CONTENTS OF THIS BOOK - Bennett Pump

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© 1993 BENNETT PRINTED IN U.S.A.

READ THIS BOOK

This book has important information for the safe maintenance and service of this equipment. Read and understand this book before applying power. Keep this book and tell all service technicians to read this book. If you do not follow the instructions, you can cause injury, death or damage to the equipment.

MECHANICAL and HYDRAULIC SERVICE MANUAL

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CONTENTS OF THIS BOOK

SERVICE SAFETY INSTRUCTIONS ...................................................................................................................iii INTRODUCTION .................................................................................................................................................. iv SECTION A. BASE DIMENSIONS AND INSTALLATION INFORMATION

3700, 4000, 3900 ....................................................................................................................................... 2 6000 ........................................................................................................................................................... 3 7000 ........................................................................................................................................................4,5 7800 .....................................................................................................................................................6,7,8 8000 ........................................................................................................................................................... 9 9000 (Remote) .........................................................................................................................................10 9400 (Remote Blender) ............................................................................................................................11 9000 (Self-Contained) ..............................................................................................................................12 9500 (Self-Contained Blender) ................................................................................................................13

SECTION B. SELF-CONTAINED PUMPS

Installation Piping Information (Type 40, 70 & 75 Pumping Units) ..........................................................16 Type 40 Pumping Unit (Production to 9-76) ............................................................................................18 Type 70 Pumping Unit (10-76 to 11-83) ...................................................................................................38 Type 75 Pumping Unit (11-83 to present) ................................................................................................50 Troubleshooting Self-Contained Pump ....................................................................................................62 The Cause Of Vapor Lock ................................................................................................... End of Section

SECTION C. REMOTE DISPENSERS

Shear Valve Installation ...........................................................................................................................72 Control Valve and Filter Assembly ...........................................................................................................72 How to Stop Pulsating Delivery ................................................................................................................75 Typical Flow Rates of Bennett Remote Dispensers ................................................................................76 Skinner Dual Flow Solenoid Valve ...........................................................................................................83 Spin-on Filter Option ................................................................................................................................84 Torque Specifications ...............................................................................................................................84 7800 Series Hydraulic Parts (Master) ......................................................................................................86 7800 Series Hydraulic Parts (Satellite) ....................................................................................................88

SECTION D. METERS

Type 40 Meter ..........................................................................................................................................90 Liquid Control Systems MSAI ..................................................................................................................96 7800 Series (Liquid Control Meter Connections ....................................................................................98 SB-100 Meter ...........................................................................................................................................99

SECTION E. CAM-AC

Servicing the Cam-Ac Operating Mechanism and Motor Switch ...........................................................110 Wiring for Cam-Ac .................................................................................................................................113 Typical Station Wiring Layout ................................................................................................................114 Servicing the Key-Op System ................................................................................................................115

How to Remove the Keytrol Assembly from a 3700 Series ..............................................................115 How to Replace the Lock Assembly .................................................................................................116 How to Reinstall the Keytrol Assembly in a 3700 Series ..................................................................117 Troubleshooting ................................................................................................................................117

SECTION F. TOTALIZERS AND GEAR PLATES

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How to Replace a 6000 Series Totalizer .............................................................................................. 120 6000/8000 Gear Plates ........................................................................................................................ 122 8000 Series Totalizers ......................................................................................................................... 123 7000/9000 Series Totalizers ................................................................................................................ 124 Service Bulletins:

M-215A - Gear Replacement (gallons to liters) ............................................................................. 125 M-224 - Quick Change Conversion Gear Box Assembly .............................................................. 126

SECTION G. MOST USED PARTS

Type 40 Pumping Unit .......................................................................................................................... 128 Type 70 Pumping Unit .......................................................................................................................... 129 Type 75 Pumping Unit .......................................................................................................................... 130 Type 40 Meter ...................................................................................................................................... 131 Control Valve & Filter Assembly .......................................................................................................... 131 Cam-Ac ................................................................................................................................................ 132 Solenoids .............................................................................................................................................. 132 Veeder-Root Components ................................................................................................................... 133 Motors .................................................................................................................................................. 133 Universal Link Assemblies ................................................................................................................... 134

UNAUTHORIZED ALTERATION OF BENNETT PRODUCTS

Bennett Pump Company products are designed to meet or exceed the standards of UL, FCC and the National Institute of Standards and Technology. These standards protect the operator and the consumer from personal injury and insure an accurate delivery of product. Any deviation from the use of authorized replacement parts or alteration of a designed product configuration may cause personal injury, death or the revocation of one or all of the above approvals. The most frequently abused design alteration of Bennett products is the conversion of a self-contained model (pumping unit in the dispenser cabinet) to a remote dispenser (submerged pump in the storage tank). This field practice has mainly occurred in an effort to overcome the problem of vapor lock. Bennett Pump Company does not condone nor offer a kit or instructions for this type of conversion. Bennett Pump Company strongly opposes this type of conversion. Safety standards required by the agencies above are violated when unauthorized conversions are performed. Bennett Pump Company recommends the replacement of a self-contained model with a remote dispenser model to overcome the problem of vapor lock. Bennett Pump Company will not assume responsibility or liability for any consequential injury or damage caused by the unauthorized alterations of its products.

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SERVICE SAFETY INSTRUCTIONS

WARNING ADVERTISSEMENT ADVERTEÑCIA For the safe maintenance, service and operation of this equipment, read and understand all warnings and cautions. Look for these warnings: “DANGER” means: If you do not follow the instructions, severe injury or death will occur. “WARNING” means: If you do not follow the instructions, severe injury or death can occur. “CAUTION” means: If you do not follow the instructions, damage can occur to the equipment.

DANGER: Fire, explosion, injury or death will occur if fuel filters are changed by untrained personnel. Make sure only trained personnel change filter. DANGER: Gasoline is flammable. NO SMOKING OR OPEN FLAME. DANGER: Disconnect all power to this equipment and associated submerged pump(s) during installation, service or any maintenance, e.g., changing filters. DANGER: Do not use self-contained dispensers with pressurized product lines, such as above ground tanks. DANGER: The emergency cut-off valve (also called the fire valve, shear valve or impact valve) must be closed when service or maintenance is performed on this equipment. WARNING: You must have training in the service or maintenance of Bennett equipment (dispenser, pump, console, control box or submerged pump) before working on it. Maintenance and repairs must be done by authorized personnel only.

WARNING: To prevent electric shock, keep the electrical parts of the dispenser dry. WARNING: Do not operate this equipment as a dispenser unless it is completely assembled. WARNING: Make sure this equipment is correctly grounded. Failure to do so can cause injury or damage equipment. WARNING: Electronic components are static sensitive. Use proper static precautions (static straps) before working on the equipment. CAUTION: Do not drill holes in fuel dispensers. Holes can cause failure of the electronic equipment and voids the UL label. The warranty will become void. Use only adhesive backed price sign mounting brackets. Order Bennett Kit KR-322.

READ AND UNDERSTAND ALL WARNING LABELS ATTACHED TO THE DISPENSER

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INTRODUCTION

This manual coves the mechanical and hydraulic service for Bennett pumps. The following pages show the various Bennett models covered by this Mechanical and Hydraulic Service Manual. For additional information on Bennett mechanical pumps, see the following Service Manual for 3700, 3900 and 4000 ...........................................................................................................................SPL-1071.1 For information concerning service requirements for the electronic heads, see the following: 7000 and 9000 Series .............................................................................................................................. N676201 6000 Series .............................................................................................................................................. N680701 8000 Series .............................................................................................................................................. SPL1105

DANGER: Before performing any type of service to the dispenser, be sure to shut off all electrical supplies and secure them in the OFF position. Close all valves in incoming piping. Maintenance must be performed by trained personnel ONLY.

Always Practice Safety First!

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Figure 1 - 3700 Series Remote and Self-Contained

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Figure 6 - 7800 Series Remote

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Figure 9 - 9400 & 9500 Series and 9032 Single Hose MPD

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SECTION A. BASE DIMENSIONS AND INSTALLATION INFORMATION

3700, 4000, 3900 .................................................................................................................................... 2 6000 ........................................................................................................................................................ 3 7000 ..................................................................................................................................................... 4,5 7800 .................................................................................................................................................. 6,7,8 8000 ........................................................................................................................................................ 9 9000 (Remote) ...................................................................................................................................... 10 9400 (Remote Blender) ........................................................................................................................ 11 9000 (Self-Contained) ........................................................................................................................... 12 9500 (Self-Contained Blender) ............................................................................................................. 13

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Figure 10

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Figure 11 - 3700, 3900, 4000 Series

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Figure 12 - 6000 Series

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Figure 13 - 7000 Series Remotes

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Figure 14 - 7000 Series Self-Contained

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Figure 15 - 7812MS-HS (master/Satellite)

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Figure 16 - 7811M-HS, 7812M-HS (Master-High Speed)

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Figure 17 - 7811S, 7812S (Satellite)

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Figure 18 - 8000 Series

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Figure 19a - 9400 Series Remote Blender

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Figure 20 - 9100 Series Self-Contained

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Figure 20a - 9500 Series Self-Contained Blender

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SECTION B. SELF-CONTAINED PUMPS

Installation Piping Information (Type 40, 70 & 75 Pumping Units) ..............................................16 Type 40 Pumping Unit (Production to 9-76) ................................................................................18 Type 70 Pumping Unit (10-76 to 11-83) ......................................................................................38 Type 75 Pumping Unit (11-83 to present) ...................................................................................50 Troubleshooting Self-Contained Pumps .....................................................................................62 The Cause of Vapor Lock ........................................................................................ End of Section

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Figure 21

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Installation Piping Information for Pumps with Type 40, 70 or 75 Pumping Units

To obtain maximum flow rates on a self-contained pump, follow these guidelines: 1. The total length of horizontal piping between the

pump and tank must be no longer than 60 feet. 2. Piping specification:

a. Use new 1-1/2” galvanized or approved non-metallic pipe for 10-15 GPM pumps. Use new 2” galvanized or approved non-metallic pipe for 20-24 GPM pumps.

b. All horizontal piping must be buried a

MINIMUM of 18” below the finished grade. c. The pipe from the tank must slope up to the

pump (approximately 1-1/2” to 2” per 10 ft.). The pipe MUST be straight. The pipe must be supported continuously to prevent sagging.

d. All piping must hold a 50 PSI pressure test for

10 minutes.

e. To absorb ground movement from settling of the tank, frost heaving of the ground or pump island settling, a swing joint must be used in the supply line at the tank and directly underneath the dispenser. Three additional directional changes using elbows are permitted. See Figure 22.

f. Only one pumping unit is permitted for each

underground pipe. Do not use a tee to connect two pumps off one line.

3. Static lift on self-contained units must not exceed

10 feet (vertical distance between product level in the storage tank and the center of the pumping unit.) See Figure 22.

Figure 22

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4. The area under the pumping unit(s) must be filled with sand or dirt as far up the suction line as possible. Use water to pack the sand or dirt when put in place. See Figure 23.

5. In accordance with new EPA regulations, install a

vertical, in line, check valve underneath the pump.

6. Avoid asphalt drive surfaces covering the piping.

Asphalt increases heat absorption causing vapor lock.

DANGER: Do not use self-contained dispensers with above ground tanks or any other arrangement where the supply line is under pressure. This configuration is extremely dangerous and can cause injury or death.

Suggested Conduit Installation for Self-Contained Equipment with Type 70 or Type 75 Pumping Units When the center conduit opening in the pump junction box is not used, access to the filter is restricted. To ensure accessibility of the pump filter, forming the conduit as shown in Figure 24, will provide adequate space to quickly replace the filter, when necessary.

Figure 23

Figure 24

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Type 40 Pumping Unit (Production to 9-76) NOTE: Beginning in November, 1967 (11N Date Code) Standard Type 40 pumping units had a filter instead of a strainer. It is a Wix PC-314P and is obtainable as a shelf item in most equipment stores. (The strainer was used in all Code D heavy duty pumping units, and was also available on standard units by specifying Code 422.) With use of the new filter, the aligning stud for the strainer was eliminated to give maximum flow through the one-inch hoe. Also, a new cover, which is held in place by three bolts, was required. The strainer can be used in new units, but the filter should not be used in units with the center stud because adequate flow will not be available.

Flow of Liquid Through the Pumping Unit, Air Eliminator and Meter.

Before studying the various components of the Bennett pumping unit, air eliminator, and meter, it is essential to visualize the travel of the liquid through the various units. See the schematic diagram in Figure 25.

1. The gasoline is drawn from the underground

storage tank through the strainer screen or filter (1).

2. The rotary vane pumping unit (2) impels the

gasoline on into the air eliminator. 3. Gasoline enters the air eliminator (3) near the top

and spirals around to the bottom and down to the control valve.

4. The control valve (4) is opened by the liquid

pressure and the gasoline is pumped up to the meter. A built-in relief valve relieves pressure caused by hot weather expansion.

5. Gasoline passes through the meter (5) and on out

through the hose. 6. When the nozzle is closed and the pump motor is

still operating, the liquid back pressure opens the bypass valve (6) which bypasses or shunts the liquid back to the pump intake port. The liquid is then re-circulated until the nozzle is reopened or the motor is shut off.

Figure 25 - Schematic Flow Diagram

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Type 40 Pumping Unit With Pre-pay Adaptor Added The Type 40 pumping unit was manufactured during the time when pre-pay operation was not prevalent. To add prepay to a pump with a Type 40 pumping unit, an adapter with a diaphragm valve was created. This adapter mounted to the outlet of the meter and was field installed. The flow diagram in Figure 26 shows the Type 40 running with solenoids de-energized (no flow).

1. Product from the pumping unit flows through the meter to the inlet (1) of the prepay adapters. Product flows to and pressurizes the back of the diaphragm valve (2).

2. Product from the meter flows through tube (5),

through the high flow solenoid, through tube (6) and to the front (3) of the diaphragm valve.

3. Equal pressure is now applied to the front and back of the diaphragm valve. The spring (4) exerts greater pressure on the front of the diaphragm valve causing it to close and preventing high flow.

4. At the same time, product from the meter flows

through tube (8) to the low flow solenoid. The low flow solenoid being de-energized prevents product flow to tube (9) and prevents low product

Figure 26 - Solenoids De-energized (No Flow)

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The flow diagram in Figure 27 shows the Type 40 running with solenoids energized.

1. Product from the pumping unit flows through the meter to inlet (1) of the prepay adapter and pressurizes the back of the diaphragm valve (2).

2. Product from the meter flows through tube (3) to

the high flow solenoid. When the high flow solenoid is energized, product flow from tube (3) to tube (4) is prevented.

3. When the high flow solenoid is energized product

pressure is relieved off the front of the diaphragm valve (5) via tube (4) through the solenoid, through tube (6) and out to the hose.

4. Higher product pressure on the back of the

diaphragm valve (2) overcomes spring tension (7) and pushes the diaphragm valve into its open position. The diaphragm valve in its open

position allows high product flow. 5. At the same time, product from the pumping unit

flows through tube (8), through the low flow solenoid, through tube (9) and out to the hose.

6. In prepay or local preset operation, the high flow

solenoid is de-energized at a point before final sale is reached. The low flow solenoid is energized from the beginning to the end of the sale. This allows the pump to slow before final sale is reached which prevents overruns.

Figure 27 - Solenoids Energized

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Type 40 Pumping Unit Single Product - 2 Hose The purpose of using directional valve assemblies on single product, two hose units is to prevent delivery from an unauthorized hose when the other one is in use. Figure 28 shows the configuration of a Type 40 pumping unit as a single product unit with two hoses (pump running and the solenoids de-energized).

1. Product from the pump flows into the directional valve casting and pressurizes the back of the diaphragm valve (1).

2. Product from the pump flows into the directional

valve casting and through tube (2) to the top of the solenoid. Because the solenoid is de-energized, product flows from tube (2), through the solenoid, into tube (3) and pressurizes the front of the diaphragm valve (4).

3. Equal product pressure is now realized on the

front (4) and back (1) of the diaphragm valve. Added spring (5) exerts greater pressure on the front of the diaphragm valve causing it to close and preventing product flow.

Figure 28 - Solenoids De-energized

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Figure 29 shows the configuration of a Type 40 pumping unit as a single product unit with two hoses (pump running and the solenoids energized).

1. Product from the pump flows into the directional valve casting and pressurizes the back of the diaphragm valve (1).


valve casting and through tube (2) to the top of the solenoid. When the high flow solenoid is energized, product flow from tube (2) to (3) is prevented.

3. When the high flow solenoid is energized product

pressure is relieved from the front of the diaphragm valve via tube (3) through the solenoid, through tube (5) and to the hose.

4. Higher product pressure on the back (1) of the

diaphragm valve overcomes the spring tension (6) and pushes the diaphragm valve into its open position. The diaphragm valve in its open position allows full product flow for that hose.

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Difference Between Standard and Heavy-Duty Pumping Units Due to the greater GPM required of heavy-duty or code D pumps over standard, a specially designed pumping unit is used. This heavy-duty pumping unit is similar in appearance to a standard unit, but it can be easily identified by a large letter “D” stamped in the upper left hand corner of the casting, on the pulley side, as shown in Figure 30. The bypass adjusting nut is also a means of identification. As shown in Figure 31, the bypass adjusting nut on a Code D unit with heavy-duty bypass valve and spring has two hexagonal portions, while on units with standard bypass valve and spring it has only one hexagonal portion. NOTE: Models 3027, 3127, 4027, 4127, and 3376

(twin single product pumps) have heavy-duty rotors (reference Figure 30) and standard bypass valves and springs.

In addition to the external means of identification, there are certain internal parts that are not the same in the two types of pumping units. The higher delivery rate of the Code D pump is obtained by a greater displacement between the bore and rotor, as shown (slightly exaggerated for purpose of illustration) in Figure 32. To obtain this, the rotor is smaller in diameter in a heavy-duty unit and can be easily identified by its three relief holes for each blade slot.

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Figure 30

Figure 31

Figure 32

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Only one relief hole is used in a standard rotor. See Figure 33. To compensate for the variation in rotor sizes, the pumping units are machined differently. The heavy-duty rotor blade is larger than the standard, as shown in Figure 34. Therefore, rotors, blades, and pumping unit castings are not interchangeable. NOTE: The bypass valves and springs will fit

either pumping unit, but should not be interchanged. All other parts in the pumping unit and air eliminator assembly are the same in both standard and heavy-duty units.

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Figure 34

Figure 33

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Air Eliminator - Its Purpose and Function The air eliminator is a combination air and vapor separator, liquid stabilizer, and pressure relief chamber all combined into one unit. Without it, nozzle valves and gasket joints would leak, and hose and see-gage glasses would burst under the effects of the summer sun. Displacement meters, no matter how accurately built, could not be made to measure accurately unless the vapors, normally present in gasoline, and the air induced by deficient installation conditions, can be eliminated and discharged before reaching the meter. The air eliminator meets every requirement for perfect air elimination, yet it is compact and simple in construction. It contains two separate chambers; the pressure chamber that is always filled with liquid and the atmospheric chamber containing only a small amount of condensed gasoline vapors which overflow through the vapor release jet. This liquid is maintained at a minimum level by the suction return float valve. A vent pipe at the top of the atmospheric chamber carries vapor outside the pump housing. This positive method of air elimination can be readily understood by referring to the cutaway views in Figure 35.

The following essential factors of the air eliminator should be carefully noted. 1. The vapor release jet is located at the highest

point in the pressure chamber where any vapor or air would normally collect.

2. The discharge opening and control valve are

located at the lowest point in the pressure chamber which would normally contain solid liquid.

3. The suction return valve is located at the lowest

point or sump in the atmospheric chamber. 4. The vent opening to the outside atmosphere is

located at the highest point in the atmospheric chamber.

5. Eliminator and pump unit are combined into one

unit. 6. Liquid is delivered from the pump into the midpoint

of the pressure chamber in a swirling motion, thus giving vapors an opportunity to separate and rise easily to the top. Pure liquid only is forced to the bottom

7. The variable orifice valve and float in the pressure

chamber normally keeps only the small jet open, but under excessive vapor conditions, it automatically opens the large jet to permit the escape of larger volumes of vapor.

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Figure 35

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8. The control valve is designed to perform three functions: (a) it maintains pressure against the flow of liquid to help force out vapor; (b) it prevents liquid from dropping back from the meter; and (c) it contains an internal relief valve to prevent excess expansion pressure from bursting the hose and see-gage.

Only under the most severe conditions should any service be necessary on any part of the air eliminator. Both float valves have positive lever action—tapered valve close into seats. The control valve has a composition disc seating against the ground surface of the pump body. Should damage occur to the pressure chamber cover, the float could be held in the down position. This could cause an excess amount of liquid to enter the atmospheric chamber and possibly flood it. The result would be a discharge of liquid from the vent tube while the pump is in operation. Should the float in the atmospheric chamber stick in the down position, the suction valve will remain closed and liquid will be discharged from the vent tube. Should the float in the atmospheric chamber stick in the up position, the suction valve will remain open, thus reducing flow and a suction can be felt at the end of the vent tube. Water is harmful to any pump, but not as great in a Bennett pump because there are no points where it can settle. It is a self-cleaning unit; however, it is a well known fact that valves exposed to water will eventually rust. In this event, it is recommended that all valves be cleaned. A water condition may mean the repairing of a broken line or fill cap and pumping any accumulation of water from underground storage tanks with a hand pump. Ordinarily, the servicing of the suction return float valve can be accomplished by removing the bypass valve cover plate. The pressure valve can be serviced by removing the pressure chamber cover at the rear of the pump housing.

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The Bypass Valve The purpose of the bypass valve is to relieve back pressure when the nozzle is closed and the motor is still operating. Thus, the valve, when open, stops the pumping of gasoline from the storage tank. The liquid in the pumping unit is bypassed or circulated until the nozzle is again opened.

The bypass valve has good self-cleaning action; however, foreign matter on the valve seat or in the dashpot could interfere with proper seating and result in slow or no delivery. If this happens, the valve is very accessible for removal and cleaning. The valve cover is labeled for identification. The Type 40 pumping unit originally employed a bronze bypass valve. Units containing the bronze valve are identified by the use of an adjustable bypass valve cover (See Figure 36). New style bypass valves are made of Delrin (See Figure 37). Pumps with the new valve were marked Code 412 on their I.D. plate. A Delrin bypass valve can be used to replace a bronze bypass valve (which are no longer available), if new bypass spring and new bypass cover are installed. These parts are included in Kit KR-0165. See Figure 38. How to Adjust Bronze Bypass Valve The original factory bypass setting on a new pump is adequate for most filed installation. (The factory

adjustments for both standard and heavy-duty pumps are shown in Figure 36.) Changing these adjustments is discouraged unless unusual installation conditions are encountered. To compensate for varying installations, the bypass valve is adjusted only by means of the adjusting screw (1). Under no circumstances should the bypass spring be stretched. This will exert uneven pressure on the valve and increase wear. If two turns of the adjusting screw do not affect the pumping characteristics, the problem is not one of bypass valve adjustment. Remove the small brass cap (2) which acts as a seal around the adjusting screw (1). Hold the adjusting screw stationary with a screwdriver while unlocking the locknut (3). Holding the locknut (3) stationary, turn the adjusting screw (1) clockwise to increase or counterclockwise to decrease spring tension until normal delivery speed is attained. Too much tension on the spring will overload the motor during the bypassing process and may also detract from the normal, quiet operation of the pump. When the desired adjustment has been made, tighten the locknut (3) and reinstall the brass cap (2).

Figure 36 - Bronze Bypass Valve

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Delrin Bypass Valve NOTE: If valve adjustment is desired, a washer may be placed over the spring boss on the cover to

increase spring tension. The boss is purposely short to prevent excessive tension on the bypass valve that could cause sufficient back pressure to overload the electric motor.

The same bypass valve is used in both standard and heavy-duty (Code D) pumping units. Bypass valve springs are not interchangeable between standard and heavy-duty pumping units. No noise eliminating dashpot plunger is required on this Delrin bypass valve due to its construction and light weight.

Figure 38 - Bypass Valve Kits

Figure 37 - Delrin Bypass Valve

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Inspecting and Cleaning the Bypass Valve 1. Bypass Plunger (Bronze Bypass Valve Only) The valve plunger (1) is a precision fit into the

dashpot (2); therefore, extreme care must be used when cleaning this portion of the valve. See Figure 39. Clean the plunger surface with crocus cloth only. Emery paper, sand paper or a file will cut too deeply and impair efficiency of the valve. Also, the dashpot (2) should be flushed with gasoline or blown out with compressed air. Note that there is a gasoline-filled chamber of sufficient length at the end of the dashpot which cushions the valve for quiet operation during the bypassing process.

2. Guide Surfaces The valve is kept in perfect alignment by the

fluted guides (3). See Figure 39. Examine for possible foreign deposits and clean with fine emery paper only.

3. Seating Surfaces A bronze valve that is seating properly will show a

hairline shiny ring completely around the seating surface. If it does not have a completed ring, examine the seating surface on the valve for possible foreign deposits and remove with a light application of emery paper. To clean the seating surface and dashpot (2) in the pump casting, a special cleaning tool (Part No. SK-2-151) shown in Figure 40 was recommended for both style valves. The tool is no longer available from Bennett. However, some long time distributors may still have this piece of equipment in their service area.

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Figure 39

Figure 40 - Bypass Valve Seat and Dash Pot Cleaning Tool

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Control Valve and Expansion Relief Valve The original control valve was constructed of bronze. Later production of the Type 40 pumping unit used Delrin control valves. The Delrin valve directly replaced the bronze valve and is the only type available.

Operation of Control Valve Some of the principles of the bypass valve are included in the construction of the control valve. The inner end (1) (See Figure 41 or 42) forms a plunger that fits into a dashpot in the air eliminator body, providing smooth operation. This plunger end also acts as a guide, together with the four “fins” or guides (2) at the center of the valve to always keep the valve in alignment. A composition washer (3) provides a seating surface and the throttle plate (4) allows the valve to be held open by the flow of liquid with much less effort than is required for its initial opening and also helps provide for positive, quick closing of the valve. Seating of Control Valve The control valve can be held off its seat by corrosion or gum deposits on the valve cavity or by foreign particles embedded in the composition washer (3). (On pumps with see-gages, if the glasses are only partially filled, it will indicate that the control valve is not seating properly, thus allowing the liquid to drain down from the see-gage, meter and adjoining piping through the control valve opening into the atmospheric or non-pressure section of the air eliminator. When the pump motor is started, computer jump will also result as the vacancy is being filled. To determine if there is a slow leak (not always evident by emptying of the see-gage glasses) we recommend that a test be made with a pressure gauge. To do this, install the pressure gauge in the drain plug hole in the control valve cover. Start the pump and pump five gallons of gasoline. Then, close the nozzle, shut off the motor and watch the gauge. If pressure holds constant or falls so slowly it is unnoticeable, the control valve is seating properly and need not be removed. However, if pressure drops rapidly, the valve is not seating and should be removed and thoroughly cleaned.

Figure 41 - Bronze Control Valve

Figure 42 - Delrin Control Valve

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Removing and Cleaning the Control Valve Remove the control valve cover, being sure to exert slight hand pressure against the cover when taking out the last cap screw. (See Figure 42). Spring tension may force the cover off and cause it to drop into the pit under the pump. Be careful not to damage the cover gasket or it will have to be replaced. Remove the spring and valve and clean off the valve with crocus or “00” emery cloth. Examine the composition washer (3) for foreign particles or marks left by them. To polish the washer, hold the valve in one hand, grasping the valve just behind the throttle plate (4). Hold crocus or “00” emery cloth in the other hand, cupping it around the valve so as to contact as much of the edge of the washer as possible. Polish with a twist or twirling motion—pressing lightly and carefully as the washer must be perfectly concentric to seat properly. Pressing too hard may cut too deeply into the composition washer. Wash the valve in gasoline before replacing it to be sure it is clean. Before installing the control valve in the pump, inspect the cavity for possible foreign matter. A special cleaning toll (Part No. SK-2-154) shown in Figure 43 was recommended for cleaning the valve seat and dashpot in the pump casting. The tool is no longer available from Bennett. However, some long time distributors may still have this piece of equipment in their service area.

Figure 43 - Control Valve Seat and Dash Pot Cleaning Tool

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Possibility of Control Valve Being Stuck in a Closed Position This rare condition is always the direct result of neglect in keeping the pumping system free of excessive water which finally leads to seizure of the control valve. It may also occur in pumps that are out of service for extended periods. If the control valve sticks in a closed position, pumping failure will result. Operation of Expansion Relief Valve Since the expansion of gasoline in warmer climates or during summer temperatures can build up sufficient pressure to burst hose (and see-gage glasses), a vent is provided in the form of a small relief valve (1) inside the main body of the control valve (See Figure 43B) or Delrin valve as shown in Figure 42. Through this valve any excess pressures in any part of the system above the air eliminator can escape through orifices (2) and (3) back into the eliminator where there is ample room to handle the expanded liquid. Removing and Cleaning Expansion Relief Valve

Bronze It seldom should be necessary to remove the small expansion relief valve (1). See Figure 43B. However, a possible accumulation of foreign matter could interfere with positive seating and result in gasoline dropping down out of the see-gage, leaving it only partially filled and cause the computer to jump when the pump is started. If such is the case, the relief valve (1) can be taken out for cleaning or replacement by removing the screw and spring at the end of the control valve body. The relief valve can be pushed out by inserting a stiff wire from the opposite end at point A. The small composition disc seat may be removed and turned over for longer life. NOTE: This disc is interchangeable with discs in

Bennett siphon and suspension valve No. E-1140 and in submerged pump check valve No. 70-N-1000.

Delrin

Use any tire valve cap to remove the Dill tire valve for cleaning or replacement. Replace with Dill brand only. See Figure 42.

32

Figure 43B

SPL1083.3 7/95

33

Pump Rotor and Seal Assembly While the rotor and shaft assembly had remained the same, the method of sealing changed during the production of the Type 40 pumping unit. The original production utilized a rotary seal as shown in Figure 44. Later production, starting with the 3000 Series, used the lip seal method as shown in Figure 45.

NOTE: Parts are no longer available for units with the rotary seal. In order to repair units with rotary seals, order KR 162-01. KR-162 contains the following: 1. Rotor cover plate H-3522-01 2. Inner seal A247014 3. Lip seal A323702 4. Seal retainer H352101 5. Screw (3 ea) A099101

How to Install the Lip Seal Remove the belt, pulley and shaft key. Remove the three screws that hold the seal retainer. Carefully pry the old seal from the recess in the cover plate—do not scratch the shaft. With a small plastic expander tool (furnished with new seal), slip the new seal over the shaft which has been wiped clean. Remove the tool. Reinstall the seal retainer screws, key, pulley, and belt.

Figure 44 - Rotor Seal

Figure 45 - Lip Seal

SPL1083.3 7/95

How to Service Rotor Assembly 1. Remove the belt and pump pulley, being careful

not to lose the shaft key. 2. Remove five cap screws, the cover plate ring,

and gasket. Be sure to mark the position of the rotor cover (1) so it is returned to the same position during reassembly. See Figure 46.

3. The rotor cover is a close fit. If it does not loosen

by hand, tap lightly with a ball hammer on the hex-shaped hub at various points until free.

4. Pull the assembly out slowly and catch the

blades (2) with a free hand. The Bennett designed rotor contributes to quiet operation and high vacuum. The blades are fitted into their slots with .002 inch clearance. The rotor, turning about 615 R.P.M. with .001 inch clearance on both faces and at the top, causes the blades to continually contact the surface of the pump body bore by centrifugal action. The blades must slide freely back and forth in their slots. If dirt, corrosion or gum forms, the result will be that one or more of the blades will bind. This causes a distinct throb or vibration that can be felt at the nozzle while delivery is being made. Clean the blades with emery paper to remove foreign matter only. Run a fine, flat file through each slot, removing only the foreign matter.

CAUTION: Be careful not to file away metal that will result in wider slots.

Before reinstalling, wash the blades and rotor in a solvent. Also, inspect and clean the holes (3) drilled in the bottom of each blade slot to give freedom from liquid blocking of the blade action.

34

Figure 46 - Rotor Assembly

SPL1083.3 7/95

35

SPL1083.3 7/95

36

NOTE: This parts list is for reference only. Consult the appropriate model parts book when ordering parts.

Figure 47 - Type 40 Pumping Unit

SPL1083.3 7/95

37

Type 40 Pumping Unit Parts List NOTE: Highlighted items no longer available.

Ref. No.

Part No.

Description

Qty.

47 48

49 50 51 52

132N012701 H366901 H367001 E008001 H461501 H389401 H389501

Sleeve, Tube Spring, Bypass Valve Spring, Bypass Valve-H.D. Spring, Control Valve Tube Assembly, Vent Valve, Bypass Valve, Control Assembly

1 1 1 1 1 1 1

53

54 55 56 57 58 59 60 61 62 63

(27)

H876901 J069701 H876501 H876701 H876401 A201301 E377301 541N010501 A256601 A255004 A238402 A219004

Valve Assembly, Atmospheric Float Assembly includes: Valve Assembly Body Float Lever Valve “E” Ring Float Gasket Washer, Flat 3/16 Screw, 8-32x2-1/2 Screw & Lockwasher, 8x1 Nut & Lockwasher, 8-32

1 1 1 1 1 1 1 1 1 1 1 1

64

65 66 67 68 69 70 71

(66)

H876801 J069601 H876501 H876301 A201301 H876601 F377201 541N010501 A238402

Valve Assembly, Float Assembly includes: Valve Assembly Body Float Lever “E” Ring Valve Float Gasket Screw & Lockwasher, 3x1

1 1 1 1 1 1 1 1 1

72 73 74 75

A028101 A064001 A000301 A003031

Washer, Flat 5/16 Washer, Flat #8 Washer, Lock 5/16 Washer, Lock 1/4

1 1 1 1

Service Repair Kit for Type 40 Pumping Unit

Ref. No.

Part No.

Description

Qty.

H626022 H626002 H626011

Pumping Unit - Type 40 Standard Heavy Duty Heavy Duty - 1/2 hp

1 1 1

1 541N040001 Body, Pumping Unit 1

2

3

541N040401 132P100001 541N100501 A254901

Body, Pumping Unit - H.D. Blade, Rotor Blade, Rotor - H.D., Plated Clamp, Tube

1 6 6 1

4 5 6 7

8

J557501 J484501 H401202 H750101 H397301

Core, Control Valve Cover, Air Elim. Chamber Cover, Atmospheric Chamber Cover, Bypass Valve (replaced H397201) Cover, control Valve

1 1 1 1 1

9 10 11 12 13 14 15

H385301 H352201 966N100201 966N010301 966N010401 966N010201 966N010501

Cover, Strainer Cover Plate, Rotor Coupling, Dresser Body Gasket Nut Retainer

1 1 1 1 1 1 1

16 17

18

19

A078601 J566901 A311901 541N010001 541N010701

Coupling, Tube 3/8 x 1/4 Filter Assembly (Strainer) Filter Assy for H626001 Pump Gasket, Air Elimination Chamber Cover Gasket, Atmospheric Chamber Cover

1 1 1 1 1

20 21 22 23 24

541N012401 541N012501 541N011801 H385001 A199501

Gasket, Bypass Valve Cover Gasket, Con. Valve Cover Gasket, Cover Plate Gasket, Strainer Cover Key

1 1 1 1 2

25 26 27 28 29

966N010401 132N012701 A219004 A019904 A044001

Nipple, Inlet 3-3/4x1-1/2 Nut, Tube Nut & Lockwasher, 8-32 Plug, 1/4 Plug, 1/8

1 1 1 1 2

30 31 32 33 34

A084201 J358701 H352101 541N011701 A236101

Plug, 3/4 Pulley Retainer, Seal Ring, Cover Plate Ring, Retaining

1 1 1 1 1

35

36 37 38 39 40

E376903 H249202 A052601 A219204 A010501 A161801 A147601

Rotor and Shaft Assembly Rotor and Shaft Assembly - H.D. Screw, 3/8-16x3/4 Screw, 3/8-16x7/8 w/lockwasher Screw, 5/16-18x1/2 Screw, 5/16-18x5/8 Screw, 5/16-18x7/8

1 1 4 5 14 1 3

41 42 43 44 45 46

A013701 A166401 A099101 A206901 A323702 A247014

Screw, 5/16-18x3/4 Screw, 1/4-20x5/8 Screw, 8-32x5/16 Screw, 8-32x7/8 Seal, Lip Seal, Square

18 4 3 1 1 1

18 19

20 21 22 71 — 23 45 46

KR36603 541N010001 541N010701 541N012401 541N012501 541N011801 541N010501 E993201 H385001 A286402 A247014

Gasket Kit Kit includes: Gasket, Air Eliminator Cover Gasket, Atmospheric Chamber Cover Gasket, Bypass Valve Cover Gasket, Control Valve Cover Gasket, Cover Plate Gasket, Float Valve Gasket, Meter (not shown) Gasket, Strainer Cover Seal, Lip Seal, Square

1 1 1 1 1 1 2 1 1 1 1

10 32 45 46 43

KR16201 H352201 H352101 A286402 A247014 A099101

Replacement Kit for Rotor Cover Plate & Seal Kit includes: Cover Plate, Rotor Retainer, Seal Seal, Lip Seal Square Screw

1 1 1 1 1 3

7 20 40 48

51

KR16501 Std KR16502 H-D H750101 541N0124-01 A147601 H366901 H367001 H389401

Kit to convert old metal bypass valve to plastic Kit Includes: Cover, Bypass Valve Gasket Screw, Hex Hd. Spring (Std.) Spring, (H-D) Valve, Bypass

1 1 1 3 1 1 1

SPL1083.3 7/95

TYPE 70 PUMPING UNIT (Production 10-76 TO 11-83) NOTE: The Type 70 pumping unit was standard on all Bennett self-contained suction pumps

manufactured on or after October 1, 1976.

Flow of Liquid Through Pumping Unit, Air Eliminator and Meter

To understand the proper operation of the Type 70 pumping unit, it is essential to visualize the flow of liquid through the pumping unit. After carefully studying the schematic flow diagram, it will be possible to diagnose field problems and make quick repairs. See the schematic diagram in Figure 48.

The Type 70 pumping unit moves product from the storage tank to the vehicle or container in the following manner: 1. The fuel is drawn from the storage tank through

the strainer screen or filter (1). 2. The rotary vane pumping unit (2) pressurizes the

fluid and sends it on into the air separator. 3. Fuel enters the centrifugal air separator and

elimination assembly (3). Any air that is present is forced out the air tube along with a small amount of liquid into the air elimination chamber (4).

4. When the liquid level in the chamber lifts the float

(5) and valve assembly, the liquid collected in the atmospheric chamber is returned to the pump intake. Air is then vented to the atmosphere through the vent tube (6).

5. The control valve (7) is opened by liquid pressure

(approximately 4 PSI). Fuel is then pumped to the meter. The control valve includes a built-in relief valve which relieves excess pressure caused by hot weather expansion.

6. Fuel passes through the meter (9) where it is

accurately measured, then through the hose and nozzle to the vehicle or container being fueled.

7. Whenever the nozzle is closed and the pump

motor is in operation, the liquid back pressure opens the bypass valve (10) which bypasses the liquid back to the pump intake. The pump pressure is thus regulated until the nozzle is opened or the pump motor is shut off.

38

Figure 48 - Type 70 Schematic Flow Diagram

SPL1083.3 7/95

39

Type 70 Pumping Unit (Prepay Valving) The flow diagram in Figure 49 shows the Type 70 running with solenoids de-energized (no flow). 1. Product from the pumping unit flows into the pre-

pay casting inlet (1) pressurizing the back of the diaphragm valve (2).

2. Product from the pumping unit flows through the

tube (3) going into the top of the high flow solenoid (4) and out the tube (5) from the side of the solenoid. Product flows through this tube (5) and pressurizes the front of the diaphragm valve (6).

3. Equal pressure is now applied to the front (6) and

back (2) of the diaphragm valve. The spring (7) exerts greater pressure on the front of the diaphragm valve causing it to close and preventing high product flow.

4. At the same time, product from the pumping unit

flows through tube (8) to the low flow solenoid (9). Because the low flow solenoid is de-energized, product flow to tube (10) is stopped preventing low product flow.

Figure 49 - Solenoids De-energized (no flow)

SPL1083.3 7/95

40

The flow diagram in Figure 50 shows the Type 70 running with solenoids energized. 1. Product from the pumping unit flows into the pre-

pay casting inlet (1) pressurizing the back of the diaphragm valve (2).


tube (3) going into the top of the high flow solenoid (4). Because the high flow solenoid is energized, product is prevented from flowing from tube (3) to tube (5) on the side of the solenoid and pressurizes the front of the diaphragm valve (6).

3. When the high flow solenoid is energized it allows

product pressure to be relieved from the front of the diaphragm valve via tube (5), through the solenoid, through tube (7) and to the meter.


diaphragm valve (2) overcomes the spring (8) tension and pushes the diaphragm valve into its open position. The diaphragm valve in its opened position allows high product flow.

5. At the same time, product from the pumping unit flows through tube (9), through the low flow solenoid (10), through tube (11) and up to the meter.

6. In pre-pay or local preset operation, the high flow

solenoid is de-energized at a point before final sale is reached. The low flow solenoid is energized from the beginning of the sale until the sale is complete. This allows the pump to slow before final sale is reached which prevents


SPL1083.3 7/95

41

Type 70 Pumping Unit (Single Product-2 Hose) The purpose of using directional valve assemblies on single product-two hose units is to prevent delivery from an unauthorized hose when the other is in use. The flow diagram in Figure 51 shows the Type 70 in a single product-2 hose unit running with the solenoids de-energized. 1. Product from the pump flows into the directional

valve casting and pressurizes the back of the diaphragm valve (1).


valve casting and through tube (2) to the top of the solenoid (3). Because the solenoid is de-energized, product flows from tube (2), through the solenoid, into tube (4) and pressurizes the front of the diaphragm valve (5).


front (5) and back (1) of the diaphragm valve. The spring (6) in the valve exerts greater pressure on the front of the diaphragm valve causing it to close and preventing product flow.

Figure 51 - Solenoids De-energized (Single Product-2 Hose)

SPL1083.3 7/95

The flow diagram in Figure 52 shows the Type 70 in a single product-2 hose unit running with solenoids energized. 1. Product from the pump flows into the directional



valve casting and through tube (2) to the top of the solenoid (3). Because the solenoid is energized, product is prevented from flowing from tube (2), through the solenoid, into tube (4) and pressurizing the front of the diaphragm valve (5).

3. Because the solenoid is energized product

pressure is relieved from the front of the diaphragm valve via tube (4), through the solenoid, through tube (6) and to the meter.


diaphragm valve overcomes the spring (7) tension and pushes the diaphragm valve into its open position. The diaphragm valve in its open position allows full product flow for that hose.

42

Figure 52 - Solenoids Energized (Single Product-2 Hose)

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43

Float And Air Separator Before gasoline can accurately be measured by the meter, air and vapors must be eliminated. The Type 70 pumping unit eliminates air and vapors by the use of the air separator and float assembly. The Type 70 employed two types of floats during its production. The original production used a cylinder type of float. See Figure 53. Later production used a rectangle type of float. See Figure 54. Early Production Conditions During initial production of the cylinder type of float, tinnerman nuts of the incorrect type were used. The fastener was too large and could come loose. If this occurs, the float moves on its stem resulting in a loss of vacuum and halting the pumping action. Production serial numbers starting with 9A through 11B may be affected. The part number for the tinnerman nut is A341501 which should be used if the above condition occurs. Another failure was reported with the use of the cylinder float. During cold temperatures, water could collect in the top cavity of the float and freeze it to its stem. If the float freezes to the stem in its up position, loss of vacuum results and halts pumping action. If the float freezes in its down position, the atmospheric chamber floods resulting in product being dispensed out the vent tube. NOTE: The above conditions would only occur if

there is an undue amount of water in the station’s gasoline.

Later production of the cylinder type of float had weep holes in its bottom cavity, thus allowing any water to drain. If the freezing condition occurs, changing the float will remedy the failure. The part number of the float is J195501.

Figure 53

Fiugre 54

SPL1083.3 7/95

44

Bypass Valve The Type 70 pumping unit employs a bypass valve in order to limit the pressure of the pumping unit when the motor is running, but no fuel is being dispensed. The bypass valve is identical on standard and heavy-duty pumping units. The bypass valve spring is different between the standard and heavy-duty units. The heavy-duty unit uses a stronger spring than the standard unit. If the bypass valve or its mating seat wears to the point of not mating properly, loss of vacuum occurs. This results in slow or no delivery. If only the valve is worn, it may be replaced. If the seat of the pumping unit is worn, a KR-332 kit must be ordered. This kit includes a brass insert, valve, and spring. The brass insert is used to address a worn casting. For instructions to install KR-332, see Figure 55. Control Valve The Type 70 pumping unit uses a control valve that aids in the elimination of air and is used as a check valve for any fuel above it. The control valve also contains a pressure relief valve. This valve ports excess hose pressure, which may result from the expansion of fuel in the hose, to the air elimination chamber. The above function prevents hoses from bursting during hot weather and prevents leaks. The control valve and springs of the standard and heavy-duty Type 70 pumping unit are identical and may be interchanged. Rotor Assembly Maintenance Should it become necessary to service the Type 70 pumping units’ rotor, shaft assembly or blades, the rotor shaft assembly should be removed as shown in Figure 56 using a conventional carpenter’s crowbar. To service the rotor, follow this procedure: 1. Remove the four bolts that hold the clamping ring

in place. 2. Let the clamping ring hang on the rotor cover. 3. Using the claw or hooked end of the crowbar,

place the claw against the pulley as close to the shaft as possible and pry against the flange of the pump body as shown in Figure 56. Depending on the size or shape of the crowbar, it may be necessary to use a small block of wood either at the pulley or at the dome flange to provide

INSTRUCTIONS: 1. Remove bypass cover, take out original spring

and valve. Discard both. 2. Slide into place the brass insert, oriented

properly as shown. This is important so the liquid does not get blocked.

3. Install the new valve and new spring and replace

the cover.* The cover with gasket will pinch the insert to the body and prevent it from turning.

*Gasket furnished is required only if original

gasket is damaged. Gasket must be installed on top of brass insert.

Figure 55

Figure 56

SPL1083.3 7/95

45

adequate leverage. 4. Apply upward pressure on the crowbar to remove

the rotor and cover. 5. It is recommended that the “O” ring which seals

the rotor cover be replaced whenever the rotor assembly is removed from the pumping unit.

6. When reassembling, tap the rotor cover into

position and carefully tighten the clamping ring. Lip Seal Replacement To replace the lip seal, follow this procedure: 1. Remove the belt, pulley, and shaft key. 2. Remove the three screws that hold the seal

retainer. See Figure 57. Carefully pry the old seal from the recess in the cover plate—do not scratch the shaft. Wipe the shaft clean.

3. With a small plastic plug tool (furnished with new

seal) slip the new seal over the shaft. Remove the tool.

4. Reinstall the seal retainer screws, key, pulley,

and belt.

Stator Removal Should it become necessary to repair or replace the stator, remove the rotor cover and rotor shaft assembly. See Figure 57. Be careful to catch the blades when the rotor and shaft is being removed. The stator, in most cases, can be slid out of the pumping unit body at this point. In some cases, the stator may be slightly wedged in the body of the pumping unit. In these cases, the filter may be removed which will expose part of the back of the stator. Using a piece of wood and a hammer, the stator may be gently tapped out. NOTE: Use caution not to tap too hard. Too

much force will wedge the stator into its body.

In extreme cases, the entire pumping unit must be removed from the unit. Once the pumping unit is removed, drain it completely.

DANGER: Do not use open flame device to heat the pumping unit.

After draining, the entire body of the pumping unit can be heated and the stator will slide out.

Figure 57

SPL1083.3 7/95

46

NOTE: Bennett stopped producing the Type 70 Pumping Unit in November, 1983. The Type 70 Pumping Unit is no longer available. Type 75 kits are available to replace Type 70 Pumping Units. Check the list of KR Kits below.

KR KIT

Conversion from Type 70 to Type 75 NUMBER For Models 5013 or 6013

Standard ............................................................................................................KR037201 Standard with prepay .........................................................................................KR037202 Heavy duty .........................................................................................................KR037203 Heavy duty with prepay ......................................................................................KR037204

For Models 5027 or 6027 Standard ..............................................................................................................KR037301 Standard with prepay ...........................................................................................KR037302

For Models 5025 or 6025, Side A Standard ..............................................................................................................KR037401 Standard with prepay ...........................................................................................KR037402 Heavy duty ..........................................................................................................KR037403 Heavy duty with prepay .......................................................................................KR037404

For Models 5025 or 6025, Side B Standard ..............................................................................................................KR037501 Standard with prepay ...........................................................................................KR037502 Heavy duty ..........................................................................................................KR037503 Heavy duty prepay ...............................................................................................KR037504

For Models 4013, 4113, 3788 or 3789 Standard ..............................................................................................................KR037701 Standard with prepay ...........................................................................................KR037702 Heavy duty ..........................................................................................................KR037703 Heavy duty with prepay .......................................................................................KR037704

For Models 4027, 4127 or 3727 Standard and Standard with prepay .....................................................................KR037801

For Models 4025, 4125 or 3725, Side A Standard ..............................................................................................................KR037901 Standard with prepay ...........................................................................................KR037902 Heavy duty ..........................................................................................................KR037903 Heavy duty with prepay .......................................................................................KR037904

For Models 4025, 4125 or 3725, Side B Standard ..............................................................................................................KR038001 Standard with prepay ...........................................................................................KR038002 Heavy duty ..........................................................................................................KR038003 Heavy duty with prepay .......................................................................................KR038004

For Model 4515 Standard ..............................................................................................................KR038101 Standard with prepay ...........................................................................................KR038102 Heavy duty ..........................................................................................................KR038103 Heavy duty with prepay .......................................................................................KR038104

For Model 4527 Standard and Standard with prepay .....................................................................KR038201

SPL1083.3 7/95

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SPL1083.3 7/95

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SPL1083.3 7/95

49

Type 70 Pumping Unit Parts List

Ref. No.

Part No.

Description

Qty.

�

� J1957 J9310

Pumping Unit - Type 70 (See appropriate model parts list for correct group.)

1 1

1

2 � 3 4

5 � 6

J481701 J481702 J189201 J189202 J843102 J800201 J800101 N047201 J927001 132P100101 J187701

Adaptor Assembly Adaptor Assembly (3727) Adaptor, Control Valve Adaptor, Control Valve Adaptor, Inlet Adaptor, Inlet-Left (3725) Adaptor, Inlet-Right (3725) Body, Pumping Unit Body, Pumping Unit - Air Eliminator Blade, Rotor Blade, Rotor - Plated

1 1 1 1 1 1 1 1 1 6 6

7 8 9

10 11 12

A254901 J557501 J189102 J188101 J195101 J186201

Clamp, Tube Core Assy w/Valve Seat Cover, Atmospheric Chamber Cover, Bypass Valve Cover, Control Valve Cover, Filter

1 1 1 1 1 1

13 14 15

135N011001 J566901 J186101

Elbow, Tubing Filter Assembly (Strainer) Flange

1 1 1

16 17 18 19 20 21 22 23

J188401 J186601 J971401 J186401 J186501 J187101 J802401 J187201

Gasket, Atmos. Chamber Cover Gasket, Bypass Valve Cover Gasket, Clamping Ring Gasket, Control Valve Cover Gasket, Filter Cover Gasket, Inlet - Separator Gasket, Inlet - Adaptor Gasket, Outlet - Separator

1 1 1 1 1 1

1 or 2 1

24 25 26 27 28

J563201 J187301 J276501 E169108 E169109

Guide, Float Insert Insert, Filter Nipple, 3x1-1/2 N.P.T. Nipple, 4-3/4x1-1/2 N.P.T.

1 1 1 1

1 or 2

29 30 31 32

135N012702 A219004 A019901 J358601 J722801

Nut, Tube Nut & Lockwasher Plug, Pipe 1/4 Pulley Pulley w/Hand Crank

1 2 2 1 1

33 34 35 36 37 38 39

J334001 A263101 A212239 A212232 A294211 J275701 A199501

Ring, Clamping Ring, Retaining Ring, “0” Ring, “0” Use J561201 Rotor and Shaft Assembly Key

1 1 1 1 1 1 1

Ref. No.

Part No.

Description

Qty.

40

41 42 43 44 45 46

J682701S H352101 A212242 A099101 A323702 A247014 J188701

Rotor Support Assembly Assembly includes: Retainer Seal Ring, “O” Screw, 8-32x5/16 Seal, Lip Seal, Square Support, Rotor

1 1 1 3 1 1 1

47 48 49 50 51 52 53 54 55

A174301 A106901 A015601 A083501 A147601 A398801 A164801 A399801 A219305

Screw, M8-1.25x15M Screw, 8-32x7/8 Screw, 3/8-16x1/2 Screw, 5/16-18x1 Hex Screw, 5/16-18x7/8 Screw, 5/16-18x1 Fil. Screw, 5/16-18x2-3/4 Screw, 1/4-20x7/8 Screw, and Lockwasher

1 1

3 or 6 11 7 2 4 4 10

56 � 57 58 59 60

61

J195601 J195602 J187601 135N012802 J506701 J906001 J910401 E008002 J325201

Separator Assembly Separator Assembly-Air Elim. Seat, Float Valve Sleeve, Tube Spring, Filter Spring, Bypass Valve Spring, Bypass Valve-H.D. Spring, Control Valve Spring, Control Valve-H.D.

1 1 1 1 1 1 1 1 1

62

63 64 � 65 66

J189001 J333901 J652801 J187401 �J927401 A327501 J186301

Stator Stator-H.D. Tube Assembly, Vent Tube & Adaptor Assembly Tube & Adaptor Assembly-Air Elim. Union, 1-1/2 Valve, Bypass Note: Order Kit (KR332) to replace original Bypass seat insert with improved brass insert.

1 1 1 1 1

1 or 2 1

67

� 68

69 70

(30) 71 72 73 74 75 76

J561201 J929901 H876902 541N010501 A219004 A166401 A255004 A238401 J069702 A003001 A256601

Valve Ass, Control w/relief valve Valve Assy, Con.-Air Elim. Valve Assy, Float Rectangle Assembly includes: Float Gasket Nut and Lock Washer Screw, 1/4-20x5/8 Screw, 8-32x2-1/4 Screw Valve Assembly Washer, Lock 1/4 Washer, Flat

1 1 1 1 1 1 2 1 1 1 1 1

77

78 79 80 81 82 83 84

J227201 J227101 A327201 J195501 A064001 A028101 A000301 A062301

Valve Assy, Float-Round Assembly includes: Bushing, Throttle Ring, Retaining Valve & Float Assembly Washer Washer Washer, Lock Washer, Lock

1 1 1 1 1 1 1 1

��For Export Only ��Order this part for pumping units with the improved

air elimination option.

SPL1083.3 7/95

50

TYPE 75 PUMPING UNIT (Production 11-83 to present) The Type 75 pumping unit is standard on all Bennett self-contained suction pumps manufactured on or after November, 1983.

Flow of Liquid Through Pumping Unit, Air Eliminator and Meter The Type 75 Pumping Unit moves product from the storage tank to the vehicle or container in the following manner: 1. The fuel is drawn from the storage tank through

the strainer screen or filter (1). See Figure 59. 2. The rotary vane pumping unit (2) pressurizes the

fluid. 3. Fuel enters the centrifugal air separator assembly

(3). Any air that is present is forced out the air tube along with a small amount of liquid into the atmospheric chamber.

4. When the liquid level in the chamber lifts the float

and valve assembly (4), the liquid collected in the atmospheric chamber is returned to the pump intake. Air is then vented to the atmosphere through the end tube (5).

5. Air free fuel leaving the air separator opens the

control valve (6) and is pumped into the meter (7). The control valve includes a built-in relief valve (8) which relieves excess pressure caused by hot weather expansion.

6. Fuel passes through the meter where it is

accurately measured, then through the hose and nozzle to the vehicle or container being fueled.

7. Whenever the nozzle is not fully opened, some

liquid is relieved into the pump intake through the bypass valve (9).

Figure 59 - Type 75 Schematic Flow Diagram

SPL1083.3 7/95

51

Type 75 Pumping Unit (Prepay Valving) The flow diagram in Figure 60 shows the Type 75 running with solenoids de-energized (no flow). 1. Product from the pumping unit flows to and

pressurizes the back of the diaphragm valve (2) which is located at the top of the atmospheric chamber (1).


tube (3) going into the top of the high flow solenoid (4), through the high flow solenoid and out the tube (5) from the side of the solenoid. Product flows through this tube and pressurizes the front of the diaphragm valve (6).

3. Equal pressure is now applied to the front (6) and

back (2) of the diaphragm valve. The spring (7) exerts greater pressure on the front of the diaphragm valve causing it to close and preventing high flow.


flows through tube (8) to the low flow solenoid (9). Because the low flow solenoid is de-energized, product flow to tube (10) is stopped preventing low product flow.


SPL1083.3 7/95

52

The flow diagram in Figure 61 shows the Type 75 running with solenoids energized 1. Product from the pumping unit flows to and

pressurizes the back of the diaphragm valve (2) which is located at the top of the atmospheric chamber (1).


tube (3) going into the top of the high flow solenoid (4). Because the high flow solenoid is energized, product is prevented from flowing from tube (3) to tube (5) and pressurizing the front of the diaphragm valve (6).

3. Because the high flow solenoid is energized,

product pressure is relieved from the front of the diaphragm valve via tube (5), through the solenoid, through tube (7) and to the meter.


diaphragm valve (2) overcomes spring (8) tension and pushes the diaphragm valve into its open position. The diaphragm valve in its opened position allows high product flow.


flows through tube (9), through the low flow solenoid (10), through tube (11) and up to the meter.

6. In pre-pay or local preset operation, the high flow

solenoid is de-energized at a point before the final sale is reached. The low flow solenoid is energized from the beginning of the sale until the sale is complete. This allows the pump to slow before final sale is reached which prevents overruns.


SPL1083.3 7/95

Type 75 Pumping Unit (Single Product-2 Hose) The purpose of using directional valve assemblies on single product-2 hose units is to prevent delivery from an unauthorized hose when the other is in use. The flow diagram shown in Figure 62 shows the Type 75 in a single product-2 hose unit running with the solenoids de-energized 1. Product from the pump flows into the directional



valve casting and through tube (2) to the top of the solenoid (3). Because the solenoid is de-energized, product flows from tube (2), through the solenoid, into tube (4) and pressurizes the front of the diaphragm valve (5).


front (5) and back (1) of the diaphragm valve. The spring (6) exerts greater pressure on the front of the diaphragm valve causing it to close and preventing product flow.

53

Figure 62 - Solenoids De-energized (Single Product-2 Hose)

SPL1083.3 7/95

The flow diagram shown in Figure 63 shows the Type 75 in a single product - 2 hose unit running with the solenoids energized 1. Product from the pump flows into the directional



valve casting and through tube (2) to the top of the solenoid (3). Because the solenoid is energized, product is prevented from flowing from tube (2), through the solenoid, through tube (4) and pressurizing the front of the diaphragm valve (5).

3. Because the solenoid is energized product

pressure is relieved from the front of the diaphragm valve via tube (4), through the solenoid, through tube (6) and to the hose.


diaphragm valve overcomes the spring (7) tension and pushes the diaphragm valve into its open position. The diaphragm valve in its open position allows full product flow for that hose.

54

Figure 63 - Solenoids Energized (Single Product-2 Hose)

SPL1083.3 7/95

Float and Air Separator Before gasoline can be accurately measured by the meter, air and vapors must be eliminated. The Type 75 pumping unit eliminates air and vapor by the use of the air separator and float assembly. The float assembly employed is as shown in Figure 64. During production of the Type 75, two problems were reported with the float assembly. 1. The valve was assembled so that its flat side was

facing the float versus its proper position as shown in Figure 64. This incorrect assembly caused the float to stick in its up position and cause loss of vacuum resulting in the loss of all delivery.

2. The float lever’s top hole diameter was on the low

side of its specified tolerance. This caused the float to stick in its up position and caused the loss of vacuum. This would result in the loss of all delivery from the pumping unit.

Both of the above conditions may be field repaired, if encountered. To correct the first problem, disconnect the float lever from the valve and turn the valve so that its flat side is away from the float. The second problem can be solved by disconnecting the float lever from the valve and opening the diameter of its top hole to 7/16 inch. NOTE: Do not enlarge any hole other than the top

hole. Bypass Valve The Type 75 pumping unit uses a bypass valve assembly in order to limit the pumping unit pressure when the motor is running, but no fuel is being dispensed. The bypass assembly includes the valve spring and guide. The entire bypass assembly is used when making repairs. The same bypass assembly is used on all Type 75 pumping units (heavy-duty and standard).

55

Figure 64

Figure 65 - Bypass Valve

SPL1083.3 7/95

56

Control Valve The Type 75 pumping unit uses a control valve that aids in the elimination of air by producing a back pressure and is also used as a check valve for any fuel above it. The control valve also contains a pressure relief valve. This valve ports excess hose pressure, which may result from the expansion of fuel in the hose during hot weather, to the air eliminator chamber. This action prevents hoses from bursting and helps to prevent pumping unit leaks. The control valve of standard and heavy-duty pumping units are identical and may be interchanged. The control valve springs for the heavy-duty and standard pumping units are different and must not be interchanged. Rotor Assembly Maintenance Should it become necessary to service the Type 75 pumping unit’s rotor, shaft assembly or blades, the rotor shaft assembly should be removed as shown using a conventional carpenter’s crowbar. 1. Remove the four bolts that hold the clamping ring

in place. 2. Let the clamping ring hang on the rotor cover. 3. Using the claw or hooked end of the crowbar,

place the claw against the pulley as close to the shaft as possible and pry against the flange of the pump body as shown in Figure 67. Depending on the size or shape of the crowbar, it may be necessary to use a small block of wood either at the pulley or at the dome flange to provide adequate leverage.

4. Apply upward pressure on the crowbar to remove

the rotor and cover. 5. It is recommended that the “O” ring, which seals

the rotor cover, be replaced whenever the rotor assembly is removed from the pumping unit.

6. When reassembling the pumping unit, tap the

rotor cover into position and carefully tighten the clamping ring.

Figure 66 - Control Valve

Figure 67

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57

Lip Seal Replacement To replace the lip seal, follow this procedure: 1. Remove the belt, pulley, and shaft key. 2. Remove the three screws that hold the seal

retainer. See Figure 68. Carefully pry the old seal from the recess in the cover plate—do not scratch the shaft.

3. Wipe the shaft clean. 4. With a small plastic plug tool (furnished with new

seal), slip the new seal over the shaft. Remove the tool.

5. Reinstall the seal retainer screws, key, pulley, and

belt.

Stator Removal Should it become necessary to repair or replace the stator, remove the rotor cover and rotor shaft assembly. See Figure 68. Be careful to catch the blades when the rotor and shaft assembly is being removed. The stator, in most cases, can be slid out of the pumping unit body at this point. In some cases, the stator may be slightly wedged in the body of the pumping unit. The filter may be removed, which will expose part of the back of the stator. Using a piece of wood and a hammer, the stator may be gently tapped out. NOTE: Use caution. Do not tap too hard as this

will further wedge the stator in its body. In extreme cases, the entire pumping unit must be removed from the unit. Once the pumping unit is removed, it should be completely drained.

DANGER: Do not use an open flame device to heat the pumping unit.

After draining, the entire body of the pumping unit can be heated and the stator will slide out.

Figure 68

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58

Pumping Units with Throw Out Rings All pumping units manufactured after February 1, 1989 (standard or heavy-duty) have rotors with throw out rings and carbon blades. Our studies conclude that pumping units with throw out rings produce greater vacuum and are more resistant to vapor lock. To determine whether a dispenser has a pumping unit with the new throw out rings, look for the date code stamped directly on the pumping unit. The date code is stamped next to the filter cover. If the date code is 2P or higher, the unit has rotors with throw out rings. Any dispenser with a serial number 3P or higher uses the throw out rings. The following part numbers can be ordered to upgrade your inventory or for a dispenser that has a vapor lock problem. Order KR042001 to receive the components listed below: -N238301 Rotor Shaft Assembly - 1 required -N238201 Carbon Blade - 6 required -N650401 Throw out Ring - 2 required To replace blades in rotors with throw-out rings, follow this procedure: 1. Install throw out rings in the recesses of the rotor. 2. Install the rotor in the stator assembly. 3. Rotate the rotor until a blade slot is at the 12:00

o’clock position. Install a blade. 4. Rotate the rotor 2 slots from the installed blade.

Make sure the second slot is at the 12:00 o’clock position. Install a blade.

5. Repeat step 4 for the third blade. 6. Repeat steps 3 for the three remaining blades.

See Figure 69.

Figure 69

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59

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60


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61

Ref.

N190730 Pumping Unit - Type 75 1

1

2 3 4 5 6 7 8

N150601 N150602 N238201 A254901 A583601 N311113 N154901 N154801 N154701

Body (non-reverse float) Body (reverse float) Blade, Rotor * Clamp Connector, Male Cover, Atmos. Chamber Cover, Bypass Valve Cover, Control Valve Cover, Filter

1 1 6 1 1 1 1 1 1

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

N888301 N888401 N162901 N162401 N162701 N162301 N162201 N162501 N162601 N190201 A199501 132N012701 A219004 A212248 A019901

Float, Non-Reversing Float Bushing, Non-Reversing Gasket, Atmos. Cham. Cover Gasket, Bypass Valve Gasket, Clamping Ring Gasket, Control Valve Cover Gasket, Filter Cover Gasket, Inlet (Separator) Gasket, Outlet (Separator) Insert Key *Nut, Tube *Nut O’Ring Plug, Pipe 1/4

1 1 1 1 1 1 1 1 1 1 1 1 1 1 2

24 25 26 27 28

29 30 31 32 33

N106901 N238101 N155901 A263101 J682702 N103801 A480001 A323702 H352101 A247014

Pulley Ring, Throw Out (H.D.) Ring, Clamping Ring, Retaining Rotor Support Assembly Assembly includes: Cover, Rotor Screw, M3.5 Flat Hd Seal, Lip (with plug) Seal, Retainer Seal, Square

1 2 1 1 1 1 3 1 1 1

34

(19) 35

N238301 A199501 A253501

Rotor and Shaft Assembly Assy. includes Rotor, Shaft and the following: Key Ring, Retaining

1 1 1

36 37 38 49 40 41 42

A206901 A479903 A479901 A479902 A480101 J195603 132N012802

*Screw Screw, M8 1.25x15MM *Screw, M8 1.25x20MM Screw, M8 1.25x25mm Screw, M6 1x20MM Separator & Air Eliminator *Sleeve, Tube

1 1

Ref 24 6 1 1

Ref.

43 44 45 46 47

48

J325201 J506701 N159501 N160301 J566901 N333501 A311901 N693101

Spring, Control Valve (H.D.) Spring, Filter Stator, H.D. Stop, Filter Insert Strainer Assembly-149 micron Metal Strainer (not shown) Paper Filter (not shown) *Tube, Vent Assy- 9024 Tube, Vent Assy- 9033 & 9036 Tube, Vent Assy- 9044 & 9048

1 1 1 1 1 1 1 2 3 4

49 50 51 52 53 54 55

N481201 N107301 A320901 H876904 A028101 A214701 A000301

Valve Assembly, Bypass Valve Assembly, Control Valve, Relief 30-50 psi Valve Assembly, Float Washer *Washer Washer, Lock

1 1 1 1 1 2 1

Ref. No.

Part No.

Description

Qty.

8

9 10

KR036604 N162901 N162401 N162701

Gasket Set Set includes: Gasket, Atmospheric Chamber cover Gasket, Bypass Valve Gasket, Clamping Ring

1 1 1 1

11 12 13 14 __

N162301 N162201 N162501 N162601 E993201

Gasket, Con. Valve Cover Gasket, Filter Cover Gasket, Inlet (Separator) Gasket, Outlet (Separator) Gasket, Meter (Dwg. #9)

1 1 1 1 1

24 26

A323702 A247014

Seal, Lip (with plug) Seal, Square

1 1

* Not part of the pumping unit.

BENNETT® 9000 Service Repair Kit For Type 75 Pumping Unit

All warranty repairs must use rebuilt parts.

NOTE: Pumping units produced before April, 1994, will require KR043801 float kit for replacement.

Type 75 Pumping Unit Parts List

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62

General Vacuum/Pressure Information The following components are normally associated with the pressure: 1. Control Valve 2. Meter 3. Computer or pulser drive linkage 4. Hose 5. Nozzle The components listed below are normally associated with vacuum: 1. Blades 2. Rotor/Stator 3. Filter 4. Bypass valve and seat 5. Float (opened) 6. Installation piping 7. Tank vent pipe 8. Angle check valve or foot valve 9. Tank burial depth

SELF-CONTAINED TROUBLESHOOTING

The following table shows normal vacuum gauge readings for a variety of lift vs. run situations.

VACUUM GAUGE READINGS (Inches of Mercury)

Vertical Lift (Feet) 3 4 5 6 7 8 9 10

Horizontal Run - 0 Feet Horizontal Run - 60 Feet

3.0 3.9

3.6 4.5

4.3 5.2

4.9 5.8

5.5 6.4

6.1 7.0

6.8 7.7

7.4 8.3

Vacuum readings can change from installation to installation. An easy method of calculating vacuum is as follows: 1. An inch of mercury is required to lift gasoline 1-

1/2 feet. Divide the total lift by 1-1/2 feet to obtain vacuum.

2. An inch of mercury is required to overcome the

restriction of an angle check, foot valve, or vertical check valve.

3. An inch of mercury is required to overcome the

restriction of 60 feet of piping. 4. Add the readings obtained in steps 1, 2 and 3 to

determine the approximate vacuum reading at fast flow.

NOTE: Excessive vacuum indicates a restriction.

Low vacuum indicates a leak.

SPL1083.3 7/95

How to Use Vacuum and Pressure Gauge Readings to Troubleshoot Self-Contained Dispensers There are a variety of conditions that can contribute to no delivery or slow delivery. A pressure/vacuum gauge is an important tool in determining whether the problem is on the vacuum side or pressure side of the pump. The vacuum gauge reading can help you determine if there are restrictions of flow in the suction piping system. It will also help you determine the ability of the pumping unit to pump. To test the vacuum of the pump, follow this procedure: 1. Remove the pipe plug in the center of the strainer

or filter cover. The cover is marked for easy identification.

2. Install the vacuum gauge. 3. Start the pump and open the nozzle to full flow for

a true reading. 4. With the nozzle open, a normal vacuum reading

is 6-8 inches of mercury for normal suction. See Figure 71.

5. With the nozzle closed, a normal vacuum reading

is 0. See Figure 72. To test the pressure of the pump, follow this procedure: 1. Remove the pipe plug in the center of the control

valve cover. Covers are marked for easy identification.

2. Install the pressure gauge. 3. Start the pump and open the nozzle to full flow for

a true reading. 4. With the nozzle open, a normal pressure reading

is 16-18 pounds per square inch pressure. 5. With the nozzle closed, a normal pressure

reading is 25-28 pounds per square inch pressure. See Figure 73.

63

Figure 71

Figure 72

Figure 73

SPL1083.3 7/95

The following examples are offered to help you determine the possible cause of a problem by knowing the gauge readings on the inlet (vacuum) and outlet (pressure) side of the pumping unit. Actual readings may vary slightly depending upon installation and environmental conditions.

64

Figure 74

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65

Figure 75

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66

Figure 76

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67

Figure 77

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68

PROBLEM CAUSE ACTION

1. The motor starts but the pump does not deliver fuel.

a. The fuel supply is below the suction stub in the storage tank.

b. The vent pipe is plugged in the

storage tank. c. The strainer screen or filter

assembly has an obstruction. d. The bypass valve is not seating

properly due to wear or obstruction. e. The v-belt is loose or broken. f. There is an obstruction in the

atmospheric float valve. g. The pump is out of prime. h. The suction line is leaking. i. The intake line, foot valve, angle

check valve, or vertical check valve have an obstruction.

j. The suction stub in the storage tank

is on the bottom of the tank. k. The control valve has an obstruction. l. The nozzle is not working. m. *Two pumps are connected to one

storage tank with one suction line. There is a faulty check valve in one of the supply lines.

*Not recommended.

a. Fill the storage tank. b. Clean the vent pipe c. Remove obstructions from the

screen or filter assembly. d. Check the valve for an obstruction

causing the valve to stay open, and/or replace the bypass valve.

e. Adjust or replace the v-belt. f. Clean the float and valve area.

Check for swelling and binding in the linkage.

g. Check for a faulty foot valve in the

storage tank or a faulty check valve in the suction line.

h. Start the pump and open the

nozzle. If bursts of air are felt while holding a finger on the vent tube, the suction line is damaged. Repair or replace.

i. Connect a vacuum gauge to the

1/4” plug on the filter cover. Turn the pump on and open the nozzle. A reading of 15 or more inches of mercury with no flow indicates a complete blockage in the suction line. Clean the line or replace.

j. Make sure there is a four inch

clearance. k. Clean the control valve. It must

slide freely in the valve cavity. l. Replace the nozzle. m. Disconnect the vent tube on the

idle pump. Install a short copper tube. Place the end of the copper tube in a container of liquid. If the liquid is drawn out of the container when the opposite pump is operated with an open nozzle, the line check valve is faulty. Replace the check valve.

HOW TO CORRECT PROBLEMS ON PUMPING UNITS

SPL1083.3 7/95

PROBLEM CAUSE ACTION

2. The pump runs, but delivery is slow.

a. The fuel supply level is low. b. The vent pipe is partially

obstructed. c. The strainer screen or filter

assembly has a partial obstruction. d. The bypass valve is not seated

properly. e. The v-belt is loose. f. The voltage is too low. g. A blade or blades in the rotary

pump will not move. h. An automatic nozzle has been

installed. i. The motor is defective j. There is a slow leak in the suction

line or intake line. k. The intake line, foot valve, angle or

vertical check valve is partially obstructed.

l. The control valve is partially

obstructed. m. The nozzle check valve is sticking n. The hose is defective (flattened).

a. Fill the storage tank. b. Clean the vent pipe. c. Remove obstructions from the

screen or filter assembly. d. Check the valve for an obstruction

causing the valve to stay open. e. Adjust the v-belt. f. Check the power supply voltage.

The dispenser uses a 115 VAC, 60 cycle electrical circuit. Check for too many pieces of equipment on one electrical line.

g. Check the rotor and blades for

damage. Replace the blades and/or rotor, if necessary.

h. Delivery speed will be reduced by

10-25%. If maximum speed is desired, replace with a standard nozzle.

i. Inspect the motor for loose

connections. If no loose connections are found, the motor is defective. Repair or replace.

j. Start the pump and open the

nozzle. If bursts of air are felt while holding a finger on the vent tube, the suction line or intake line is damaged. Repair or replace.

k. Connect a vacuum gauge to the

1/4” plug on the filter cover. Turn the pump on and open the nozzle. A reading of 11 to 13 inches of mercury with no flow indicates a partial obstruction in the suction line. Clean or replace the suction line components.

l. Check the valve for an obstruction.

Replace if necessary. m. Clean or replace the nozzle check

valve. n. Replace the hose.


69

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70


PROBLEM CAUSE ACTION 3. The motor will not run. a. The power is off.

b. The motor is defective.

a. Check the circuit breaker in the station.

b. Disconnect the power supply. Inspect the motor for loose connections. If none are found, repair or replace the motor.

4. The dispenser does not deliver an accurate amount of product.

a. There is an obstruction in the control valve.

b. There is an obstruction in the air eliminator vent tube.

c. The meter needs calibration.

a. Clean the control valve. It must slide freely in the valve cavity.

b. Clean the vent tube. c. Check calibration test equipment

for accuracy. Calibrate the meter.

5. There is fuel running out the vent tube opening when the pump is in operation.

a. There is an obstruction in the atmospheric float valve. The valve is being held closed.

b. The suction chamber in the pump is flooded. *(Above ground tank)

a. Clean the float and valve area. Make sure the float opens completely.

b. Check the storage tank level. If it is higher than the pumping unit *(above ground tank), the condition will continue. Install Tokheim 52 valve.

* Not recommended.

6. The computer jumps when the pump is turned on.

a. The control valve is not seated properly.

b. There is an obstruction in the

expansion relief dill valve. c. The gaskets are leaking. d. There is a worn nozzle. e. There is a leak in the hose. f. Temperature extremes cause the

liquid to expand or contract.

a. Check the valve for an obstruction between the o’ring and the seat. Inspect the o’ring for damage. Replace the valve or o’ring, if needed.

b. Check the valve by pulling the spring loaded seat. Clean any foreign matter from the valve. To install the dill valve in the control valve, use a valve tool.

c. Replace worn gaskets. d. Replace the nozzle. e. Replace the hose. f. Problem will be solved when the

pump begins to operate.

SPL1083.3 7/95

Vapor Lock is a

problem that

results from

ambient

temperatures,

vapor

pressure of the

product and the

installation.

It is not a

characteristic of a

pump.

The Reason for Vapor Lock Atmospheric Pressure of 14.7 PSI (Sea Level) presses on the liquid in the tank. See Figure 1. Vapor Pressure (the amount of pressure required to keep the product in a liquid form at 60°F) of today’s product is approximately 10 PSI. See Figure 2 The difference between Atmospheric Pressure and Vapor Pressure is known as the Working Pressure. The Working Pressure is all that the pump can create without the product turning to vapor. 14.7 PSI Atmospheric Pressure -10.0 PSI Vapor Pressure 4.7 PSI Working Pressure

May 1990 Revised 12/92

S-130

The Cause of Vapor Lock

Figure 1

Figure 2

Figure 3

Atmospheric Pressure (14.7 PSI)

60°F

10 PSI required to keep product in liquid form

60°F

Atmospheric Pressure

Less

Vapor 60°F Pressure equals Working Pressure

14.7 PSI

10.0 PSI

4.7 PSI

SPL1083.3 7/95

May 1990 Revised 12/92 The Cause of Vapor Lock

Page Two

To measure a pump’s suction, the Working Pressure must be converted to inches of vacuum. To do this, multiply the Working Pressure by 2. The result is the number of inches of vacuum that a pump can create before the product changes to a vapor. See Figure 4. 4.7 PSI Working Pressure = 9.4 inches of vacuum. See Figure 5. Installation is the Key The condition of installation dictates how much suction a pump must create to pump the product. A. It takes 1 inch of vacuum to lift gas

1.5 feet vertically. To determine the inches of vacuum required to lift the gas in a system, follow this procedure:

Measure the distance from the top of

the product in the tank to the center of the pumping unit. See Figure 6. Divide the distance by 1.5 to obtain the inches of vacuum required by the pump to lift the product.

Example: 9 feet of lift requires 6

inches of vacuum by the pump. See Figure 6.

Atmosphere Pressure (14.7 PSI) equals

3 0 ” o f

14.7 PSI of Atmospheric Pressure pushes down on the bowl of mercury and causes it to rise to 30”.

Figure 4

4.7 PSI = 9.4” of Vacuum

PSI Vacuum

Figure 5

Lift

Amt. of Vacuum Req’d

60°F

Figure 6

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The Cause of Vapor Lock Page Three

B. It takes 1 inch of vacuum by the pump to overcome the restriction of an angle check or foot valve. (Not part of the pump, but a necessary part of the installation.)

See Figure 7. C. It takes 1 inch of vacuum by the

pump to overcome the restriction of 60 feet of horizontal piping from the tank to the pump.

See Figure 8. To obtain the inches of vacuum to deliver product, simply add A, B and C. A. 9 feet of lift = 6” of suction B. Angle check or foot valve = 1” of suction C. 60 feet horizontal run = 1” of suction TOTAL = 8” of suction With 9.4” of suction to work with and only 8” of vacuum required, conditions are normal and the pump delivers product without vapor locking. Remember this condition exits when the product is at 60°F. Vapor Lock Conditions Using the same example as above, 8” of vacuum is still required to deliver product. With higher ambient temperatures, the vapor pressure of the product changes. As mentioned above, the Vapor Pressure of today’s product is 10 PSI at 60°F. At temperatures of 90°F or higher, it can go as high as 12 PSI.

S-130

1” of vacuum to o v e r c o m e t h e restriction of angle check valve or foot

Angle Check Valve 60°F Foot Valve

60 feet of horizontal piping = 1” of vacuum.

60°F

Figure 7 Figure 8

N o r m a l product

95°F

Vapor pressure of product may be as high as 12 PSI.

Figure 10

Figure 9

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May 1990 Revised 12/92 The Cause of Vapor Lock

Page Four

Using the same formulas as above, the Working Pressure equal Atmospheric Pressure less the Vapor Pressure. 14.7 PSI Atmospheric Pressure - 12.0 PSI Vapor Pressure of the product 2.7 PSI Working Pressure Multiplying the 2.7 Working Pressure by 2 equals 5.4 inches of vacuum that the pump can create before the product turns to vapor. It still takes 8 inches of vacuum to deliver product, but with higher temperatures there is only 5.4 inches of vacuum to lift the product. The result is Vapor Lock. As we have explained, the pump plays a very small part in vapor lock situations. Installation, the amount of product in the storage tank and the Vapor Pressure of the product are the main reasons for vapor lock. Example: Have you ever heard of vapor lock in a diesel pump? No, because the Vapor Pressure of diesel is approximately 8 PSI. The only real cure for vapor lock in hot climates is to keep the installation and pump cool.

1218 E. Pontaluna Road Spring Lake, Michigan 49456 - 616/798-1310

S-130

Atmospheric Pressure Less Vapor Pressure equals Working Pressure

95°F 14.7 PSI 12.0 PSI

2.7 PSI

Figure 11

2.7 PSI = 5.4” of Vacuum

PSI Vacuum

Figure 12

Figure 13

SPL1083.3 7/95

71

SECTION C. REMOTE DISPENSERS

Shear Valve Installation ...............................................................................................................................72 Control Valve and Filter Assembly ..............................................................................................................72 How to Stop Pulsating Delivery ...................................................................................................................75 Typical Flow Rates of Bennett Remote Dispensers ....................................................................................76 Skinner Dual Flow Solenoid Valve ..............................................................................................................83 Spin-on Filter Option ....................................................................................................................................84 Torque Specifications ..................................................................................................................................84 7800 Series Hydraulic Parts (Master) ..........................................................................................................86 7800 Series Hydraulic Parts (Satellite) ........................................................................................................88

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72

Installers must be aware of the requirement that the shear section of Impact Safety Valves for remote dispensers must be in line with the surface of the concrete island within +/- 3/4 inch. See Figure 78. Since the location of the shear section varies between valve manufacturers as well as between the various connection styles of each manufacturer, it may be necessary to use a longer or shorter nipple than the standard stub height nipple supplied with the

PROPER SHEAR VALVE INSTALLATION

CONTROL VALVE AND FILTER ASSEMBLY The control valve and filter assembly have been used on all remote dispensers with the exception of the 7000 and 9000 series. Its primary purpose is to prevent flow from an unauthorized dispenser if the submerged pump of the same product is on.

The control valve and filter assembly consist of the following: 1. Casting - Two types are used. One houses an

internal filter or strainer and the other allows the use of a Wix spin-on filter. (Internal Filter Type-H914701; Wix spin-on Filter Type-H914702)

NOTE: These two castings are different and there

is no adapter to adapt one type of filter system to the other. If a change is to be made, the entire casting must be changed.

2. Filter or Strainer: Filter-A311901; Strainer-

J566901; Wix: A270501 3. Check Valve - H914201 4. Diaphragm Valve - N334901 The diaphragm valve of the assembly is controlled by a solenoid which ports or relieves pressure. For a better understanding of how the valve and filter assembly operates, consult the following flow schematics.

Figure 78

SPL1083.3 7/95

3700, 3900, 4000, 4100, 6000, 8000 Series Schematic of Remote Dispensers (No Product Flow) The flow diagram in Figure 79 shows the submerged pump running with the solenoids de-energized. 1. Product flow opens the check valve (1) and flows

through the casting to the back of the diaphragm (2), trying to push it open.

2. Product flows through the small openings of the

check valve (1), through tube (3) to the top of the high flow solenoid.

3. Product flows through the top port of the high flow

solenoid to the middle port of the solenoid and through tube (4) to the front of the diaphragm valve (5). This causes equal pressure to be applied to both sides of the diaphragm valve.

4. The diaphragm valve spring (6) causes greater

pressure to be applied to the front of the diaphragm valve. This action causes the

diaphragm valve to close and prevents flow. 5. At the same time, because the low flow solenoid

is de-energized, product flow is prevented from flowing from the check valve (1) openings through tube (7) to the middle port of the low flow solenoid and to tube (8).

73


SPL1083.3 7/95

74

The flow diagram in Figure 80 shows the submerged pump running with the solenoids energized. 1. Product flow opens the check valve (1) and

product flows through the casting to the back of the diaphragm valve (2).

2. Product flows through the small holes of the

check valve through tube (3) going into the top of the high flow solenoid. Because the high flow solenoid is energized, product is prevented from flowing from tube (3) to tube (4) and pressurizing the front of the diaphragm valve.

3. Because the high flow solenoid is energized,

product pressure is relieved from the front of the diaphragm valve (5) via tube (4), through the solenoid, through tube (6) and to the meter.

4. Product pressure in back of the diaphragm valve

(2) is greater than the spring tension (7) causing the valve to open and allow product flow to the meter.

5. In pre-pay deliveries, product flows through the

openings in the check valve (1) through tube (8) through the low flow solenoid, through tube (9)

and up to the meter. The low flow solenoid is energized and allows flow through tube (8) and tube (9) from the beginning to the end of a fuel sale.

NOTE: The high flow solenoid is de-energized

before final fuel sale is reached.


SPL1083.3 7/95

How to Stop Pulsating Delivery

Occasionally, air may accumulate on the front side of the diaphragm valve. This condition will result in the hose pulsating during a fuel delivery. To remedy this problem, loosen the four screws on the diaphragm valve’s end cap. See Figure 81.

DANGER: Gasoline is flammable. NO SMOKING OR OPEN FLAME. Turn on the dispenser and fuel will start to spew out from the loosened cap. This will bleed the trapped air and normal delivery will result.

8000 Series - Pulsating and/or Slow Delivery Some 8000 Series have had pulsating hoses or slow flow during a fuel delivery. Teeing the bottom ports of the high and low flow solenoids together rather than at the control valve and filter assembly was the cause. See Figure 82. A kit has been developed that allows the two solenoids to be teed at the control valve and filter assembly for field repairs. If an 8000 Series has pulsating hoses or slow delivery and the normal repairs do not correct the situation, order KR 407-01 (Upgrade tubing kit). Each kit will repair one hose. NOTE: Special fittings are required which may

not be readily available from outside supply houses.

75

Figure 81

Figure 82

SPL1083.3 7/95

TYPICAL FLOW RATES OF BENNETT REMOTE DISPENSERS 3700, 3900, 4000, 6000 & 7800 Series

(Including single product singles, single product twins,

and twin product twins)

The graphs on the following pages are intended to be used as a guide in determining typical flow rates through Bennett conventional dispensers as well as the high speed 7800 Series. Graph 1 and Graph 2 indicate flow rates through conventional dispensers using 5/8” and 1” nozzles. Graph 3 indicates the flow rates which may be expected through the high speed 7800 Series (Big Squirt). The graphs also indicate the different flow rates that can be expected when the dispensers are run on different sizes of submerged pumps. NOTE: Since actual conditions may vary from test

conditions, actual flow rates may be somewhat different.

Submerged pump manufacturers generally state the flow rates of their pumps in terms of the gallons they deliver while maintaining a certain “head” in feet of gasoline. Differences in installations, such as: the lift, length of the piping run, and the size of the piping employed, can cause different flow rates through a dispenser. Therefore, Bennett prefers to rate the flow rates of its remote dispensers by the amount of “inlet pressure” that is required to produce a certain GPM output. Inlet pressure is the pressure measured at the inlet of the dispenser. To us, it makes more sense to state that it requires “X” number of lbs./per sq. inch of pressure at the inlet to produce a certain number of GPM. If you are more familiar with using “ft. of head” rather than “pressure” or the other way around, the formulas for the conversions are as follows: Head (ft) = Pressure (lb/in.sq.) x 2.31 Specific Gravity Pressure (lb/in.sq) - Head (ft) x Specific Gravity 2.31 NOTE: Specific gravity is the direct ratio of any

liquid’s weight to that of water at 62°F. Water at 62°F weighs 8.33 lb/gallon and has a designated specific gravity of 1.

How to use the Dispenser Flow Rate Graphs 1. Locate the restriction curve that reflects the

number of nozzles operating simultaneously (1 through 8).

NOTE: Graph 3 shows a restriction curve with

one nozzle open (Master or Satellite) and a restriction curve with two nozzles open (Master and Satellite).

2. Locate the point that the selected nozzle curve

intersects the appropriate submerged pump curve.

3. Refer to the GPM listing directly below that point. 4. To obtain the approximate output of each nozzle

when all nozzles are operating simultaneously, divide the above GPM figure by the number of nozzles in operation.

5. Refer to the pressure listing directly to the left of

the intersecting point (Step 2). This is the pressure required to obtain the GPM as specified in Step 3.

6. To obtain the approximate output for a given inlet

pressure, locate the pressure reading on the left side of the graph and determine where it intersects Restriction Curve #1. Read the GPM directly below the intersecting point.

76

SPL1083.3 7/95

Dispenser Flow Rates w/Red Jacket Pumps - 5/8” Hose and Automatic Nozzle

77

Dispenser Flow Rates w/Red Jacket Pumps - 1” Hose and Automatic Nozzle

Graph 1 - 3900, 4000 & 6000 Series in any Combination

NOTES: 1. Data based on gasoline S.G. 0.72. 2. Pump curves assume 125 feet of 2” pipe with fittings. 3. Dispenser outlets: .625 I.D. x 12 ft. hose. .75 N.P.T. swivel and automatic nozzle. 4. A5232 WIX spin-on filter. 5. Numbered curves represent the number of nozzles operating simultaneously at fast flow.

Graph 2 - 3900, 4000 & 6000 Series in any Combination

NOTES: 1. Data based on mineral spirits S.G. 0.79. 2. Piping losses must be included to determine actual pump performance at dispenser inlets. 3. Dispenser outlets: 1” x 12 ft. hose. High speed automatic nozzle. 4. J5669 strainer or A3119 filter. 5. Numbered curves represent the number of nozzles operating simultaneously.

SPL1083.3 7/95

78

Dispenser Flow Rates w/Red Jacket Pumps - 1” Hose and 50 GPM Automatic Nozzle

Graph 3 - 7800 Series

TEST CONDITIONS: 1. Diesel Fuel 2. 8 foot lift, 20 ft. horizontal run, 2” pipe 3. 22 foot 2” pipe between Master and Satellite DISPENSER OUTLETS: 1. 1” x 16 ft. hardwall hose 2. OPW 36-S 1” x 1” single axis swivels 3. 50 GPM automatic nozzle

SPL1083.3 7/95

79

Graphs 4 and 5 represent typical flow rates of remote dispensers using a control valve and filter assembly. The first graph shows flow rates of control valve and filter assemblies using internal filters or strainers. The second shows flow rates with a Wix spin-on filter. These graphs are for reference only. Actual flow rates may vary from installation to installation. The flow rates are plotted on the curves of various Red Jacket submerged pumps. The dispenser curves indicate the amount of pressure which is required at the inlet of the dispenser to obtain a specified flow rate.

Graph 4 - Internal Filters

NOTES: 1. Data based on mineral spirits, S.G. 0.79. 2. Pump curves based on a 10 foot lift. No horizontal run losses. 3. Dayco Flex-ever hardwall hoses. 4. 3/4” H1964 meter outlet swivels, 1” swivel for curve 5 - Metal Diaph. Valve N3349 2.050 lg

DISPENSER CURVE

1 5/8 x 12’ hose, OPW 11A unlead nozzle 2 3/4 x 12’ hose, OPW 11A unlead nozzle 3 5/8 x 12’ hose, 3/4” OPW 811 nozzle 4 3/4 x 12’ hose, 3/4” OPW 811 nozzle 5 1 x 12’ hose, OPW 7H or Husky 1 + VIII nozzle

SPL1083.3 7/95

80

NOTE: 1. Data based on mineral spirits, S.G. 0.79. 2. Pump curves based on a 10 foot lift. No horizontal run losses. 3. Dayco Flex-ever hardwall hoses. 4. 3/4” H1964 meter outlet swivels, 1” swivel for curve 5 - Metal Diaph. Valve N3349 2.050 lg

body.

DISPENSER CURVE 1 5/8 x 12’ hose, OPW 11A unlead nozzle 2 3/4 x 12’ hose, OPW 11A unlead nozzle 3 5/8 x 12’ hose, 3/4” OPW 811 nozzle 4 3/4 x 12’ hose, 3/4” OPW 811 nozzle 5 1 x 12’ hose, OPW 7H or Husky 1 + VIII nozzle

Graph 5 - Spin-on Filters

SPL1083.3 7/95

81

NOTES: 1. Data based on gasoline, S.G. 0.72. 2. Pumps curves based on a 10 foot lift and 125 feet of 2” pipe with fittings. 3. Dispenser outlets: 0.625” ID x 10.5’ hose, 0.75” NPT swivel and automatic nozzle. 4. Numbered curves represent the number of 50:50 blending transactions or nozzles in operation

simultaneously at fast flow.

Graph 6 - 9436 Remote Blender

NOTES: 1. Data based on gasoline, S.G. 0.72. 2. Pump curves based on a 10 foot lift and 125 feet of 2” pipe with fittings. 3. Dispenser outlets: 0.625” ID x 10.5’ hose, 0.75” NPT swivel and automatic nozzle. 4. Numbered curves represent the number of nozzles in operation simultaneously at fast flow.

Graph 7 - 7000 & 9000 High Hose Remote

SPL1083.3 7/95

SKINNER DUAL FLOW SOLENOID VALVE The Skinner Dual Flow Solenoid Valve is presently used on the 7000 and 9000 Series remote and self-contained dispensers. It is mounted after the meter and its main function is to prevent product flow from an unauthorized hose when the pump motor of the same product is on. The Skinner solenoid valve is a dual function solenoid valve. One function is to control high or fast flow while the other is to control a low or dribble flow required in prepay or local preset operation. For a better understanding of the Skinner solenoid valve, consult the following flow schematic.

82

Skinner Solenoid Valve Circuit Description Product enters from the right into the inlet chamber (A) and fills the area (B) from the diaphragm orifice to the control seat. See Figure 83. The net forces on the diaphragm, (spring and pressure) are downward holding the diaphragm closed. When the solenoid coils (high and low) are energized, the plunger is pulled up, off the control seat, venting high pressure (B) fluid into the low pressure outlet chamber (C). The fluid in high pressure chamber (A) now lifts the diaphragm against the spring and low pressure (B) fluid. Product flows directly from the inlet chamber (A) to the outlet chamber (C). Low flow is achieved by de-energizing the high flow coil. This allows the bottom half of the plunger to fall, partially restricting flow through the control seat. Pressure at area B rises causing the diaphragm (high flow) to close. Low flow is directed through the diaphragm orifice, then through a .093 diameter drilled hole in the high flow plunger into the outlet chamber (C). When power to the low flow coil is cut, the top plunger drops against the low flow seat and all flow stops. Order Bennett Part No. N8376 (Skinner Valve Repair Kit) for solenoid repair. N837601 is for a 3/4” Valve Kit. N837602 is for a 1-1/2” Valve Kit.

SPL1083.3 7/95

83

Figure 83

SPL1083.3 7/95

SPIN-ON FILTER OPTION for 8000, 6000, and 4000 REMOTE

DISPENSERS Problem: The spin-on filter adapter threads stick to the spin-on filter threads. When this happens and the spin-on filter is removed, the filter adapter is removed along with the filter. See Figure 84. To correct the problem, follow this procedure: 1. Remove the adapter from the old filter. 2. Put the spin-on filter adapter back into the H9147

valve and filter assembly and tighten the adapter finger tight.

CAUTION: Do not use pipe dope or any other sealing compound on the adapter threads.

3. Install the spin-on filter desired, and secure as usual to avoid leaks.

TORQUE SPECIFICATIONS 7000 & 9000 Series To prevent environmental damage due to leaks, Bennett has exercised extreme care in developing and applying the torque specifications for the bolts shown in Figure 85. Due to rough handling and shipping, it is imperative that these fasteners be rechecked for their proper torque specifications before the unit is placed in service.

84

Figure 84

Figure 85

SPL1083.3 7/95

85

SPL1083.3 7/95

86

NOTE: This parts list is for reference only. For ordering 7800 Series parts, see Parts List N747701

Figure 85A - 7800 Series Hydraulic Parts (Master)

SPL1083.3 7/95

87

Ref. No.

Part No.

Description

7811M

7812M

7822M

7812M

S

1 2 3 4 5 6

7

8 9

10 11 12 13 14

�15

N738201 A584501 A035801 A163101 N737801 A584201 A584202 N779401 N737601 N733501 N733502 N746301 E169122 735N010004 735N010003

Adaptor - Flange (1-1/2” NPT) Bolt, Round Head Square Neck Bushing Bushing, Reducer Check Valve Clamp, Hose Outlet Pipe includes clamp, nut and u’bolt Clamp, Hose Inlet/Outlet Pipe includes clamp, nut, and u-bolt Elbow Meter, Liquid Controls� (Model No. P954902) Meter Outlet - Top Meter Inlet - Bottom Nipple, Pipe 1-1/4 Nipple, Pipe 1-1/2x2-1/4 Nipple, Pipe Nipple, Pipe 28-3/16

1 2 1 1 1 1 1 1 1 1 1 1 1 1 —

2 4 2 2 2 2 2 2 2 2 2 2 2 2 —

2 4 2 2 2 2 2 2 2 2 2 2 2 2 —

1 2 2 1 1 2 1 2 1 1 1 1 1 — 1

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

�37 38

J794701 J771501 A001701 A219104 A212252 A212253 N747301 N767601 N219504 A015601 N738701 N744001 N734201 —- N712701 N769701 N769901 N769601 N712501 N769501 A584301 A486301 A217501

Nut, Conduit 1/2” Small - 1” Nut, Conduit 1/2” Large - 1-1/4” Nut, Jam Nut, Hex O’ring (Satellite Outlet Cover) O’ring (Meter Outlets) Plate, Outlet Cover Plate, U’bolt Screw, 1/4-20 Screw, 3/8-16 Solenoid Valve Assembly Spacer Strainer Assembly Body Cap Gasket Nut, Hex Jam Screw, Set Screen, Mesh w/baffle Yoke U-bolt, Strainer retainer Union, 2” Washer, lock

1 1 2 2 2 2 1 1 8 4 1 1 1 1 1 1 1 1 1 1 1 1 2

2 2 4 4 3 4 2 2

16 8 2 2 2 2 2 2 2 2 2 2 2 2 4

2 2 4 4 3 4 2 2 16 8 2 2 2 2 2 2 2 2 2 2 2 2 4

1 1 2 2 2 2 1 1 8 4 1 2 1 1 1 1 1 1 1 1 1 2 2

7800 Series Hydraulic Parts (Master)

�Items required for Spec. 1000 only.

��Contact the manufacturer for a distributor in your area for meter parts at: Liquid Controls Corp., Wacker Park, N. Chicago, IL 60064-3599

Telephone: (708) 689-2400 FAX: (708) 689-8090

SPL1083.3 7/95

Ref.

1 2 3 4 5 6 7 8 9

10 11 12 13 14

A035801 A163101 A584201 A584202 A584401 N779401 N746301 E169120 735N01000S J794701 J771501 N738701 N744001 A486301

Bushing Bushing, Reducer Clamp Assy, Hose Outlet Pipe Clamp, Hose Inlet Elbow Elbow Nipple, Pipe 1-1/4 Nipple, Pipe 1-1/2 Nipple, Pipe 2x30-3/4 Nut, Conduit 1/2” Small - 1” Nut, Conduit 1/2” Large - 1-1/4” Solenoid Valve Assembly Spacer, Hose Outlet Pipe Union, 2”

1 1 1 1 1 1 1 1 1 1 1 1 1 1

2 2 2 2 2 2 2 2 2 2 2 2 2 2

2 2 2 2 2 2 2 2 2 2 2 2 2 2

88

7800 Series Hydraulic Parts (Satellite)

Figure 85B - 7800 Series Hydraulic Parts (Satellite)

SPL1083.3 7/95

SECTION D. METERS

Type 40 Meter ................................................................................................................................................ 90 Liquid Control Systems MSAI ........................................................................................................................ 96 7800 Series (Liquid Control Meter Connections) ........................................................................................... 98 SB-100 Meter ................................................................................................................................................. 99

89

SPL1083.3 7/95

90

TYPE 40 METER The Bennett Type 40 meter is a precision device built to maintain accurate measurement under normal operating conditions. The meter employs a controlled tolerance between its four pistons and cylinder sleeves to maintain accurate measurement. Because there are no internal seals, the Type 40 meter should last the lifetime of the dispenser. During the first year of use, the meter’s calibration should be checked upon installation, after 90 days, and after 180 days in order to ensure accurate measurement. After the break-in period, semi-annual calibration checks are all that is required.

To check calibration of the Type 40 meter, perform the following: 1. Fill an official test measure with fuel to wet its

interior. Return the fuel to the proper storage tank and drain the test measure for 10 seconds. Failure to drain the test measure for 10 seconds may cause different calibration readings.

2. Dispense five gallons (20 liters) of fuel at full flow

into the official test measure. If calibration readings are within the local Weights and Measures tolerance, return the fuel to its proper storage tank and perform the required slow flow test.

The slow flow test is performed when the latch on

the nozzle is at its lowest setting or a five gallons (20 liters) per minute, whichever is least. The slow flow calibration readings must be within tolerance to the fast flow calibration readings as well as to the zero reading of the official test measure. Failure to maintain the above tolerance during the slow flow test indicates a defective meter which must be replaced. Calibration adjustment will not alter tolerances between slow flow and fast flow test.

To calibrate the Type 40 Meter, follow this procedure: 1. Cut and remove the seal wire. 2. To increase the volume delivered, move the

locking pin ONLY one hole at a time in a counter clockwise direction. See Figure 86. Each insertion of the pin in an adjacent hole provides a volume change of 1/3 to 1/2 cubic inch in a five gallon (20 liter) test measure.

CAUTION: To prevent damage to the meter or cause incorrect readings, move the locking pin only one hole at a time. DO NOT JUMP OVER HOLES OR TURN DIALS.

Figure 86

SPL1083.3 7/95

91

NOTE: Calibration adjustments must be made to as close to zero reading of the test measure as possible.

3. To decrease the volume delivered, perform the

above except move the locking pin in the clockwise position.

4. After a calibration adjustment has been made,

dispense five gallons (20 liters) of fuel before taking the final calibration reading. This allows the meter to adjust to its new setting.

5. After the desired calibration is obtained, reseal

the meter (See Figure 87) and contact your local Weights and Measures authority.

To reseal the meter, follow this procedure: Insert a seal wire through an adjacent hole in the

adjusting dial and then through the hole of the locking pin. Seal the wire.

Insert a second seal wire through the hole in the

drive coupling screw and around the meter shaft. NOTE: After each wire is sealed, cut off any

excess wire. Make sure there are no loops or excess wire to restrict the meter when it is operating.

Determining Whether Meter Calibration is the Cause of Inaccurate Measurement. Not all inaccurate measurement is the result of meter calibration. Things such as gear boxes, drive links, electronic pulsers and computers, whether they are mechanical or electronic, may affect accurate measurements. In order to determine whether meter calibration or some other component in the dispenser is affecting accurate measurement, a simple test may be performed. 1. Make a mark on the top rotating dial or coupling

of the meter. See Figure 88. Make a corresponding mark on the top of the body of the meter.

2. Dispense fuel in an official test measure until the

meter rotates 40 revolutions and the two marks align (See Figure 88.) since the Bennett Type 40 meter rotates eight revolutions per gallon of gas, five gallons of fuel would result in 40 revolutions.

Figure 87

Figure 88

SPL1083.3 7/95

a. If the two marks align and the dispenser’s display indicates five gallons, but the test measure is either high or low, the problem is with the meter.

b. If the two marks align, but the display

indicates something different, the meter is not at fault. Some other device such as the gear box, pulser or computer is at fault.

Meter Bearing Block Assembly Repair NOTE: Due to the obsolescence of parts, repair

of meters shown in Figure 89 and 90 requires that the entire “bearing block assembly” be replaced with the lip seal type of assembly. Please order a KR-181 kit.

The universal couplings between the meter and computer will differ when changing types of bearing block assemblies. Because of various models of dispensers, a measurement between the meter and the computer must be supplied when ordering a replacement link or consult the Most Used Parts section of this manual.

92

Figure 89 - Old Style

Figure 90 - Later Revised Version

Figure 90a - Current Version

SPL1083.3 7/95

How to Replace Eccentric Sleeve O’Ring and Lip Seal Assembly To improve seal performance, standardize product, and handle higher line pressures, a Teflon lip seal was developed for the Type 40 meter. The lip seal went into production in October, 1967 (10N) and is easily identified as it is only used in models with the calibration device shown in Figure 91. To remove and replace the meter lip seal assembly, follow this procedure: 1. Remove the computer, universal link between the

meter and the computer, gearing, pulser or any other item impairing access to the top of the meter.

2. Remove and discard the wire seal on the meter

calibrating mechanism. Take out screw (1) and remove half meter coupling (2) and locking pin (3). See Figure 91.

3. In early production, the retaining ring (4) was

under spring pressure and must be removed to change the seal. Remove the ring carefully by cupping a hand over the meter shaft during removal. Current design makes it unnecessary to remove the retaining ring (4) to replace the lip seal assembly.

4. Take off the upper adjusting dial and coupling

assembly (5) and the lower adjusting dial (6) from the top of the meter.

5. Remove the screws that hold the lip seal retainer (7) and remove it. Take out and discard the lip

seal (8) and square seal (9). 6. Install new lip seal and square seal. New lip seal

shown in Figure 92 has a plastic collar insert which is necessary for installation of the lip seal. Push the collar and lip seal over the shaft and into the recess in the top of the meter bearing. When the lip seal is in proper position, carefully lift out the plastic collar and discard it. The smooth side of the seal assembly housing must be facing up.

7. If leakage occurs at the point between the meter

shaft and the eccentric sleeve, o’ring (10) located in the eccentric sleeve must be replaced. To replace the o’ring the meter must be removed to remove the bearing block assembly. The bearing block assembly is held in place by six bolts on its top and retaining ring (4). Lift the bearing block assembly up until it is clear of the meter drive shaft. Remove and discard the o’ring. Apply oil to the new o’ring and meter shaft. Install the new o’ring and reassemble in reverse order.

8. After the meter is installed in the dispenser,

calibrate and seal the meter. Contact your local Weights and Measures office, if appropriate.

93

Figure 91

SPL1083.3 7/95

NOTE: The meter lip seal assembly is the same as the lip seal used in the Type 40, Type 70, and Type 75 pumping units. See Figure 92.


94

Figure 92

Figure 93 - Type 40 Meter Assembly

SPL1083.3 7/95

95

Ref. No.

Part No.

Description

Qty

.

H607001 H607022

Meter Assembly - Type 40 Standard Export

1 1

1

�2 3 4 5 6

�7 8 9

10 11 12 13 14 15 16 17

H625801 H781501 H394501 E008801 H371901 H371701 H650401 A212220 541M012501 H352101 A194601 A099101 H650501 A247014 A323702 H371501 N339401

Bear ing & Adj. Dial Assembly Assembly includes: Adj. Dial & Coupling Assy. Adj. Dial, Lower Bearing, Ball Bearing & Bushing Assy. Crankshaft Assembly Coupling, Half Ring, O Plate, Retaining Retainer, Lip Seal Ring, Retaining Screw, Flat 8-32x5/16 Screw, Coupling Seal Seal Lip Sleeve, Eccentric Washer, Thrust

1 1 1 1 1 1 1 1 1 1 1 1 7 1 1 1 1 1

18 19 20 21 22

541M400001 541M011701 E009001 E993201 541M010501

Body and Sleeve Assembly Gasket, Bearing Gasket, Cylinder Head Gasket, Inlet Gasket, Outlet

1 1 4 1 1

Re f. No.

Part No.

Description

Qty

.

23 �2

4 25 �2

6 27

E008901 A184403 A201801 H552301 H395301

Head, Cylinder Nipple, 1 x 1-1/2 Nut, 3/8-24 Outlet Pin, Locking

4 1 1 1 1

28 29 30 31 32 33

��

��

��

��

��

��

Piston Assembly, Right Piston Assembly, Left Rod, Connecting Screw, Set Pin, Piston Piston

2 2 4 4 4 4

34 35 36 �3

7 38

A281801 A226901 A174301 A063501 A013701

Plug, Pipe Screw, 1/4-28x5/8 Screw, 5/16-18x3/4 Screw, 3/8-16x2 Screw, Hex 5/16-18x3/4

2 40 6 3 4

39 40 41 42

371M011401 746M014301 746M013101 132X100101

Sleeve, Crank Pin Washer Washer, Crankshaft Wire, Seal

1 1 1 1

�Not sold separately. The manufacturer recommends these parts not be replaced in the field. �Part numbers may vary on different models.

Re f. No.

Part No.

Description

Qty

.

19 20 21 22 14 15

KR-366-01 541M011701 E009001 E993201 541M100501 A247014 A323701

Gasket Set Set includes: Gasket, Bearing Cover Gasket, Cylinder Head Gasket, Meter Inlet Gasket, Meter Outlet Seal Seal, Lip

1 4 1 1 1 1

BENNETT® Service Repair Kit for Type 40 Meter

Type 40 Meter Assembly Parts List

SPL1083.3 7/95

96

LIQUID CONTROL M5A1 METER Bennett Pump Company uses Liquid Control Systems’ M5A1 meter in its 7800 High Capacity Series. The M5A1 meter allows the accurate measurement of motor fuel when delivering up to 60 GPM. The meter is calibrated at the factory using a solvent for safety purposes. The meter must be checked and recalibrated, if necessary, at the time of installation. After the initial installation, Bennett recommends follow-up checks at 90 and 180 days to insure accurate measurement. After the break-in period, semi-annual calibration checks are all that is required. Following is the procedure to calibrate the M5A1 meter.

How to Calibrate the Meter To gain access to the meter, follow this procedure: 1. Use the Bennett 001 key to remove the lower

door (1) on the junction box side of the dispenser. See Figure 94. Set the doors aside in a protected area to avoid damage.

2. Remove the two screws (2) that hold the nozzle

boot cover to the frame. See Figure 94. Remove the cover and set aside.

3. Cut and remove the meter seal wire (1). See

Figure 95. 4. Remove the four screws (2) holding the adjuster

housing cover (3). See Figure 95. Remove the cover.

To calibrate the meter, follow this procedure: 1. Dispense 50 or 100 gallons (200 or 400 liters) of

fuel into an official test measure to determine the amount of adjustment necessary.

NOTE: A minimum of a 50 gallon test

measurement must be used. 2. Read the setting on the calibration adjuster. The

amount of error is added to or subtracted from this reading. If an adjustment in calibration is required, loosen the screw (1) holding the clamp on the adjuster. See Figure 96.

3. Turn the adjuster thimble (2) IN (top of thimble

moves away from you) on the adjuster barrel to decrease the amount delivered. Turn the thimble OUT (top of the thimble moves towards you) on the adjuster barrel to increase the amount delivered. See Figure 96.

NOTE: One complete turn of the thimble is equal

to 1 gallon in 100 gallons or 1% of delivered volume. The adjuster is graduated in divisions of 1%, 0.1% and 0.02%.

Figure 94

Figure 95

Figure 96

SPL1083.3 7/95

4. Dispense 50 or 100 gallons (200 or 400 liters) of fuel to allow the meter to adjust to the new setting. Do not make any adjustments based on this delivery.

5. Make sure the meter is properly calibrated.

Dispense another 50 or 100 gallons (200 or 400 liters) of fuel into an official test measure to check the calibration.

6. After resetting the calibration adjuster, tighten the

clamp to hold the adjustment. See Figure 97. NOTE: Always make the final adjustment by

turning IN on the thimble. If the new setting is a higher number than the original, turn beyond the desired figure and come back to it.

The following example will help explain the calibration: Assume the adjuster setting at the start of the test read 2.05. Product was dispensed until the dispenser registered 100 gallons. The official test measure or prover registered 98.7 gallons or 1.3 gallons short. Add the 1.3 gallon reading to the beginning adjuster reading to get the new setting. Beginning Adjuster Reading 2.05 + Amount Short in Prover 1.30 New setting on Adjuster = 3.35 Another test through the meter should then show 100 gallons both on the dispenser volume window and the official test measure or prover.

For test volumes other than 100 gallons, the following formula applies:

Divide the result of Gallons on Prover minus = Adjuster Percent to increase

By this Amt. Gallons on Dispenser or decrease prover volume

97

Figure 97

SPL1083.3 7/95

Ref.

1 2 3 4 5 6 7 8 9

10 11 12 13 14

N778701 A533101 N748101 N748401 N747201 J794701 J771501 A219010 A219004 N237903 N746401 A228502 A099001 A188601

Bracket, Totalizer Clamp, Cable Cover, Gear Plate Cover & Conduit Assembly-Pulser Gear Plate Assembly Nut, Conduit Nut, Conduit Nut, 1/4-20 Nut & Washer Pulser Assembly Retainer, Gear Plate Rivet, Pop Screw Screw

1 1 1 1 1 1 1 4 2 1 1 2 1 2

2 2 2 2 2 2 2 8 2 2 2 4 2 4

2 2 2 2 2 2 2 8 2 2 2 4 2 4

15 16 17 18 19 20 21 22

23

24 25

A277601 A397202 N749201 132X100101 132X100102 A585001 N789401 N780901 N780908 J992813 J992817 A294701 A584101

Screw, 10-24x3/4 Screw, Flat head Screw, Special Seal Wire Seal Wire Standoff Support Strap, Cable Totalizer & Cable Assembly Totalizer & Cable Assembly Cable Assembly, 14.13 Cable Assembly, 31.88 Pin Totalizer (Counter)

4 4 2 1 1 3 — 1 — 1 — 1 1

8 8 4 2 2 6 — 2 — 2 — 2 2

8 8 4 2 2 6 1 1 1 1 1 1 1

Figure 97A - 7800 Series (Liquid Controls Meter Connections)

98

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99

SB-100 METER The SB-100 Meter was introduced in Bennett’s 3900 and 4000 Series in the last quarter of 1991. The introduction of the meter in other models began in the first quarter of 1992. The SB-100 meter is a precision device built to maintain .3% accuracy for flow rates from 1.5 GPM (5 LPM) to 26 GPM (100 LPM). The SB-100 is a volumetric meter employing four pistons with seals and associated chambers. During the first year of use, the SB-100 meter’s calibration should be checked upon installation, after 90 days and after 180 days in order to insure accurate measurement. After the break-in period, semi-annual calibration checks are all that is required.

To check the calibration of the SB-100 meter, perform the following: 1. Fill an official test measure with fuel to wet its

interior. Return the fuel to the proper storage tank and drain the test measure for 10 seconds. Failure to drain the test measure for 10 seconds may cause different calibration readings.

2. Dispense five gallons of fuel at full flow into the

official test measure. If calibration readings are within the local Weights and Measures tolerance, return the fuel to its proper storage tank and perform the required slow flow test.

The slow flow test is performed when the latch on

the nozzle is at its lowest setting or at five gallons per minute, whichever is least. The slow flow calibration readings must be within tolerance to the fast flow calibration readings as well as to the zero reading of the official test measure. Failure to maintain the above tolerance during the slow flow test indicates a defective meter which must be replaced. Calibration adjustment will not alter tolerances between slow flow and fast flow test.

SB-100 METER - FIELD CALIBRATION Each SB-100 meter is provided with the following calibration information.

• The dial adjusting cover has (+) and (-) arrows to indicate the correct direction to rotate the dial to either increase or decrease delivery.

• A self-adhesive metal label listing the

minimum incremental adjustment is attached to the collector housing immediately above the adjusting dial.

These provisions were made to assist the service person in making a quick and accurate change to the meter’s calibration. The dial cover has two pin hubs, one to the left of the shaft and one to the right. The seal pin may be inserted in either hub. See Figure 98. The smallest adjustment (.6 cu. in.) occurs when the pin is pulled from one side and inserted in the other side by moving

Figure 98

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the dial the least amount or half a hole. A 1.2 cu. in. adjustment is made by pulling the pin and turning the dial until the next adjacent hole aligns with the same hub and re-inserting the pin. To calibrate the meter, follow this procedure: 1. Measure the actual delivery of the meter at fast

flow in an accurate test measure. 2. Cut and remove the existing seal wire and

remove the seal pin. See Figure 99. 3. Turn the dial the necessary amount in the (+) or

(-) direction to increase or decrease the quantity of fuel delivered.

4. Re-insert the seal pin in the desired pin hub. 5. Test calibration at the new setting by dispensing

five gallons (20 liters) of fuel to allow the meter to adjust to the new settings. Do not make any adjustments based on this delivery.

6. Make sure the meter is properly calibrated.

Dispense another five gallons (20 liters) of fuel into an official test measure to check the calibration and make adjustments, if necessary.

7. Reseal the meter adjustment.

Example 1 1. A fast flow test at 11 GPM shows a +3 cu.

in. reading in a five gallon test measure. 2. Remove the existing seal and pin and turn

the dial clockwise (-) 5 minimum adjustments (half holes) and reinsert the pin.

3 cu. in. = 5 half holes (-) CW 6 cu. in./adjustment 3. Test and reseal.

Example 2

1. A fast flow test at 25 GPM shows a -2 cu. in. reading in a five gallon test measure.

2. Remove the existing seal and pin and turn

the dial counterclockwise (+) 3 minimum adjustments (half holes) and reinsert the pin.

2 cu. in. = 3.333 = 3 half holes 6 cu.in./adjustment (+) CCW 3. Test and reseal.

100

Figure 99

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101

SB-100 Flow Schematic 1. Product enters at the bottom inlet (1) and fills the

inner cavity of the meter. See Figure 100. 2. As the meter body fills, product passes around

the crankshaft and up to the top throat of the meter body. From the top throat, product flows to the distributor (2) which either ports product “to” or “from” each of the four piston chambers.

3. When the distributor (2) is in a position that allows

product to be ported “to” a piston chamber (3), equal pressure is applied across both sides of the piston. Equal pressure applied across a piston offers zero resistance to the crankshaft (5) via the piston’s connecting rod (6).

4. When the distributor (2) is in a position that allows

product to be ported “from” a piston chamber (4), there is greater product pressure applied to the inside of the piston than to its outer side. The differential of pressure causes the piston to travel in an outward direction. As the piston travels in an outward direction, product is ported to the meter’s top collector and to its outlet.

5. As a piston is forced in its outward direction, a

rotational force is applied to the crankshaft via the piston’s connecting rod. This rotational force of the crankshaft is then applied to adjacent pistons, which offering zero resistance, allows them to be pulled in their inner direction easily. This allows product from the distributor to fill the piston chamber. The above process is repeated by all four pistons.

6. A spring and pressurized countervalve (7)

employing a diaphragm imparts a downward thrust on the rotating distributor to seal its surfaces and prevent internal leakages which would result in unmeasured product being delivered.

Figure 100

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102

HOW TO CORRECT PROBLEMS ON THE SB-100 METER

PROBLEM CAUSE SOLUTION 1. Over delivery and out of

tolerance difference between fast and slow delivery.

a. Dirty or gummed pistons and/or piston chambers.

b. Damage or worn piston seals.

a. Remove cylinder covers. Remove screw holding piston to connecting rod. Using vise grips, secure the center hub of the piston and pull straight out. Clean piston seal and piston chamber using mineral spirits. Reassemble in reverse order.

b. Replace all pistons.

NOTE: To install piston in piston chamber, the piston must be rotated 90 degrees and the seal depressed with thumb and forefinger. Install the piston into the chamber. Rotate the piston back 90 degrees and install the screw that connects the piston to the connecting rod. See Figure 101.

CAUTION: When the piston is removed from the chamber, use extreme caution so that the connecting rods do not scratch the cylinder or chamber sleeves. When the piston is re-installed or a new piston is installed, extreme caution must be used to prevent damage to the piston seal.

Figure 101

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PROBLEM CAUSE SOLUTION 2. Leakage between meter shaft

and collector body. a. Top lip seal is damaged a. Replace top lip seal.

3. Internal leakage between the d i s t r i b u t o r a n d t o p countervalve assembly or bottom valve plate resulting in over delivery.

a. Dam aged counter va lve assembly distr ibutor, and countervalves.

NOTE: Replace all items to insure

proper mating surfaces.

a. Re p l ace c o u n t e r v a l ve assembly, distributor, and countervalves.

See Figure 102A. 1 Remove coupling half. 2 Remove lip seal retainer 3 Remove lip seal 4 Remove four screws holding

collector body 5 Remove collector body 6 Remove six screws holding

retainer to bottom of collector body

7 Remove retainer 8 R e m o v e a n d r e p l a c e

countervalve assembly 9 Remove and replace distributor

HOW TO CORRECT PROBLEMS ON THE SB-100 METER

103

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104

Figure 102A

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105

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106


Figure 102 - SB-100 Meter Assembly

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SB-100 Meter Assembly Parts List

Ref. No.

Part No.

Description

Qty.

N723501 N723502

Meter Assembly - SB-100 Gallons Liters

1 per hose

1 2 3 4 5 6 7

N782801 N779601 N683701 N701601 A212247 A282501 A586401

Body Assembly, Meter Calibration Cover Assembly - Standard Cover, Calibration - Standard Dial Assembly O’Ring, 1/16 x 7/16 O.D. Pipe Plug (Temp. Component only) Retaining Ring

1 1 1 1 1 2 1

8 9

10 11 12 13 14

N779701 N780201 N685801 N673201 A212207 A586801 N694101

Collector Assembly Counter Valve Assembly Diaphragm Retainer, Outer Gasket, Diaphragm O-Ring, 1/8 x 4-3.8 O.D. Screw, M5 x .8 x 12MM PanHd Phillips Spring

1 1 1 1 1 6 1

15 16

17 18 19 20 21 22 23 24

N659201 N780301 N780302 A578301 A201801 A578901 H650402 H651203 N515501 A578701 A212237

Cover, Cylinder Crankshaft & Bearing Assy - Gallons Crankshaft & Bearing Assy - Liters Ball Bearing Nut, 3/8-24 self-locking Washer, Bearing spacer Coupling, Half Coupling, Half - Threaded Distributor Element, Lip Seal O-Ring, 1/8 x 3-7/8 O.D.

3 1 1 2 1 1 1 1 1 1 4

25 26 27 28 29 30 31 32

N672601 N675801 N701501 N792201 N666401 A579901 N654801 N654802

Pin, Drive Pin, Calibration Seal Piston Assembly Screw, Special self-locking Retainer, Lip Seal Ring, Retaining Rod, Connecting (Calibration) - black Rod, Connecting (Opposite Calibration)

1 1 4 4 1 1 1 1

33 34 35

�36 �37

38

H650501 A480001 A586901 132X100101 may vary A584001

Screw, Meter Coupling Screw, M3.5 x 0.6 x 8MM flathead Screw, M6 x 1 x 20MM hexhead Seal Wire Universal Link Washer

1 3

20 2 2 1

�Not part of meter assembly.

107

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108

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109

SECTION E. CAM-AC

Servicing the Cam-Ac Operating Mechanism and Motor Switch ................................................................... 110 Wiring for Cam-Ac ......................................................................................................................................... 113 Typical Station Wiring Layout ........................................................................................................................ 114 Servicing the Key-Op System ........................................................................................................................ 115

How to Remove the keytrol Assembly from a 3700 Series ................................................................... 115 How to Replace the Lock Assembly ...................................................................................................... 116 How to Reinstall Keytrol Assembly in 3700 Series ................................................................................ 117 Troubleshooting ..................................................................................................................................... 117

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Servicing the Cam-Ac Operating Mechanism and Motor Switch The Cam-Ac handle assembly is used with Veeder-Root computers equipped with a mechanical reset. The computer is reset by a separate reset mechanism that is part of the computer. The reset mechanism is activated by a small lever located next to the operating handle. The Cam-Ac assembly was designed to alleviate computer and linkage damage due to activating the handle if the computer was not reset. This is accomplished by the use of a “clutch” which disengages if the computer exerts more pressure than a spring in the Cam-Ac assembly. If the computer is reset, there is more pressure exerted by the Cam-Ac spring than the computer thus allowing the handle to activate the computer and a pump motor switch. Operation Once the computer is reset, turning the handle (1) clockwise rotates the shaft (2), engages the clutch (3-5), and rotates the universal link (6). The clockwise rotation of the universal link activates the computer to its ON position. At the same time, the cam lobe of the clutch half (5) rotates to its smaller diameter side. This allows the switch shaft (9) to be in its down position which activates the motor switch to its ON position. See Figure 104. If the computer is not reset, turning the handle clockwise forces the computer to exert greater pressure on the clutch half (5) than the spring (4) forces on clutch half. This forces the clutch halves apart preventing the universal link from rotating and trying to activate the computer. The above action prevents damage to the computer as well as the universal link. When the handle is turned to its OFF position, the clutch stays engaged which rotates the universal link in a counter clockwise position. This locks out the computer until it is reset again. At the same time, clutch half (5) rotates to the position that its large diameter side forces the switch shaft to its UP position. This action opens the switch and shuts off the pump motor.

110

Figure 104

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111

Computer Reset Motor Switch ON Position. See Figure 105. The linkage connecting the switch actuating mechanism to the computer should be adjusted so the pump motor does not turn on until the reset latch pawl (A) fully engages the deep notch in the shaft cam (B). This makes certain that the computer reset mechanism is in proper position to function when released by the trip lever next to the operating handle. Motor Switch OFF Position. See Figure 106. The operating linkage must be adjusted so the motor turns off after pawl (C) engages notch (D) of shaft cam (B). This happens before second notch (E) is engaged. This assures proper function of the interlock mechanism. Also, the stop adjustment should be set so approximately 1/8” overtravel is allowed after pawl (C) engages third notch (F). Make sure that all rods or connecting links attached to the computer are free and do not exert thrust against the computer or introduce binds when being operated. Maintenance Lubricate all points marked “A” in Figure 104 with a light weight engine oil twice a year. The Cam-Ac assembly does not require adjustment. If a failure occurs, the individual part of the assembly may be replaced. NOTE: D u e t o n o n - i n t e r c h a n g e a b l e

improvements, be certain to specify model and specification numbers when ordering replacement parts.

Figure 105

Figure 106

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112

Switch Adjustment

DANGER: To prevent personal injury and/or equipment damage, all power must be removed from the pump or dispenser before adjusting the switch.

To adjust the motor switch, remove the junction box cover of the Cam-Ac assembly. Using a continuity tester across the terminals of the switch, rotate the switch cam follower to the position where the operating handle operates the switch as shown in Figure 107. NOTE: Before rotating the cam follower, the jam

nut must be loosened. When proper switch adjustment is complete, tighten the jam nut securely.

Figure 107

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113

Figure 108 - Wiring for Cam-Ac

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114

Figure 109 - Typical Station Wiring Layout

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115

Servicing the Bennett Key-Op System Operation - 3700 Series Pumps Some Fleetmaster pumps and dispensers are built to Code 401, which is a standard Fleetmaster unit equipped with a Key-Lock control system. Key-Op units cannot be operated until a registered numbered key is inserted in the lock (with the corresponding number) on the Keytrol panel located on the side of the pump or dispenser. The Bennett Key-Op system comes with 6, 10, or 20 individually serial-numbered locks and keys. The key releases the pump motor switch interlock so the pump motor can be turned on in the normal manner by the operating handle. The gallons delivered are recorded automatically on the individual key totalizer adjacent to that particular lock. How to Remove the Keytrol Assembly from a 3700 Series Pump 1. Set the computer clock wheels to read zero. 2. Unlock both locks in the lower housing panels

and lift the upper and lower housing panels off the pump.

3. Remove the motor switch lever (1) by unhooking

the spring (2) and removing the retaining ring (3) at the pivot. Pull the lever off the pivot. See Figure 110.

4. Take out the screws (4) in the side of the switch

box and push the switch box assembly (5) and conduit (6) aside to gain access to the hex nuts (7) holding the Keytrol assembly to the side panel. See Figure 110.

5. Remove the hex nuts and lockwashers and lift the

Keytrol assembly away from the side of the pump.

Figure 110

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116

How to Replace the Lock Assembly 1. Place the Keytrol assembly on a bench and

remove the screws and back cover. On die cast units used on 3700 Series, also remove four screws from the front.

2. On die cast units used on the 3700 Series, slide

bars are attached to the reverse side of the back cover. See Figure 111.

3. On die cast assemblies used on 3700 Series,

remove screws from the channel slide and lift off. LEAVE ALL OTHER CHANNEL SLIDES IN PLACE.

NOTE: When removing the channel slide, the

spring-loaded bevel gears on the totalizer shaft are allowed to engage. These gears must be in a disengaged position when reassembled. Do not attempt to rotate universal shaft assembly extending through the top of the Keylock housing. This will cause the totalizer wheels to jump and disrupt assembly of the slide channels and bevel gears.

4. Remove the hex nut and lockwasher (3) and the

disc and pin assembly (4) from the lock in question.

5. Remove the large hex nut (5) and drop the lock (6) through the Keylock housing.

6. Install new lock in reverse order of steps 3 and 4

above. Disk and pin assembly must be in the same position as the other disk.

7. Install the channel slide (2). Be sure the LIP on

the bottom side causes bevel gears to disengage. (Left and right channel slides are not interchangeable.) When properly placed, the channel slide will snap into place. Check all other channel slides to be sure the bevel gears are disengaged.

8. Lay the slide bar (1) pin side up, over the lock disc

and pin assemblies (4) and channel slides (2). Reinstall the back cover with the pin of slide bar (1) protruding through the slot in the back cover. Reinstall the screws.

9. Check all locks for ease of operation. Also check

to determine if all totalizers are disengaged when all locks are in the OFF position.

Figure 111

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117

How to Reinstall Keytrol Assembly in 3700 Series Pump 1. With locks in the “locked” position, attach the

Keytrol assembly to the side of the pump by reinstalling four hex nuts and lockwashers. Make sure the universal link is properly engaged with the drive assembly. Check to be sure the slide bar extends through the slotted hole of the motor switch lever.

2. Reconnect the conduit and switch box assembly

by installing two screws that hold the switch box to the mounting bracket. Reassemble the motor switch lever and retaining ring. Be sure the follower on the switch box is properly engaged with the motor switch lever. Hook the spring back on the lug on the motor switch lever.

3. Check all keys for proper operation. Reinstall the

external housing panels in reverse order of removal.

NOTE: Lubricate only with a dry type lubricant

that will not attract dust or dirt. TROUBESHOOTING 1. If more than one totalizer advances,check to see

if the channel slide is out of place allowing gears to engage.

2. On 20-key units, if the ten lower panel keys fail to

operate mechanism, the connecting link between the slide bar in the top panel may be disconnected from the slide bar in the lower panel or out of adjustment. The slide bar lip faces should be spaced 30/32” apart.

3. If the switch cuts out during delivery, check the

spring connection to the motor switch lever. 4. If the lock turns hard on a 3700 Series pump,

check to be sure the spring is connected to the stud on the motor switch lever. This condition could also be due to lack of lubrication. Lubricate only with a dry type lubricant that will not attract dust or dirt.

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118

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119

SECTION F. TOTALIZERS AND GEAR PLATES

How to Replace a 6000 Series Totalizer .....................................................................................................120 6000/8000 Gear Plates ...............................................................................................................................122 8000 Series Totalizers ................................................................................................................................123 7000/9000 Series Totalizers .......................................................................................................................124 Service Bulletins: M-215A - Gear Replacement (gallons to liters) ..............................................................................125 M-224 - Quick Change Conversion Gear Box Assembly ...............................................................126

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How to Replace a Totalizer on a 6000 Series Replacement materials required may be ordered from Bennett (KR-0370-01). The kit includes the following components:

To install the kit, follow this procedure: 1. Remove both the lower doors. IMPORTANT:

Note the routing of the cable and location of totalizer components before proceeding.

2. Rotate the totalizer drive gear to obtain access to

the seal wire on the pin. 3. Cut and remove the seal wire and pin through the

cable coupling. Save the pin. 4. Cut the cable ties and remove “L” shaped bracket,

screws, and nuts from the pulser support bracket. 5. Drill out pop rivets attached to the totalizer

brackets through the side panel.

DANGER: Extreme caution must be used when operating an electric drill in the area of gas dispensers. Use of a hand crank drill is recommended.

6. Install the window on the inside of the pump

(awning up) with one pop rivet at the location shown in Figure 112.

7. Install the new totalizer with two pop rivets

through the panel, window, and totalizer bracket. See Figure 113.

120

Part No. Description Qty.

J992702 N296401 A228505 132X100101 N511701 A533101 A099001 A219004 N512201

Totalizer, Bracket & Cable Window Pop Rivet Seal Wire Bracket Clamp, Nylon Cable Screw, #8-32x5/8 Nut w/lw, 8-32 Label, Cable Lubrication

1 1 3 2 3 3 4 1

Figure 112

Figure 113

SPL1083.3 7/95

8. Assemble cable bracket, cable clamp, screw, and nut around new cable as shown in Detail A, B, and C in the order shown. See Figure 114.

9. Loosen two meter cover bolts and slip the clamp

assemblies (Detail A and B) under the screw heads and retighten. See Figure 115.

10. Insert screw from Detail C through the bottom

hole of the pulser support bracket (where the L-shaped bracket was removed.)

11. Slip cable end onto the gear shaft, insert pin, seal

wires, and seal. NOTE: Before sealing, check to see if the cable

spins freely and set numbers to 0. 12. Apply cable lubrication label to clean pulser

bracket in area shown in Figure 115.

121

Figure 114

Figure 115

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122

6000/8000 Series Gearplates Due to some contamination of gear plate shafts and Delrin gears, we have experienced a number of gear plate failures on the 6000 and 8000 product lines. The contamination can cause the brass stationary shafts to wear excessively. This can cause the shafts to break or the gears to jam or break. All gear plates with brass shafts and/or studs should be replaced with gear plates that have stainless steel shafts or studs. The symptoms to look for are: squeaky gear plates, inoperative mechanical totalizers or a display that appears to stop while pumping gas. Due to the nature of the problem, we are asking you to respond immediately if you receive a complaint. If upon investigation you find one of the above-mentioned symptoms or notice any evidence of wear or brass shavings, please replace the gear plate at once. While at the site, please take the additional time to inspect all remaining 6000 and 8000 Series. Remember: 1. Lubricate all accessible shafts with a light oil. 2. Look for evidence of any brass shavings.

Replace the gear plate, if found. 3. Order gear plate N183802 for replacement. If additional information is required, please feel free to contact the Service Department at 1-800-423-6638.

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123

8000 Series Totalizer Field Rework to assure Drainage of Totalizer Housing If water enters the totalizer it can cause the totalizer to fog up and become difficult to read. If it accumulates it can also freeze and damage the totalizer. If this problem is encountered, follow this procedure: 1. Unlock and remove the lower door. 2. Remove the machine screw and nut from the

lower left hand corner of the totalizer as shown in Figure 116.

3. Carefully slip the tip of a pocket knife between the

totalizer housing and the bracket as shown in Figure 116 and insert a #6 or #8 machine screw flat washer between the housing and the bracket.

NOTE: Do not try to bend the bracket, use the

knife blade only as a temporary wedge to allow insertion of the washer.

4. Align the hole in the washer and replace the

screw and nut. 5. Check the position of the bracket and totalizer. If

necessary, carefully pull out on the bottom of the bracket to bend the bracket at the point of the attaching bolt. See Figure 116.

Bend the bracket only as far as needed to lower

the surface of the totalizer housing to a downhill position. See Figure 117. This will assure drainage if water enters the totalizer housing.

6. Make sure the totalizer and flex cable drive are in

proper working order. 7. Replace the lower door.

Figure 116

Figure 117

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124

7000/9000 Series Totalizers Kr-Kits have been developed to address the replacement of totalizers in the field. The KR-Kits listed below are now available for replacement of old totalizer and cable assemblies. The kits includes the following individual pieces: Required 9000/7000 KR-Kit Totalizer Parts Per hose A533101 Bracket Clamp 1 N778701 Bracket 1 A099001 Screw 1 A219004 Nut 1 A228502 Pop Rivet 2 A597301 Washer 2 N7809XX* Totalizer/Cable Assembly 1 *See Chart below

KR-KIT ASSEMBLIES FOR 9000 SERIES KR Number Description 9133/9033 9136/9036 9144/9044 9148/9048

0421-02 Side 1C, 10.25” cable Side 2A, 10.25” cable

1 1 - -

0421-03 Side 1A, 1B, 1C, 10.50” cable Side 2B, 2C, 2D, 10.50” cable

- -

- -

3 -

3 3

0421-04 Side 1A, 10.81” cable Side 2C, 10.81” cable Side 1D, 10.81” cable Side 2A, 10.81” cable

1 - - -

1 1 - -

- - 1 -

- - 1 1

0421-05 Side 2B, 11.19” cable - 1 - -

0421-06 Side 1B, 14.44” cable 1 1 - -

KR-KIT ASSEMBLES FOR 7000 SERIES

KR Number

Description

7012/7112 7212/7312

7011/7111 7211/7311

7011/7122 7222/7322

7024/7124 7224/7324

0421-03 Side A, 10.50” cable Side 1A, 1B, 10.50” cable Side 2A, 2B, 10.50” cable

1 - -

1 - -

- 2 -

- 2 2

0421-07 Side 2A, 16.00” cable 1 - - -

KR-KIT ASSEMBLIES FOR 7800 SERIES

KR Number Description 7811 7812

0421-01 Side 1 and 2, 15.25” cable 1 2

TOTALIZER AND CABLE ASSEMBLY

Part No. Description KR Kit No.

N780901 Totalizer and cable, 15.25” 0421-01 Please call the Technical

N780902 Totalizer and cable, 10.25” 0421-02 Service Department at

N780903 Totalizer and cable, 10.50” 0421-03 1-800-4-BENNET if you

N780904 Totalizer and cable, 10.81” 0421-04 have any questions.

N780905 Totalizer and cable, 11.19” 0421-05 Michigan residents call

.N780906 Totalizer and cable, 14.44” 0421-06 1-616-633-1302.

N780907 Totalizer and cable, 16.00” 0421-07

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125

REPRINT OF SERVICE DEPARTMENT BULLETIN M-215A

4-18-80

GEAR REPLACEMENT GALLONS TO LITERS

With the very real possibility of the United States going metric, two gears may be replaced in order to make the conversion of a dispenser using a 101 or 2002E Veeder-Root computer. The conversion is made by simply removing the Veeder-Root computer from the dispenser and changing one gear in the gear box and one gear on the bottom of the computer. The part numbers of the metric gears as well as the exploded view of their replacement are illustrated below. IMPORTANT: The price per gallon setting must be changed to the new liter price before operating the pump. If this is not done, damage to the Veeder-Root computer may occur due to excessive wheel speed. For example, if product is selling at 99.9 cents per gallon, the right-hand money wheel speed would be almost 400 RPM if this same price setting is used per liter. TO AVOID DAMAGE TO THE VEEDER-ROOT COMPUTER, CHANGE THE PRICE SETTING TO THE NEW PER LITER PRICE BEFORE OPERATING THE PUMP IN THE METRIC MODE. If additional information is needed, please feel free to contact the Service Department in Muskegon.

Figure 118

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REPRINT OF SERVICE DEPARTMENT BULLETIN M-224

6-18-80

INSTRUCTIONS TO CONVERT FROM U.S. GALLONS TO LITERS WHEN USING THE BENNETT QUICK CHANGE CONVERSION GEAR BOX ASSEMBLY

1. Cut seal wire on locking pins. 2. Remove locking pins from gallons position. 3. Push shift plate up until locking pin holes align

with liter position. 4. Place locking pins in liter holes. 5. Install new seal wire in locking holes. 6. Apply liter decals on computer cover or dial face. 7. Set computer to new liter price before operating

pump. 8. Perform a 5-gallon (19 liter) calibration test to

insure accuracy of measurement. 9. Notify local Weights and Measures officials, if

required, of liter conversion.

NOTE: The Bennett Quick Change Gear Box Assembly cannot be converted back to gallons without removing the entire gear box from the computer.

126

Figure 119

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127

SECTION G. MOST USED PARTS

Type 40 Pumping Unit .................................................................................................................................128 Type 70 Pumping Unit .................................................................................................................................129 Type 75 Pumping Unit .................................................................................................................................130 Type 40 Meter .............................................................................................................................................131 Control Valve & Filter Assembly ..................................................................................................................131 Cam-Ac .......................................................................................................................................................132 Solenoids .....................................................................................................................................................132 Veeder-Root Components ..........................................................................................................................133 Motors .........................................................................................................................................................133 Universal Link Assemblies ..........................................................................................................................134

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Most Used Parts List for the Type 40 Pumping Unit

Description Part Number

Standard Blades (6 required) Heavy Duty Blades (6 required)

132P100001 541N100501

Control Valve Control Valve Spring

H389501 E008001

Bypass Valve Bypass Valve Spring (standard) Bypass Valve Spring (heavy duty)

H389401 H366901 H367001

Rotor and Shaft (standard) Rotor and Shaft (heavy duty)

E376903 H249202

Lip Seal Square Seal (under lip seal)

A323702 A247014

Atmospheric Float Assembly (top) Air Eliminator Float Assembly

H876901 H876801

Gasket Kit Rotor Kit for rotor cover plate and seal

KR36603 KR16201

Kit to convert old metal bypass valve to plastic

KR16501 (standard) KR16502 (heavy duty)

Strainer J566901 (100 mesh)

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Standard Blades (7 required) Heavy Duty Blades (7 required)

132P100101 J187701

Control Valve Control Valve Spring (standard) Control Valve Spring (heavy duty)

J561201 E008001 J325201

Bypass Valve KR332 (includes spring)

Rotor and Shaft (standard & heavy duty) Stator (standard) Stator (heavy duty)

J275701 J189001 J333901


A323702 A247014

Float Assembly (rectangle) Float Assembly (round)

H876902 J227201

Gasket - Atmos. Chamber Cover Gasket - Bypass Valve Cover Gasket - Clamping Ring (rotor) Gasket - Control Valve Cover Gasket - Filter Cover Gasket Kit

J188401 J186601 J971401 J186401 J186501 KR036601

Strainer J566901 (100 mesh)

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Standard & Heavy Duty Carbon Blades (6 required)

N238201 (Used in Std. after 2-1-89)

Control Valve Control Valve Spring (standard) Control Valve Spring (heavy duty)

N107301 E008001 J325201

Bypass Valve Assembly (including spring)

N481201

Rotor and Shaft (standard & heavy duty for throw out rings type) Rotor and Shaft (standard without throw out rings) Stator (standard) Stator (heavy duty) Throw Out Rings (standard) Throw Out Ring (heavy duty)

N238301 Use KR042001 N156401 N159501 N650401 N238101


A323702 A247014

Filter (35 micron) A311901

Gasket Set Gasket - Bypass Valve Cover Gasket - Clamping Ring (rotor) Gasket - Control Valve Cover Gasket - Filter Cover

KR36604 N162401 N162701 N162301 N162201


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131


Bearing and Adj. Dial Assembly O’Ring (eccentric sleeve) Lip Seal Square Seal (under lip seal) Coupling Half Coupling Screw Gasket - Inlet Gasket - Outlet Gasket - Cylinder Head Gasket - Bearing & Adjusting Dial Gasket Kit

H625801 A212220 A323701 A247014 Part Number differs between models H650501 E993201 541M100501 E009001 541M011701 KR036602

Most Used Parts List for the Type 40 Meter


Diaphragm Valve Diaphragm Valve Spring Check Valve Internal Paper Filter (35 micron) Internal Strainer (100 mesh) Gasket - Filter Cover Gasket - Check Valve & Diaphragm Valve Cover

N334901 H384701 H914201 A311901 J566901 H385001 H384901

Most Used Parts List for the Control Valve & Filter Assembly

SPL1083.3 7/95

Most Used Parts List for Cam-Ac

Solenoid Parts


Compression Fitting (115V)* Compression Fitting (220V) Flare Fitting (115V)* Flare Fitting (220V) Skinner (115V) for 7000 & 9000 Skinner (220V) for 7000 & 9000 *NOTE: Four screws may be removed and top half of solenoid may be rotated to accommodate electrical opening direction.

J295006 J295010 N530506 N530510 N655801 N655802


Clutch and Cam Assembly Clutch Half Plate and bearing Assembly Plate and Bracket Assembly Switch - single contact Switch - double contacts

H673902 H658901 E981902 H550101 A278201 A275901

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2002E Computer (for Electric Reset) VR101 Non-Computer (Cam-Ac Reset) VR101 Non-Computer (for Electric Reset) Electric Reset Electric Reset Motor Electric Reset S1 & S2 switch Electric Reset S3 switch Pulser Pulser 100 to 1 (Electronic)

N126101 H956101 N570601 J210001 321475-001 510908-405 510907-701 J497401 N785301

Most Used Parts List for Veeder-Root Components

Most Used Motors


1/3 hp (56 frame) 115/230, 60 cycle, 1725 RPM, Int. Duty, 3 o’clock (shaft side)

J129601

1/3 hp (56 frame) 115/230, 60 cycle, 1725 RPM, Int. Duty, 6 o’clock (shaft side)

J451501

1/3 hp (56 frame) 115/230, 60 cycle, 1725 RPM, Int. Duty, 9 o’clock (opposite shaft side)

J129701

1/3 hp (56 frame) 115/230, 50/60 cycle, 1425/1725 RPM, Cont. Duty, 6 o’clock (shaft side)

J127401

3/4 hp (56 frame) 115/230, 60 cycle, 1725 RPM, Cont. Duty, 6 o’clock (shaft side)

H921101

3/4 hp (56 frame) 115/230, 60 cycle, 1725 RPM, Cont. Duty, 12 o’clock (opposite shaft side)

J127801

NOTE: Any self-contained dispenser with a Type 70 or Type 75 Pumping Unit, use an H921101 (3/4 hp) or J451501 (1/3 hp) motor.

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Length

5 J849101

7/8 E991916

1 541M100801

1-1/16 E991901

1-3/16 H902414

1-1/4 E991606

1-5/16 E991903

1-7/16 E991912

1-5/8 H902404

1-11/16 E991902

1-13/16 E991905

2-1/8 H902410

2-3/16 E991904

2-9/16 H902402

2-11/16 H902406

2-15/16 H902416

3-1/8 E991919

3-3/8 E991921

3-1/2 H902412

3-9/16 E991920

3-5/8 H902411

3-13/16 H902407

3-15/16 E991910

4-1/16 H902403

4-1/4 H902405

4-1/2 E991918

4-9/16 H902409

5 H902401

5-5/8 E991917

5-15/16 H094201

6-1/16 E991914

6-1/4 E991911

6-5/8 E991909

6-13/16 E991907

Universal Link Assemblies

SPL1083.3 7/95

SPL1083.3 7/95

The material included in this Service Manual is accurate at the date of publication. The intent of this manual is to assist. If further assistance is required, please contact the Bennett Technical Service Department.

1218 E. Pontaluna Road Spring Lake, MI 49456

Documents

CONTENTS OF THIS BOOK - Bennett Pump