M-285

Rev. G
P.D. Oscillating Piston Flowmeter
1″ 4D-MD LP Gas

Operating and Maintenance

Manual LPG
 WARNING!!
To ensure compliance with
U.L. Listing, use only
Genuine Neptune®
Replacement Parts.

TORQUE REQUIREMENTS Torque Requirements

for Bolts Used in
The Type 4D-MD primary components (maincase, air/vapor release and valves) are now made of Type 4D-MD Aluminum
cast aluminum alloy. The bolts used to assemble these components are made of steel, with a special Meters
zinc plating to help resist corrosion. Aluminum is lightweight and durable, but sensitive to bolt and
component overtorquing and overtightening. To avoid problems associated with these conditions,
follow the guidelines given below for all bolt tightening for this meter:

Bolt Size and TORQUE

Threads per Inch IN.-LBS FT.-LBS
7/16 - 14 264 - 336 22 - 28
3/8 - 16 264 - 336 22 - 28
5/16 - 18 144 - 192 12 - 16
1/4 - 20 96 - 144 8 - 12

Aluminum itself is relatively impervious to corrosion, much more so than cast iron or non-stainless Recommended
steel alloys. To prevent possible seizing of the bolts, Loctite® Anti-Seize Thread Compound No. 767 Anti-Seize
is applied to bolts during the factory assembly of the meter. Compound

Make sure that this or equivalent anti-seize compound is used when the meter parts are reas-
sembled after service to prevent bolt seizing.
 TABLE OF CONTENTS

General Information................................................................................................................... 1

Installation................................................................................................................................. 1

Operation................................................................................................................................... 3

Calibration................................................................................................................................. 4

Preventative Maintenance Schedule......................................................................................... 6

Registration............................................................................................................................... 7

Storage...................................................................................................................................... 7

Register Maintenance............................................................................................................... 7

Measuring Chamber Maintenance............................................................................................ 8

Gear Train Maintenance............................................................................................................ 9

Vapor Release Maintenance................................................................................................... 10

Strainer Maintenance...............................................................................................................11

Differential Valve Maintenance.................................................................................................11

Temperature Compensator Maintenance................................................................................ 12

Troubleshooting....................................................................................................................... 13
 4D-MD LP-GAS COMPACT FLOWMETERS
GENERAL INFORMATION GENERAL INFORMATION
This manual covers the installation and maintenance of the Type 4D-MD LP-Gas Compact
Flowmeter (Figure 1) which includes a Strainer, Vapor Release, Differential Valve and Automatic
Temperature Compensator.
The housing and pressure components of the 4D-MD are constructed of A356 aluminum with
T6 heat treatment. Nominal line connections of 3/4″ and 1″ (ductile iron connections) are available.
The meter is fully rated to 350 psi and has been approved by UL.
The strainer, housed in the Vapor Release at the intake of the flowmeter, is of a fine (either
an 80-84 mesh or special 30 micron) mesh double sleeve construction with O-rings for positive
sealing. It is accessible by removing the strainer cover.
The Vapor Release, which prevents entrapped vapor from passing through the flowmeter, has
a float-operated valve. When vapor collects in the Vapor Release, the valve opens venting vapor
to the supply tank establishing pump pressure to close the Differential Valve. The vapor release
employs a sleeve-type valve that permits a constant “leak” flow of approximately 0.2 gpm from the
vapor vent back to the supply tank.
The Differential Valve is piston, plug type construction and opens when at least 15-psi pump
pressure is established. This valve serves three functions to assure system measurement accuracy
by requiring:  (1) pump operation for delivery, (2) adequate back pressure to prevent product va-
porization during measurement, and (3) blockage of flow when the Vapor Release valve opens.
The type 4D-MD is available with outlet/inlet flanges of 3/4″ and 1″ diameters to permit con-
nection to varying pipe dimensions. Please refer to the current price list or your RSM distributor
for additional information.
The optional temperature compensator, by sensing product temperature, controls the readout
drive ratio to provide a registration compensated by 15°C (60°F).
The Type 4D-MD is available with a choice of 600 or 800 Series mechanical resettable total-
izing registers. Pulse output is also optionally available.
The recommended temperature range for operation of the 4D-MD is -23° to 60°C (-10° to 140°F)
or -23°C to 52°C (-10° to 125°F) for automatic temperature compensator equipped meter.

INSTALLATION INSTALLATION
1. Plan the installation for maximum rate of delivery, sizing the supply tank outlet, piping and Before Installing the
valve for free gravity flow to the pump suction. To accomplish this, locate the pump as Flowmeter
close as possible to the supply tank and use short inlet connections with few restrictions.
Keep the number of elbows to a minimum, and use large radius elbows, wherever possible.
To further reduce the likelihood of causing vapor in the pump suction line, install a pump
bypass valve in a return line to the supply tank as shown in the installation drawing. (See
Figure 2).
2. Locate the flowmeter at any convenient place in the pump discharge line. If the flowmeter
is to be operated under extremes of environment (dirt, water, physical damage, etc.), an
enclosure or other protection should be provided. Allow sufficient clearances for removal of
the register, strainer and vapor release as shown in Figure 14. Do not install any bypass
around the flowmeter; the valve in such a line might eventually leak, work open, or be left
open causing improper measurement.
To conform with Weights and Measures requirements, install flowmeter so that the flowmeter
nameplate is visible.

NOTE
All piping on the inlet side of the flowmeter should be very thoroughly cleaned out. Flush
out all lines thoroughly before installing the flowmeter.
While the installation is still new, the strainer should be cleaned once per month mini-
mally for the first three (3) months. After the system has been thoroughly flushed of foreign
material, only periodic (minimum annually) cleaning is recommended.

The majority of service calls on new installations would be eliminated if these directions were
followed.

Page 1
 In order to comply with the European Pressure Directive 97/23/EC the following information is
required to be included in the flowmeter manual as part of the Installation instructions.
CAUTION!!
Always install the flowmeter according to local Safety Codes for LP Gas equipment.
The flowmeter shall be installed outdoors, away from buildings and sources of ignition.
External examination is recommended every 2 years and a pressure test
at the maximum working pressure (24 bar) every 10 years.

FIGURE 1.
4D-MD COMPACT FLOWMETER

Secure the connecting piping to prevent strain on the flowmeter. Use UL approved pipe com- When Installing
pound sparingly or suitable pipe tapes on male threads only.
Provide the installation with means for pressure relief as outlined in the National Fire Protection
Association Pamphlet 58. Although the differential valve is technically not a completely positive
seat, it is positive enough that we recommend the use of a hydrostatic relief valve downstream of
the meter to protect the delivery hose.
The vent line from the flowmeter’s vapor vent to the vapor space of the supply tank should Vent Line
be 1/4-inch inside diameter tubing or equivalent pipe size. A shut-off valve must be installed in the
vapor vent line to permit removal of the strainer for cleaning or when other service is performed on
the flowmeter. The Vapor Release vent line must be returned to the vapor space of the supply tank
and normally should not be made a common connection with other vapor lines or pump bypass
lines. When properly installed, this line must permit free flow in either direction. To assure free flow
in either direction, do not install a check valve in the vent line and use a full port ball valve for the
shut-off valve. If valve in vent line is closed, flowmeter will not function. These instructions must
be followed in order to maintain proper function of the differential valve.
NOTE:  A vapor equalizing line should not be used from supply tank to tank being filled, as
such connection would cause confusion as to the amount delivered due to possible passage of
vapor in either direction.

FIGURE 2.
INSTALLATION ARRANGEMENT

Page 2
OPERATION OPERATION
Pressurize the system slowly by allowing vapor flow through the vent line. Check for system
leaks. Then pass sufficient liquid through the system to clear the lines of air and vapor.
After starting pump, slowly open outlet valve downstream of the flowmeter. Check the rate of
flow after the system is filled; it should not exceed rated maximum flow of flowmeter.
Adjust the external pump bypass to deliver the maximum practical rate of flow for the least
amount of pump pressure.
NOTE:  The pump relief valve (normally built into the pump assembly) should relieve at a
pressure above which the external bypass has been set.
Maximum working pressure on the system must not exceed 350 psi. Avoid the use of small
diameter hose or pipe and resultant need for excessive pressures to achieve the desired flow rates;
these may result in leakage, undue wear on pump and unsafe operation.
All flowmeters are carefully calibrated and tested after assembly and no changes should be
necessary.
While the installation is still new, clean the strainer frequently. After the system has been in
service, only periodic cleaning is necessary.
To Operate the Flowmeter To Operate
1. Start pump. The Flowmeter
2. To prevent register creep, reset register to zero by turning operating knob to the rear stop.
On Printer models (800 Series Register), first insert ticket. (See Figure 3.)
3. Open hose valve and make delivery.
4. After completion of delivery on Printer models, stamp final reading on ticket by turning reset
knob to the front stop and remove ticket.
5. The cumulative totalizer is visible through the mask at the upper right-hand corner of
­register.

STOP PINS

TOTALIZER DUST BAR

RESET KNOB

TRIP ADJUSTING
SCREW COVER

CLAMP SCREWS LETTER WHEELS

FIGURE 3
PRINTER REGISTER FIGURE 4
(800 Series) PRINT UNIT ADJUSTMENTS
PRINTER MODELS (800 Series Register) Totalizer
To insert a ticket be sure that the reset knob is turned forward to a stop. Then depress the dust PRINTER MODELS
bar above the ticket slot (see Figure 3), and insert ticket either “face down, bottom end first” or “face To Insert and
up, top end first” as noted on instruction plate. Turn reset knob backward to stop. This resets the Remove Tickets
visible wheels to zero, locks the ticket in place, and prints the initial reading on the ticket. (Ticket
now cannot be removed without tearing it.)

Page 3
 Upon completion of delivery, turn the reset knob forward to stop. This operation prints the final
reading and releases the ticket.
Printer registers are shipped from factory with the ticket guides properly adjusted. If it is neces- To Adjust
sary to reposition ticket, proceed as follows: Ticket Guides
1. Remove top cover.
2. Insert ticket into printer. Loosen screws on rear of ticket guides. Move guides to right or
left as required. Tighten screws. The ticket must slide freely between the guides. If ticket
bends at forward end of guide, remove guide and rebend tail.
3. To raise or lower printing, push the two stop pins to the front or rear with end of a screw-
driver.
4. Replace top cover and reseal.
To Change “Letter Wheel” Setting: To Change
1. With top cover removed the “letter” wheels are visible. (See Figure 4) “Letter Wheel” Setting
2. Using screwdriver or similar tool, turn wheels until desired letters are in position to print.
The letters appearing at top are in position to print.

CALIBRATION CALIBRATION
Test the flowmeter using a volumetric prover large enough to permit the flowmeter to operate for
at least one minute at maximum flow rate. Slip tube and rotary gauge readings are not sufficiently
accurate for proving flowmeters. A detailed description of LP-Gas test procedure may be found in
the NIST/Weights and Measures Training Module, “Liquefied Petroleum Gas Liquid – Measuring
Devices” Inspector’s Manual. Specifications and Tolerances are contained in NBS Handbook H-44.
For meters used outside the USA, please consult your local weights and measures authority for
the correct procedures and tolerances.
A thermometer well is provided for taking temperature readings while calibrating. It is located in
the vapor release. It is covered by a snap plug to keep dirt from entering the well. The well should
be filled with permanent type anti-freeze, if available, or with a light oil when temperature readings
are to be obtained.
If a gravimetric test is used, the conversion to gallons must be on the basis of:  (1) specific
gravity determined at the time of test (not an assumed value), (2) the temperature of the product
as it passed through the flowmeter.
Slip tube and rotary gauge readings are not sufficiently accurate for use as flowmeter checks
and will produce erratic results.
Erratic registration may be an indication of vapor or dirt in the measuring chamber. It cannot Erratic Registration
be corrected by recalibration. Clean the strainer and if necessary the flowmeter as directed in the
section “Preventative Maintenance Schedule.” For proper operation the installation must be as
shown in Figure 2.
When the flowmeter registers consistently either more or less than is delivered, the calibration Consistent Over- or
may be corrected in the following manner: Under-Registration
ON UNCOMPENSATED FLOWMETERS WITH 800 SERIES PRINTER REGISTER ON UNCOMPENSATED
Test the flowmeter to determine any error in registration. If there is an error less than 0.30%, FLOWMETERS WITH
proceed as follows: 800 SERIES
1. Remove the register top cover. PRINTER REGISTER
2. Lift and turn change gear shifter (see Figure 5) in the direction indicated on the top of the
shifter.
3. There is a series of holes in the plate into which the guide pin enters at different settings.
Altering the setting by one hole changes the calibration approximately 34 cubic inches in
100 gallons.
Example:  Suppose that the flowmeter consistently gives 68 cubic inches too much when it
registers 100 gallons. After removing the cover plate move the gear shifter 2 spaces to the right
(from position E to position C) to decrease the delivery about 68 cubic inches in 100 gallons.
After changing the calibration always replace the top cover, making sure that the sheet steel
housing on the sides and back fits into the groove in the bottom edge of cover. Run a small amount
of liquid through the flowmeter before testing. In order to prevent tampering, always reseal after
calibration is completed.

Page 4
 If there is an error greater than 0.30% (approx. 68 cu. in. in 100 gals.), proceed as follows:
1. Remove the register. (Refer to REGISTER MAINTENANCE.)
2. Looking into the bottom of the register, determine the number of teeth on the “R” and “S”
change gears. (See Figures 6 & 8.)
3. Refer to CHANGE GEAR CHART (Figure 7) and select the proper gears.
4. Install new gears being sure to put change gear “R” on the “R” spindle and change gear
“S” on the “S” spindle.
5. Replace register and tighten two screws.
6. Run a few gallons through the flowmeter, and retest.

GEAR SHIFTER

CHANGE GEAR “R” CHANGE GEAR “S”

(ON “STD” SPINDLE)

FIGURE 5 FIGURE 6
GEAR SHIFTER ADJUSTMENTS CHANGE GEAR ARRANGEMENT

ON UNCOMPENSATED FLOWMETERS WITH 600 SERIES REGISTER ON UNCOMPENSATED

1. The 600 Series Register Change Gears are located inside the register, directly beneath an FLOWMETERS
access plate on top of the register. (See Figure 8.) Remove the two screws on the plate, WITH 600 AND 157
the cover plate, and replace gears as above. Spread the ends of both spindles and replace SERIES REGISTER
the access plate.

ON UNCOMPENSATED FLOWMETERS WITH 157 REGISTER

1. Determine the number of cubic inches of over- or under-delivery for each test conducted.
2. Remove the register box screws or clamps and take off register.
3. Note the numbers stamped on the Register Change Gear (on register spindle) and on the
Stuffing Box Change Gear (on flowmeter spindle). Locate the gear-tooth combination on
the CHANGE GEAR CHART.
4. Add the step-wise increments of change in registration until the desired amount is reached.
If the flowmeter is under-registering (delivering too much), select a new pair of gears farther
up on the chart. If the flowmeter is over-registering (delivering too little), select a new pair of
gears farther down on the chart. The right-hand columns of the chart show the difference in
delivery between each set of gears in percent or in cubic inches per 5 gallons delivered.
5. Remove the old Change Gears and replace them with the new pair. (New gears may be
obtained from the nearest Neptune Distributor). To remove the Register Change Gear on
the 157 registers, close the split end of the spindle slightly with a pair of pliers to permit
removal of the change gear. After slipping on the new gear, spread the ends of the spindle
slightly. The Stuffing Box Change Gear should lift off easily, and the new one should slide
on without forcing. Do not spread the ends of the stuffing box spindle.
6. Reinstall the register, run a few gallons through the flowmeter, and retest.

Page 5
 FIGURE 7 FIGURE 8
REGISTER CHANGE GEARS REMOVING REGISTER CHANGE GEARS

ON COMPENSATED FLOWMETERS WITH 600 SERIES REGISTER ON COMPENSATED

1. Remove the two seal screws and cover from the temperature compensator. (See Figures FLOWMETERS
9 & 13). (Do not remove sealing wax at top of lever arm.) WITH 600 SERIES
2. Move anchor pin from “Compensated Anchor” to “Uncompensated Anchor.” (Flowmeter REGISTERS
readings will not be uncompensated.) (See Figure 9.)
3. Perform same LP-Gas flowmeter test procedure as outlined under CALIBRATION.
4. If necessary to change flowmeter calibration, refer to ON UNCOMPENSATED FLOWME-
TERS with 600 Series Register.
5. Move anchor pin to “Compensated Anchor” and operate flowmeter for at least 50 gallons
before proceeding with calibration tests. (Flowmeter readings will now be temperature
compensated.)
6. Perform same flowmeter test procedure used for uncompensated flowmeter. Temperature read-
ings must be taken at the prover only. (Temperature at flowmeter is assumed to be 60°F.)
7. If necessary to adjust compensated registration, turn calibration dial located at the lower
end of the Lever Arm (to turn adjustment, use wrench on hex hub of dial.) Turn clockwise
“To Give More” or counterclockwise “To Give Less.” Each dial graduation will change com-
pensated delivery approximately 0.15%; that is, 34 cubic inches per 100 gallons.
8. Replace cover and seal screws.
CALIBRATION DIAL UNCOMPENSATED
ANCHOR

FIGURE 9
REMOVING ANCHOR PIN
FOR CALIBRATION
OF TEMPERATURE
COMPENSATED
FLOWMETER
COMPENSATED ANCHOR
ANCHOR
PIN

PREVENTATIVE MAINTENANCE SCHEDULE PREVENTATIVE

or sustained accuracy of RSM LP-Gas Flowmeters, little maintenance is required other
F MAINTENANCE SCHEDULE
than to see that the proper conditions of operation are preserved. Once the flowmeter has been General Maintenance
installed correctly, these conditions consist merely in guarding against foreign matter, such as
vapor, sediment or water entering the measuring chamber. However, should any malfunction
develop, do not dismantle the flowmeter until the cause of the trouble has first been determined.
Refer to suggestions in “TROUBLESHOOTING.”

Page 6
 The liquid passing through the measuring chamber must be free of grit and other forms of Sediment
sediment to prevent unnecessary friction and to eliminate scoring of the piston and chamber
walls. Evidence of trouble from this source will be found in under-registration of the flowmeter.
Periodic cleaning and inspection of the flowmeter strainer will help to ensure maximum flow rate
and to prevent possible damage of the flowmeter if clogged strainer ruptures.
Being an instrument that measures by volume, a flowmeter will record the passage of va- Vapor
pors as well as the liquid being measured, resulting in over-registration. This will not occur with
proper Vapor Release and Differential Valve function and installation.
Incidental water will cause no damage to the flowmeter. Trouble from this source may be Water
expected only when water is allowed to remain in the flowmeter.

REGISTRATION REGISTRATION
Erratic registration is usually caused by vaporization of the product, faulty differential valve Erratic Registration
or vapor release valve function or installation (over-registration), or by dirt or pipe scale in
the measuring chamber (under-registration). Clean the flowmeter, if necessary, as directed in
MEASURING CHAMBER MAINTENANCE. If flowmeter continues to creep when outlet valve is
closed, check differential valve seals.
When the flowmeter has a consistent error either more or less than is delivered, and no Consistent Over- or
other cause in system function can be determined, calibration of the metering system is recom- Under-Registration
mended.

STORAGE STORAGE
Before placing in storage the flowmeter assembly must be flushed with a light lubricating oil
of good quality to prevent corrosion from condensation.

REGISTER MAINTENANCE REGISTER

Register parts are such that only minor field repairs are advisable. When a register is in MAINTENANCE
need of service other than that for which instruction is given here, it should be returned to an
authorized RSM distributor.
Loosen the two clamp screws on lower front of the 800 series register. Lift the register off. To Remove Register From
Remove the two screws holding the 600 series register to the register cup. Lift the register Flowmeter or Temperature
off. On temperature compensated flowmeters remove the four screws holding the register to the Compensator
compensator adapter housing. Life the register off.
When one register is removed and another substituted:  (1) Check the number of teeth on
the “change gears” (See Figures 6 & 8). They must be the same as gears on the old register
and on the same respective spindles. The number of teeth is stamped on each gear. To remove
these gears, close the split end of the spindle slightly with a pair of pliers and pull off the gear.
After putting on a gear, spread the end of the spindle slightly. (2) Make sure that the position of
the “Gear Shifter” on the 800 series register is the same on the new register as on the old one.
Register masks are made of plastic and require special treatment. A water solution of non- To Clean Register Masks
abrasive soap is recommended for washing grease, oil, or dirt from the mask. It is then cleansed
by rubbing gently with a soft cloth, in a manner similar to cleaning window glass, rinsing the
plastic in clean water, and finally drying.
Scouring cleanser and similar material must not be used for cleaning masks, since they
contain abrasives that scratch the surface.
The use of solvents, such as acetone, ethyl acetate, benzene, and ethylene dichloride, to
brighten the surface is never recommended since these substances soften the surface of the
plastic.

Page 7
 CAUTION!!
Perform all operations that involve opening any part of the flowmeter out-
doors, away from buildings and sources of ignition.
!! Before opening any part of the flowmeter, close all valves between supply
tank and flowmeter and loosen coupling at vapor release cover to relieve pres-
sure on the flowmeter. All necessary replacement parts should be on hand.

FIGURE 10
CHECKING PISTON FREEDOM

To Remove and Disassemble

This operation is not difficult and may be performed by any competent mechanic. No special
tools are required. No trouble need be expected, if these few simple but important directions are To Remove
followed. Do not open the flowmeter until you have checked over all other possible causes of er-
and Disassemble
ratic registration. Refer to TROUBLESHOOTING.
1. Prepare a clean surface on which to place the parts as they are removed. (The parts are
machined to close tolerances and should be handled with care.) Also check that a replace-
ment gasket is on hand before opening the flowmeter.
2. Remove the flowmeter top taking care not to damage the gasket, if it is to be re-used.
3. Lift the measuring chamber from the flowmeter casing.
4. Remove the upper cylinder head by inserting a screwdriver in one of the slots provided,
and prying it off. Be careful not to scratch or nick any part of the chamber.
5. Lift out the piston by its spindle. If care if taken to draw it straight, it should come out easily.
Do not force it.
6. Remove the control roller from the lower cylinder head. If the diaphragm or seal pin requires
replacement, they may be removed by pulling upward, using pliers if necessary.

To Clean the Measuring Chamber

The parts may be most easily cleaned of scale, embedded chips, heavy corrosion and other
foreign matter, using gasoline and a coarse, stiff-bristle (not wire) brush. Do not use abrasives, To Clean the
such as emery cloth or sandpaper. When the piston is badly corroded, replace the whole cham- Measuring Chamber
ber.
The sliding surfaces between the chamber and piston take on a burnished finish and wear
little if any. The parts of the measuring chamber which may show wear after long periods of ser-
vice are the diaphragm and the control roller. These parts will not require replacement until the
accuracy of the flowmeter begins to fall at low rates of flow. To change these parts, merely sub-
stitute new parts for the old, when the flowmeter is disassembled for cleaning.

Page 8
 CAUTION!!
Perform all operations that involve opening any part of the flowmeter out-
doors, away from buildings and sources of ignition.
!! Before opening any part of the flowmeter, close all valves between supply
tank and flowmeter and loosen coupling at vapor release cover to relieve pres-
sure on the flowmeter. All necessary replacement parts should be on hand.

To Reassemble the Chamber in the Flowmeter To Reassemble the

Before assembling the flowmeter, make sure all parts are clean. If possible, flush out the Chamber in the Flowmeter
flowmeter body. Assemble the parts carefully; they should slide together easily without ham-
mering or forcing. It is essential that all contact surfaces between the upper and lower cylinder
heads and the cylinder, or between the measuring chamber and its seat in the casing, be clean
and free from nicks.

1. Assemble the diaphragm and seal pin in the chamber, if replacement of these parts
was necessary.
2. Place the control roller on its pin, and see that it will rotate freely.
3. Reinstall the piston, and oscillate it carefully by hand; it should move easily without
binding. (See Figure 10.) If it sticks, do not force it, but remove it and locate the cause. Do not
file down the roller as this will destroy the accuracy of the flowmeter.
4. Reinstall the upper cylinder head, and again oscillate the piston to make sure that it is
free.
5. Before installing the measuring chamber in the casing, make sure that the seat is clean
and free of nicks. Install the chamber, making sure that the dowel pin in the main casing enters
the slot in the bottom cylinder head properly and allows the chamber to rest squarely on the
seat. The top of the chamber should be flush with the gasket seal. (Refer to page 11, item 9.)

NOTE: Do not overtorque the bolts! Tighten in accordance with torque specifications
inside the front cover of this manual.

GEAR TRAIN MAINTENANCE GEAR TRAIN

MAINTENANCE
1. Remove the register.

2. Remove stuffing box nut (1).

3. Remove shaft seal (2). Inspect top spindle

to be sure it is free of nicks or burrs which
might damage the new shaft seal when it
is placed on spindle.

4. Replace shaft seal with new part. Be sure

expander (3) and spring (4) are in position
before inserting new seal.

5. Assemble nut (1) and tighten down all the

way.

Page 9
 CAUTION!!
Perform all operations that involve opening any part of the flowmeter out-
doors, away from buildings and sources of ignition.
!! Before opening any part of the flowmeter, close all valves between supply
tank and flowmeter and loosen coupling at vapor release cover to relieve pres-
sure on the flowmeter. All necessary replacement parts should be on hand.

To Replace Gear Train To Replace Gear Train

1. Remove the register

2. Remove the star connection.

3. Remove the flowmeter top casing, with gear train assembly attached. Be careful to keep
dirt out of the flowmeter, and avoid damage to the cover gasket. (A replacement gasket
may be necessary.)

4. Unscrew the stuffing box nut.

5. Take off the clamp nut and remove the gear train assembly from the underside of the flow-
meter top casing.

6. Install replacement gear train, making sure that the replacement has the same gear reduc-
tion.

7. Before reinstalling the top casing, inspect the gasket and replace it, if necessary. Next,
position the driving arm of the gear train so that it will not rest on the piston spindle. Then
reassemble the top casing on the main casing and secure it with the four cap screws.

VAPOR RELEASE MAINTENANCE VAPOR RELEASE

Servicing of the vapor release and strainer portion of the assembly consists only of occasional MAINTENANCE
cleaning of the strainer, and when required, replacement of a collapsed float or servicing a stick-
ing valve.

To Disassemble the Assembly: To Disassemble

the Assembly
1. Disconnect the tubing between the differential valve and the vapor release cover. (See
Figure 12, Item 18)

2. Remove the cap screws on the vapor release cover, and lift off cover and float assembly.

3. If float is crushed or damaged, remove cotter pin and replace float.

4. Carefully inspect the valve sleeve for any resistance to smooth movement of the sleeve
on the stem. Inspect all holes in the sleeve and the stem for foreign material which could
cause sticking of the valve and obstruct the flow through the valve. If defective, replace
sleeve and stem assembly.

5. Inspect the vapor release cover O-ring and O-ring groove.

6. Install the float and cover assembly and tighten cover bolts.

NOTE: Do not overtorque the bolts! Tighten in accordance with torque specifications inside
the front cover of this manual.

Page 10
 CAUTION!!
Perform all operations that involve opening any part of the flowmeter
outdoors, away from buildings and sources of ignition.
!! Before opening any part of the flowmeter, close all valves between supply
tank and flowmeter and loosen coupling at vapor release cover to relieve pres-
sure on the flowmeter. All necessary replacement parts should be on hand.

  1 – VAPOR RELEASE COVER

  2 – O-RING 1 2
  3 – STRAP ASSEMBLY (OBSOLETE 6/99)
  4 – MAIN CASING
  5 – O-RING 1 2
  6 – FLANGE INLET AND OUTLET
  7 – MAIN CASE COVER
  8 – GEAR TRAIN
  9 – GASKET 1 2
10 – MEASURING CHAMBER 2
11 – DIFFERENTIAL VALVE PLUG
12 – U-CUPS 2
13 – SPRING
14 – SLEEVE
15 – O-RING 1 2
16 – DIFFERENTIAL VALVE COVER
17 – ELBOW FITTING
18 – VAPOR RELEASE TUBE
19 – O-RING 1 2
20 – STRAINER
21 – STRAINER ASSEMBLY COVER
22 – THERMOWELL
23 – FLOAT AND SLEEVE VALVE ASS’Y.
24 – STAR CONNECTION
25 – REGISTER CUP
26 – REGISTER ADAPTER

NOTES:
1
General Maintenance Parts (minimum)
2
Major Service (minimum)

FIGURE 12
FLOWMETER PARTS EXPLODED

STRAINER MAINTENANCE STRAINER

MAINTENANCE
1. Remove the four cap screws on the strainer cover, and lift off cover.
2. Remove the strainer assembly and clean it with compressed air. Inspect it for any breaks
or other defects, and replace if necessary.
3. Reinstall the strainer in the housing and replace the cover.

DIFFERENTIAL VALVE MAINTENANCE DIFFERENTIAL

VALVE MAINTENANCE
Faulty operation of this valve may be caused by defective valve seats, spring or O-ring. To
disassemble this valve:
1. Remove connecting tube.
2. Remove four cover screws, cover and spring.
3. Insert a 1/4-20 x 4-inch screw with “T” handle into valve plug and pull from housing.
4. Inspect O-ring, U-cups and seats of valve plug and housing. Replace defective parts. Inspect
I.D. of sleeve for roughness and smooth with fine emery cloth if necessary.

Page 11
 CAUTION!!
Perform all operations that involve opening any part of the flowmeter out-
doors, away from buildings and sources of ignition.
!! Before opening any part of the flowmeter, close all valves between supply
tank and flowmeter and loosen coupling at vapor release cover to relieve pres-
sure on the flowmeter. All necessary replacement parts should be on hand.

5. Replace U-cups on valve plug and insert into sleeve. Assemble spring. Push valve and
sleeve into casing and press against spring. Valve plug should move to its closed position
by spring force only. If valve remains partly open, locate cause and correct.
6. Replace cover and tubing and reconnect vapor vent line.
TEMPERATURE
COMPENSATOR
TEMPERATURE COMPENSATOR MAINTENANCE MAINTENANCE
The Compensator (Figures 9 & 13) is designed to give long and dependable service when To Repair Compensator
properly installed. The unit has been thoroughly performance-tested prior to shipment, and in
normal service requires no further lubrication.
Maintenance of the compensator should be limited to those operations outlined below. If it
becomes apparent that the unit is in need of repair, the compensator should be returned to the
nearest authorized RSM distributor.
To Remove Compensator To Remove Compensator
1. Remove the register.
2. Remove vapor line and connecting tube.
3. Remove bolts at the base of the compensator and lift the unit off.
To Replace Thermostat (Figure 13) To Replace Thermostat
1. Remove two seal screws and take off “Neptune” cover.
2. Withdraw anchor pin after removing cotter pin.

FIGURE 13
ATC COMPONENTS WITH
600 SERIES REGISTER

Page 12
 CAUTION!!
Perform all operations that involve opening any part of the flowmeter
outdoors, away from buildings and sources of ignition.
!! Before opening any part of the flowmeter, close all valves between supply
tank and flowmeter and loosen coupling at vapor release cover to relieve pres-
sure on the flowmeter. All necessary replacement parts should be on hand.

3. Remove three screws and take off lever arm plate.

4. Remove four screws and lift off thermostat cover being careful not to damage thermostat
O-ring gasket.
5. Lift out thermostat.

TROUBLESHOOTING TROUBLESHOOTING
1. Register Not Working When Liquid is Flowing
a. Bypass around flowmeter not shut off.
b. Ice inside register.
c. Loose register or worn gear train.
d. Register in need of repair.
e. Sheared key on Change Gear — caused by ice in register or mechanically tight mecha-
nism.
f. Connector on top of gear train (and/or ATC) not properly installed — set screw may not
be tightened on flat of 0.125″ steel spindle.
2. Leakage at the Stuffing Box
a. Worn shaft seal or spindle.
3. Chronic Leakage at the Main Case Gaskets
a. Excessive line or shock pressure.
b. Defective gasket or loose bolts.
4. Unsatisfactory Flow Rate or Complete Stoppage of Flow
a. Obstruction in vapor vent line between differential pressure valve and vapor space in
tank.
b. Pump too small or inefficient. (The pump must have sufficient capacity and pressure to
pump against higher heads than are normally found in gasoline or fuel oil installations.
This is especially true when the delivery nears completion.)
c. Pump vapor bound due to improper installation by bypass relief valve or a restriction in
suction line. (Refer to “INSTALLATION.”)
d. Pump bypass stuck open or spring weak.
e. High loss of head. (This is caused by too many valves and elbows and the length, di-
ameter and condition of the delivery hose.)
f. Pressure buildup in tank being filled. Condition becomes worse as delivery nears comple-
tion unless vapor return line (not recommended) is used or vapor space type filling is
used.
g. Blocked strainer, or piston in flowmeter stuck. Clean strainer and measuring chamber.
h. Open valve in piping allowing liquid to circulate around pump.
i. Worn pump.
j. Vapor release valve fails to close, causing differential to remain closed or open slight-
ly.
k. Vent line connection to supply tank must be minimum 1/4″ diameter. Any orifice or par-
tially closed valve will result in malfunction of differential valve.
5. Under-Registration — Erratic
a. Dirt in the measuring chamber.
b. Badly worn control roller or diaphragm.
c. Main casing distorted or damaged.
d. Dirt under seat of measuring chamber (after cleaning).

Page 13
 CAUTION!!
Perform all operations that involve opening any part of the flowmeter out-
doors, away from buildings and sources of ignition.
!! Before opening any part of the flowmeter, close all valves between supply
tank and flowmeter and loosen coupling at vapor release cover to relieve pres-
sure on the flowmeter. All necessary replacement parts should be on hand.

6. Over-Registration — Erratic
a. Leaking O-ring on differential valve.
b. Vapor release valve jamming, allowing vapor to pass through the flowmeter.
c. Vent line from the vapor release valve plugged causing vapor to pass through the flow-
meter.
7. Consistent Over- or Under-Registration
a. Flowmeter in need of calibration.

135

DIMENSIONS mm (Inches) (5 5/16)

800 Series 33
(1 5/16)

406
(16)
406
(16)

251
(9 7/8)

3
/4 NPT OR 1”
INLET AND
OUTLET

38
(1 1/2)

93
308 (3 21/32)
(12 1/8) 110 60
(4 5/16) (2 3/8)

/16 - 18 UNC 2B
5

(3 HOLES)

44.5 (1 3/4)

89 (3 1/2)

13
(1/2)
184
(7 1/4)

Page 14
 DIMENSIONS mm (Inches)
600 Series
149
(5 7/8)

87 87
(3 13/32) (3 13/32)

41
(1 5/8)

359
(14 1/8)
359
(14 1/8)
251
(9 7/8)
/ NPT OR 1”
3 4

INLET AND
OUTLET

38
(1 1/2)
93
(3 21/32)
308
(12 1/8)

110 60
(4 5/16) (2 3/8)

/16 - 18 UNC 2B
5

(3 HOLES)

44.5 (1 3/4)

89 (3 1/2)

13
(1/2)
184
(7 1/4)

Page 15
DIMENSIONS mm (Inches)
600 Series with ATC
47/8 4

149
(5 7/8)

87
(3 13/32)
87
(3 13/32)

41
(1 5/8)

422
(16 19/32)

422
(16 19/32)
3
/8 - FLARED
TUBE FITTING
251
(9 7/8)

3
/4 NPT OR 1”
INLET AND
OUTLET

38
(1 1/2)
93
308 (3 21/32) 110 60
(12 1/8) (4 5/16) (2 3/8)

/16 - 18 UNC 2B
5

(3 HOLES)

44.5 (1 3/4)

89 (3 1/2)

13
(1/2)
184
(7 1/4)

Page 16
U.S.A./International
1310 Emerald Road
Greenwood, SC 29646-9558
Tel.:  Toll-Free (800) 833-3357
(864) 223-1212
Fax: (864) 223-0341
© 2012 Red Seal Measurement   500   10/12

Specifications subject to change without prior notification.