air manifold assembly - betts ind

INSTALLATION, OPERATION,

MAINTENANCE MANUAL #:

AIR MANIFOLD ASSEMBLY

PART NUMBERS MS34V1XXXX – 3 compartment single manifold, 14” centersMD41V12XXX – 4 compartment dual manifold, 11” centers

INSTALLATION, OPERATION,MAINTENANCE MANUAL

MAINTENANCE MANUAL #: MM-AM001 12/08 Rev. A

AIR MANIFOLD ASSEMBLY

PART NUMBERS (Including, but not inclusive)

3 compartment single manifold, 14” centers4 compartment dual manifold, 11” centers

INSTALLATION, OPERATION, MAINTENANCE MANUAL

Rev. A of 21

(Including, but not inclusive)

3 compartment single manifold, 14” centers 4 compartment dual manifold, 11” centers

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INSTALLATION, OPERATION & MAINTENANCE MANUAL

PNEUMATIC MANIFOLD MM-AM001 Rev. A of 22

Table of Contents

1.0 General Page 4

2.0 Parts Breakdowns & Measurements Page 5

3.0 Description and Intended Usage Page 14

4.0 Installation Page 14

5.0 Inspection, Maintenance, & Testing Page 16

6.0 Disassembly and Rebuild Page 18

7.0 Troubleshooting Guide Page 20

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A representative part numbering system is used for air manifolds. Each letter or digit in the part number is

indicative of a particular feature or option as shown in the chart. If a particular option is not covered by the

standard numbering system, a three digit suffix will apply.

Number of Compartments: 2 = 2 Compartments 3 = 3 Compartments 4 = 4 Compartments Etc. for larger manifolds

M = Air Manifold

Sample Part #: MD34V12BCX001

Style: S = Single D = Dual

On Center Measurements: 1 = 11” On Center 4 = 14” On Center

Seal Material: V = FKM “BLT” (Standard) Q = Fluorosilicone F = FKM “GFLT-s”

Three Digit Suffix: May be used to denote specials

API Outlet: X = No API (Standard) A = Openable API w/ Site Glass B = Openable API w/o Site Glass C = Non-Openable API w/ Site Glass D = Non-Openable API w/o Site Glass

Options: P = Product Return G = Guard Bar B = Product Return & Guard Bar X = None

A = 3” TTMA Flange Outlet Here 1 = 3” Grooved Outlet Here B = 3” TTMA Flange Outlet Here 2 = 3” Grooved Outlet Here C = 3” TTMA Flange Outlet Here 3 = 3” Grooved Outlet Here * Continue sequence for larger manifolds

Manifold Outlet Location (Rear Bank) (For Dual Manifold Only) X = For Single Manifold A = 3” TTMA Flange Outlet Here 1 = 3” Grooved Outlet Here B = 3” TTMA Flange Outlet Here 2 = 3” Grooved Outlet Here C = 3” TTMA Flange Outlet Here 3 = 3” Grooved Outlet Here

Manifold Outlet Location

Site Glass Option: C = 1 Connector Site Glass in Each Bank X = No Connector Site Glass

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1.0 General 1.1 It is strongly recommended that this entire manual be read prior to any operation, disassembly,

or assembly of this equipment.

1.2 Betts Industries, Inc. provides this manual as a guideline for reference only and assumes no responsibility for personal or property damage that may occur in conjunction with this manual. Betts Industries, Inc. cannot be held responsible for incorrect installation, operation or maintenance of product.

1.3 Betts Industries, Inc. recommends all equipment be placed on a regular maintenance schedule that includes the routine replacement of seals and gaskets and visual inspection for leaks and corrosion. The end user must make their own determination and set their own schedule based upon use and environment. In some cases, regulations may dictate the minimum testing frequency of items. Make sure operators are aware of all applicable codes.

1.4 Only trained personnel should attempt to perform maintenance on this equipment.

1.5 As with any maintenance work, proper safety gear and procedures must be used at all times. A list of hazards may include, but are not limited to, contents under pressure, loaded springs, residual product, flammable liquid and vapors, and pinch points.

1.6 Safety alert symbols are used to alert operator to potential personal injury hazards. These symbols are per ANSI 2535.5 and are listed below. Operator MUST obey all instructions that follow a safety symbol.

Alerts will be used to indicate known safety concerns. Additional concerns are possible and

should be identified and avoided by the operator.

Indicates an imminently hazardous situation which, if not avoided, will result

in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

1.7 Product Warranty shall be void if product is subject to misapplication, misuse, neglect, alteration or damage.

1.8 Specific design details described in this document are for reference only and are subject to change without notice. See Betts Industries, Inc. web page for the most recent revision to this document. www.bettsind.com

1.9 For additional questions or more detailed technical assistance, contact the Betts Industries, Inc. Sales or Engineering Department at (814)723-1250.

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2.0 Parts Breakdowns and Measurements

• Inlet/outlet flanges are 4” TTMA.

• Tee outlets are 3” Victaulic grooved or 3” TTMA flanged.

• Product return inlets (when equipped) are 2” male NPT.

• Each endplate has two 7/16-14 mounting holes located 2.75” apart horizontally, on center with each manifold bank,

4.92” below the main 4” TTMA flanges.

NUMBER OF COMPARTMENTS

DIMENSION / FEATURE ON-CENTER DISTANCE 2 3 4 5 6 7 8

A 11" CENTERS 22.2

563 mm

33.2 843 mm

44.2 1123 mm

55.2 1410 mm

66.2 1682 mm

77.2 1961 mm

88.2 2240 mm

14" CENTERS 25.2 640 mm

39.2 996 mm

53.2 1351 mm

67.2 1707 mm

81.2 2063 mm

95.2 2418 mm

109.2 2774 mm

B 11" CENTERS 22.6

574 mm

33.6 853 mm

44.6 1133 mm

55.6 1412 mm

66.6 1692 mm

77.6 1971 mm

88.6 2250 mm

14" CENTERS 28.6 726 mm

42.6 1082 mm

56.6 1438 mm

70.6 1793 mm

84.6 2148 mm

98.6 2504 mm

112.6 2860 mm

C 11" CENTERS 10.4 [264 mm]

14" CENTERS 9.9 [252 mm]

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PNEUMATIC MANIFOLD

ITEM PART NUMBER

1 47098ALVB SINGLE MANIFOLD ASSEMBLY

2 9Q5929 HH CAP SCREW 1/2"

3 9Q8613 BRASS WASHER

4 9Q8614 BELLVILLE WASHER

5 9Z6192 BRONZE BEARING

6 75520AL END CAP W/ THREADED MOUNTING HOLES

7 9Z6193 PLASTIC END CAP - GUARD BAR

8 36067AL TEE-CONNECTOR - 14" CENTERS

9A 28480ALBN SITE GLASS CONNECTOR - 14" CENTERS

9B 28427AL STRAIGHT CONNECTOR - 14" CENTERS

10 47088AL GUARD BAR SWING ARM

11 9Q5805 HEX NUT 1/4"


13 9Q5844 1/4" SPRING LOCK WASHER

14 9Q5942 1/4" FLAT WASHER

15 9Q3004 HH BOLT 7/16"


17 28461AL-3 3 COMP. GUARD BAR - 14" CENTERS (3 COMP)

18 18134VB FACE-SEAL O-RING

19 18283VB BORE-SEAL O-RING

11

15

17

16

12 13

10

14

8

9A


MM-AM001 Rev. A

DESCRIPTION

SINGLE MANIFOLD ASSEMBLY

HH CAP SCREW 1/2"

BRASS WASHER

BELLVILLE WASHER

BRONZE BEARING

END CAP W/ THREADED MOUNTING HOLES

PLASTIC END CAP - GUARD BAR

TEE-CONNECTOR - 14" CENTERS

SITE GLASS CONNECTOR - 14" CENTERS

STRAIGHT CONNECTOR - 14" CENTERS

GUARD BAR SWING ARM

HH CAP SCREW 1/4"

1/4" SPRING LOCK WASHER

1/4" FLAT WASHER


3 COMP. GUARD BAR - 14" CENTERS (3 COMP)

FACE-SEAL O-RING

BORE-SEAL O-RING

7

SINGLE MANIFOLD

9B 18 19


of 22

6

3 4 2

1

SINGLE MANIFOLD, 14” CENTERS

5

19

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PNEUMATIC MANIFOLD

ITEM PART NUMBER

1 47108ALVB DUAL MANIFOLD ASSEMBLY


3 9Q8613 BRASS WASHER

4 9Q8614 BELLEVILLE WASHER

5 9Z6192 BRONZE BEARING

6 9Q3004 HH BOLT 7/16"


8A 28528ALBN SITE GLASS CONNECTOR - 11" CENTERS

8B 28490AL STRAIGHT CONNECTOR - 11" CENTERS

9 28492AL TEE-OUTLET CONNECTOR - 11" CENTERS

10 47088AL GUARD BAR SWING ARM

11 9Q5805 HEX NUT 1/4"




15 9Q5985 STUD

16 9Q5984 JAM NUT

17 28500AL-3 GUARD BAR - 11" CENTERS

18 75520AL MANIFOLD END CAP

19 9Z6193 GUARD BAR END CAP

20 18134VB FACE-SEAL O-RING

21 18283VB BORE-SEAL O-RING


23 9Q3006 HH BOLT 7/16"

9

11

17

12 13

10

14

15 16 7


MM-AM001 Rev. A

DESCRIPTION

DUAL MANIFOLD ASSEMBLY

HH CAP SCREW 1/2"

BRASS WASHER

BELLEVILLE WASHER

BRONZE BEARING

HH BOLT 7/16"


SITE GLASS CONNECTOR - 11" CENTERS

STRAIGHT CONNECTOR - 11" CENTERS

TEE-OUTLET CONNECTOR - 11" CENTERS

GUARD BAR SWING ARM

HH CAP SCREW 1/4"


1/4" FLAT WASHER

GUARD BAR - 11" CENTERS

MANIFOLD END CAP

GUARD BAR END CAP

FACE-SEAL O-RING

BORE-SEAL O-RING

7/16" FLAT WASHER

HH BOLT 7/16"

DUAL MANIFOLD

11” CENTERS

8A

1819

7 16

15

15


of 22

MANIFOLD,

11” CENTERS

6

3 4 2

1

5

7

2120 8B

23 22 7

15

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PNEUMATIC MANIFOLD

ITEM PART #

1A 36082ALVB

1B 36085ALVB

2 9Q5822

3 9Q5844

4A 75553VB

4B 17944VB

5 36083ALVB

6 18832VB

7A 47079AL

7B 47081AL

8A 47086AL

8B 47084AL

9 9Q3004

10 9Q8616

11 9Z6192

12 47088AL

13 9Q8613

14 9Q8614

15 9Q5986

MANIFOLD BODY ASSEMBLY

47108ALBN – DUAL MANIFOLD

1A

8A

5

6

7A


MM-AM001 Rev. A

DESCRIPTION

AIR CYLINDER ASSEMBLY - DUAL MANIFOLD

AIR CYLINDER ASSEMBLY - SINGLE MANIFOLD

HH BOLT - 1/4"


MAIN SEAL O-RING - DUAL MANIFOLD

MAIN SEAL O-RING - SINGLE MANIFOLD

PRODUCT RETURN ASSEMBLY

PRODUCT RETURN O-RING

UNLOADING BODY - DUAL MANIFOLD

UNLOADING BODY - SINGLE MANIFOLD

MANIFOLD BODY - DUAL MANIFOLD

MANIFOLD BODY - SINGLE MANIFOLD

HH BOLT - 7/16"


GUARD BAR BEARING

GUARD BAR SWING ARM

BRASS WASHER

BELLEVILLE WASHER

HH BOLT 1/2"

MANIFOLD BODY ASSEMBLY

DUAL MANIFOLD 47098ALBN – SINGLE

1A

2

3

4A

12

9 10

13 14 15

11


of 22

SINGLE MANIFOLD

1B

4B

7B

8B

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PNEUMATIC MANIFOLD

ITEM PART NO DESCRIPTION

1A 36062AL AIR CYLINDER - SINGLE MANIFOLD

1B 36064AL AIR CYLINDER - DUAL MANIFOLD

2 75543AL INDICATOR PIN

3 75516AL PISTON

4 75527VB INSERT O-RING

5 19395AL U-SEAL INSERT

6 9Q4984 INSERT SNAP-RING

7 75525SL SPRING

8A 28434AL O-RING HOLDER - SINGLE MANIFOLD

8B 28436AL O-RING HOLDER - DUAL MANIFOLD

9A 18134VB O-RING - SINGLE MANIFOLD

9B 19115VB O-RING - DUAL MANIFOLD

10 75531PY INDICATOR SCRAPER

11 17946BN INDICATOR O-RING

12 75529BN PISTON O-RING

13 19509BN STEM O-RING

14 19510SSTF U-SEAL

15 9Q4983 U-SEAL SNAP-RING

16 28441AL INSERT

17 28440SL STEM

18 9Q5920 ROLL-PIN

36082ALVB &

36085ALVB

AIR CYLINDER

ASSEMBLY

1A

9A

8A


MM-AM001 Rev. A

AIR CYLINDER - SINGLE MANIFOLD

AIR CYLINDER - DUAL MANIFOLD

U-SEAL INSERT

INSERT SNAP-RING

O-RING HOLDER - SINGLE MANIFOLD

O-RING HOLDER - DUAL MANIFOLD

O-RING - SINGLE MANIFOLD

O-RING - DUAL MANIFOLD

INDICATOR SCRAPER

INDICATOR O-RING

U-SEAL SNAP-RING

AIR CYLINDER ASSEMBLY

DETAIL A

1A

2

3

4

6

7

9A

8A


of 22

5

13

14

15

DETAIL A

11

12

16

17

18

10

SEE DETAIL A

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PNEUMATIC MANIFOLD

ITEM PART NUMBER

1 36065AL

2 9Q4985

3 75533SL

4 9Q4986

5 75545VB

6 75544AC

7 75547SLVB

8 75548SL

9 75542SL

10 75546AL

11 3645NY

12 9Q8220

13 9Z6196

14 9Z6194


36083ALVB

PRODUCT RETURN

ASSEMBLY


MM-AM001 Rev. A

PART NUMBER DESCRIPTION

36065AL PRODUCT RETURN BODY

9Q4985 SCREEN SNAP RING

75533SL SCREEN

9Q4986 SITE-GLASS SNAP RING

75545VB SITE-GLASS O-RING

75544AC SITE-GLASS

75547SLVB CHECK VALVE POPPET

75548SL SPRING

75542SL SHAFT

75546AL BEARING INSERT

3645NY NYLON WASHER

9Q8220 LOCK NUT

AIR VALVE

CHECK VALVE SNAP RING


2 3

4 5 6

7 8

10 9 14


of 22

1 2

13 12

11

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ITEM PART NUMBER DESCRIPTION

1 28455SL PISTON

2 9Q4929 SNAP-RING

3 75532PY PISTON WIPER

4 75317BN INSERT O-RING

5 4118BN STEM O-RING

6 75536AL INSERT

7 17946BN PISTON O-RINGS

8 75524SL SPRING

9 9Z6195 MAGNET

10 28454AL BODY

GUARD BAR AIR CYLINDER

* Use (3) - 9Q5844 and (3) – 9Q3005 to attach air cylinder body to manifold body.

28456ALBN PRODUCT

RETURN AIR-CYLINDER

ASSEMBLY

1 2 3 4 5 6 7 8 9 10

IN - ACTUATION

IN - CONSTANT

OUT – BRAKE INTERLOCK

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ITEM PART NUMBER DESCRIPTION

1A 28478AL SITE GLASS CONNECTOR - 14" CENTERS

1B 28508AL SITE GLASS CONNECTOR - 11" CENTERS

2A 75551AC SITE GLASS - 14" CENTERS

2B 75560AC SITE GLASS - 11" CENTERS

3 18134BN SITE GLASS BUSHING O-RING

CONNECTOR SITE GLASS DETAIL

28480ALBN

CONNECTOR SITE-

GLASS ASSEMBLY

1A 2A 3

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PNEUMATIC MANIFOLD

ITEM PART NUMBER

1 9Q5844

2 9Q5849

3 75561ZC

MAGNET STRIKE PLATE DETAIL

1


MM-AM001 Rev. A

PART NUMBER DESCRIPTION

9Q5844 HH BOLT 1/4-20

9Q5849 1/4" LOCKWASHER

75561ZC MAGNET STRIKE PLATE

MAGNET STRIKE PLATE DETAIL

2 3


of 22

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3.0 Description and Intended Use

3.1 The pneumatic manifold is an air-operated valve system designed to be used on tanker trucks hauling a variety of products that unload multiple compartments by a pump system through one or two outlets. It can be specified to accommodate bottom-loading, gravity-unloading and product return.

3.2 The pneumatic manifold is an assembly of chambers, associated with different, independent valves controlled by air pressure, that, when used properly, can effectively control the loading and unloading of several different products from different compartments.

3.3 The pneumatic manifold comes with several different distinct options:

• Single bank or dual bank – The single bank configuration is used for trucks equipped with a single pump-off system. In this configuration, all products are unloaded through a common manifold outlet. The dual bank configuration should be used on trucks equipped with two pump-off systems. This is common on trucks that haul both gasoline and diesel.

• Guard bar – The guard bar is a device meant to increase the safety and security of the manifold. It can be plumbed in series with the brake interlock, or used with only the manifold air control. Its function is to help prevent unauthorized loading or unloading of fuel and loading rack errors.

• Product Return – The product return is used to return product remaining in an unloading hose to the compartment prior to switching to a different fuel. Product return systems must have strict guidelines established for the operators to insure proper and effective usage.

• Numbers of compartments – Both single and dual bank manifolds are available in one to eight compartments.

• On-center distance – Both single and dual bank manifolds are available with on-center distances of 11” and 14” (on-center distance is the distance between the centerlines of the outlet flanges.)

• Seals – The manifold is available with a variety of seals for hauling different products. It is the responsibility of the end user to insure all seals and gaskets are compatible with the product being hauled.

• API load heads – the manifold is available with API load heads and dust caps.

• Site Glasses – the manifold is available with acrylic site-glasses in the product return spout (standard) and between compartments.

4.0 Installation

Tank may contain residual pressure. Failure to relieve pressure may

result in sudden loss of pressure and could result in death or serious

injury.

Before working on a cargo tank, insure tank is completely free of

vapor and/or product that could present a risk of fire explosion,

asphyxiation or other hazard. Failure to remove vapors could result

in death or serious injury.

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PNEUMATIC MANIFOLD

4.1 Instructions for installing air manifold onto truck with proper

4.1.1 Care should be taken to ensure manifold is properly supported and risk of injury due to poorly supported manifold is minimized.

4.2 Piping and Bracketing Connections

4.2.1 Proper piping and bracketing must be installed before the pneumatic manifold can be mounted to the truck.

4.2.1.1 Piping spacing must match the on

4.2.1.2 Bracketing must be installed to support the manifold in at least two locations for a two or three compartment manifold, and at least three locations for anything larger. of the 4” shown belowProper truckcorrect attachment of the manifold is solely in the discretion of the manufacturer

4.2.2 Once manifold piping and bracketing is in place and the manifold is properly supported in the vicinity of its brloosely at first, and then tightened progressively. nuts and bolts with matching washers and lockflange gaskets, for the piping

4.2.2.1 Install all eight bolts into each flange, and secure loosely with a lockand nut. Do the same for the end plateconnections. Tighten the flange bolts first, working one

Manifold must be supported properly and safely prior to and during

installation. Failure to do so could result in serious injury or death.


MM-AM001 Rev. A

Instructions for installing air manifold onto truck with proper plumbing.

Care should be taken to ensure manifold is properly supported and risk of injury due to poorly supported manifold is minimized.

Piping and Bracketing Connections

Proper piping and bracketing must be installed before the pneumatic manifold can be mounted to the truck.

Piping spacing must match the on-center spacing of the manifold

Bracketing must be installed to support the manifold in at least two locations for a two or three compartment manifold, and at least three locations for anything larger. Supplemental bracketing can also be mounted on the back of the 4” TTMA flanges. Some suggested bracketingshown below. Note: These bracketing arrangements are suggestions. Proper truck-building practice should always be followed, and the correct attachment of the manifold is solely in the discretion of the manufacturer.

piping and bracketing is in place and the manifold is properly supported in the vicinity of its bracketing and piping connections, all bolts should be installed loosely at first, and then tightened progressively. Betts recommends using 3/8

bolts with matching washers and lock-washers, as well as RGA401 round flange gaskets, for the piping and endplate connections.

Install all eight bolts into each flange, and secure loosely with a lockand nut. Do the same for the end plate connections and any bracketing connections. Tighten the flange bolts first, working one



SUGGESTED BRACKETING ARRAGEMENTS


of 22

Care should be taken to ensure manifold is properly supported and risk of injury due to

Proper piping and bracketing must be installed before the pneumatic manifold can be

center spacing of the manifold

Bracketing must be installed to support the manifold in at least two locations for a two or three compartment manifold, and at least three locations for

racketing can also be mounted on the back bracketing arrangements are

These bracketing arrangements are suggestions. building practice should always be followed, and the

correct attachment of the manifold is solely in the discretion of the

piping and bracketing is in place and the manifold is properly supported ll bolts should be installed

Betts recommends using 3/8-16UNC washers, as well as RGA401 round

Install all eight bolts into each flange, and secure loosely with a lock-washer ons and any bracketing

connections. Tighten the flange bolts first, working one full flange at a time



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from right to left, using a star pattern bolt tightening scheme (ref. Engineering Bulletin 1-09). Then tighten the mounting bolts.

4.2.2.2 The outlets should be the last to be connected. For flanged connections, 3/8-16 UNC bolts are recommended. These should be tightened in the same manner as mentioned in step 4.2.3. Follow standard grooved outlet sealing techniques for all grooved outlets.

4.2.2.3 Bolts may loosen over time. Re-tightening may be required, and is recommended.

4.3 Air Connections

4.3.1 Install air fittings into air cylinders. Betts recommends ¼” quick connect fittings. Apply Teflon tape or pipe dope as necessary.

4.3.2 If manifold is equipped with a guard bar, connect necessary air hoses. If not using brake interlock, connect only the ‘IN – ACTUATION’ port. In this case, the other two ports do not need to be plugged. When using brake interlock, connect all three hoses to the necessary ports.

4.3.3 If manifold is equipped with product return spouts, connect air valve to constant air source.

4.4 Connect all hoses to control panel, valves, or solenoids.

4.5 Testing

4.5.1 Test all piping and air connections for leaks prior to placing manifold into service.

5.0 Inspection, Maintenance, and Testing

U.S. DOT Requirements for Testing Cargo Tanks: 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 two basic tests/inspections that pertain to the cargo tank piping 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)



injury.

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5.1 External Visual Inspection: As part of the annual external visual inspection, 49CFR180.407(d)(2)(ii) requires that all piping and valves must be inspected for corroded areas, defects in welds, and other conditions, including leakage, that might render the tank unsafe for transportation service.

Note: Betts recommends external visual inspection be performed monthly.

5.1.1 Visually inspect all external surfaces of the manifold and its connections for corrosion, leakage, or damage. NOTE: If any corrosion or damage to the manifold is observed, it must be repaired and successfully tested prior to returning to service.

5.1.1.1 Examine air cylinder assembly for signs of leakage or damage. If possible, actuate air cylinder and check indicator pin (pg. 8, item 2) for signs of scratching, gouging, or corrosion.

5.1.1.2 If applicable, inspect acrylic site glasses in connectors (pg. 5, item 9A) for signs of cracking, crazing, cloudiness, or yellowing. Replace if necessary.

5.1.1.3 Inspect all joints between bolted connections for leakage, cracking, or damage of any kind. Clean sealing surfaces and replace o-rings or gaskets if necessary.

5.1.1.4 Inspect all bolted connections to make sure all bolts are in place and appear tight. Replace missing or damaged bolts.

5.2 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 valves with a set pressure less than the leakage test pressure. These must be removed or rendered inoperative during the test. 5.2.1 Render inoperative or plug any vents set to discharge at less than the leakage test

pressure.

5.2.2 Apply test pressure in accordance with 49CFR180.407(h). The leakage test must include testing product piping with all valves and accessories in place and operative during the test. All internal or external self-closing stop valves must be tested for leak tightness. Since a pneumatic manifold will typically be used in tandem with an emergency valve, it will likely be necessary to test the emergency valves and the pneumatic manifold valves in separate steps.

5.2.3 Inspect all joints and seals for leakage. Repair or replace any worn or damaged seals in

accordance with maintenance section of this manual.

6.0 Disassembly and Rebuild Instructions

Before working on a cargo tank, insure tank is completely free of vapor

and/or product that could present a risk of fire explosion, asphyxiation or

other hazard. Failure to do so could result in death or serious injury.



injury.

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6.1 Manifold Removal and Disassembly

Note: for any maintenance to the manifold connectors, it will likely be necessary to remove the entire manifold from the truck. Most other repairs can be made without a full removal.

6.1.1 Make sure truck is degassed and air reserves are empty. Disconnect all air lines to the manifold

6.1.2 Make sure manifold is properly supported and balanced in at least three points. Loosen any bracketing or mounting bolts.

6.1.3 Disconnect any outlets.

6.1.4 Loosen any flange mounting bolts one flange at a time.

6.1.5 Remove all mounting, supporting, and flange bolts from the manifold.

6.1.6 Connectors can be removed by removing all mounting bolts in both flanges (pg. 5, items 15 & 16). In the case of a dual manifold, both connectors will need to be loosened at the same time. When dealing with dual manifold ‘T’ connectors (pg. 5, item 8) all four mounting bolts will need to be loosened before ANY can be removed. Then, turn the connector as far as it will go in one direction, and remove the bolts on the opposite side. Reverse and repeat for the other side. A rubber hammer may be needed to turn the connectors.

6.1.7 Inspect connector seals (items 18, 19) for wear, swelling, or damage. Replace if necessary.

6.1.8 It may be necessary to remove the guard bar (if equipped) to work on some components though there may be enough flexibility to remove connectors on some occasions. Remove large guard bar bolt (item 2) if equipped on all compartments. Remove guard bar. Inspect brass washer (item 3), Belleville washer (item 4), and bearing (item 5) for excessive wear. Replace if necessary.

6.2 Manifold Body Disassembly (pg. 8)

6.2.1 Air Cylinder Removal (item 1)

6.2.1.1 Remove the four bolts on the top of the air cylinder body (item 2).

6.2.1.2 Pull the air cylinder assembly up and out of the manifold body.

6.2.1.3 Examine large o-ring (item 4) for damage, dirt, or swelling. Replace if necessary.

6.2.1.4 Examine small o-ring (item 9) for damage, dirt, or swelling. Replace if necessary.

6.2.2 Remove large guard bar bolt (item 15) if equipped. Inspect brass washer (item 13), Belleville washer (item 14), and bearing (item 11) for excessive wear. Replace if necessary.

6.2.3 Unbolt product return assembly (item 5) from manifold body (if equipped).

Before working on a cargo tank, insure tank is completely free of vapor

and/or product that could present a risk of fire explosion, asphyxiation or

other hazard. Failure to do so could result in death or serious injury.

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6.2.4 Inspect product return o-ring (item 6) for damage. Replace if necessary.

6.2.5 Remove the four large bolts (items 9, 10) holding the manifold body halves (items 7, 8) together. Pull both halves apart. This could take substantial force, so caution should be exercised

6.2.6 Inspect large o-ring(s) (item 4) for swelling, cracking, or damage of any kind. Replace if necessary.

6.3 Air Cylinder Disassembly (pg. 9)

6.3.1 Make sure assembly is secured in vise or clamp prior to beginning disassembly.

6.3.2 Remove large snap-ring (item 6).

6.3.3 Grasping o-ring holder and spring firmly, pull sub-assembly directly out of air cylinder body (item 1).

6.3.4 Sub-assembly is held together by indicator pin (item 2). Using a 5/16 hex key, turn pin counter-clockwise while keeping o-ring holder (item 8) stationary. This will unload the spring. Inspect pin for damage.

6.3.5 Remove insert (item 16) and piston (item 3) from stem. Be careful to avoid threads as they can damage the internal seals of both of these components.

6.3.6 To check u-seal (item 14), removed snap-ring (item 15) and u-seal insert (item 5). Carefully remove u-seal and examine for scratches, nicks, and damage of any kind. Replace if necessary.

6.3.7 To check internal insert o-ring (item 13), use a small screwdriver to carefully remove the o-ring. Care must be taken not to scratch any sealing surfaces. Examine for scratches, nicks, swelling, and damage of any kind. Replace if necessary.

6.3.8 Examine external insert o-ring (item 4) for any scratches, nicks, swelling and damage. Replace if necessary.

6.3.9 Examine both the external and internal o-rings of the piston (items 12 and 13) for scratches, nicks, swelling, and damage of any kind. Replace if necessary.

6.3.10 Examine stem (item 17) for any scratches or bending. Replace if necessary.

6.3.11 Examine spring (item 7) for cracking, chipping, or apparent reduction of mechanical properties. Replace if necessary.

6.3.12 Examine indicator o-ring (item 11) and scraper (item 10) for damage. Replace if necessary.

6.4 Product Return Disassembly (pg. 10)

6.4.1 Remove screen snap ring (item 2) and remove screen (item 3). Empty and clean screen if necessary.

6.4.2 Remove site glass snap-ring (item 4) and remove site glass (item 6). Inspect site glass for cracking, crazing, cloudiness, yellowing, or damage of any kind. Replace if necessary.

6.4.3 Inspect site glass o-rings (item 5) for damage or swelling. Replace if necessary.

6.4.4 Remove check valve sub-assembly (items 7-12). Inspect sealing disc (item 7) for swelling or damage of any kind. Inspect spring (item 8) for damage or apparent loss of

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mechanical properties. Ensure shaft (item 9) moves smoothly through insert (item 10). Replace any damaged components as necessary.

6.4.5 Ensure check valve (item 13) is in good working order. Replace if necessary.

6.5 Guard Bar Air Cylinder Disassembly (pg. 11)

6.5.1 Remove snap-ring (item 2).

6.5.2 Grasp piston (item 1) and pull out of body (item 10). Insert (item 6), wiper (item 3), and o-ring (item 5) will come out as well. Remove insert from piston and inspect all seals for swelling, tearing and damage of any kind. Replace if necessary.

6.5.3 Inspect wiper for cracking, tearing, or damage. Replace if necessary.

6.5.4 Inspect magnet (item 9) for signs of cracking or corrosion. Replace if necessary.

6.5.5 Examine spring (item 8) for signs of cracking or any apparent loss of mechanical properties. Replace if necessary.

6.6 Connector Site Glass Disassembly (pg. 12)

6.6.1 Remove air manifold assembly from truck.

6.6.2 Slide site glass (item 2) from site glass connector (item 1). Inspect site glass for cracking, crazing, cloudiness, yellowing or damage of any kind. Replace if necessary.

6.6.3 Inspect site glass bushing o-rings (item 3) for damage or swelling. As these are not sealing o-rings, some deterioration in their appearance and mechanical properties is acceptable.

6.7 Rebuild Instructions

6.7.1 Assembly for all parts is reverse of disassembly.

6.7.2 All parts must be clean and free of all dirt, debris, and corrosion.

6.7.3 All seals must be lubricated with a low temperature silicone based lubricant prior to assembly.

7.0 Troubleshooting Guide

Problem Cause Solution

Air cylinder does not open completely

Worn or damaged seals Replace worn or damaged seals.

See section 6.3 for details.

Bent stem Replace stem. See section 6.3 for

details.

Insufficient air pressure Air cylinders need at least 70psig to

open completely. Check truck pressure.

Damaged or kinked air line Check air pressure at valve. Replace

air lines if necessary.

Guard bar falls down

Damaged magnet Check magnet for cracks or chips.


Guard bar air cylinder stuck open Check air cylinder for damaged or

swollen seals, or debris. See section 6.5 for details.

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Problem (cont’d) Cause (cont’d) Solution (cont’d)

Guard bar falls down (cont’d)

Improperly routed air supply Check plumbing schematic for errors.


Manifold leaks

Damaged or swollen seals

Disassembly leaky section and replace worn or damaged seals. See

section 6 for details.

Verify fluid compatibility and temperature

Damaged component

Disassemble leaky section and replace worn or damaged

component. See section 6 for details.

Products mixing during loading, unloading or

transportation

Damaged or worn poppet o-rings Replace seals. See section 6.2.1 for

details.

Air cylinder open Check air cylinder plumbing for

errors. See section 7.0.

Air cylinder jammed open

Check air cylinder for worn or damaged seals. See section 6.3.

Check for obstruction. See section 6 for details.

Main seal leaks

Replace Seals. See section 6.2 for details

Verify fluid compatibility and temperature

Guard bar will not drop

Damaged or jammed guard bar air cylinder

Air cylinder seals worn or piston damaged. See section 6.5 for

details.

Excessive side load on air cylinder Put upward force on guard bar and

try again.

Insufficient air to guard bar air cylinder

65 psi necessary to release guard bar. Check air lines and truck

plumbing for errors. Also looked for kinked or damaged air lines. See

section 7.0 for details.

Parking brake will not disengage

Guard bar down Raise guard bar and try again.

Damaged or jammed guard bar air cylinder

Air cylinder seals worn or piston damaged. See section 6.5 for

details.

Flange gaskets leak

Damaged gasket Replace gasket.

Improper torque or tightening procedure employed

Re-torque bolts to recommended specs. See section 4.2 for details.

air manifold assembly - betts ind

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