AIR MANIFOLD ASSEMBLY - Betts Ind
Transcript of 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 Page 1 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 Page 2 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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INSTALLATION, OPERATION & MAINTENANCE MANUAL
PNEUMATIC MANIFOLD MM-AM001 Rev. A Page 3 of 22
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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INSTALLATION, OPERATION & MAINTENANCE MANUAL
PNEUMATIC MANIFOLD MM-AM001 Rev. A Page 4 of 22
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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INSTALLATION, OPERATION & MAINTENANCE MANUAL
PNEUMATIC MANIFOLD MM-AM001 Rev. A Page 5 of 22
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]
TM
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"
12 9Q5822 HH CAP SCREW 1/4"
13 9Q5844 1/4" SPRING LOCK WASHER
14 9Q5942 1/4" FLAT WASHER
15 9Q3004 HH BOLT 7/16"
16 9Q8616 7/16" SPRING LOCK WASHER
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
INSTALLATION, OPERATION & MAINTENANCE MANUAL
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
7/16" SPRING LOCK WASHER
3 COMP. GUARD BAR - 14" CENTERS (3 COMP)
FACE-SEAL O-RING
BORE-SEAL O-RING
7
SINGLE MANIFOLD
9B 18 19
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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
2 9Q5929 HH CAP SCREW 1/2"
3 9Q8613 BRASS WASHER
4 9Q8614 BELLEVILLE WASHER
5 9Z6192 BRONZE BEARING
6 9Q3004 HH BOLT 7/16"
7 9Q8616 7/16" SPRING LOCK WASHER
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"
12 9Q5822 HH CAP SCREW 1/4"
13 9Q5844 1/4" SPRING LOCK WASHER
14 9Q5942 1/4" FLAT WASHER
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
22 9Q5915 7/16" FLAT WASHER
23 9Q3006 HH BOLT 7/16"
9
11
17
12 13
10
14
15 16 7
INSTALLATION, OPERATION & MAINTENANCE MANUAL
MM-AM001 Rev. A
DESCRIPTION
DUAL MANIFOLD ASSEMBLY
HH CAP SCREW 1/2"
BRASS WASHER
BELLEVILLE WASHER
BRONZE BEARING
HH BOLT 7/16"
7/16" SPRING LOCK WASHER
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" SPRING LOCK WASHER
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
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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
INSTALLATION, OPERATION & MAINTENANCE MANUAL
MM-AM001 Rev. A
DESCRIPTION
AIR CYLINDER ASSEMBLY - DUAL MANIFOLD
AIR CYLINDER ASSEMBLY - SINGLE MANIFOLD
HH BOLT - 1/4"
1/4" SPRING LOCK WASHER
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"
7/16" SPRING LOCK WASHER
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
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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
INSTALLATION, OPERATION & MAINTENANCE MANUAL
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
INSTALLATION, OPERATION & MAINTENANCE MANUAL
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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
PRODUCT RETURN ASSEMBLY
36083ALVB
PRODUCT RETURN
ASSEMBLY
INSTALLATION, OPERATION & MAINTENANCE MANUAL
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
PRODUCT RETURN ASSEMBLY
2 3
4 5 6
7 8
10 9 14
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Page 10 of 22
1 2
13 12
11
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INSTALLATION, OPERATION & MAINTENANCE MANUAL
PNEUMATIC MANIFOLD MM-AM001 Rev. A Page 11 of 22
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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INSTALLATION, OPERATION & MAINTENANCE MANUAL
PNEUMATIC MANIFOLD MM-AM001 Rev. A Page 12 of 22
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
TM
PNEUMATIC MANIFOLD
ITEM PART NUMBER
1 9Q5844
2 9Q5849
3 75561ZC
MAGNET STRIKE PLATE DETAIL
1
INSTALLATION, OPERATION & MAINTENANCE MANUAL
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
INSTALLATION, OPERATION & MAINTENANCE MANUAL
Page 13 of 22
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INSTALLATION, OPERATION & MAINTENANCE MANUAL
PNEUMATIC MANIFOLD MM-AM001 Rev. A Page 14 of 22
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.
TM
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.
INSTALLATION, OPERATION & MAINTENANCE MANUAL
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
Manifold must be supported properly and safely prior to and during
installation. Failure to do so could result in serious injury or death.
SUGGESTED BRACKETING ARRAGEMENTS
INSTALLATION, OPERATION & MAINTENANCE MANUAL
Page 15 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
Manifold must be supported properly and safely prior to and during
installation. Failure to do so could result in serious injury or death.
TM
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PNEUMATIC MANIFOLD MM-AM001 Rev. A Page 16 of 22
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)
Tank may contain residual pressure. Failure to relieve pressure may
result in sudden loss of pressure and could result in death or serious
injury.
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INSTALLATION, OPERATION & MAINTENANCE MANUAL
PNEUMATIC MANIFOLD MM-AM001 Rev. A Page 17 of 22
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.
Tank may contain residual pressure. Failure to relieve pressure may
result in sudden loss of pressure and could result in death or serious
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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PNEUMATIC MANIFOLD MM-AM001 Rev. A Page 19 of 22
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.
See section 6.5 for details.
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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PNEUMATIC MANIFOLD MM-AM001 Rev. A Page 21 of 22
Problem (cont’d) Cause (cont’d) Solution (cont’d)
Guard bar falls down (cont’d)
Improperly routed air supply Check plumbing schematic for errors.
See section 7.0 for details.
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.