Trouble ShootingHow to Recognize Improper Installations

January 2013

The Ford Meter Box Company, Inc.

Table of Contents

Valves and Corp Stops Pages 1 - 18

Tubing and fitting problemsPages 19 - 21

Repair Clamp and FAST Pages 22 - 33

Coupling End Ring Pages 34 - 38

NOTE: Do not take apart and inspect - return items to the Ford Quality Assurance Staff in the exact condition that it is received from the field.

Leaking valve. Pipe wrench distortions shown on a key style corp stop.

1. Iron teeth easily distort brass material

2. Increased torque on wrench handle squeezes jaws more tightly against the valve or fitting.

3. Typical pipe wrench jaws are 5 to 7 degrees from parallel

Why pipe wrenches should not be used.

A dye test shows that pipe wrench distortions

transferred through body. View 2 of 2

Raised Area

Proper Tools

A loose-fitting, smooth-jawed wrench can distort valve body.

Wrench placement or looseness that caused valve body distortion.

Dye test shows loose wrench distortions transferred through valve body.

Valve leaks at valve body. Pipe wrench distortions break the machined seal between the valve body and the outlet assembly.

Outlet assembly

Valve body

Teeth marks from pipe wrench

Should locate smooth jaw

wrench on the flat area here

Valve leaks after backfill. A dye test shows a key style corp stop with an arched body.

No dye = lack of seal because of

no key contact

Incorrect!Vertical key

placement can distort or “arch” the valve when

backfilled

Correct!Valve installed on

its side will absorb higher backfill force

Valve leaks during pressure test. The grooves (scars) on the key are caused by operating the valve against stones or shavings. This valve was not properly flushed after installation.

The key port is distorted from a drilling operation that was done with the key not completely open.

The machined surface of a key corp body is scored from turning a distorted key.

Valve is hard to operate. Ball distortion results from freezing.

Valve leaks / Hard to operate. The key is bulged from the expansion of frozen water. The key was in the closed position when frozen. View 1 of 2

Valve leaks / hard to operate. The key is bulged from the expansion of frozen water. The key was in the closed position when frozen. View 2 of 2

Valve appears to be closed but allows water flow. A ball valve not fully closed when the tee-head is in a fully closed position. View 1 of 3

Valve appears to be closed but allows water flow. Note the twisted tee-head spade due to valve operation while frozen. View 2 of 3

Valve appears to be closed but allows water flow. The distortion of the ball slot is the result of operating the valve while frozen. View 3 of 3

Leaking compression fitting. Out-of-round copper tubing can cause a poor gasket seal.

Copper Rounding Tool

Leaks after in service for weeks or months. Deflected copper can cause a poor gasket seal.

The narrowing of the shiny band shows an uneven gasket seal. The leak usually occurs at the most narrow part of the shiny area.

An incomplete insertion of the copper tube into the fitting allows too much deflection.

TAPPING MACHINE/REPAIR CLAMPINSTALLATION

A torque wrench is highly recommended and required to ensure proper torque.

Equal torque must be applied to all bolts/nuts to prevent leak. The wavy side bar shows over-torque. An over-torque can break the weld between the side bar and the band.

The cupped lifter bar indicates proper installation torque. View 1 of 2

Displaced metal on washer (left) is the result of proper torque. View 2 of 2

Protrusions on the band show that the finger lugs were placed under the band. Most commonly found on the underside of pipe.

Leak. The bulge on the band shows that debris was trapped under the clamp.

This repair clamp was used where a coupling should be installed. The indentations on the band show the end of the pipe. See Catalog Section L for proper applications.

A repair clamp as a "transition" coupling. View 1 of 3

PVC pipe side11.10" (smaller) diameter

Cast iron pipe side likely 11.60" (larger) diameter

Additional stress on the band-to-sidebar weld at the pipe diameter transition area

Sidebar

A repair clamp as a "transition" coupling. View 2 of 3

PVC pipe side11.10" (smaller) diameter

Cast iron pipe side likely 11.60" (larger) diameter

Broken band-to-sidebar weld

A repair clamp as a "transition" coupling. View 3 of 3

PVC pipe side Cast iron pipe side

Lifter Bar

Stud

Set of finger lugs

Sidebars

WasherLubricant

This 3-piece tapping sleeve leaked because the bottom row of bolts was not torqued.

Unequal gap - no gap on left, large gap on right and bottom nuts not torqued.

During installation, tighten so the torque

and gap are equal. This will prevent leaking.

Gasket Displacement - not enough bolt torque was applied during installation.

Coupling End RingOver tightening the fasteners may break the casting. View 1 of 3

Over tightening may deflect the bolts. View 2 of 3

Over tightening may deflect the casting. View 3 of 3

FORD METER BOX