Fast Fill Systems

Owner’s Manual for End Users

N150PSL Piston SureLoc

N150PSL800 Piston SureLoc

Diesel Fuel Nozzles

June 2013

+1 (801) 491-3600 © 2010 FFS www.fastfillsystems.com

 Owner’s Manual

N150PSL SureLoc
Diesel Fuel Nozzle

WARNING
Only certified factory trained persons are to service this
device. Failure to follow these procedures will void all
warranties and may result in serious personal injuries,
or permanently damaging the diesel fuel nozzle.

For use with diesel fuel only. Use with other fluids will void warranty and may
result in permanent damage to the diesel fuel nozzle or other property.

All references in this manual to fuel, means diesel fuel.

This document is the property of Fast Fill Systems and contains proprietary
and confidential information which must not be duplicated, used, or disclosed
other than expressly authorized by Fast Fill Systems.

© 2013 FFS
+1 (801) 491-3600 Page. 1 www.fastfillsystems.com
 Owner’s Manual
INDEX

Service Caution Statement page. 1

Index page. 2

N150PSL General Information page. 3

N150PSL800 General Information page. 4

Pressurized Diesel Fueling System page. 5

Pressureless Diesel Fueling System page. 6

Care and Maintenance page. 7

Trouble Shooting page 8 & 9

Nozzle Repair: K1-N150PSL page. 10

K2-N150PSL page. 11

N150PSL Piston SureLoc Parts List page. 12

N150PSL800 Piston SureLoc Parts List page. 13

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 Owner’s Manual
N150PSL SureLoc
General Information

The Piston Conversion SureLoc exchanges the high-precision diaphragm shutoff

mechanism for a rugged piston-driven mechanism. The piston sleeve is nickel-plated steel
for extreme durability. It is ideal for filling conditions where unfiltered diesel fuel may be a
concern. Nozzles with plugs are manufacturer recommended.

Part # N150PSL (N150PSLp with Plug)

Max. Flow Rate: 150 gpm/567 lpm
Min. Flow Rate: 25 gpm/94.5 lpm
Operating Pressure: Max. 75 psig/5.17 bar
Fuel Inlet Port: 1-1/2”
Weight: 7 bls 15 oz./3.600 kg
Min Operating Temp: -30 deg C

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 Owner’s Manual
N150PSL800 SureLoc
General Information

The N150PSL800 comes with a 2” fuel inlet port. It contains the same rugudized
construction as the N150PSL.
Disassembly and Reassembly instructions and procedures are the same as the N150PSL.

Part # N150PSL800 (N150PSL800p with Plug)

Max. Flow Rate: 211 gpm/800 lpm
Min. Flow Rate: 150 gpm/567 lpm
Operating Pressure: Max. 75 psig/5.17 bar
Fuel Inlet Port: 2”
Weight: 7 bls 15 oz./3.600 kg
Min Operating Temp: -30 deg C

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 Owner’s Manual
Pressurized Diesel Fueling System

REQUIRED COMPONENTS:

2” NPT opening at top of fuel tank

2” NPT opening at bottom of fuel tank
Fuel vent (V150)
Diesel Fuel Receiver (R150S)
Diesel Fuel Nozzle (N150PSL)

V150

Air

N150PSL
R150S
Diesel Fuel On

Diesel Fuel

HOW IT WORKS:

The standard fueling system works on a sealed tank system. The fuel nozzle is connected to the fuel receiver
located at the bottom of the fuel tank. The fuel nozzle handle is then turned to the “on” position and the pump
begins pumping the diesel fuel into the fuel tank. Air will escape through the vent located at the top of the fuel
tank as the tank continues to fill. When the diesel fuel reaches the desired level, the plastic balls in the vent ball
cage will rise with the diesel fuel and seal on the o-ring so that air can no longer escape from the fuel tank.
When this happens, pressure rapidly builds within the fuel tank. The fuel nozzle will sense this pressure and
automatically shut-off; stopping the flow of fuel to the fuel tank. The fuel nozzles are calibrated to shut-off
between 7-9 psi.

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 Owner’s Manual
Pressureless Diesel Fueling System

REQUIRED COMPONENTS:

2” NPT opening at top of fuel tank

2” NPT opening at bottom of fuel tank
PLA150-M w/FFV150-PL (includes: PLA150-M SV, R150CVRc-J, PLA150-M VLCE, FFV150-PL, and PL-P-6)

FFV150-PL

PLA150-M VLCE Air

(Shut off Level)

Diesel Fuel
R150CVRc-J N150PSL

On
PL-P-6

PLA150-M SV

Diesel Fuel

HOW IT WORKS:

The pressureless fueling system eliminates tank pressure. The fuel nozzle is connected to the fuel receiver
located at the bottom of the fuel tank. The fuel nozzle handle is then turned to the “on” position and the pump
begins pumping the diesel fuel into the fuel tank. Air will escape through the Vent Level Controller located at the
top of the fuel tank as the tank continues to fill. When the diesel fuel reaches the desired level, the float in the
Vent Level Controller will rise and seal on the internal O-ring so that fuel can no longer escape through the
signal line. When this happens, back pressure rapidly builds within the Signal Line, closing the diaphragm in the
Shut off Valve. The fuel nozzle will sense this pressure and automatically shut-off; stopping the flow of fuel to
the fuel tank. The fuel nozzles are calibrated to shut-off between 7-9 psi.

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 Owner’s Manual
Care and Maintenance

Care is essential for maximizing the service life of fuel nozzles.

Dirt is the primary cause of leaking seals and premature nozzle failure.

Attaching a diesel fuel nozzle to a diesel fuel receiver that is dirty or damaged in any way can
damage the wiper seal and cause the fuel nozzle to leak.

We recommend purchasing caps and plugs for all nozzles and receivers. If plugs or caps are
damaged or missing; replace as soon as possible.

RECOMMENDED CLEANERS FOR DIESEL FUEL NOZZLES AND RECEIVERS:

Water, Wd40, Diesel Fuel, etc.. may be used. Apply cleaners with a cleaning rag, and clean as often
as needed.
(Note: Using products such as “Starting Fluid” and “Brake Cleaner” will damage some seals)

Damaged wiper seals are the primary cause for leaking fuel nozzles. The replacement wiper seal part number
is fn-se-4.

REPLACING WIPER SEALS: Wiper Seal

1) Place the On/Off Handle in the “Off” position.

2) With an O-Ring pick, remove the old Wiper Seal.
3) Lubricate the new seal with petroleum jelly before installing.
4) The flat side of the seal faces the fuel receiver (”V” side faces the On/Off Handle).
5) Run your finger all around the seal to make sure it is properly seated in the gland.

OTHER REPLACEMENT KITS AVAILABLE:

K1-N150PSL On/Off Handle Kit

K2-N150PSL Carry Handle Kit

Refer to diesel fuel nozzle drawing on page 14 for items included in each kit.

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 Owner’s Manual
Trouble Shooting

PROBLEM: Diesel fuel nozzle leaks from front end of nozzle during fueling and/or
when disconnected and pressurized.
POSSIBLE CAUSES: REMEDY:

1) Wiper Seal is damaged or missing. 1) Replace the Wiper Seal.

2) Excessive dirt or debris on fuel receiver and/or 2) Clean fuel receiver and nozzle.
on fuel nozzle. 3) Replace the fuel receiver.
3) Fuel receiver is worn. 4) Replace fuel nozzle and return for repair.
4) Internal dynamic O-Ring.

PROBLEM: Diesel fuel nozzle leaks from back end of nozzle during fueling and/or
when disconnected and pressurized.
POSSIBLE CAUSES: REMEDY:

1) Back end seals are damaged. 1) Replace fuel nozzle and return for repair.

PROBLEM: Diesel fuel nozzle fails to remain connected to the fuel receiver.

POSSIBLE CAUSES: REMEDY:

1) Excessive dirt or debris in front end of fuel nozzle. 1) Clean fuel receiver and fuel nozzle.
2) Actuating Ring is not fully securing the fuel nozzle to 2)Check for dirt or debris between the actuating ring
the fuel receiver. and the fuel nozzle.
3) Fuel receiver is worn. 3) Replace the fuel receiver.

PROBLEM: Diesel fuel nozzle shuts off before the desired fueling level is reached.

POSSIBLE CAUSES: REMEDY:

1) Vent is clogged or blocked.
2) Fuel receiver is remotely mounted.
(Remote mounting may cause an increase in
head pressure as a result of elevation or
additional piping.)
1) Check any hose or pipe leading from end of vent for
any blockage. Clean and replace vent or vent
components as required.
2) Replace fuel receiver for one which has a lighter
spring. (Compensates for increased head pressures)
Verify application with authorized distributor.

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 Owner’s Manual
Trouble Shooting

PROBLEM: Diesel fuel nozzle shuts off late; resulting in fuel escaping through the vent.

POSSIBLE CAUSES: REMEDY:

1) Fuel tank is not completely sealed.
2) Low flow rate.
3) Inadequate amount of ullage.
4) Fuel nozzle is worn or damaged.
1) Inspect fuel tank for any possible leaks, it must be
completely sealed (except for a Fast Fill Systems vent)
in order for the system to properly function. (Check for
staining on the fuel tank caused by fuel or air escaping
from the fuel tank).
2) The fuel nozzle requires a minimum 25 gpm to
function properly; increase flow rate.
3) Replace standard series vent for a vent with a
extended vent stem.
4) Replace fuel nozzle and return for repair.

PROBLEM: Diesel fuel nozzle fails to shutoff; resulting in overfilling the fuel tank.

POSSIBLE CAUSES: REMEDY:

1) Fuel tank is not completely sealed.
2) Vent stem O-ring seal is missing or damaged.
3) Vent ball cage is missing and/or flotation balls are
cracked and filled with fuel, or dirty.
4) Inadequate amount of ullage.
5) Fuel tank geometry and/or vent location does not
allow proper ullage.
6) Fuel nozzle is worn or damaged.
1) Inspect fuel tank for any possible leaks, it must be
completely sealed (except for a Fast Fill Systems vent)
in order for the system to properly function. (Check for
stains on the fuel tank caused by fuel or air escaping
from the fuel tank).
2) Remove the vent from the fuel tank and inspect O-
ring at bottom of vent stem. Replace if missing or
damaged.
3) Remove vent from fuel tank and inspect the ball cage
at the bottom of the vent stem. Replace if missing or
damaged.
4) Replace standard series vent for a vent with a
extended vent stem.
5) Contact vendor for assistance in properly placing the
proper vent in the correct fuel tank location.
6) Replace fuel nozzle and return for repair.

© 2013 FFS
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 Owner’s Manual
Nozzle Repair

WARNING
Only certified factory trained persons are to service this
device. Failure to follow these procedures will void all
warranties and may result in serious personal injuries,
or permanently damaging the diesel fuel nozzle.

Only Fast Fill Systems components are to be used in repair or maintenance on any Fast
?
Fill Systems diesel fuel nozzle.

Fast Fill Systems diesel fuel nozzles contain high pressure spring-loaded components
?
which may cause serious injury. Appropriate safety equipment and a full face shield are
required at all times during repair or maintenance of any Fast Fill Systems diesel fuel
nozzle.

Any additional repairs to what is outlined below are not authorized and must be performed
?
by an authorized Fast Fill Systems rebuild facility.

*Refer to diesel fuel nozzle drawing on page 14 for item number reference*

K1-N150PSL
1) Properly clean all outer surfaces of dirt and contaminants before disassembly fuel nozzle.
CAUTION: Failure to do so may result in further damaging the fuel nozzle.

2) Secure fuel nozzle in a vise.

3) Remove the Shaft Truarc Ring (7).

4) Remove the Square Shaft (8).

5) Remove the On/Off Handle (1).

6) Install the new On/Off Handle (1).

7) Secure the On/Off Handle into place with the Square Shaft (8).

8) Install the Shaft Truarc Ring (7).

© 2013 FFS
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 Owner’s Manual
Nozzle Repair

K2-N150PSL
1) Properly clean all outer surfaces of dirt and contaminants before disassembly.
CAUTION: Failure to do so may result in further damaging the fuel nozzle.

2) Secure fuel nozzle in a vise.

3) Remove the Carry Handle Screws (12).

4) Remove the Carry Handle (29).

5) Install the new Carry Handle (29).

6) Secure the Carry Handle in place by installing the Carry Handle Screws (12).

© 2013 FFS
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 Item Part Number Description Qty

1 fn-cahtmpc-19a On / Off Handle 1

2 fn-sp-6 On / Off Handle spring 1
3 fn-m-20 On / Off Handle Pull Tabs 2
20 35 4 fn-p-14 On / Off Handle Roll Pin 1
5 fn-m-21 On / Off Handle Detent Pin 1
8 7 6 13 27 15 16 17 22 21 29 12 31 30 34 14 6 fn-lz-2 Lever Arm 1
7 fn-p-1 Shaft Truarc Ring 2
25 26 33 24 8 fn-m-1 Shaft 1
9 fn-m-2 Bushing 2
10 fn-p-2 Dust Seal 2
11 fn-cahtmpc-3a End Cap 1
12 fn-p-3 End Cap & Carry Handle Screw 8
13 fnt-m-13 Link Pin 2
14 fn-p-15 Ball 8
15 fn-lz-1 Link 2
16 fn-m-4 Spring Retainer 1
17 fn-p-4 Spirolox Ring 1
18 fn-sp-1 Piston Spring (14 # Shutoff) 1
19 fn-macl-6p Diaphragm Piston Piston 1
20 fn-se-7 Sleeve Seal 3
1 21 fn-m-5p Diapragm Piston Sleeve 1
2
22 fn-p-6 Cap Screw 6
3 23 fn-sp-7 Sleeve Spring 1
5
24 fn-sp-10 Retainer Clip 1
4 11 25 fn-sp-8 Actuating Ring Spring 1
26 fn-m-3 Sleeve 1
9
27 fn-p-9 Spirolox Ring 4
10 28 fn-cahtmpcl-22p Housing 2” Connection 1
23 29 fn-cahtmpc-18a Carry Handle 1
12 18 20 19 28 32 30 fnr-macl-26 SureLoc Ball Castle 1
31 fn-se-6 Body Oring 1
32 fn-m-10 Tube 1
33 fn-m-13 Mushroom Retainer 1
34 fn-cahtmpc-15ar Actuating Ring 1
35 fn-se-4 Wiper Seal 1
Kit Number Kit Description Items Included

K1-N150PSL Piston SureLoc On/Off Handle Kit 1, 2, 3, 4, 5, 7, 8

K2-N150PSL Piston SureLoc Carry Handle Repair Kit 12. 29

DRAWN
This document is the property Materials: MRM Fast Fill Systems
of Fast Fill Systems and contains DATE 1195 Spring Creek Pl Suite G Springville, Utah 84663
proprietary and confidential Tolerance: .XXX +- .005
4/5/13
information which must not be
CHECKED N150PSL Piston SureLoc Nozzle
duplicated, used, or disclosed ALL CHAM. = 45
other than expressly authorized
by Fast Fill Systems. R&D

REV. DESCRIPTION DATE APPROVAL SIZE SCALE: none DWG. NO. REV.
© 2013 FFS MFG
Revisions A SHEET: 1 OF 1 A
 Item Part Number Description Qty

1 fn-cahtmpc-19a On / Off Handle

2 fn-sp-6 On / Off Handle spring
3 fn-m-20 On / Off Handle Pull Tabs
20 35 4 fn-p-14 On / Off Handle Roll Pin
5 fn-m-21 On / Off Handle Detent Pin
8 7 6 13 27 15 16 17 22 21 29 12 31 30 34 14 6 fn-lz-2 Lever Arm
7 fn-p-1 Shaft Truarc Ring
25 26 33 24 8 fn-m-1 Shaft
9 fn-m-2 Bushing
10 fn-p-2 Dust Seal
11 fn-cahtmpc-3a End Cap
12 fn-p-3 End Cap & Carry Handle Screw
13 fnt-m-13 Link Pin
14 fn-p-15 Ball
15 fn-lz-1 Link
16 fn-m-4 Spring Retainer
17 fn-p-4 Spirolox Ring
18 fn-sp-1 HP1 High Pressure Piston Spring
19 fn-macl-6p Diaphragm Piston Piston
20 fn-se-7 Sleeve Seal
1 21 fn-m-5p Diapragm Piston Sleeve
2
22 fn-p-6 Cap Screw
3 23 fn-sp-7 Sleeve Spring
5
24 fn-sp-10 Retainer Clip
4 11 25 fn-sp-8 Actuating Ring Spring
26 fn-m-3 Sleeve
9
27 fn-p-9 Spirolox Ring
10 28 fn-cahtmpcl-22p Housing 2” Connection
23 29 fn-cahtmpc-18a Carry Handle
12 18 20 19 28 32 30 fnr-macl-26 SureLoc Ball Castle
31 fn-se-6 Body Oring
32 fn-m-10 Tube
33 fn-m-13 Mushroom Retainer
34 fn-cahtmpc-15ar Actuating Ring
35 fn-se-4 Wiper Seal
Kit Number Kit Description Items Included

K1-N150PSL Piston SureLoc On/Off Handle Kit 1, 2, 3, 4, 5, 7, 8

K2-N150PSL Piston SureLoc Carry Handle Repair Kit 12. 29

DRAWN
This document is the property Materials: MRM Fast Fill Systems
of Fast Fill Systems and contains DATE 1195 Spring Creek Pl Suite G Springville, Utah 84663
proprietary and confidential Tolerance: .XXX +- .005
4/5/13
information which must not be
CHECKED N150PSL800
duplicated, used, or disclosed ALL CHAM. = 45
other than expressly authorized 800 LPM Piston SureLoc Nozzle
by Fast Fill Systems. R&D

REV. DESCRIPTION DATE APPROVAL SIZE SCALE: none DWG. NO. REV.
© 2013 FFS MFG
Revisions A SHEET: 1 OF 1
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