory
this time. The system may be filled by gravity (preferred)
for assistance.
or by use of the pump (if required) when filling the system
with liquid for the first time.
Never operate the meter or system when partially
Gravity filling - systems with positive head pressure filled with liquid, or with pockets of compressed air
from product storage above the inlet port of the meter. or vapor present. If these conditions cannot be
avoided, air and vapor elimination systems may be
1. Make sure all valves (up stream and down stream of required. If you cannot fill the meter slowly by
the meter) in the system are closed. gravity or by using a valve to throttle back the flow,
consult the factory
factory..
2. Crack open the valve located at the storage tank. The
meter’s register/counter will start to move and then Do not operate the meter at a pressure exceeding that
stop, provided there is not a valve between the tank marked on the Serial Number Plate. Under any and all
and the meter inlet. If there is another valve between pressure producing circumstances, for instance, thermal
the tank and meter, repeat this process with each valve expansion and hydraulic shock, the working pressure
until the meter is exposed to the liquid. must not exceed the indicated maximum.
3. Once you are assured that the meter has registered If the meter is operated at a rate greater than the
some volume and stopped, continue to fully open the maximum recommended GPM, excessive wear and
tank valve. premature failure may occur.
4. With the valve(s) open between the tank and the meter, The meter can be calibrated for flows below minimum
now go to the valve located down stream of the meter. ratings if the flow remains constant and varies within
Open the down stream valve slowly until the meter’s narrow limits or if the product is viscous. A meter should
register/counter starts to move. Do not run the meter never be run beyond the maximum flow rate determined
any faster than 25% of its rated flow during start-up. for that class meter and/or liquid measured.
Once the product is flowing out the end of your system,
the outlet valve can be opened all the way provided
that the system is designed not to exceed the flow ! WARNING
WARNING
rate marked on the meter.
NOTE
NOTE: If the valves are not manual, consult the valve disassembly or inspection of the strainer, air eliminator,
manufacturer for slow flow start-up. any valves in the system, the packing gland, and the
(page 11).
8
Reversing the Meter Registration
The direction of flow is specified by the customer when

the meter is ordered. The standard direction of flow is
from left to right when facing the front of the meter. A red
pressure sensitive label indicating inlet is affixed to the
meter at time of shipment.
If the meter is equipped with a strainer and/or valve, the

strainer (and/or valve) MUST be moved when reversing the
direction of flow through the meter. The strainer should
always be located on the inlet side of the meter
meter.. When
the meter is equipped with a valve, it is moved to the outlet Adjuster drive gear
side of the meter. Some repositioning of the valve engaged from the top.
components may be required. See the Valve Manual in Adjuster drive gear
the Owner’s Information Packet. engaged from the
bottom.
When the meter is first installed, check the register. If the
register counts DOWN, meaning that the register numbers
decrease rather than increase, you must reverse the
direction of registration by reversing the position of the
adjuster drive gear.
7. Reassemble the parts in reverse order. Make sure
that the adjuster drive gear meshes with the packing
Reversing the drive to the register is accomplished by
gland’s pinion gear (6) without being too tight. Make
reversing the position of the adjuster drive gear relative to
sure there is a little play in the gear teeth. The retaining
the pinion gear of the packing gland, as shown to the left.
ring (4) should be placed in the groove provided on the
See below for step-by-step instructions.
drive shaft (3), regardless of the adjuster drive gear
position. The packing gland pinion gear to adjuster
drive gear ratio is either 1:1 or 2:1. In the 2:1 ratio, the
pinion of the packing gland is smaller in diameter.
2. Remove the retaining ring (4) with a screwdriver or

pliers.
3. Remove the two retaining spring screws (1) with a

standard screwdriver. Note: For M-15, M-25, M-30,
and M-40 models loosen the single set screw.
4. Remove the retaining spring (2).
5. Remove the drive shaft (3) mounted with the adjuster

drive gear assembly including (4) Retaining Ring and
(5) Adjuster Drive Gear.
6. Remove the adjuster drive gear (5) and turn it 180° so

that it is upside down from the original installation
position. The bushing (7) supports the adjuster drive
gear in the lower position. The retaining ring (4)
supports the adjuster drive gear in the upper position.
Packing Gland
9
Setting the S
Sttandard Adjuster
NOTE: These instructions apply to meters equipped with

mechanical output accessories only. If your meter is
equipped with an electrical output (i.e., electronic pulser)
refer to your accessory manual, such as the Pulser Manual

2. Check meter registration by delivering product to a

reliable, accurate prover. Perform multiple delivery tests
to verify the meter repeatability.
3. Record the setting indicated on the adjuster:
4. Note the difference between the volume of the prover

and the volume indicated on the meter counter.
Calculate the % correction required, as follows:
Volume in prover - volume on meter counter

% correction = X 100
volume in prover
5. Loosen the adjuster clamp screw.
6. When the prover volume is less than the meter counter

volume, add the percentage to the original adjuster
setting by turning the thimble towards the arrow marked
larger (volume). Correct the original setting by
approaching the number desired from the next larger
number. For example, if the desired adjuster setting
is 2.4, turn the adjuster thimble to the left to number
5, then to the right to obtain the 2.4 setting. Adjuster
is currently set at 2.3 in the illustration to the right.
7. When the prover volume is more than the meter

counter volume, subtract the percentage from the
original adjuster setting by turning the thimble in the
direction of the arrow marked smaller volume percent.
8. Retighten the adjuster clamp screw. Run product

through the meter to allow the adjuster to take a set.
Then make several prover runs to check for accuracy
Meter Maintenance and Seasonal meter storage If the meter is used for seasonal
work, at the end of each season the meter should be
repeat ability
ability..
repeatability removed from the system and thoroughly flushed with a
Prevent pipe strain or stress from occurring when making compatible liquid. This includes removing the drain on the
meter or accessory repairs. Pipe strain and stress occurs front and rear covers. Then flush the product from the front
when the pipes are not supported or are not aligned and rear covers. If flushing with water is preferred, extra
correctly to the meter. The weight of the pipes must always care should be taken to drain the meter completely and
be supported independent of the meter. This means that dry all internal parts. Immediate refilling with a compatible
the meter and accessories can be easily removed without liquid (or oil misting) is essential to prevent corrosion as
affecting the pipes or the pipe alignment. Never leave any well as ice damage to parts from moisture that was
of the pipes hanging. overlooked after flushing and drying.
10
Meter Maintenance
Do not mar or scratch any of the precision machined appear evenly placed. If the bolts are bent, check the
surfaces by prying or sanding parts. housing and cover for flatness. Use a straight edge to
determine flatness.
Torque all fasteners such as screws and bolts in
accordance with specifications listed in the ‘Torque Chart’ Look for gap
gaps s when disassembling a meter. Use a feeler
in this manual (page 22). gauge to check for gaps between the bearing plate and
housing. If you do find gaps, check the bearing plates for
Stone the machined surfaces when reassembling the flatness with a straight edge. Gaps can be caused by
meter to assure that the machined surfaces are free of shock problems that must be resolved. Contact your full-
burrs and mars. service distributor for assistance if this occurs.
Repair pulled threads with threaded insert fasteners. Check the O-rings for damage. Cracked, rough, or worn
These can be used in many instances. Contact your full- O-rings should be replaced. However, a more serious
service distributor for advice if this occurs. problem of shock may be indicated if the O-rings look
nibbled. Shock problems must be verified and resolved.
Coat threads with anti-seize when removing and replacing Contact your full-service distributor for assistance if this
bolts and castings in a meter. occurs.
Removing flange gaskets When removing the flange Check the bearing plates for flatness. Use a straight
assembly, always carefully scrape off the flange gaskets. edge. Warped bearing plates can be caused by shock
Make sure that the flange surface has been scraped clean. problems that must be resolved. Contact your full-service
Discard the old flange gasket and install a new flange distributor for assistance if this occurs.
gasket. Never reuse old flange gaskets.
Check with regulatory agency that governs Weights &
Examine all fasteners to make sure they are not bent, Measures in your area. Removing the dust cover seal
rusted, or have pulled threads. The threads should all wire or other maintenance procedures may require Weights
& Measures recalibration.
! WARNING
WARNING
Relieving Internal Pressure

All internal pressure must be relieved to zero pressure
before disassembly or inspection of the strainer, air eliminator any valves in the system,
the packing gland, and the front or rear covers.
Serious injury or death from fire or explosion could result from maintenance of an
WARNING
improperly depressurized and evacuated system.
Procedure for Non-LPG Meters 4. Slowly open the valve/nozzle at the end of the supply
1. Turn off pump pressure to the system. line.
2. Close valves before and after the meter. 5. After product has bled off, close the valve/nozzle at
3. Remove pressure by removing the drain plugs and the end of the supply line.
draining the meter. 6. Slowly crack the fitting on top of the differential valve
to relieve product pressure in the system. Product
Procedure for LPG Meters will drain from the meter system.
1. Close the belly valve of the supply tank. 7. As product is bleeding from the differential valve, slowly
2. Close the valve on the vapor return line. reopen and close the valve/nozzle on the discharge
3. Close the manual valve in the supply line on the inlet line. Repeat this step until the product stops draining
side of the meter. If no manual valve exists on the from the differential valve and discharge line valve/
inlet side, consult the truck manufacturer for nozzle.
procedures to depressurize the system. 8. Leave the discharge line valve/nozzle open while
working on the system.
11
Componentss
Removing the Dust Cover
1. Cut the dust cover seal wire with a side cutters.
Remove the dust cover screws with a 5/16’ wrench or
slotted screwdriver and then remove the dust cover.
See “Relieving Internal Pressure” and “Regulatory
Agency” in the ‘Meter Maintenance’ section (page
11) of this manual.
Removing the Adjuster and Adjuster Drive Assembly
1. Record the adjuster micrometer setting.
2. Carefully note the adjuster drive gear position. The

gear engages the packing gland pinion from below or
above. This gear must be reinstalled in its original
position or the meter counter will run backwards.
12
Componentss
3. Use a standard screwdriver to loosen (or remove) the

two retaining spring screws.
4. Swing the retaining spring off the adjuster drive bushing.
5. Loosen the adjuster mounting clamp screw with a

phillips head screwdriver.
Removing the adjuster from the top of the meter when top
access is easiest. Front access instructions are on the
next page.
6. Remove screws that secure adjuster mounting plate

to counter adapter.
7. Lift adjuster mounting bracket with adjuster out of the

counter adapter.
13
Componentss
Removing the adjuster from the front of the meter when

front access is easiest. Top access instructions are on
the previous page.
10. Remove the slotted head screw that secures the

adjuster to the mounting plate.
11. Bring the adjuster out through the front of the meter
by rotating it from left to right to clear the adjuster
mounting plate and then pull down to remove from the
meter.
! WARNING
WARNING
(page 11).
Servicing the Packing Gland

The packing gland is affected by the liquid being metered,
the operating temperature, and other system conditions.
After prolonged use, the gland may show leakage from
the metering chamber. This is a sign of wear. The gland
should be replaced or repaired if this occurs. It can be
serviced in the field.
1. Remove the two packing gland retaining plate screws

with a 5/16” socket and ratchet drive extension or
5/16” nut driver.
2. Pull out the packing gland.
3. Take apart the packing gland by gently prying off the

retaining ring with a standard screwdriver.
4. Pull the driver out from the assembly.
14
Buna/V iton/T
Buna/Viton/T eflon Packing Gland
iton/Teflon
Packing Gland Component

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

Retaining
The retaining plate has four holes: two that are drilled 1-1/
2” on center and two that are drilled 1-5/8” on center. If
your meter has a counter adapter dust cover (Item #0366)
shaped like the illustration shown below, use the holes
drilled 1- 5/8” on center to mount the packing gland retaining
plate.
If your meter does not have the counter adapter dust cover
shaped like the illustration shown on the right, use the two
holes drilled 1-1/2” on center to mount the packing gland
retaining plate.
Item 11 (above)
Adapter Dust Cover for holes

drilled 1-5/8” on center
15
Mechanical Output Meters*
! WARNING
WARNING
(page 11).
* For electrical output meters refer to the Pulser Manual

1. Remove the counter bracket screws with a box wrench

or socket driver. The counter bracket can be removed
with or without removing the adjuster assembly.
NOTE: For Aluminum M-30 and M-40 models the counter

bracket and front cover are one piece. Go to step 2.
2. Turn the meter on either the inlet or outlet side. Let it

stand to allow the product to drain from the meter
chamber.
3. Locate the drain plugs on the front and rear covers.

Remove the drain plugs using an allen wrench. Let the
meter stand to allow product to drain from the front
and rear covers.
16
4. Use a socket wrench or box end wrench to remove

the screws securing the front cover. Remove the
screws that hold the rear cover. The number of screws
will vary depending on meter size.
5. Remove the front and rear covers. MA-4, M-5, and

MA-5 old style models, M-60 and M-80 current
models have a driven reduction gear attached with a
shoulder bolt to the center of the front bearing plate.
6. Carefully remove the O-rings / flat gaskets from front

and rear of the housing. Undamaged Buna or Viton O-
rings may be reused. Flat gaskets and Teflon O-rings
should always be replaced and never reused.
7. Hold a spare displacement rotor gear between the right

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

Rotor gears are on the front.
8. Hold the spare gear between the left displacement

rotor gear and blocking rotor gear. Use the rotor gear
wrench or socket to remove the screw and the packing
gland driver held by the screw.
9. Hold the spare gear between the right displacement

rotor gear and the blocking rotor gear. Use the rotor
gear wrench or socket to remove the left displacement
rotor gear screw and washer.
17
Removing Non-Corroded Rotor Gears
1. Insert two standard screwdrivers behind the blocking
rotor gear: Gently pry the gear off its rotor tapered
end. If the gears show signs of corrosion, or do not
pry off easily, use the alternative method described in
steps 5-8.
2. Use the same method to remove the left rotor gear

and the right rotor gear. Remember, if the gear does
not pry off easily, or feels stuck, use the alternative
method described in steps 5-8.
3. As each gear comes off the rotor remove the key (1)
from the rotor keyway (2). Save the key to use when
reassembling the meter.
4. Use the bearing plate wrench to remove the screws

that hold the front bearing plate to the meter housing.
On the back of the meter housing, remove the screws
that hold the rear bearing plate to the housing. Go to
step 1, Removing the Bearing Plates.
Removing Corroded Rotor Gears

5. Replace all three rotor gear screws, without washers,
halfway onto each of the rotor ends.
6. On the back of the meter housing, remove the screws

that hold the rear bearing plate to the housing using
the bearing plate wrench or socket. The number of
screws varies with the size of meter.
18
7. With a plastic or non-metallic mallet, tap on the heads

of the screws lightly and equally. As you tap on the
screw heads, the gears are driven off the rotors. As
the rotors are driven in, the rear bearing plate and the
rotor assembly are pushed away from the housing.
NOTE
NOTE: For carbon insert bearing plates, remove the
rear plate first and then each rotor as it is hand
supported.
8. Use the bearing plate wrench or socket to remove the

screws that hold the front bearing plate to the meter
housing. The number of screws varies between different
meter sizes.
Removing the Bearing Plates

and Rotors
1. Insert a screwdriver into each of the two notches near
the dowel pins. Be careful not to mar any of the
surfaces. Gently pry the front bearing plate off the dowel
pins.
2. Remove the front bearing plate and rotor assembly by

pulling a rotor straight out from the housing. Be careful
not to mar any of the surfaces. MA-4, M-5, and MA-5
Pull the rotor from the rear bearing plate. This will also
remove the drive reduction gear which is attached to
the blocking rotor.
3. Remove the remaining bearing plate from the other

side by inserting a screwdriver into each of the two
notches near the dowel pins. Be careful not to mar
any surfaces. Gently pry the front bearing plate off the
dowel pins. NOTE: MA-4, M-5, and MA-5 old style
models, M-60 and M-80 current models have a
driven reduction gear in attached with a shoulder bolt
to the center of the front bearing plate.
4. Inspect and clean all critical surfaces like gear teeth,

rotors and internal housing faces. Remove any
crystalline formations using fine emery cloth or a fine
wire brush. Be careful not to mar or alter the shape of
any of the parts. Changing the shape of the parts may
interfere with their operation. Remove nicks and burrs
on metal parts with a stone. Remove all grit and other
foreign particles. These may also damage parts and
interfere with proper operation. Replace all parts that
appear worn or damaged.
19
1. MA-4, M-5, and MA-5 old style models, M-60 and

M-80 current models: Rotor gears are on the rear
bearing plate. All other models: Rotor gears are on
the front bearing plate. Install the non-rotor gear bearing
plate using the bearing plate screws and wrench.
2. Insert the non-tapered ends on the three rotors into

the housing. Place each rotor into its respective bore
in the installed bearing plate. MA-4, M-5, and MA-5
Make sure that the teeth of the driving reduction gear
mesh with the teeth of the driven reduction gear.
3. Place the remaining bearing plate over the three tapered

rotor ends and fasten it with the bearing plate screws.
Use the bearing plate wrench. The number of screws
varies with meter size.
4. The rotors should have a small amount of end-play

and be easy to turn. Test each rotor, one at a time.
Turn the rotors to make sure that they revolve freely.
Jog the rotors from end to end to check for end-play.
If they do not move easily in both tests, remove the
rotors and check for burrs and corrosion deposits.
Clean them thoroughly.
Repeat Steps 2, 3 and 4.
5. The rotor key is a small wedge of metal. Each rotor

has a notch, or “keyway”, to hold a key. Position a
key into each one of the three rotors. Press the keys
into the rotor keyways with your thumb and forefinger.
6. Slide the blocking rotor gear on its tapered rotor end.

Slide the right displacement rotor gear on its tapered
rotor end so that the timing marks line up between the
two gears. See ‘Timing the Rotor Gears’ on the next
page. Hint: Before you place the right displacement
rotor gear on its tapered end, hold the right rotor gear
in position. Turn the blocking rotor gear. Try to line up
the timing marks before you place the right
displacement rotor gear on its tapered rotor end.
7. Position the left displacement rotor gear on its tapered

rotor end so that its timing mark lines up with the
blocking rotor gear. See ‘Timing the Rotor Gears’.
20
Timing the Rotor Gears
Rotor gears are timed by lining up the timing marks. The
blocking rotor gear has a tooth directly in front of its
timing mark. On the displacement rotor gears, the timing
mark falls in front of the space between two gear
teeth. Make sure that the tooth in front of the timing mark
on the blocking rotor gear connects with the space in
front of the timing mark on the displacement rotor gear.
You may need to remove the gears and reposition them
several times on their rotor ends in order to get the timing
marks to line up correctly. For more information, See
‘Troubleshooting’.
1. Position the spare displacement rotor gear between 7. Install the front drain plug (6) in the front drain plug
the left displacement rotor gear and the blocking rotor hole (7) using the drain plug allen wrench.
gear to prevent the gears from moving. Attach the right
displacement gear washer and screw using the rotor 8. Install an O-ring (8) into the groove (9) on the rear of
gear wrench. Tighten the screw to the torque the meter housing. The M-60 and M-80 models use
specification listed in the Torque Chart (page 22). a flat gasket.
2. Keep the spare displacement rotor gear positioned by 9. Fasten the rear cover (10) with the cover screws (11)
the left displacement rotor gear. Attach the left using the cover socket or open end/box end wrench.
displacement gear washer and screw using the rotor NOTE: 9A.
9A LC recommends tightening the rear cover
gear wrench. Tighten the screw to the torque screws in a criss-cross or “star” pattern with a minimum
specification listed in the Torque Chart. of two passes. First pass should be at half torque,
3. Position the spare displacement rotor gear between uniform seal compression on cover O-ring or gasket.
the right displacement rotor gear and the blocking rotor See M-7 pattern on page 22 reference.
gear. Attach the blocking rotor gear with the packing
gland driver and screw using the rotor gear wrench. 10. Install the rear drain plug (12) in the rear drain plug
Tighten the screw to the torque specification listed in hole (13) using the drain plug allen wrench.
the Torque Chart.
4. Rotate the gears to make sure that the rotors turn 11. If your meter is equipped with an electrical output
freely. Burrs, foreign material, or marred surfaces can accessory, such as a digital pulser, reinstall it according
restrict the rotor movements. It may be necessary to to the instructions outlined under ‘Reinstalling...’ in
remove the gears and rotors and deburr and clean the your accessory manual, such as the Pulser
surfaces again. Installation, Operation and Maintenance Manual
supplied in your owner’s information packet. Install
5. Install an O-ring (1) into the groove (2) on the front of the front drain plug (6) in the front drain plug hole (7)
the meter housing. The M-60 and M-80 models use a using the drain plug allen wrench.
flat gasket.
6. Fasten the front cover (3) with the cover screws (4)
using the cover socket or open end/box end wrench.
NOTE: 6A. LC recommends tightening the front cover
screws in a criss-cross or “star” pattern with a minimum
of two passes. First pass should be at half-torque,
uniform seal compression on cover O-ring or gasket.
See M-7 pattern on page 22 for reference.
Meter Assembly Exploded View
21
Torque Chart
TORQUE PATTERN M-7 COVERS
PA
Torque Chart
*Torque Tolerance is ± 10%
22
Wrench and Socket Size Chart
NOTE: FOR ROTOR GEAR SCREWS
Please apply these techniques when repairing meters in the field.
1. Prior to installation, apply a small amount of Locquic Primer N764 to each screw.
2. Apply a light coat of Loctite 242 in three even strokes to each screw. The Loctite and Locquic primer are not
to be applied to the female connection in the rotor.
23
Troubleshooting
! WARNING
WARNING
All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in the
system, the packing gland, and the front or rear covers. See “Relieving Internal Pressure” (page 11).
PROBLEM:
Leakage past packing gland drive shaft housing from internal metering chamber.

Internal seal of packing gland assembly is worn. Replace packing gland and O-ring seal.
OPERATING NOTE:
OPERATING
Two common causes of packing gland leakage are thermal expansion and hydraulic shock. If two valves in a
piping system (on either side of the meter) are closed at one time, and if the temperature rises as little as 1°F in
the system, it could result in a rise in pressure within the system that would exceed the working pressure rating
of the meter. To avoid this hazard caused by thermal expansion, a pressure-relief valve of some kind must be
installed in the system. Hydraulic shock occurs when a large volume (mass) of liquid is moving through a pipe line
at some flow rate and a valve is suddenly closed. When the flow is stopped, the entire mass of the liquid in the
piping system acts as a battering ram causing a shock effect within the meter. The greater the mass length of line
and/or velocity, the greater the hydraulic shock. Since the valve is usually located at the meter outlet, the meter
housing, packing gland and the meter internal members receive the full impact of such hydraulic shock. To prevent
this hazard a slow closing two-stage valve should be used with the meter. On those systems where mass length
of line, etc. are of such magnitude as to preclude the elimination of hydraulic shock with the use of a two-stage
slow closing valve, an impact-absorbing air cushioning device should be used.
PROBLEM:
Leakage from the cover gasket.

Gasket has been damaged due to shock pressure or cover bolts have not been tightened sufficiently.
PROBLEM:
Product flows through meter but the register does not operate.

A. Check packing gland, and gear train.
B. If all meter parts are moving then problem is in register. Faulty register should be checked and repaired by
trained mechanic.
C. Remove register from meter. If all meter parts are moving but output shaft of adjuster assembly is not, adjuster
is worn and must be replaced.
D. If totalizer numerals (small numbers) on register are recording, but the big numerals are not moving, register
needs repair.
E. Packing gland gear not turning. For M-60 and M-80 meters, the drive blade may be sheared. Replace the
packing gland. This may be caused by starting the flow too rapidly.
24
Troubleshooting
PROBLEM:
Breaking teeth on timing gears.

A. Starting or stopping flow in meter too rapidly.
B. Pump bypass not adjusted properly.
PROBLEM:
Product flows through meter but register does not record correctly.

A. Adjuster not properly calibrated.
B. Incorrect gear plate or gear ratio has been installed.
C. Air is in the system.
PROBLEM:
No flow through meter.

A. Faulty non-functioning pump.
B. Valve not open or not functioning.
C. Meter “frozen” due to build-up of chemical “salts” or foreign material inside metering chamber. To correct,
clean the meter and inspect for damage.
PROBLEM:
Meter runs too slowly.

A. Valve internal mechanism faulty. Valve does not open fully.
B. Meter gears or rotors partially “salted” enough to slow up rotation of parts. To correct, clean the meter.
C. Downstream restriction.
D. Clogged strainer basket.
PROBLEM:
The meter counts down in reverse (the meter numbers decrease).

It is necessary to reverse the direction of flow by reversing the adjuster drive gear. See ‘M-7/MA-7 Meter Start Up
and Operation: Reversing the Meter Registration’ in this manual.
25
How to Order Replacement Parts
Parts
1. Refer to the exploded view drawings on Pages 27-31. The Bills of Material for most meter classes are on
Find the four digit item number for the part you want to the LC public website. Always check the website for
order. The item numbers are listed on the exploded the most current BOM.
drawings.
2. Find the computer printout titled Parts List that has

been inserted in the Owner’s Information Packet which
was shipped with your order. Look up the item number
on the Parts List. The Parts List shows each item
number with a corresponding part number. Find the
corresponding five digit part number for the item you
want to order. The part number represents an individual
piece, a kit, or a complete assembly.
3. Inform your distributor of the part number that you need.

The part number is the only number that allows the
distributor to find the correct component for your meter.
26
Illustrated Part
Partss Breakdown
M5 through M25 Meters (including MA Meters)
NOTE
ART NUMBERS.
NOTE
27
Illustrated Part
Partss Breakdown
M30, M40 Meters
NOTE
ART NUMBERS.
NOTE
28
Illustrated Part
Partss Breakdown
M60, M80 Meter Cover
NOTE
ART NUMBERS.
NOTE
29
Illustrated Part
Partss Breakdown
M60, M80 Meter Element
NOTE
ART NUMBERS.
NOTE
30
Quality S
Sttatement
At Liquid Controls, we are dedicated to being the world leader in the field of liquid measurement.
Everyone associated with the enterprise must be committed to our quality effort and pursuing perfection.
To gain satisfaction in the eyes of our customers, we must accurately define and fulfill the customers’ present and
continuing needs.
We will strive to minimize the users’ cost by providing products of high reliability, maintainability, serviceability, and no of
no planned obsolescence, which combine to give the customer superior value.
Our people are our greatest resource. We will create a positive, team-oriented environment which every person has trust
and respect for one another, is recognized for achievement, and motivated toward excellence.
Absolute accountability for our efforts is determined by significant measures: our customers’ level of satisfaction, the
development of our people, and our contribution to the community.
Our goal is to be Simply the Best

Best.
31
A Unit of IDEX Corporation
105 Albrecht Drive
1.800.458.5262 • 847.295.1050 © 2004 Liquid Controls
Fax: 847.295.1057 Pub. No. 48683
www.lcmeter.com (05/04)
PARTS MANUAL
LIQUID
® ® ® CONTROLS
M-7, MA-7, M-10 Meters A Unit of IDEX Corporation
Exploded View: M-7/MA-7/M-10 Meter Covers
CAUTION
T
SHA F LO
T WITH S E
AL RIV
IGN COUNTER D
0
2
1 0202 Adjuster
6
0
1
2 4
5 assembly
3
0609 Screw, mounting

plate (2)
0364 Plate, adjuster mounting
0613 Screw, adjuster 0126 Bracket, counter adapter
0366 Plate, 0382 Shaft,

dust cover adjuster
0336 Gear
0574 Ring,
retaining
LIQUID
CONTRO
LAKE BL LS CO
UFF, IL, RP.
MODEL USA
NO.
SERIAL
NO.
®
VOL/REV
ACCURA
CY
TEMP ER
FLOW ATURE
RATE
MAX PRES
PRODUC SURE
T
UK81
1783
0165 Gear,
packing gland
0250 Packing 0705 Washer,
Gland Assy. flat (4)
0673 Screw (4)
0780 Seal
wire
Driveshaft bushing (2)
0630 Screw (2)
0603 Screw (2)
How to Order
Replacement Parts 0566 Plug,
pipe-hex socket
(2, one for each cover)
1. Find the item number listed on the exploded
drawing. The 4 digit item numbers are listed
with a word description. 0125 Cover, rear
2. Find the computer printout titled Parts List that
has been inserted in this manual. Look up the item 0627 Hex washer head screw
number on the Parts List. The Parts List shows each (20, for both covers)
item number with a corresponding part number.

Find the corresponding 5 digit part number for the
item you want to order. The part number represents
an individual piece, a kit or a complete assembly.
3. Inform your distributor of the part number that you
need. The part number is the only number that
allows the distributor to find the correct component
for your meter.
When placing order for replacement parts please
reference the meter's serial number.
®
Front cover Rear cover

0570 Pipe plug (optional)
0153 Rotor, blocking

0611 Screw, hex head
w/lockwasher (64 per plate)
0528 Key (3)
0161 Gear, (1 per rotor)
blocking rotor
0326 Driver,
packing gland
*0675 Screw,
cap socket head .
CORP
ROLS A
CONT US
LIQUID BLUFF, IL,
LAKE L NO.
MODE
NO.
SERIAL
0765 Washer, Lock
0673 Screw, 0318 Pin, dowel (4)

0163 Gear,
hex washer head (2)
displacement pinion (2) 0372 Plate, serial number
0771 Bellevue washer, 0144 Plate, bearing (2) 0155 Rotor, displacement (2)
0110 Housing
rotor gear (2)
0430 O-Ring (2)

Exploded View: M-7/MA-7/M-10 Meter Housing
*For M-10 Meter Blocking Rotor,

#0672 Shown HereReplaces #0675
0672 Screw, blocking rotor
SOLD AND SERVICED BY
A NETWORK OF HIGHLY TRAINED
FULL SERVICE DISTRIBUTORS
Backed By Our Worldwide Reputation For

Quality, Accuracy and Advanced Design.
WARRANTY: charge, ex-works factory. In no event shall Seller be liable of installation, start-up and servicing of Electronic Products
Liquid Controls (“Seller”) products are warranted against for any special, consequential, incidental, indirect or by Seller trained service representatives, this warranty is
defects in material or workmanship for a period of one (1) exemplary damages arising out of warranty, contract, tort null and void. Seller’s obligations as set forth above shall
year from date of installation, provided that the (including negligence) or otherwise, including but not lim- not apply to any product, or, or any component or part
warranty shall not extend beyond twenty-four (24) months ited to, loss of profit or revenue, loss of use of the product or thereof, which is not properly installed, used, maintained
from the date of original shipment from Seller. Seller’s any associated products and/orequipment, cost of substitute or repaired, or which is modified other than pursuant to
obligations, set forth below, shall apply only to failure(s) to goods or services, downtime costs or claims of or by Seller’s instructions or approval. NOTE: The above
meet the foregoing obligations provided that Seller is given Purchaser’s clients or customers. In any event, the total warranty applies only to products manufactured by Liquid
written notice within thirty (30) days of any occurrence liability of Seller for any and all claims arising out of or Controls, Lake Bluff, Illinois. Private label, OEM, and/or
from which a claim of defect arises. If a warranty dispute resulting from the performance, non-performance or use of products manufactured by Liquid Controls licensee(s) are
occurs, the Purchaser shall be required to provide Seller the product shall not exceed the purchase price of the indi- specifically excluded from the above warranty. Consult
with proof of date of sale. The minimum requirement to vidual product giving rise to the claim. All other guaranties, factory for all non-Liquid Controls manufacturers’
establish date of sale shall be a copy of the Seller’s invoice. warranties, conditions and representations, either express or warranties. NO IMPLIED OR STATUTORY WARRANTIES
In the event that a factory inspection by Seller or its implied, whether arising under any statute, common law, OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
designee(s) supports the validity of a claim, at the commercial usage or otherwise are excluded. Electronic PURPOSE SHALL APPLY.
discretion of Seller, repair, replacement or refund shall be Products require installation, start-up and servicing by
the sole remedy for defect and shall be made, free of local factory-trained service representatives. In the absence
Backed By Our Worldwide Reputation For Quality, Accuracy and Advanced Design.
LIQUID LIQUID CONTROLS
A Unit of IDEX Corporation Distributed By:
CONTROLS 105 Albrecht Drive
A Unit of IDEX Corporation (847) 295-1050
FAX: (847) 295-1057
Website: www.lcmeter.com
Printed with vegetable inks on recycled paper. Please Recycle!
© 2001 Liquid Controls Printed in U.S.A.(03/01) Bulletin #48496B $1

VALUE 90 11/2"
AUTOMATIC BULK FUELING NOZZLE
Catlow’s Value 90 Nozzle is an extra heavy duty, high flow, bulk fueling nozzle for marine, truck and bus or home fuel
oil delivery.
The Value 90 has been designed for durability and yet economically priced. This rebuildable nozzle comes complete
with automatic venturi shut-off and a dual position, hold-open mechanism.
Features:
• Curved lever design for easier gripping
• Dual Poppet Assembly makes nozzle easier to open against high inlet pressure
• Dash Pot minimizes line shock
• Dual position hold-open mechanism for user friendly operation
• BSPP and BSPT threads available upon request
Benefits:
• Strong body casting resists cracking
• Venturi type automatic shut-off prevents accidental spillage
• Spout assembly easily replaced
• Nozzle design allows easy access to awkward fueling
positions
• Lighter in weight
Materials:
• Body.......Aluminum
• Weight....5.3 lbs.
• Inlet........11/2" NPT
• Spout.....Aluminum 1 3/8" OD
• Seals......Viton and Buna
Ordering Specifications:
• CV90-001 11/2" Bulk Fueling Nozzle, New
• CV90-002 11/2" Bulk Fueling Nozzle, New (ULC)
• RV90 11/2" Bulk Fueling Nozzle, Rebuilt
Accessories:
• V90S Replacement spout assembly
• V90SW 1 1/2" x 1 1/2" Swivel
CATLOW Inc. Sales Desk (800) 222-8569

Sales Fax (937) 898-8631 Phone (937) 898-3236
2750 US RT 40, Tipp City, OH 45371
© 2006 CATLOW Inc. All Rights Reserved CV900306
BLACKMER TRUCK PUMPS 960280
INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS INSTRUCTIONS NO. 201-A00
Page 1 of 12
MODELS: TX, TXS, TXD, TXSD 1.5, 2A, 2.5A, 3E, 4A Section 200
TXV 2.5B, 3B Effective March 2003
Replaces June 2001
and Discontinued TX(S) 2, 21/2, 3; TXV 2(A)(B), 21/2(A), 3(A) Models
SAFETY DATA
This is a SAFETY ALERT SYMBOL.

When you see this symbol on the product, or in the manual, look for
one of the following signal words and be alert to the potential for
personal injury, death or major proper ty damage.
Warns of hazards that WILL cause serious personal injury,

death or major proper ty damage.
TABLE OF CONTENTS Page
SAFETY DATA .................................................................1-2 Warns of hazards that CAN cause serious personal injury,
PUMP DATA .........................................................................2 death or major property damage.
Technical Data.......................................................2
Initial Start Up Information .....................................2
Warns of hazards that CAN cause personal injury
INSTALLATION ...............................................................2-3 or property damage.
Pre-Installation Cleaning .......................................2
Location and Piping...............................................2 NOTICE:
Truck Mounting......................................................3 Indicates special instructions which are very
Pump Drive............................................................3 impor tant and must be followed.
Pump Rotation.......................................................3
To Change Pump Rotation ....................................3
OPERATION .....................................................................4-5
NOTICE:
Pre-Start Up Check List.........................................4
Blackmer truck pumps MUST only be installed in
Start Up Procedures ..............................................4
systems which have been designed by qualified
Pump Speed..........................................................4 engineering personnel. The system MUST conform to
Reverse Rotation...................................................4 all applicable local and national regulations and safety
Flushing the Pump ................................................4 standards.
Relief Valve ...........................................................4
Relief Valve Setting and Adjustment .....................5 This manual is intended to assist in the installation
and operation of the Blackmer truck pumps, and
MAINTENANCE ...............................................................5-8 MUST be kept with the pump.
Lubrication.............................................................5
Vane Replacement ................................................5 Blackmer truck pump service shall be performed by
Pump Disassembly................................................6 qualified technicians ONLY. Service shall conform to
Pump Assembly ....................................................6 all applicable local and national regulations and safety
standards.
GENERAL PUMP TROUBLESHOOTING .................9-10
Thoroughly review this manual, all instructions and
hazard warnings, BEFORE performing any work on
the Blackmer truck pumps.
NOTE: Numbers in parentheses following individual
parts indicate reference numbers on the Maintain ALL system and Blackmer truck pump
operation and hazard warning decals.
corresponding Blackmer Parts Lists.
SAFETY DATA
FAILURE TO SET THE VEHICLE DISCONNECTING FLUID OR
EMERGENCY BRAKE AND CHOCK PRESSURE CONTAINMENT
WHEELS BEFORE PERFORMING COMPONENTS DURING PUMP
SERVICE CAN CAUSE SEVERE OPERATION CAN CAUSE SERIOUS
Hazardous machinery Hazardous pressure PERSONAL INJURY, DEATH OR MAJOR
can cause severe PERSONAL INJURY OR PROPERTY can cause
personal injury or personal injury or PROPERTY DAMAGE.
property damage. DAMAGE. property damage.
FAILURE TO RELIEVE SYSTEM IF PUMPING HAZARDOUS FLUIDS

PRESSURE PRIOR TO PERFORMING SYSTEM MUST BE FLUSHED PRIOR
PUMP SERVICE OR MAINTENANCE TO PERFORMING SERVICE.
Hazardous pressure
can cause PROPERTY DAMAGE. Hazardous or toxic
personal injury or fluids can cause
property damage. serious injury.
PUMP DATA
TECHNICAL DATA INITIAL START UP INFORMATION
TX(S)(D) TXV
Models Models Model No.
Maximum Temperature* 300oF (149oC) 375oF (190oC)
Serial No.
Maximum Pump Speed 640 RPM1
Maximum Viscosity* 50,000 SSU (10,800 cSt) Date of Installation:

Maximum Differential Pressure 125 psi (8.6 bar)
Pressure Gauge Reading:
Maximum Working Pressure 175 psi (12.1 bar)
(Inlet Pressure + Differential Pressure)
Vacuum Gauge Reading:
* Optional materials of construction may be required to meet the
operating limits listed above. Refer to Blackmer Material Specs Flow Rate:
201/91-92 for TX(S)(D) models or 202/91-92 for TXV models.
1 780 RPM maximum pump speed for TX(S)(D)1.5, 2 and 2.5 models.
500 RPM maximum pump speed for TX4A pump models.
INSTALLATION
NOTICE: PRE-INSTALLATION CLEANING
BLACKMER TRUCK PUMPS MUST ONLY BE Foreign matter entering the pump WILL cause extensive
INSTALLED IN SYSTEMS DESIGNED BY QUALIFIED damage. The supply tank and intake piping MUST be cleaned
ENGINEERING PERSONNEL. SYSTEM DESIGN MUST and flushed prior to pump installation and operation.
CONFORM WITH ALL APPLICABLE REGULATIONS
AND CODES AND PROVIDE WARNING OF ALL LOCATION AND PIPING
SYSTEM HAZARDS. An improperly designed piping system or unit installation WILL
significantly reduce pump performance and life. Blackmer
recommends the following piping system layout and unit
FAILURE TO SET THE VEHICLE installation.
EMERGENCY BRAKE AND CHOCK 1. To minimize intake losses, locate the pump as close as
WHEELS BEFORE PERFORMING possible to the source of supply.
SERVICE CAN CAUSE SEVERE 2. Piping MUST be properly supported to prevent any piping
Hazardous machinery
PERSONAL INJURY OR PROPERTY loads from being placed on the pump.
can cause severe
personal injury or
property damage. DAMAGE. 3. Intake piping and fittings MUST be at least as large in
diameter as the pump intake connection.
2
INSTALLATION
4. Minimize the number of intake line fittings (valves, elbows, long as the pump is shimmed to have its shaft parallel in all
etc.) and piping turns or bends. respects to the PTO shaft.
5. Temporarily install vacuum and pressure gauges in the 1/4" 5. The yokes of the universals at both ends of the jack shaft
NPT intake and discharge ports located on the pump must be parallel and in phase.
cylinder to check pump performance at start-up. 6. The maximum recommended angle between the jack shaft
and the pump shaft is 15 degrees. Refer to Table 1.
6. Install a strainer in the inlet line to protect the pump from
foreign matter. Placement of intake strainers should
Failure to follow any of these guidelines may result in a gallop
facilitate frequent cleaning.
or uneven turning of the pump rotor, which will in turn cause a
7. Intake and discharge piping MUST be free of all leaks. surging vibration to the liquid stream and piping system.
Contact the supplier of the drive line components for specific
TRUCK MOUNTING design assistance.
The pump will operate satisfactorily in any position. Consult

Blackmer factory for vertical shaft mounts. The pump can be Hydraulic Drive
bolted to the truck frame or on a saddle hung below the frame, The pump may also be driven hydraulically. Hydraulic motors
and MUST be adequately supported. Mounting the pump with must be well supported with their shafts parallel to the pump
the cylinder feet down, or with the intake port up, is shaft in all respects. Blackmer provides an optional close-
recommended for thorough draining of the pump. coupled hydraulic motor adapter. The adapter provides for
straight alignment of a hydraulic motor drive through a solid
coupling connected to a straight key pump shaft. This
PUMP DRIVE
coupling connection requires grease lubrication every three
The pump may be driven by a power take-off through universal months at minimum. Refer to the "Lubrication" section of this
joints. When using universal joints, a splined slip joint, manual.
properly lubricated, must be used on the connecting jack shaft
to prevent end thrust on the pump shaft. PUMP ROTATION
It is very important to install a proper drive line to avoid NOTICE:
excessive wear, vibration and noise (see Fig. 1 and Table 1). CONFIRM CORRECT PUMP ROTATION BY CHECKING
THE PUMP ROTATION ARROWS RESPECTIVE TO PUMP
DRIVER ROTATION.
TO CHANGE PUMP ROTATION

TX(S)D and TXV Models
The TX(S)D and TXV pump models are equipped with a
double ended rotor and shaft, enabling them to be driven from
either shaft end. To change rotation, rotate the pump 180
degrees so that the opposite shaft becomes the driven shaft.
(Yokes must be in phase) On TX(S)D pump models, the shaft protector (186) MUST be
mounted over the non-driven shaft end. On TXV pump
Figure 1 - Pump Drive models, the outboard bearing cover (27) MUST be mounted
over the non-driven shaft end.
Angle of Drive Shaft OPERATION WITHOUT SHAFT

PROTECTOR CAN CAUSE SERIOUS
1o through 5o 6o through 10o 11o through 15o
Very Good Good Fair
Table 1 Do not operate
without guard
in place.
General guidelines to follow for proper pump drive:
1. Do not use square slip joints. TX1.5, TX4 Models and Discontinued TX(S) Models
2. Use the least number of jack shafts as is practical. To reverse the pump rotation, remove the bearing covers,
3. Use an even number of universal joints. locknuts/lockwashers or lock collars (if equipped), from both
4. The pump shaft and power take-off shaft should be parallel inboard and outboard heads. Remove the inboard head
in all respects. Use an angular level measuring device to assembly and reverse the rotor and shaft, so that the driven
ensure the PTO and pump shaft are parallel to each other. end of the shaft protrudes from the outboard head. Remove
If necessary, the pump can be shimmed to correct any and replace the vanes so that the relief grooves face in the
misalignment. The PTO shaft coming off at the direction of pump rotation. Refer to the "Maintenance" Section
transmission does not need to be perfectly horizontal as of this manual for pump disassembly and assembly.
3
OPERATION
PRE-START UP CHECK LIST REVERSE ROTATION
1. Check the alignment of the pipes to the pump. Pipes must
NOTICE:
be supported so that they do not spring away or drop down
when the pump flanges or union joints are disconnected. PUMPS OPERATED IN REVERSE MUST HAVE A
SEPARATE PRESSURE RELIEF VALVE INSTALLED TO
2. Temporarily install vacuum and pressure gauges in the 1/4" PROTECT THE PUMP FROM EXCESSIVE PRESSURE.
NPT ports located on the pump cylinder. These can be
used to check the actual suction and discharge conditions It may be desirable to run the pump in reverse rotation for
after pump start-up. system maintenance. The pump will operate satisfactorily in
reverse rotation to strip lines, at a reduced performance level.
3. Inspect complete piping system to ensure that no piping
When operating the pump in reverse, a separate bypass valve
loads are being placed on the pump.
MUST be installed to protect the pump from excessive
4. Secure appropriate hose connections. pressure.
START UP PROCEDURES FLUSHING THE PUMP
NOTICE:
PUMP OPERATING AGAINST A IF FLUSHING FLUID IS TO BE LEFT IN THE PUMP FOR
CLOSED VALVE CAN CAUSE AN EXTENDED TIME, IT MUST BE A LUBRICATING,
NON-CORROSIVE FLUID. IF A CORROSIVE, NON-
SYSTEM COMPONENT FAILURE,
LUBRICATING FLUID IS USED, IT MUST BE FLUSHED
PERSONAL INJURY AND PROPERTY
Hazardous pressure
FROM THE PUMP IMMEDIATELY.
can cause DAMAGE.
personal injury or
property damage.
To flush the pump, use the following procedure:
1. Allow the pump to evacuate as much fluid as possible.

2. Run cleaning fluid through the pump intake. The cleaning
NOTICE:
fluid must be compatible with the pump O-rings and vane
CONSULT THE "GENERAL PUMP TROUBLESHOOTING" material. When handling "sticky" fluids that solidify within
SECTION OF THIS MANUAL IF DIFFICULTIES DURING the pump (i.e., waxes, adhesives, resins, asphalts, etc.),
START UP ARE EXPERIENCED. use a fluid that will prevent solidification of the fluid being
transferred and facilitate flushing.
1. Start the pump. Priming should occur within one minute. 3. Operate the pump against a closed discharge for 15
seconds to allow the cleaning fluid to recirculate through
2. Check the vacuum and pressure gauges to ensure the
the internal relief valve.
system is operating within expected parameters. Record
the gauge readings in the "Initial Start Up Information"
section of this manual for future reference. RELIEF VALVE
3. Inspect piping, fittings, and associated system equipment NOTICE:
for leaks, noise, vibration and overheating. THE PUMP INTERNAL RELIEF VALVE IS DESIGNED TO
4. Check the flow rate to ensure the pump is operating within PROTECT THE PUMP FROM EXCESSIVE PRESSURE
the expected parameters. AND MUST NOT BE USED AS A SYSTEM PRESSURE
CONTROL VALVE.
5. Check the pressure setting of the relief valve by
momentarily closing a valve in the discharge line and Pumping volatile liquids under suction lift may cause
reading the pressure gauge. This pressure should be 15 - cavitation. Partial closing of the discharge valve WILL result in
20 psi (1.0 - 1.4 bar) higher than the maximum system internal relief valve chatter and must not be done. For these
operating pressure, or the external bypass valve setting (if applications, install an external bypass valve, and any
equipped). DO NOT operate the pump against a closed necessary piping, back to the storage tank. This bypass
discharge valve for more than 15 seconds. If system must be used when operating for extended periods
adjustments need to be made, refer to the "Relief Valve (more than 1 minute) against a closed discharge valve.
Setting and Adjustment" section of this manual.
PUMP SPEED RELIEF VALVE SETTING AND ADJUSTMENT

PTO and hydraulically driven units MUST contain speed The relief valve pressure setting is marked on a metal tag
control devices to prevent pump speeds above the maximum attached to the valve cover. Generally, the relief valve should
RPM specifications, regardless of the truck engine unloading be set at least 15 - 20 psi (1.0 - 1.4 bar) higher than the
speeds. Should fluid delivery be appreciably less than operating pressure, or the external bypass valve setting (if
expected, see the "General Pump Troubleshooting" section. equipped).
4
OPERATION
Relief Valve Adjustment Procedure: NOTICE:
1. To INCREASE the pressure setting , remove the relief WHERE REGULATIONS REQUIRE, HOLES IN R/V CAP (1) AND
valve cap, loosen the locknut, and turn the adjusting screw CAPSCREW W / HOLE (5C) ARE USED BY THE WEIGHTS AND
inward, or clockwise. Replace the valve cap. MEASURES OFFICIAL (S) TO APPLY A SECURITY SEAL OR TAG.
2. To DECREASE the pressure setting, remove the relief
valve cap, loosen the locknut, and turn the adjusting screw
outward, or counterclockwise. Replace the valve cap. INCORRECT SETTINGS OF THE
PRESSURE RELIEF VALVE CAN
Refer to the individual Blackmer pump parts lists for various
spring pressure ranges. The pumps are supplied from the CAUSE SYSTEM COMPONENT
factory with the relief valve adjusted to the mid-point of the FAILURE, PERSONAL INJURY AND
spring range. If the pump is equipped with a Blackmer air Hazardous pressure
can cause PROPERTY DAMAGE.
valve, refer to setting and adjustment procedures covered in personal injury or
property damage.
Blackmer Air Valve Instructions and Parts List No. 201-F00,
286/F or 201-B00.
MAINTENANCE
NOTICE: LUBRICATION
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED Ball bearings and hydraulic motor couplings (if equipped) must
TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE be lubricated every three months at a minimum. More frequent
PROCEDURES AND WARNINGS AS PRESENTED IN lubrication may be required, depending on the application and
the operating conditions. TXV pump model bearings MUST
THIS MANUAL.
be replaced after each 1000 hours of service if fluid
temperature is greater than 250oF (120oC).
FAILURE TO SET THE VEHICLE
Recommended Grease:
EMERGENCY BRAKE AND CHOCK
WHEELS BEFORE PERFORMING TX(S)(D) Models - Exxon (Esso) - Ronex MP or Mobile -
Mobilith AW-2, or equivalent Lithium grease.
SERVICE CAN CAUSE SEVERE
Hazardous machinery TXV Models - Exxon (Esso) - Polyres or Mobile - Mobile Poly
can cause severe PERSONAL INJURY OR PROPERTY
372, or equivalent Polyurea grease.
personal injury or
property damage. DAMAGE.
Greasing Procedure:
1. Remove the grease relief fittings (76A) from the bearing
FAILURE TO RELIEVE SYSTEM covers (27 and 27A) or hydraulic motor adapter (135).
PRESSURE PRIOR TO PERFORMING 2. SLOWLY apply grease with a hand gun until grease begins
PUMP SERVICE OR MAINTENANCE to escape from the grease relief fitting port. Discard
excess grease in accordance with the proper codes and
regulations.
Hazardous pressure PROPERTY DAMAGE.
can cause 3. Replace the grease relief fittings (76A).
personal injury or
property damage.
DO NOT overgrease pump bearings. While it is normal for
some grease to escape from the grease tell-tale hole after
DISCONNECTING FLUID OR lubrication, excessive grease on pumps equipped with
PRESSURE CONTAINMENT mechanical seals can cause seal failure.
COMPONENTS DURING PUMP

OPERATION CAN CAUSE SERIOUS VANE REPLACEMENT
PERSONAL INJURY, DEATH OR MAJOR
Hazardous pressure
can cause
NOTICE:
personal injury or PROPERTY DAMAGE. MAINTENANCE SHALL BE PERFORMED BY QUALIFIED
property damage.
TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE
PROCEDURES AND WARNINGS AS PRESENTED IN
IF PUMPING HAZARDOUS FLUIDS THIS MANUAL.
SYSTEM MUST BE FLUSHED PRIOR 1. Remove the head assembly from the outboard (non-
driven) side of the pump according to steps 2 - 6 in the
TO PERFORMING SERVICE.
"Pump Disassembly" section of this manual.
2. Turn the shaft by hand until a vane comes to the top (12
Hazardous or toxic
fluids can cause o'clock) position of the rotor. Remove the vane.
serious injury.
3. Install a new vane, ensuring that the rounded edge is UP,
5
MAINTENANCE
and the relief grooves are facing towards the direction of a. Bend up the engaged lockwasher tang and rotate the
rotation. See Figures 2 and 3. locknut counterclockwise to remove it from the shaft
4. Repeat steps 2 and 3 until all vanes have been replaced. b. Slide the lockwasher off the shaft. Inspect the
lockwasher for damage and replace as required.
5. Reassemble the pump according to steps 2 - 7 and 12 - 17
of the "Pump Assembly." section of this manual. c. Repeat steps a and b on the opposite shaft end.
5. The TX(S)4-inch pump model is equipped with bearing lock
collars (24A). To remove:
a. Remove the jam nuts (24C) and loosen the two set
screws (24B).
b. Slide the lock collar off the shaft.
c. Repeat steps a and b on the opposite shaft end.
6. Remove the head capscrews (21) and carefully pry the
head (20) away from the cylinder (12).
7. Slide the head off the shaft. The head O-ring (72), bearing
(24), and mechanical seal (153) or lip seal (152) will come
off with the head assembly. Remove and discard the head
Figure 2 - Vane Installation - TX(S)(D) Models* O-ring.
*NOTE: 1.5 and 2-inch pump models have four (4) vanes.
a. Pull the bearing (24) from the housing in the head (20).
b.To remove the mechanical seal (153), use two screw
drivers to gently push the backside of the seal jacket to
push the seal from the head (see Figure 4). Use care
when placing the screw drivers to prevent damage to
the seal faces. Remove and discard mechanical seal
O-rings.
Figure 3 - Vane Installation - TXV Models*

Figure 4 - Mechanical Seal Removal
*NOTE: 2-inch pump models have four (4) vanes.
PUMP DISASSEMBLY c. To remove the lip seal assembly (152), use a thin pry
bar against the lip seal retaining ring to gently push the
NOTICE: housing (152B) out of the head (20). Use care not to
FOLLOW ALL HAZARD WARNINGS AND damage the lip seal (152A). To remove the lip seal
INSTRUCTIONS PROVIDED IN THE "MAINTENANCE" (152A), remove the retaining ring (152D) from the
SECTION OF THIS MANUAL. housing, and gently pry the lip seal from the housing.
Remove and discard the housing O-ring(s) (152C and
1. Starting on the inboard (driven) end of the pump, clean the 152E).
pump shaft thoroughly, making sure the shaft is free of
8. Pull the rotor and shaft (13) from the cylinder (12). While
nicks and burrs. This will prevent damage to the
one hand is pulling the shaft, the other hand should be
mechanical seal or lip seal when the inboard head
cupped underneath the rotor to prevent the vanes (14) and
assembly is removed.
push rods (77) from falling out. Carefully set the rotor and
2. Remove the inboard bearing cover capscrews (28) and shaft aside for future vane replacement and reassembly.
slide the inboard bearing cover (27A) and gasket (26) off
9. Remove the remaining components from the outboard side
the shaft. Discard the bearing cover gasket. On the 1.5, 2,
of the pump, as instructed in steps 6 and 7 above.
2.5, and 3-inch pump models, the dirt shield (123A) will
come off with the bearing cover.
PUMP ASSEMBLY
3. Remove the outboard bearing cover capscrews (28) and
slide the outboard bearing cover (27) and gasket (26) off Before reassembling the pump, inspect all component
parts for wear or damage, and replace as required. Wash
the shaft. Discard the bearing cover gasket.
out the bearing /seal recess of the head and remove any
4. If equipped with locknuts and lockwashers (24A and 24B): burrs or nicks from the rotor and shaft.
6
MAINTENANCE
e. Install new housing O-ring(s) (152C and 152E) in the
1. Reassemble the OUTBOARD side of the pump first:
groove(s) of the housing. Lightly grease the housing O-
a. For a CLOCKWISE rotation pump, position the pump ring(s) and push the lip seal and housing assembly into
cylinder with the INTAKE port to the left. the head recess with the lip seal inward. The lips of the
lip seal will face the rotor when the housing is installed.
b. For a COUNTERCLOCKWISE rotation pump, position
Make sure the housing is bottomed out in the back of
the pump cylinder with the INTAKE port to the right.
the head (20).
2. Install a new head O-ring (72) in the groove on the inside
face of the head (20). Lay the O-ring flat and start in on
one side of the groove, stretching ahead with the fingers,
as shown in Figure 5.
Figure 6 - Lip Seal - TXV “B” Models
Figure 5 - Head O-ring Installation
3. Install the head (20) on the outboard side of the cylinder

(12). Install and uniformly tighten four head capscrews
(21) 90o apart, torquing to 25 lbs ft (34 Nm).
4. MECHANICAL SEAL (If equipped)

Apply a small amount of motor oil in the head recess. Push
the mechanical seal assembly (153) into the recess of the
head with seal jacket drive tangs inward. The pin in the
stationary seat must be between the lugs in the back of the
head recess.
5. LIP SEAL ASSEMBLY (if equipped) Figure 7 - Lip Seal - Discontinued TXV “A” Models
The lip seal assembly (152) consists of a metal housing
with elastomer(s) around its outer diameter(s), and a teflon
6. Hand pack the ball bearing (24) with grease. Refer to the
lip seal in its inner diameter. TXV “A” model pumps are
"Lubrication" section for the recommended grease.
equipped with spacer washers. Refer to Figures 6 and 7.
7. Install the bearing (24) into the head recess. The bearing
a. Apply a small amount of light motor oil on the inner
balls must face outward, with the grease shield inward.
diameter of the lip seal housing (152B) to facilitate lip
Ensure the bearing is fully and squarely seated against the
seal (152A) installation.
lip seal housing (152B) or mechanical seal (153). On TXV
Note: When installing the lip seal, be careful not to pump models, install two 3/8" (10 mm) washers and two
damage the lip seal O-ring. bearing cover capscrews (28) to clamp the bearing and
b. On TXV “B” model pumps, push the lip seal (152A) compress the lip seal housing inner O-ring (152E) for
squarely into the housing (152B) with the pin in the lip proper bearing locknut adjustment (see Figure 8). The
seal aligned with the hole in the back of the housing. washers and capscrews will be removed after the locknuts
The lip seal should seat flush or slightly recessed in the are adjusted.
housing, around its entire diameter.
c. On TXV “A” model pumps, insert the spacer washers
(152F) into the housing, then push the lip seal (152A)
squarely into the housing (152B) with flat side of the lip
seal against the spacer washers. The lip seal should
seat flush or slightly recessed in the housing, around its
entire diameter. Note: If necessary, the spacer
washers can also be located after the lip seal, as shown
in Figure 7, to re-position the lip seal on the pump shaft.
d. Insert the retaining ring (152D) into the groove in the
housing. Figure 8 - Clamping the Bearing
7
MAINTENANCE
8. Turn the pump cylinder (12) around and begin assembly on c. Loosen both locknuts (24A) one complete turn.
the opposite, inboard end. d. Tighten one locknut (24A) until a slight rotor drag is felt
9. Remove the vanes (14) and push rods (77) from the rotor when turning the shaft by hand.
and shaft assembly (13). Inspect for wear and damage, e. Back off the nut the width of one lockwasher tang "B".
and replace as follows: Secure the nut by bending the closest aligned
a. Partially install the non-driven end of the rotor and shaft lockwasher tang into the slot in the locknut. The pump
(13) into the open side of the pump cylinder (12). should turn freely when rotated by hand.
b. Leave part of the rotor outside of the cylinder so that the f. Tighten the opposite locknut (24A) by hand until it is
bottom vanes (14) can be installed and held in place as snug against the bearing (24). Then, using a spanner
the push rods (77) are installed in the push rod holes of wrench, tighten the nut the width of one lockwasher
the rotor. Insert the new vanes into the rotor slots with tang. Tighten just past the desired tang, then back off
the rounded edges outward, and the vane relief the nut to align the tang with the locknut slot. Secure
grooves facing TOWARDS the direction of rotation. the nut by bending the aligned lockwasher tang into the
Refer to Figures 2 and 3. slot in the locknut. The pump should continue to turn
freely when rotated by hand.
c. After the bottom vanes (14) and push rods (77) are
installed, insert the rotor and shaft (13) fully into the g. To check adjustment, grasp the nut and washer with
fingers and rotate back and forth. If this cannot be
cylinder (12).
done, one or both locknuts (24A) are too tight and
d. Install the remaining vanes (14) into the top positions of should be alternately loosened one stop at a time
the rotor. If equipped with a mechanical seal (153), (.001") (25 microns). Begin by loosening the locknut
rotate the shaft by hand to engage the drive tangs adjusted last.
of the seal jacket in the rotor slots.
h. On TXV pumps, after adjustment is complete, remove
10. Install the inboard head (20), mechanical seal (153) or lip the bearing cover capscrews (28) and 3/8" washers from
seal (152), and bearing (24) as instructed in steps 2 both ends of the pump.
through 7. Apply a thin coating of motor oil on the inboard
shaft to aid installation. 13. LOCK COLLAR INSTALLATION - TX(S)4 Pump Models
a. Slide the lock collar (24A) over the shaft and against the
11. Rotate the shaft by hand to engage the mechanical seal
drive tangs (if equipped), and to test for binding or tight bearing (24), with the counterbored side towards the
spots. If the rotor does not turn freely, lightly tap the rims of bearing.
the heads (20) with a soft faced mallet until the correct b. Push the collar (24A) forcibly against the bearing (24)
position is found. Install all of the remaining head by hand, while tightening the two setscrews (24B).
capscrews (21) for each head (20) and uniformly torque to Install and tighten the two jam nuts (24C) against the
25 lbs ft (34 Nm). collar.
12. LOCKNUT INSTALLATION (if equipped) c. Repeat this procedure on the opposite pump end. After
installing both lock collars, verify the shaft turns freely
It is important that the bearing locknuts (24A) and when rotated by hand.
lockwashers (24B) be installed and adjusted properly.
14. Inspect the grease seal (104) for wear or damage and
Overtightening locknuts can cause bearing (24) failure or a
replace as required. Grease the outside diameter of the
broken lockwasher tang. Loose locknuts will allow the rotor grease seal and push it into the bearing cover (27 or 27A)
(13) to shift against the heads, causing wear. See Figure 9. with the lip of the seal inward. The lip will face outward
when the bearing cover is installed on the head.
15. Attach a new bearing cover gasket (26) and the bearing
cover (27 or 27A) to the head (20). Install and torque the
bearing cover capscrews (28) to 15 lbs ft (20 Nm).
16. Follow steps 14 and 15 to install the grease seal (104) and
bearing cover (27 or 27A ) on the opposite side of the
pump. On TXV pump models, the outboard bearing cover
(27) is also a shaft protector and must be installed on the
non-driven shaft end.
17. On 1.5, 2 and 2.5-inch pump models, push the dirt shield
(123A) over the inboard shaft and firmly against the
bearing cover (27).
Figure 9 - Locknut Adjustment 18. On TX(S)D pump models, attach the shaft protector (186)
on the non-driven shaft end.
a. On both ends of the pump shaft, Install a lockwasher
(24B) with the tangs facing outward, followed by a OPERATION WITHOUT SHAFT
locknut (24A) with the tapered end inward. Ensure the PROTECTOR CAN CAUSE SERIOUS
inner tang "A" of the lockwasher is located in the slot in
the shaft threads, bending it slightly, if necessary.
b. Tighten both locknuts (24A) to ensure that the bearings
(24) are bottomed in the head recess. DO NOT Do not operate
without guard
overtighten and bend or shear the lockwasher inner in place.
tang.
8
NOTICE:
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANS
ONLY, FOLLOWING THE APPROPRIATE PROCEDURES AND
WARNINGS AS PRESENTED IN THIS MANUAL.
Pump Not Priming 1. Pump not wetted.

2. Worn vanes.
3. Suction valve closed.
5. Strainer clogged.
6. Suction line or valves clogged or too restrictive.
7. Broken drive train.
8. Pump vapor-locked.
9. Pump speed too low for priming.
10. Relief valve partially open, worn or not seating properly.
Reduced Capacity 1. Pump speed too low.

2. Suction valves not fully open.
4. Excessive restriction in the suction line (i.e.: undersized piping, too many elbows
& fittings, clogged strainer, etc.).
5. Damaged or worn parts.
6. Excessive restriction in discharge line causing partial flow through the relief valve.
7. Relief Valve worn, set too low, or not seating properly.
8. Vanes installed incorrectly (see "Vane Replacement").
Noise 1. Excessive vacuum on the pump due to:

a. Undersized or restricted fittings in the suction line.
b. Pump speed too fast for the viscosity or volatility of the liquid.
c. Pump too far from fluid source.
2. Running the pump with a closed discharge line.
3. Pump not securely mounted.
4. Improper drive line (see "Pump Drive").
5. Bearings worn or damaged.
6. Vibration from improperly anchored piping.
7. Bent shaft, or drive coupling misaligned.
8. Excessively worn rotor.
9. Malfunctioning valve in the system.
10. Relief valve setting too low.
11. Damaged vanes (see following category).
Damaged Vanes 1. Foreign objects entering the pump.

2. Running the pump dry.
3. Cavitation.
4. Viscosity too high for the vanes and /or the pump speed.
5. Incompatibility with the liquids pumped.
6. Excessive heat.
7. Worn or bent push rods, or worn push rod holes.
10. Vanes installed incorrectly (see"Vane Replacement").
Troubleshooting continued on page 10.
9

Broken Shaft 1. Foreign objects entering the pump.
2. Viscosity too high for the pump speed.
3. Relief valve not opening.
5. Pump/driver misalignment.
6. Excessively worn vanes or vane slots.
Lip Seal / Mechanical Seal Leakage 1. O-rings not compatible with the liquids pumped.
2. O-rings nicked, cut or twisted.
3. Shaft at seal area damaged, worn or dirty.
4. Ball bearings overgreased.
5. Excessive cavitation.
6. Lip seal not seated properly.
7. Corrosion on lip seal housing.
8. Mechanical seal faces cracked, scratched, pitted or dirty.
10
NOTES
11
1809 Century Avenue, Grand Rapids, Michigan 49509-1595, U.S.A.
Telephone: (616) 241-1611 • Fax: (616) 241-3752
E-mail: blackmer@blackmer.com • Internet Address: www.blackmer.com Litho in U.S.A • © Copyright 2003
INSTALLATION INSTRUCTIONS
The RCI Technologies water sensor and indicator have been designed to operate when the RCI Technologies Fuel
Purifier is in need of purging. A buzzer followed by a red indicator light will come on when the water level in the
purifier reaches the sensor level. The buzzer will last 10 seconds. The light will stay on until the unit is purged.
466 W. Arrow Hwy, Ste D

San Dimas, CA 91773
Tel: 800-868-2088
Fax: 909-305-1245
Email: rrandle@rcipurifier.com
International Email: rrandle@az.uia.net
INSTALLATION AND WIRING INSTRUCTIONS
NOTE: First determine power supply – 12 volt or 24 volt.
Installation:
Remove heater from package. Apply Teflon tape (or other approved thread
sealant) to the threads of the heater. Insert heater into the heater coupling and
tighten into the body of the purifier.
1. Connect the two black leads together and attach to the negative
side of a switch controlled fused circuit (using appropriate wire
connectors).
2. Connect the common lead (white with black tracer) to the positive
side of the switch controlled fused circuit (again using the
appropriate wire connectors).
1. Remove excess wire from the common lead (white with black
tracer) leaving 1 to 2 inches of wire. Cap common lead with
appropriate wire cap and crimp.
2. Connect the two black leads to the 24-volt switched fused power 12 Volt – 6 amps
supply (using the appropriate connectors). 24 Volt – 3 amps
For Assistance or Technical support call:

(800) 868-2088
Operator Accessories
1.00
2.75
.75 .75
1.97
1.91
7.26
1.64
1.07
Ø.56 HOLE (5) Ø.28 HOLES

Description Part No. Material Weight (lb)
Remote Control Assy. 35603SL 1.10
Stainless
Cable Clamp only 9Q1660 .10
New design provides greater stroke (2-1/8”) and leverage. Stainless steel to resist corrosion. Remote attaches to trip
lever on operator using cable. Pulling remote lever rotates operator trip lever and bar assembly, causing all open
emergency valves to close. Per 49CFR178.345-11, remote must be located at least 10 feet away from
loading/unloading outlet (where vehicle length allows) or on the end of the cargo tank farthest from the
loading/unloading outlet. Test cable remote controls and operators at least once a day to insure proper functioning.
3.86 .40
Ø.31 x .75
Fusible Link
CLEVIS PIN .60
.28
1.71
7
.47 16-20 UNF
COTTER PIN HEX NUT Part No. Material Weight (lb)
21050A Steel .17
Heavy duty fusible cable links are designed to attach the cable to the emergency valve cable lever arm and to provide
thermal activation at the emergency valve. Fusible element melts at not more than 250°F, releasing the cable tension
and allowing the emergency valve to close. Uses same non-slip, adjustable cable attachment as on Betts operators.
TM
May 1999 Section 29 Page 1A
INDUSTRIES, INC.
WARREN, PA.
VEEDER-ROOT
INSTALLATION, OPERATION
AND SERVICE INSTRUCTIONS
SERIES 7886
HIGH-
HIGH-CAPACITY
CAPACITY
& SERIES 7887
METER REGISTERS
Manual No. 251325 (REV. B)
VEEDER-ROOT
Petroleum Products
Installation, Operation and Service Manual
Series 7886 High-Capacity & 7887 Meter Registers
TABLE OF CONTENTS
A. General ..................................... I
A. General ..................................... I
A. General ..................................... 3
SECTION 4. PERIODIC INSPECTION
A. General ..................................... 5
B. Disassembly Prior to Cleaning ............... 5
C. Cleaning .................................... 5
D. Inspection ................................... 5
E. Lubrication .................................. 5
F. Troubleshooting .............................. 7
SECTION 5. DISASSEMBLY AND ASSEMBLY
A. General ..................................... 8
B. Removal of Major Groups ...................... 8
C. Individual Parts Replacement .................. 10
D. Installation of Major Groups .................... 10
E. Final Checks and Adjustments ............. 15
F. Operational Check ............................ 16
SECTION 6. DAMAGE CLAIMS AND WARRANTY
A. Damage Claims ............................... 16

B. Return Shipping .............................. 16
C. Warranty and Conditions ...................... 16
Where manufacturer's replacement stocks are available, it is important
A. GENERAL. These instructions are for servicing that no attempt be made to repair any meter register defective within
the Series 7886 High-Capacity and Series 7887 Meter the terms of the warranty as by doing so, the warranty is void and the
Registers user is deprived of the protection provided by the warranty. It is
designed and manufactured by the Veeder-Root Company, recommended that, when possible, meter registers be replaced and
6th Avenue at Burns Crossing. P.O@ Box 1673, Altoona, PA the defective unit returned to the meter manufacturer.
16603. Phone: (814) 695-4476. Note: See Section 6 for complete Damage Claims and Warranty.
When a vertical bar I appears adjacent to text orILlu strations,
information has been added or changed at the last issue IMPORTANT!
date. The instructions, photographs and drawings in Sec tions 4 and
Note- Consult Veeder-Root on any unusual application,
installation or possible modification of this basic design.
5 are based on the Series 7887 Meter Register. With the
Every Meter Register is thoroughly tested at the Veeder-Root exception of an additional counting wheel, the Series 7886
factory and by the meter manufacturer when installed on the High-Capacity Meter Register is physically similar and the
meter. However, like any precision mechanism, it requires same procedures should be followed.
periodic care to ensure maximum service. This manual is for
use in areas where factory rebuilding facilities and adequate
exchange stocks are not readily accessible.
SECTION 2. SERIES 7887 DESCRIPTION clutch assembly which in turn drives a gear on the right (unit)
wheel assembly. Revolutions are then accumulated on the
A. GENERAL. 1. Physical. The Series 7887 Meter Register, wheels. In addition, this rotating shaft drives the bracket
Figure 1, displays a running account, final total and accumulated group connected to the accumulative totalizer shaft, thus both
total of the quantity of liquid product delivery. Contained in a 4'x I displays are driven from the same source, assuring accurate
O'diecast enclosure, individual delivery data is displayed on five recording of information. During the reset operation, the
3/4' high flgures while totalizer information is recorded on eight clutch is disconnected from the drive shaft, a shutter moves
1/8' high figures. Reset of the Meter Register is accomplished into place covering the display wheels and reset fingers
through a reset knob on the right-hand side of the unit. engage heart-shaped cams on the individual wheels to move
them back to a zero position. In addition, a set of anti-topping
2. Operational. The Meter Register is operated by a drive shaft fingers engages the wheels to preventjamming. At the
connected to a group of gears on the gear plate which converts completion of reset, the display wheels will read all zeros,
the drive revolutions to the appropriate ratio. The output bevel and the shutter will rise to the normal operating position. The
gear of the group drives a bevel gear, Figure 5, which is clutch will engage the drive shaft to transfer the information
connected to the drive shaft and clutch assembly. In rotating, this from the next delivery. The totalizer wheels will be unaffected
shaft drives a gear on the by this reset operation, thus displaying an accurate measure
of the accumulated totals of many deliveries.
B. SPECIFICATIONS.
Specifications listed are standard unless otherwise noted. Optional Style of Figures: Veeder-Root/Cornell for optimum read- ability.
features are available at additional cost.
Character Configuration: 0 to 9 (options available).
Speed: 250 rpm.
Reset: Single handle on register. Designed for one-handed
Torque: Average running torque at room temperature with 1: I input: operation.
4 oz-in. During display wheel transfer from all 9's to all O's, the
instantaneous peak torque may reach 40 oz-in. Mounting: Eight 1/4 x 28 tapped holes with steel inserts on a 6.625'
(168.28 mm) diameter. Special adaptors are available for nearly all
Operating Temperature Range: -40' to +710C (-400 to + I 60'F). meters.
Number of Figures: Meter Register: 5. Accumulative Totalizer: 8 Construction: Cover: cast aluminum. Case and sub frame: cast
Zamak. Wheels, pinions, and clutch: acetal resin.
Size of Figures: Meter Register: 0.750' high x 0.400' wide
(I 9.05 x 10. 16 mm). Totalizer: 0. 1 25' high x 0.078' wide (3.175 x Gearing: 1:1 is standard. 1:1 through 42:1 are available.
1.98 mm). Lubrication: Periodic.
Color of Figures: White on black, except right-hand totalizer OPTIONS

wheel which is black on white when recording tenths of units, and
white on black when recording whole units. Nonreset Pulser: Meter Register with Series 1871 or 7671 Pulse
Transmitter.
SECTION 3. SERIES 7886 DESCRIPTION B. SPECIFICATIONS.
Specifications listed are standard unless otherwise
A. GENERAL. noted. Optional features are available at additional cost.
1. Physical. The Series 7886 High-Capacity Meter Register, Speed: 250 rpm.
Figure 3, displays a running account, final total and Torque: Average running torque at room temperature
accumulated total of the quantity of liquid product delivery. with
Contained in a 4' x 10' die cast enclosure, individual delivery 1:1 input: 4oz-in. During displaywheeltransfer from all 9s
data is displayed on six 5/8' high figures while totalizer to all O's, the instantaneous peak torque may reach 40
information is recorded on eight 1/8' high figures. Reset of the oz-in.
Meter Register is accomplished through a reset knob on the Operating Temperature Range: -40' to +71'C (-40' to +
right-hand side of the unit. 160'F).
Number of Figures: Meter Register: 6. Accumulative
2. Operational. The Meter Register is operated by a drive Totalizer: 8
shaft connected to a group of gears on the gear plate which Size of Figures: Meter Register: 0.625' high x 0.300'
converts the drive revolutions to the appropriate ratio. The wide (15.87 x 7.62 mm). Totalizer: 0.125' high x 0.078'
output bevel gear of the group drives a bevel gear, Figure 5, wide (3.175 x 1.98 mm).
which is connected to the drive shaft and clutch assembly. In Colorof Figures: White on black, except right-hand
rotating, this shaft drives a gear on the clutch assembly which totalizer wheel which is black on white when recording
in turn drives a gear on the right (unit) wheel assembly. tenths of units, and white on black when recording whole
Revolutions are then accumulated on the wheels. In addition, units.
this rotating shaft also drives the bracket group connected to Style of Figures: Veeder-Hoot/Cornell for optimum
the accumulative totalizer shaft, thus both displays are driven read- ability.
from the same source, assuring accurate recording of Character Configuration: 0 to 9 (options available).
information. During the reset operation, the clutch is Reset: Single handle on register. Designed for one-
disconnected from the drive shaft, a shutter moves into place handed operation.
covering the display wheels and reset fingers engage heart- Mounting: Eight 1/4 x 28 tapped holes with steel inserts
shaped cams on the individual wheels to move them back to on a 6.625' (168.28 mm) diameter. Special adaptors are
a zero position. In addition, a set of anti-topping fingers available for nearly all meters.
engages the wheels to prevent jamming. At the completion of Construction: Cover: cast aluminum. Case and sub
reset, the display wheels will read all zeros, and the shutter frame: cast Zarnak. Wheels, pinions, and clutch: acetal
will rise to the normal operating position. The clutch will resin.
engage the drive shaft to transfer the information from the Gearing: 1:1 is standard. 1:1 through 42:1 are available.
next delivery. The totalizer wheels will be unaffected by this Lubrication: Periodic.
reset operation, thus displaying an accurate measure of the OPTIONS
accumulated totals of many deliveries. Nonreset Pulser: Meter Register with Series 1871 or
7671 Pulse Transmitter.
SECTION 4. PERIODIC INSPECTION c. 57 tooth gear on clutch assembly with gear on right wheel
(For Series 7886 High-Capacity and Series 7887 Meter assembly.
Registers) d. Gear drive shaft with gear train that operates the totalizer,
and gear connecting the drive train to the totalizer.
A. GENERAL The Meter Register is fully lubricated and property
adjusted at manufacture. However, periodic cleaning and lubrication 3. Rotate drive shaft by hand to see that unit operates freely
are required. and then reset, checking for proper reset and shutter action.
Adjust pointer after reset as required.
Judgment of the intervals at which the meter register requires such
service must necessarily be left to the individual user due to varying 4. Check all screws, retaining rings and groove pins to see that
conditions of service. Under normal conditions, this will be at least they are tight and seated properly.
once a year, or after each 2-1/2 million units of measure delivered,
whichever comes first. E. LUBRICATION.
1. Recommended Lubricants
B. DISASSEMBLY PRIOR TO CLEANING. Remove the meter Note: Chelae and Vischem products are manufactured
register from its housing as follows: by Ultrachem Inc.,
1400 N. Walnut St., P.O. Box 2053 Wilmington, DE 19899
I .Remove the bolts securing the cover (if present) to the top of the
housing. These bolts are hex head and are located at the four Oil: Chemlube 201 or equivalent with a temperature range of -
corners of the bottom of the housing. Remove the cover. 65F to + 275F (-54'C to + 135'C).
Grease: Vischem 352 or equivalent with a temperature range of
2. Remove the three button-head bolts securing the meter register -65'F to +300'F (-54'C to + 149'C).
to the housing. Remove the meter register. Note: All lubricants used in the register must be of a type
which remains fluid over the full temperature range
3. Remove the screws securing the gear plate to the bottom of the to which the register will be subjected. Also, they
housing. Remove the gear plate. should not oxidize or dry out leaving a gummy or
perceptible residue.
C. CLEANING. If the Chemlube 201 oil lubricant is not available, a substitute
with equivalent properties may be used. To assist field
CAUTION: DO NOT USE A WIRE BRUSH. personnel in obtaining suitable lubricants for the meter register
and ticket printers, the following list showing equivalent
1. Wipe bezel crystal with a clean lint-free rag. lubricants has been prepared:
OIL
2. If the wheel faces are dirty, gently clean with a clean AEROSHELL FLUID NO. 3
lint-free rag dipped in mild soapy water. REGENT SPINTEX OIL 60
GARGOYLE ARCTIC OIL LIGHT
3. Clean the gears on the base plate by flushing or with a brush CASTROL HYSPIN 40
dipped in solvent. Blow dry with compressed air. ANDEROL 401D
GREASE
4. Clean housing by dipping, flushing or brushing with solvent. Blow AEROSHELL 14
dry with compressed air. ESSO BEACON 325
ANDEROL 795
D. INSPECTION. A periodic inspection of the entire meter register,
housing and gear plate is required to make sure that they function 2. Points to Lubricate
property, parts are in place, and no binding or excessive side-to-side
motion of shafts occurs. A checklist on such procedures follows: Oil: All points indicated as "Oil" on Figure 6 should be lubricated
with oil as described above. This includes all shafts, studs, and
1. Check the following shafts for perceptible side-to-side motion. bosses on which a moving part bears.
Note: Remove the meter register from the housing before checking Grease: Grease should be applied to all points indicated as
shaft freedom. "Grease' on Figure 6. This includes gears and the no-back
a. Wheel Shaft ratchet and pinion.
b. Anti-Topping Finger Group Shaft
c. Reset Finger Group Shaft Note: The oil and grease should be applied with a small
d. Clutch Group Shaft brush to make certain that all areas will he properly
e. Pinion Shaft lubricated. In this manner, the amount of lubrican
t being used will be more easily controlled.
2. Temporarily install the base plate and meter register in
the housing and check for proper engagement and freedom of
movement of: a. All gears on gear plate.
b. Output bevel gear on gear plate with the bevel drive gear on drive
shaft.
F. TROUBLESHOOTING. Tabel 1 is used to assist in
locating problems and making repairs and corrections. In
some problems, similar defects can be produced by several
causes of an entirely different nature. Cause of trouble must
be determined and the correction made.
Table 1. Troubleshooting
TROUBLE POSSIBLE CAUSE CORRECTION

1. Drive shaft hard to turn. Pointer or brake rubbing on first wheel Check pointer and break positioning.
Adjust as required.
Dirt or pieces of foreign material in teeth Remove case. Check all gears, clean and
of drive gears, gear plate, totalizer or lubricate as necessary. See Sect 4.
bevel gear train driving totalizer.
2. Binding occurs during reset cycle Missing washers on outside of clutch Check end play and washer as required.
shaft.
Pinion jam, anti-topping finger(s) broken Check end play of wheel shaft. Replace
or spring(s) missing broken anti-topping finger(s) or missing
spring(s)
3. Reset knob turns hard Reset knob flange on the case binds on Remove reset knob. Loosen flange
reset shaft. screws, center the flange on the shaft
and tighten the screws.
Wheel shaft group is bent. Replace wheel shaft.
Reset fingers rubbing on wheel or Check for missing retaining rings on reset
retaining rings. finger and wheel shafts. Replace as
required.
4. Any one wheel will not reset to zero Broken reset finger. Replace reset fingers as required.
Locking disc pin out of wheel groove. Disassemble wheel group and insert
locking disc pin into groove in wheel.
5. Incomplete reset cycle. Knob turns but Key in large multiple cam broken. Replace cam with new cam and key.
reset does not occur. Reset actuating lever not engaged in cam Remove cam, inspect and replace parts
or reset arm broken. as required, and assemble properly.
6. Shutter partially obscured wheels at Shutter disconnected from reset lever. Connect shutter to reset lever.
completion of reset cycle or completely
covers wheels at reset cycle.
7. Shutter will not drop into place or loss Detent lever spring missing or broken. Install new spring.
of detent action during reset.
8. Pointer not aligned with unit wheel. Improper adjustment of brake or pointer. Adjust brake to proper clearance.
Adjust pointer to center mark.
9. Unit wheel can be turned in reverse by Dirty drive shaft clutch assembly. Clean clutch group and lubricate. See
hand. Section 4.
10. Cannot drive meter register. Pinion jam, reset fingers are engaged, Check washers on pinion shaft. Check
heart cams hit on detent lever shutter and play of shafts. Clean and lubricate
stud, clutch not engaged. clutch.
SECTION 5. DISASSEMBLY AND ASSEMBLY (For Series 1. If present, remove the retaining ring securing the reset idler
7886 High-Capacity gear to the reset idler gear shaft.
and Series 7887 Meter Registers) 2. Remove retaining rings and washers securing the pinion,
reset, anti-topping and clutch shafts to the right-hand side plate
A. GENERAL. When disassembling the meter register, be (Figure 7). Remove screws and lockwasher securing the
extremely careful not to lose or intermix any of the washers found totalizer group and rear mounting bar from right-hand side plate.
on the shafts. By doing so, potential problems with end-play and 3. Remove side plate.
backlash adjustments will be greatly lessened. When removing
retaining rings or other parts from shafts, do not hold the shaft CAUTION: DO NOT LOSE OR INTERMIX WASHERS FROM
with any tool that might gouge or create burrs on the shaft. EACH SHAFT.
B. REMOVAL OF MAJOR GROUPS. Instructions for removal of Note: Remove only those shaft groups necessary to gain
all shaft groups are provided. access to parts being replaced.
4. Clutch Shaft Group Removal. Note: If the inoperable totalizer has a small bevel gear
a. Remove retaining ring and washers securing the clutch (approx. 11/32 inch dia.) on the drive shaft, replace the
shaft group to the left-hand side plate. See Figure 8. bracket group on the left side frame as well as the totalizer
b. Move clutch lever group so clutch is free. See Figure 9. group (see Figure 31 and Paragraph D, 7 and E, 5).
Remove clutch shaft group. See Paragraph C, 1 for Remove the screw holding the pointer onto the old totalizer
parts replacement. and save for installation on new totalizer.
5. Reset Finger Group Removal.
a. Remove retaining ring and washer securing the reset 9. Pinion Removal.
group to the left-hand side plate. See Figure 8. a. Remove retaining ring securing pinion shaft to the left-
b. Disengage the reset fingers and no-back pawl from th hand side plate. See Figure 8.
wheels. SeeFigure 10. Rernovethegroup. See Paragraph C, b. Rotate the detent lever group so it will clear the reset
2 for parts replacement. cam. Remove shaft. c. Remove pinions, detent lever group
washers and retaining rings from shaft.
6. Stop Shaft Removal.
a. Remove the springs from between the anti-topping 10. Wheel Group Removal.
fingers and the stop shaft. a. Mark relationship of reset gear to wheel group shaft to
b. Remove the spring from between the detent lever group assure proper positioning during assembly.
and the stop shaft. b. Remove pin securing reset gear to the wheel group shaft.
c. Remove the stop shaft. c. Remove gear, retaining ring and washer. Remove shaft.
See Paragraph C, 4 for parts replacement.
7. Anti-Topping Finger Group Removal.
a. Remove the retaining ring and washers securing the anti-
topping finger group shaft to the left-hand side plate. See
Figure 8.
b. Disengage the anti-topping fingers and the clutch lever
group from the wheels. See Figure I 1.
c. Remove the group from the side plate. See Paragraph C,
3 for parts replacement.
8. Totalizer Group Removal.

a. Remove the screws securing the totalizer group to the
left-hand and right-hand side plates. See Figures 7 and 8.
b. Remove the totalizer group.
c. No additional disassembly of the totalizer is possible. If the
totalizer is inoperable, replace the group.
C. INDIVIDUAL PARTS REPIACEMENT
1. Clutch Shaft Parts Replacement. See Figure 12.

a. Totalizer and Drive Bevel Gears.
(1) Drift out pin securing gear to shaft.
(2) Remove gear.
(3) Remove retaining rings and washers that position drive
gear. Do not change the order of the rings and
washers.
(4) Drift out pin holding drive gear and remove gear.
(5) Install new gear, pin, retaining rings and washers.
Use new pin if required.
(6) Install totalizer bevel gear and secure with pin.
CAUTION: CHECK SHAFT FOR STRAIGHTNESS AFFER

PINNING. A BENT SHAFT WILL CAUSE BINDING DURING
DRIVING OF METER REGISTER. CLUTCH MUST NOT BE
DISASSEMBLED OR REPLACED AS AN INDIVIDUAL
GROUP. IF CLUTCH IS BROKEN OR MALFUNCTIONS,
REPLACE COMPLETE SHAFT AND CLUTCH AS AN
ASSEMBLY.
2. Reset Finger Group Parts Replacement. See Figure 13. Individual

reset fingers, reset arm, no-back pawl and pawl spring may be
a. Remove retaining rings and appropriate washer to reach
particular part.
b. Replace defective items with new part. Assemble remaining parts
on shaft. Install retaining rings and washers. Check end play per
Figure 28.
3. Anti-ToppingFingerGroupPartsReplacement.SeeFigure 14.
Individual anti-topping fingers, reset lever and clutch lever may be
a. Remove retaining rings, washers and parts as required to get to
part that is to be replaced.
b. Install parts, retaining rings and washers in the sequence shown
in Figure 14. Be sure to install parts so they are in the proper
direction. Check end play per Figure 28.
4. Wheel Group Parts Replacement. See Figures 15, 16, 17 and 18.
The reset cam, individual wheels, locking discs and eccentrics may
be replaced as required.
a. Remove retaining rings, washers and key as required to remove
reset cam, wheels, locking discs and eccentrics.
b. Install parts, retaining rings, washers and key in the sequence
shown in Figure 17. When installing wheels, be sure the pin on the
locking disc engages the groove in the wheel as shown in Figure 18.
Check end play per Figure 28.
D. INSTALLATION OF MAJOR GROUPS
Prior to installing each shaft, lubricate per Paragraph E in Section 4.
During assembly, do not intermix washers from one shaft to another.
1. Wheel Group Installation.
a. lfnotpresent,installaO.030inchthickwasheroverthe end of the
wheel group shaft opposite the cam.
b. Install the shaft into the proper hole in the left-hand side plate.
See Figure S.
2. Anti-Topping Finger Group Installation. See Figure 19.
a. Hold wheel and side plate assembly upside down.
b. Install anti-topping finger group in proper hole in left- hand side
plate (see Figure 8). Be sure all fingers and clutch lever are free of
wheels and the pin on the reset ievel, engages the track on the cam.
c. Seat the shaft, install washers and retaining ring to
secure shaft to left-hand side plate.
d. See that all fingers are free to engage wheels.
3. Stop Shaft Installation.
a. Install retaining rings on ends of shaft.
b. Insert stop shaft into proper hole in left-hand side
plate. See Figure 8.
4. Reset Finger Shaft Group Installation.
a. Rotate no-back pawl so that spring puts pawl under
tension. Slip an elastic band over the reset fingers
and pawl to hold pawl in position. See Figure 20.
b. Install shaft into left-hand side plate and secure
with retaining ring and washers. See Figure 8.
c. Engage pin on reset lever group with slot in reset
arm. See Figure 22.
5. Clutch Shaft Group Installation.
a. Install shaft in proper hole in left-hand side plate.
Add washers and secure with retaining ring. See Figure 8.
b. Make sure that bevel gears that drive the totalizer
are free to turn.
6. Right-Hand Side Plate Installation 8. Spring Installation.
a. Hold meter register assembly as shown in Figure 22 and a. See Figure 23 for identification of springs.
place a rubber band around the assembly to hold it together. Be b. Install the five anti-topping finger springs between the anti-
sure the pin in the reset lever group remains engaged in the slot topping fingers and the stop shaft. See Figure 24.
in the reset arm. c. Install the reset spring between the reset lever and the pinion
b. Install side plate over wheel shaft first, then engage the other shaft.
shafts. d. Install the detent spring between the detent lever group and
c. Temporarilysecure the side plate to the rear mounting bar the stop shaft.
with screws. e. Install the clutch spring between the clutch lever group and
7. Bracket Group (if required) and Totalizer Installation. the pinion shaft.
a. If required, install new bracket group to inside of left side
frame and secure with two screws and lockwashers. See 9. Pinion Shaft Assembly Installation
Figure 31. a. If not previously accomplished, remove all parts from pinion
b. Install pointer with screw (saved from old totalizer) onto new shaft.
totalizer group but do not tighten screw securely. Pointer b. Rotate wheel shaft so reset fingers are fully engaged in the
position must be adjusted after totalizer group is installed. See heart-shaped cams on each wheel.
Paragraph F, 2. c. Place pinions, with short finger up, in between each wheel as
c. Install the totalizer group so that the bevel gear is in mesh shown in Figure 25.
with the top bevel gear on the bracket group and secure with d. Install the end of the shaft closest to the two retaining ring
retaining screws. For adjustment of bevel gear drive, see slots into the left-hand side plate and through each pinion.
Paragraph E, 5.
e. Install washers and detent lever group onto shaft and engage
shutter with tab on detent lever.
f. Push shaft through the right-hand side plate and secure with
washer and retaining ring.
g. Secure detent lever group into position with retaining rings.
h. After assembly, rotate wheel shaft to make sure all pinions
have been positioned properly. If binding occurs, reposition
pinions per step c.
10. Reset Gear Installation.

a. Install reset gear on wheel shaft, aligning orientation mark
made at disassembly.
b. Secure gear to shaft with pin. II. Reset Idler Gear Installation.
a. If present, install reset idler gear on the reset idler gear shaft.
See Figure 8.
b. Secure with retaining ring.
Note: This gear will be tirned when the meter duplicator and
meter register are assembled together.
E. FINAL CHECKS AND ADJUSTMENTS.
1. End Play Check: Check end play (back and forth motion) of
shafts and parts as follows:
a. For proper measurement, the meter register must be installed in

the TD-42383 mounting fixture, Figure 26, to constrain the frame
into the same position that it is when installed in the housing.
b. Secure the meter register to the fixture with two 1/4-28 button-
head bolts. See Figure 27.
c. Take end play measurements of each shaft. Add or subtract
washers as necessary to obtain correct end play.
2. Input Drive Bevel Gear Engagement Adjustment.
a. Install the gear plate onto the fixture using the

appropriate hardware.
b. Remove the retaining ring behind the bevel gear and add or
subtract washers as required for proper rnesh between the bevel
gear on the gear plate and the drive bevel gear on the clutch shaft.
The shaft end play must be maintained as specified in Figure 28.
c. Replace the retaining ring after adjustment.
3. Clutch Lever
Positioning Adjustment.
a. Rotate the reset gear until the clutch is fully disengaged.
b. Measure the clearances as shown in Figure 29.
c. If the dimensions cannot be obtained, add or remove washers as
required, or replace the clutch and shaft.
d. The amount of face engagement between the spur gear on the
input clutch and the first wheel should be 75% + 20%.
4. Wheel Brake Adjustment.
a. Rotate reset gear to position earn as shown in Figure 30.

b. Measure clearance between brake and first wheel. If
clearance is not within the dimensions given, adjust brake by
loosening screw and moving brake into position.
c. Remove the meter register from the fixture by removing the two
button-head screws. Remove the gear plate from the fixture.
5. Gearing Adjustment for Totalizer. See Figure 31.
Loosen set screw on bottom bevel gear. Mesh the top bevel
gear tightly with the totalizer bevel gear. Press the register clutch
shaft toward the left side frame. Adjust the bottom bevel gear such
that it has 0.012 - 0.015 end play when meshing with the clutch
shaft bevel gear. Tighten set screw and secure with a sealant
(Loctite 222 or equivalent) to prevent loosening.
6. ApplyAnderoIL-795orequivalentgreaseonteethofbevel gears.
7. Backlash Compensating Mechanism Adjustment for

EEC UNITS ONLY.
While unit is running at 100-200 RPM, adjust screw so that pawl is
approximately in the middle of clip as shown in Figure 32 (on Page
16). Oscillation of pawl is permissible.
To check for proper operation, use a 1: I gear plate and operate

register at 100-200 RPM. Stop counting, hold input shaft of gear
plate and reset register. Wheel should reset so that some part of
graduation at zero always aligns with pointer.
B. RETURN SHIPPING. All shipments of Veeder-Root
products must be prepaid. Equipment must be packed in a
strong exterior container and surrounded by shock absorb-
ing material. Veeder-Root will accept no liability foi- damage
caused by improper packing. It is suggested that the original
shipping containei- be used if it is available. Address
shipment to Veeder-Root Co., 6t]i Avenue at Burns Crossing,
11.0. liox 1673, Altoona, I'A 16603.
C. WARRANTY AND CONDITIONS

1. WARRANTY. We warrant that our products shall he free
from defects in material and workmanship for a period of one
year from the date of shipment thereof or the product's total
rated life, whichever first occurs. Within the warranty period
we shall repair or replace such products which are returned
to us with shipping charges prepaid and which are deter-
inined by us to be defective. This warranty will not apply to
any product which has been subjected to misuse, negligence,
or accident; or misapplied; or used in violation of product
manuals, instructions, or warnings; or modified or repaired by
unauthorized persons; or improperly installed.
2. INSPECTION. You shall inspect the produ(-t promptly after

i-eceipt and shall notify us at oui- Altoona office, in wi-
F. OPERATIONAL CHECK. Before returning the meter register iting,ofanyclaims,includingclaii-nsofbreactiofwarraiity, within
to normal service, check that it operates properly as follows: thirty days aftei- you discover or should have dis- (-ovei-
edtliefactsuponwliielitlieclaimishased.Yourfailtire to give
1. Rotate the input bevel gear and see that the totalizer and written notice of a (-Iaiin within the time period shall be
individual delivery wheels are driven and that they record the deeiiie(i to be a waivei- of sii(-Ii claim.
same amount. There should be no binding or drag.
3. LIMITATION OF REMEDY AND WARRANTY. The
2. Rotate the reset gear and see that the shutter drops into provisions of Paragraph I are our sole obligation and exclude
place, the wheels all reset and that there is no binding or drag. all other remedies or warranties, express or implied, including
At the completion of reset, the zeros should align with the warranties of MERCHANTA-BILITY and FITNESS FOR A
pointer. PARTICULAR PURPOSE, whether or not purposes or
specifications are described herein. We further disclaim any
3. See Troubleshooting, Table 1. Page 5, if there are any responsibility whatsoever to you or to any other person for
problems. injury to person or damage to or loss of property or value
caused by any product which has been subjected to misuse,
negligence, or accident; or misapplied; or used in violation of
SECTION 6. DAMAGE CLAIMS AND WARRANTY product manuals, instructions, or warnings; or modified or
repaired by unauthorized persons; or improperly installed.
A. DAMAGE CLAIMS
1. Thoroughly examine the enclosure as soon as it is received. 4. LIMITATION OF DAMAGES. Under no circumstances
If damaged, write on the face of the freight bill a complete and
shall we be liable for any incidental, consequential or special
detailed description of the damage. Have the carrier's agent damages, losses or expenses arising from this contract or its
sign the description. performance or in connection with the use of, or inability to
use, our product for any purpose whatsoever.
Note: Insist that the carrier's agent verify the inspection
and sign the description. 5. LIMITATION OF ACTIONS. No action regardless of form
arising out of this contract may be commenced more than
2. Immediately notify the delivering carrier of damage or loss. one year after- the cause of action has accrued, except an
This notification may be given either in person or by telephone. action for nonpayment.
Written confirmation must be mailed within 48 hours. Railroads
and motor carriers are understandably reluctant to make 6. COLLATERAL PROMISES. There are no representations,
adjustments for damaged merchandise unless inspected and warranties, or conditions express or implied, statutory or
reported promptly. otherwise except those herein contained, and no agreements
or waivers collateral hereto shall be binding on either party
3. Riskoflossofordamagetomerchandiseremainswiththe liuyer. It unless in writing and signed by you and accepted by us at our
is the liuyer's responsibility to file a claim with,,the carrier Altoona office.
involved.
7. INTERPRETATION. Rights and liabilities arising out of any
4. Imniediately advise your Veeder-Root representative,
contract with us shall be determined under the Uniform
distributor, oi, the factory so that we may assist you. Commercial Code as enacted in Connecticut.
VEEDER-
VEEDER-ROOT
Petroleum Products
6th Avenue at Burns Crossing

P.O. Box 1673
Altoona, PA 16603-1673
Phone (800) 873-3313
Fax (800) 234-5350
or
Phone (814) 695-4476
Fax (814) 695-7605
Copied from
Veeder-Root Technical Manual
8-014
Issued:12/95
Supersedes: 5/93
Compiled by:
Michael Leffew,
Isometrics, Inc.
Reidsville, NC
Wet-R-Dri Valve TTMA STYLE
LIGHTWEIGHT
COMPACT
VERSATILE
I.D.
O.D.
Standard Model Detent Model Standard Material Max. Working Temperature

Size Wt. Wt.
Assembly No. Assembly No. Body Disc Pressure Range
2” Buna-N 75 PSI
See Chart Below

3” Buna-N 75 PSI
WD400 AL V 4.5 WD401 AL V 4.5 Aluminum
4” Viton 75 PSI
WD400 GI V 8.3 WD401 GI V 8.3 Grey Iron
5” WD500 AL V 7.9 WD501 AL V 7.9 Aluminum Viton 50 PSI
NOTE: Standard drilling fits TTMA recommended standards.
Valves are available with the following options: Stainless steel liners and shafts, grease fittings installed in the drive and
bearing shafts, and “E” Coating of aluminum valves (recommended for aluminum valves used in water service).
For repair kit, see Section 20, Page 5B.
Dimensions Suffix for Disc Material

Buna-N Urethane
Size A B C I.D. O.D. B.C. Holes Viton EPDM
Black White Black White
3 1 1 1 3 3 7
2” 6 /4 4 /4 1 /8 2 /4 3 /4 3 /4 6- /16 B WB V U WU E
3 5 1 3 5 7 7
3” 6 /4 4 /8 1 /8 3 /8 5 /8 4 /8 8- /16 -40°F -40°F -0°F -40°F -40°F -50°F
3 1 1 3 5 7 7
4” 6 /4 5 /8 1 /8 4 /8 6 /8 5 /8 8- /16 +200°F +200°F +400°F +200°F +200°F +300°F
3 3 1 7 5 7
5” 6 /4 6 /8 2 /8 5 /16 7 /8 7 12- /16 NOTE: Temperature ranges based on
1 1 5 1 7
6” 12 7 2 /8 6 /8 8 /8 8 /8 12- /16 published information and may vary
1 7 1 7
8” 12 8 2 /2 8 10 /8 10 /8 16- /16 due to actual operating conditions.
INSTALLATION:
The Wet-R-Dri Valve may be mounted in any position with handle located for easy operation. Valve, as assembled, opens by
1
turning handle /4 turn counter clockwise (right hand operation). If clockwise rotation is desired (left hand operation) please
specify. Care should be taken when mounting valve to be sure the I.D. of adjoining flanges or pipe is large enough to allow
disc of valve to open freely. We suggest using our accompanying flanges and adapters shown in Section 20, Page 5A.
TM
INDUSTRIES, INC. Feb 1995 Section 20 Page 1A

WARREN, PA.
PARTS LIST
Wet-R-Dri VALVE
2 2
6
4 5 6
10
12
11
9 WD101-3 BU
1 9 WD101-3 BU
1
92 92
7 7
8 8
STANDARD MODEL DETENT MODEL
2” Size 3” Size 4” Size 5” Size 6” Size 8” Size

No. Description Material
Part No. Part No. Part No. Part No. Part No. Part No.
Buna-N WD101-2 BN WD101-3 BN WD101-4 BN WD101-5 BN WD101-6 BN WD101-8 BN
Viton WD101-2 VT WD101-3 VT WD101-4 VT WD101-5 VT WD101-6 VT WD101-8 VT
1 Disc
Urethane WD101-2 PY WD101-3 PY WD101-4 PY WD101-5 PY WD101-6 PY WD101-8 PY
EPDM WD101-2 EP WD101-3 EP WD101-4 EP WD101-5 EP WD101-6 EP WD101-8 EP
Handle Mall. “E” Coated 25884EY 25884EY 25884EY 25884EY 25933AL 25933AL
2 Cap Screw Steel Zinc Plt. 9Q5813 9Q5813 9Q5813 9Q5813 9Q5898 9Q5898
Hex. Nut Steel Zinc Plt. 9Q5808 9Q5808 9Q5808 9Q5808 9Q5808 9Q5808
4 Drive Shaft Steel 27053MS 27050MS 27050MS 27051MS 16229MS 16229MS002
5 Drive Shaft Steel 27053MS001 27050MS001 27050MS001 27051MS001 16229MS 16229MS002
7 Bearing Shaft Steel 16006MS 15913MS 15913MS 15913MS 16230MS 16230MS002
9 Driv-Lok-Pin Steel Zinc Plt. 9Q4893 9Q4893 9Q4893 9Q4925 9Q4926 9Q4938
10 Detent Ball 440 Stnls 9Z4856 9Z4856 9Z4856 9Z4856 9Z4856 9Z4856
11 Detent Spring 304 Stnls 15229SL 15229SL 15229SL 15229SL 15229SL 15229SL
12 Ret. Screw 304 Stnls 9Q5838 9Q5838 9Q5838 9Q5838 9Q5838 9Q5838
** O-Ring material suffix to match Disc suffix (i.e.-17889VT)
WARNING Use only genuine Betts Industries Inc. replacement parts. Use of substitute parts can impair the proper
functioning of the Wet-R-Dri Valve.
TM
INDUSTRIES, INC. Jan 1993 Section 20 Page 1B

WARREN, PA.

2009 C300 Operators and Maintenance Manual

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OPERATION,

MAINTENANCE AND PARTS MANUAL

TRUCK, TANK, FUEL SERVICING

ISOMETRICS MODEL 505T1200

Post Office Box 660

Reidsville, North Carolina 27320

LIST OF TABLES page

1. Model No.: 505T1200

1-3. FUNCTIONAL DESCRIPTION.

To avoid running the pump dry make sure the emergency

c. Bottom Loading System.

f. Gravity Unloading. Gravity unloading can be accomplished by attaching a hose to the

1-5. SHIPPING, HANDLING, AND STORAGE DATA.

American Petroleum Institute

The butterfly valves are closed when the lever is 90

d. Verify all valves in the pumping compartment are closed.

2-5. BOTTOM LOADING.

c. Perform the prefueling check in paragraph 2-4.

d. Electrically bond the refueler to the fill stand.

e. Move lever on interlock air valve (18) to side.

g. Make the necessary connections to the Scully socket, if available

If the flow does not stop soon after the precheck

Do not load at a rate exceeding 600 GPM (gallons

An indication that the tank is full is a sudden

n. Remove fill stand bonding cable and disengage Scully system.

2-6. TOP LOADING.

b. Shut down the engine.

c. Perform the prefueling check in paragraph 2-4.

d. Electrically bond the refueler to the fill stand.

If a top loading rack is not available for fueling,

h. Remove fill stand bonding cable.

b. Shut down the engine.

c. Perform the prefueling check in paragraph 2-4.

d. Connect one of the static bond cables to a suitable connection.

g. Open faucet (17).

h. When draining is complete, close faucet (17).

i. Push the emergency valve operator lever (22) to the in position.

k. Stow the static cable.

Do not allow the cable to wind freely onto the reel.

If at any time during the fueling operation an

b. Perform the prefueling check in paragraph 2-4.

c. Connect one of the static bond cables to a suitable connection.

d. Engage the PTO control (4) located in cab.

e. Note: all pumping will be done at idle speed (700 rpm).

f. Reset meter (13) to zero (rotate knob on register clockwise).

j. When fueling is complete, rewind hose onto reel (9).

m. Disengage the PTO control (4) located in cab.

Do not allow the cable to wind freely onto the reel.

c. Perform the prefueling check in paragraph 2-4.

d. Connect one of the static bond cables to a suitable connection.

f. Engage the PTO control (4) located in cab.

If the flow does not stop soon after the precheck

m. Disengage the PTO control (4) located in cab.

q. Disconnect and stow the static cable.

Do not allow the cable to wind freely onto the reel.

c. Perform the prefueling check in paragraph 2-4.

d. Connect one of the static bond cables to a suitable connection.

f. Engage the PTO control (4) located in cab.

If the flow does not stop soon after the precheck

o. Disconnect and stow the static cable.

Do not allow the cable to wind freely onto the reel.

b. Shut down the engine.

c. Perform the prefueling check in paragraph 2-4.