FILL-RITE 807C1 3-Digit Mechanical Fuel Transfer Meter Instruction Manual

FILL-RITE 807C1 3-Digit Mechanical Fuel Transfer Meter

Safety Instructions

To ensure safe and efficient operation, it is essential to read each of these warnings and precautions and to follow all instructions listed in this manual.

DANGER
Improper use or installation of this product can cause serious bodily injury or death.

1. DO NOT smoke near the meter or use the meter near an open flame when dispensing flammable fluids. Fire could result.
2. Do not exceed 50 PSI / 3.5 BARS line pressure.

CAUTION
Do not install an additional foot valve or check valve during installation without a pressure relief valve. Cracking may result.

3. This product should not be used for fluid transfer into aircraft.
4. This product is not suited for use with fluids for human consumption, including potable water.

Operating Instructions

For accurate measurement, the meter and piping must always be filled with liquid and free of air. The meter should be calibrated per instructions in this manual prior to its use.

1. Stop the flow of liquid.
2. Reset the meter to 0.
3. The meter is ready for use. Start the flow of liquid. Do not exceed 50 PSI line pressure.

Installation

Meters are furnished for horizontal piping, left to right flow unless otherwise specified. Use oil and gasoline-resistant pipe compound on all threaded joints. Flow ports can be located in any of four positions for horizontal or vertical piping.

1. If fluid flow is left to right, install the meter.
2. If fluid flow is other than left to right, determine direction of fluid flow.
3. Lay the meter dial face down on a clean flat surface.
4. The arrow mark on the meter housing indicates fluid flow direction.
5. Remove four screws (item 20).
6. Lift meter housing (item 19) and chamber assembly (item 26) and rotate together to the desired flow direction.
7. The Chamber opening must face toward the inlet port of the meter.
8. Replace four screws (item 20).
9. Install meter.

Maintenance

Meter should operate maintenance free. However, certain liquids can dry out while in the meter housing, causing the meter to stop. If this happens, meter should be thoroughly cleaned (see instructions below).
Cleaning Instructions:
Run a flushing fluid through meter. For a more thorough cleaning, disassemble meter per ASSEMBLY / DISASSEMBLY section, Meter Chamber Assembly subsection. Rinse all meter components. Recalibrate meter following calibration instructions above.
Storage:
If meter is to be stored for a period of time, clean thoroughly. This will help protect meter from damage.
Calibration
The Fill-Rite Series 800C meters can be calibrated for either U.S. gallons or liters. Calibration is required after disassembly, when metering a different fluid, or after significant wear. Depending on the model, Series 800C meters are factory calibrated in either U.S. gallons or liters using mineral spirits. Meter calibration can be easily changed by using the calibration procedure noted. A container of KNOWN volume will be needed for the calibration procedure. It is recommended that the container’s volume be at least five gallons or larger.

Product Information: The 800C Series Fuel Transfer Meters (806C, 807C) are designed to accurately measure fluid flow during fuel transfer. The meters can be calibrated to measure either U.S. gallons or liters and are suitable for horizontal or vertical piping. The meters should be filled with liquid and free of air for accurate measurement. The maximum line pressure for these meters is 50 PSI / 3.5 BARS, and they should not be used for fluid transfer into aircraft or with fluids for human consumption.

Product Usage Instructions

1. Prior to use, read all safety instructions and precautions listed in the Installation and Operation Manual.
2. Install the meter according to the Installation instructions. Use oil and gasoline-resistant pipe compound on all threaded joints.
3. Ensure that the meter and piping are filled with liquid and free of air for accurate measurement.
4. Calibrate the meter prior to use using the Calibration instructions.
5. To use the meter, stop the flow of liquid, reset the meter to 0, and then start the flow of liquid. Do not exceed 50 PSI line pressure.
6. If the meter stops working due to dried-out liquid in the meter housing, clean the meter thoroughly per the Maintenance instructions.
7. If storing the meter for a period of time, clean it thoroughly per the Maintenance instructions to protect it from damage.

Safety Instructions

To ensure safe and efficient operation, it is essential to read each of these warnings and precautions and to follow all instructions listed in this manual.

DANGER: Improper use or installation of this product can cause serious bodily injury or death.

1. DO NOT smoke near meter or use meter near an open flame when dispensing flammable fluids. Fire could result.
2. Do not exceed 50 PSI / 3.5 BARS line pressure.
   • CAUTION: Do not install additional foot valve or check valve during installation without pressure relief valve. Cracking may result.
3. This product should not be used for fluid transfer into aircraft.
4. This product is not suited for use with fluids for human consumption, including potable water.

Installation

Meters are furnished for horizontal piping, left to right flow, unless otherwise specified. Use oil and gasoline resistant pipe compound on all threaded joints. Flow ports can be located in any of four positions for horizontal or vertical piping.

1. If fluid flow is left to right, install meter.
2. If fluid flow is other than left to right, determine direction of fluid flow.
3. Lay meter dial face down on a clean flat surface.
4. Arrow mark on meter housing indicates fluid flow direction.
5. Remove four screws (item 20).
6. Lift meter housing (item 19) and chamber assembly (item 26) and rotate together to desired flow direction.
   • CAUTION: Chamber opening must face towards inlet port of meter.
7. Replace four screws (item 20).
8. Install meter.

Calibration

The Fill-Rite Series 800C meters can be calibrated for either U.S. gallons or liters. Calibration is required after disassembly, when metering a different fluid, or after significant wear. Depending on the model, Series 800C meters are factory calibrated in either U.S. gallons or liters using mineral spirits. Meter calibration can be easily changed by using the calibration procedure noted. A container of KNOWN volume will be needed for the calibration procedure. It is recommended that the container’s volume be at least five gallons or larger.

Procedure for Calibration

1. For the most accurate calibration, install the meter in the application. Fill a container to a known volume with the liquid to be measured.
2. If indicated amount does not match known volume, insure pump is off and pressure relieved, then remove seal screw (item 23) and turn calibration screw (item 21) counterclockwise to reduce indicated amount or clockwise to increase the amount. A full turn will change the indicated amount by approximately 0.1 Gal. (0.4L). Reinstall seal screw.
3. Repeat step 1 and 2 until calibration is acceptable.

Operating Instructions

For accurate measurement, meter and piping must always be filled with liquid and free of air. Meter should be calibrated per instructions in this manual prior to its use.

1. Stop flow of liquid.
2. Reset meter to “0”.
3. Meter is ready for use. Start flow of liquid. Do not exceed 50 PSI line pressure.

Maintenance

The meter should operate maintenance-free. However, certain liquids can dry out while in the meter housing, causing the meter to stop. If this happens, the meter should be thoroughly cleaned (see instructions below).
Cleaning Instructions:
Run a flushing fluid through the meter. For more thorough cleaning, disassemble the meter per the “ASSEMBLY / DISASSEMBLY” section, “Meter Chamber Assembly” subsection. Rinse all meter components. Recalibrate the meter following the calibration instructions above.
Storage:
If the meter is to be stored for a period of time, clean thoroughly. This will help protect the meter from damage.

Troubleshooting Guide

• The counter is reading high or low:
  Check calibration and recalibrate if necessary. Check for air in the product and repair air leaks. The measuring chamber or gears could be sticking. Correct by cleaning or replacing internal metering components.

• Shaft seal leakage:
  Possible causes are dirty or damaged seals. Correct by cleaning o-ring and seat area or replacing seal.

• Gasket leakage:
  Correct loose gasket by tightening joints. Clean dirty gaskets and seat area. Replace damaged gaskets.

• Low flow capacity:
  Clean clogged meter chamber; clean or replace screens and filters in piping.

• Meter body cracks:
  Install pressure relief valve to allow high pressure to bleed back to tank.

• Nutating disc breaks:
  Avoid flow surge by putting a shut-off valve on outlet of a meter; place meter as close as possible to pump; keep piping full of liquid.

Fluid Compatibility

The 800C is compatible with the following fluids:

• Diesel Fuel, Gasoline, Kerosene, Mineral Spirits, Heptane, and Hexane The 800C is NOT compatible with the following fluids:
• Bleach, Hydrochloric Acid, Ink, Sulfuric Acid, and Salt Water If in doubt about the compatibility of a specific fluid, contact the supplier of the fluid to check for any adverse reactions to the following wetted materials.

Assembly/Disassembly

The meter consists of a chamber housing, measuring chamber, gear train, counter assembly and cover. Meter can be completely disassembled without disturbing piping.
Counter Assembly
For access to counter assembly, remove reset knob (item 3) by grasping edges and pulling firmly. Remove two screws (item 29) and lift counterface (item 2) and cover (item 1) off. Remove two screws (item 13) to extract counter (item 4). Reassemble by reversing procedure.
Meter Chamber Assembly
To expose meter chamber assembly, tilt the meter at least slightly face down, so that no parts fall out when removing meter housing. Remove the four screws (item 20), then remove meter housing (item 19). Meter chamber assembly consists of upper and lower chambers, a nutating disc and seal gasket. Reassemble by reversing the procedure. If the replacement of any components of the meter chamber assembly is required, the complete assembly must be replaced due to the precise method of its construction. This assures a proper fit and a correctly operating chamber.
Gear Train and Seal
To disassemble gear train and seal, remove gear frame (item 12) by prying slightly. Remove cluster gear (item 10) and washer (item 11) from shaft (item 9). Remove drive gear (item 8) and washers (item 7) by rotating and pulling drive gear. Remove O-ring seal (item 6). When reassembling seal, lubricate O-ring liberally with oil or petroleum jelly and replace in cover. Place washer on drive gear shaft. Carefully rotate and push shaft through O-ring and cover to prevent damage to O-ring. Shaft must then be guided into pinion bevel (item 28) if counter has not been removed. Replace remaining parts to complete assembly by reversing disassembly procedure.
Repair
Meters needing repair should be taken to an authorized repair shop for service. Meters must be thoroughly triple-rinsed before being taken in for repair.
PRIOR TO SERVICE, ADHERE TO FOLLOWING INSTRUCTIONS:
Meters must be triple-rinsed and accompanied by a note indicating the chemicals which have been pumped through the unit. Meters not adhering to these specifications may be refused service.

800C SERIES STRAINER KIT

800B/800C SERIES REPAIR PARTS KITS

PART NO.| DESCRIPTION
800KTG2540| Repair Kit, U.S. Gallon (Standard Seals) (Includes items 6-12, 18, 22, 24-26, 28)
800KTG2541| Repair Kit, U.S. Gallon (Viton Seals) (Includes items 6-12, 18, 22, 24-26, 28)
800KTG2542| Repair Kit, Liter (Standard Seals) (Includes items 6-12, 18, 22, 24-26, 28)
800KTG2543| Repair Kit, Liter (Viton Seals)

(Includes items 6-12, 18, 22, 24-26, 28)

800KTG2579| Repair Kit, U.S. Gallon, (EPDM Seals) (Includes items 6-12, 18, 22, 24-26, 28)
800C METER PARTS LIST

ITEM NO.| PART NO.| DESCRIPTION| QTY.| | ITEM NO.| PART NO.| DESCRIPTION| QTY.
1| 800G2246| Counter Cover| 1| | 20| 800G8892| 5/16-18 x 1 HWTRS| 4
2| 800G0208| Counter Face, U.S. Gallon| 1| 21| 800F4463| Calibration Screw (Includes Item 24)| 1
800G0241| Counter Face, Liter| Opt.| 22| 800F4449| O-ring (-012) Fluorocarbon| 1
3| 800G8870| Knob| 1| 800F3389| O-ring (-012) EPDM| Opt.
4| 800F4080| Counter – U.S. Gallon| 1| 23| 800F4440| Seal Screw| 1
800F4081| Counter – Liter| Opt.| 24| 800F4036| O-ring (-008) (Included w/Item 21) Fluorocarbon| 1

5

| 800G2246| Meter Cover| 1| 800F4034| O-ring (-008), EPDM| Opt.
800G2247| Meter Cover, Nickel Plated| Opt.| ****

25*

| 800F4010| O-ring (-156), Buna-N| 1
800G2248| Meter Cover, Teflon® Coated| Opt.| 800F4011| O-ring (-156), Fluorocarbon| Opt.
6*| 800F4191| O-ring (5-106) Fluorocarbon| 1| 800F4032| O-ring (-156), EPDM| Opt.
800F4033| O-ring (5-106) EPDM| Opt.| ****

26

| 800G2262| Meter Chamber Assembly – Buna-N| 1
7*| 800F3980| Washer| 2| 800G2599| Meter Chamber Assembly – Fluorocarbon| Opt.

8*

| 800F3845| Drive Gear (70T) – U.S. Gallon| 1| 800G2600| Meter Chamber Assembly – EPDM| Opt.
800F3846| Drive Gear (84T) – Liter| Opt.| 27| 800G2531| Meter Chamber Assembly, Buna-N

(Includes Items 12 & 26)

| 1
800F4185| Drive Gear (73T) – Imperial Gallon| Opt.
9| 800F3820| Shaft, Cluster Gear| 1| 28| 800F3959| Pinion Bevel| 1

10*

| 800F3841| Cluster Gear (22T/67T) – U.S. Gallon| 1| 29| 35F1397| #4 x 3/8 PHSMS| 2
800F3843| Cluster Gear (10T/67T) – Liter| Opt.| ****

30

| 800G2532| Cover Assembly – U.S. Gallon| 1
800F3541| Cluster Gear (19T/67T) – Imperial Gallon| Opt.| 800G2533| Cover Assembly – U.S. Gallon – Nickel Plated| Opt.
11| 800F3830| Washer| 1| 800G2534| Cover Assembly – U.S. Gallon – Teflon® Coated| Opt.
12| 800G2250| Gear Frame Assembly| 1| 800G2535| Cover Assembly – Liter| Opt.
13| 900F4007| #8-32 x 5/16 PHMS ACR II| 2| 800G2536| Cover Assembly – Liter, Nickel Plated| Opt.

18*

| 700F2800| O-ring (-218), Buna-N ( 800A, 700A/B)| Opt.| 800G2537| Cover Assembly – Liter, Teflon® Coated| Opt.
700F2801| O-ring (-218), Fluorocarbon (800A, 700A/B)| Opt.| 800G2544| Cover Assembly – Imperial Gallon| Opt.
800G2601| O-ring (-218), EPDM (800A, 700A/B)| Opt.| 800G2765| Cover Assembly – U.S. with EPDM Seal| Opt.

19

| 800G2236| 3/4 Inlet – 3/4 Outlet Housing| 1| 800G2778| Cover Assembly – U.S. Nickel with EPDM Seal| Opt.
800G2237| 3/4 Inlet – 3/4 Outlet Hsg., Nickel Plated| Opt.| 800G2900| Cover Assembly – Liter with EPDM Seal| Opt.
800G2238| 3/4 Inlet – 3/4 Outlet Hsg., Teflon® Coated| Opt.| *These parts are in the 800C Series Repair Parts Kit.

NOTE: When ordering repair parts, be sure to give replacement part number, date of manufacture and meter series number. This will ensure that the correct replacement part is supplied.

800G2242| 1 Inlet – 1 Outlet U.S. Housing| Opt.
800G2243| 1 Inlet – 1 Outlet U.S. Hsg., Nickel Plated| Opt.
800G2244| 1 Inlet – 1 Outlet U.S. Hsg., Teflon® Coated| Opt.
800G2255| 1 Inlet – 1 Outlet BSPT Housing| Opt.
800G2256| 1 Inlet – 1 Outlet BSPT Hsg., Nickel Plated| Opt.
800G2257| 1 Inlet – 1 Outlet BSPT Hsg., Teflon® Coated| Opt.

Fill-Rite Company

• 8825 Aviation Drive
• Fort Wayne, Indiana 46809 USA
• T 1 (800) 720-5192
• 1 (260) 747-7524
• F 1 (800) 866-4681
• fillrite.com.
• sotera.com.
• gormanrupp.com.

References

• Fill-Rite® Fuel Transfer Equipment
• Gorman-Rupp Company
• Sotera® Oil and Chemical Transfer Equipment

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