FILL-RITE 806C Fuel Transfer Meters Instruction Manual

FILL-RITE 806C Fuel Transfer Meters

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.

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 the 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.
   CAUTION
   The Chamber opening must face toward the inlet port of the 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 the indicated amount does not match the known volume, insure the pump is off and the pressure is relieved, then remove the seal screw (item 23) and turn the 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 the seal screw.

3. Repeat steps 1 and 2 until calibration is acceptable.

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.

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 a 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 the o-ring and seat area or replacing the 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 a pressure relief valve to allow high pressure to bleed back to the tank.

• Nutating disc breaks:
  Avoid flow surge by putting a shut-off valve on the outlet of a meter; place the meter as close as possible to the pump; keep the 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. The meter can be completely disassembled without disturbing the piping.

Counter Assembly
For access to the counter assembly, remove the reset knob (item 3) by grasping the 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 the counter (item 4). Reassemble by reversing procedure.

Meter Chamber Assembly
To expose the meter chamber assembly, tilt the meter at least slightly face down so that no parts fall out when removing the meter housing. Remove the four screws (item 20), then remove meter housing (item 19). The meter chamber assembly consists of upper and lower chambers, a nutating disc, and a sealing gasket. Reassemble by reversing procedure. If 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 the gear train and seal, remove the gear frame (item 12) by prying it slightly. Remove cluster gear (item 10) and washer (item 11) from the shaft (item 9). Remove the drive gear (item 8) and washers (item 7) by rotating and pulling the drive gear. Remove the O-ring seal (item 6). When reassembling the seal, lubricate the O-ring liberally with oil or petroleum jelly and replace in the cover. Place a washer on the drive gear shaft. Carefully rotate and push the shaft through the O-ring and cover to prevent damage to the O-ring. The shaft must then be guided into the pinion bevel (item 28) if the counter has not been removed. Replace remaining parts to complete assembly by reversing the 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 that have been pumped through the unit. Meters not adhering to these specifications may be refused service.

Parts List

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 the 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.

Contact Information

• 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.

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