service sheet ssj0452p j0452 coupler with pump ... - emco ike · emco wheaton uk limited, channel...

Emco Wheaton UK Limited, Channel Road, Westwood Industrial Estate,

Margate, Kent, CT9 4JR, UK Tel: +44 (0) 1843 22152, Fax: +44 (0) 1843 295444

[email protected], www.emcowheaton.co.uk

Service Sheet SSJ0452P

Sheet:

SS

J0

45

2P

, 1

7/0

4/1

2,

Rev:

2

A

s a

part

of

a c

ontinu

ous c

om

mitm

ent

to p

rod

uct

de

velo

pm

ent

the c

om

pa

ny r

eserv

es t

he r

ight to

alter

the s

pecific

atio

n o

f its p

roducts

witho

ut

prio

r n

otice

NOTE: API couplers should always be used in conjunction with primary shutoff system such as a meter with preset valve. A relief valve must be provided for the trapped product between the primary shutoff and the API coupler.

WARNING care must be taken when manually operating the lugs as the sleeve is under considerable spring pressure. Ensure that nothing will become trapped between the body and sleeve when it moves forward.

IMPORTANT: Before you begin, drain the line of all product. This can be done by depressing the 5 interlock claws on the coupler (23), the safety lug (24) and turning the lever (3).

J0452 Coupler with Pump API Coupler Note: Pump not shown

in this view for clarity. Please see page 3 for

information on the pump. (J0452-15* Shown)

Fig. 1





Sheet:

SS

J0

45

2P

, 1

7/0

4/1

2,

Rev:

2

A

s a

part

of

a c

ontinu

ous c

om

mitm

ent

to p

rod

uct

de

velo

pm

ent

the c

om

pa

ny r

eserv

es t

he r

ight to

alter

the s

pecific

atio

n o

f its p

roducts

witho

ut

prio

r n

otice

ITEM QTY 051

P

052

P

151

P

152

P

DESCRIPTION PART

NUMBER MATERIAL

1 1 ● ● Body, Side Lever & Pump 673258 Aluminum 356-T6

1 1 ● ● Body, Top Lever & Pump 673298 Aluminum 356-T6

2 1 ● ● ● ● Sleeve 673260 Aluminum 356-T6

3 1 ● ● ● ● Lever 673259 Aluminum 356-T6

4 1 ● ● ● ● Nose Piece 673991 Aluminum 6061-T6

5 1 ● ● Retractor Bale, Side Lever 673440 Aluminum 356-T6

5 1 ● ● Retractor Bale, Top Lever 673255 Aluminum 356-T6

6 1 ● ● ● ● Retractor Handle 673264 Stainless Steel

7 1 ● ● ● ● Nose Ring 673265 Aluminum 6082-T6

8 1 ● ● Nose Seal 672213 Viton

8 1 ● ● Nose Seal 672550 Buna

9 1 ● ● ● ● Shaft 672319 Stainless Steel

10 1 ● ● ● ● Poppet 673992 Aluminum 356-T6

11 1 ● ● ● ● Bearing 560594 Plastic

12 1 ● ● ● ● Bearing 560595 Plastic

13 1 ● ● O-Ring 407433 Viton

13 1 ● ● O-Ring 564769 Buna

14 1 ● ● ● ● Spacer 240805203 Nylon

15 1 ● ● ● ● O-Ring (Dust Seal) 561320 Buna

16 1 ● ● ● ● Retaining Ring 408169 Steel

17 1 ● ● ● ● Link 408254 Stainless Steel

18 2 ● ● ● ● Bent Link 408262 Stainless Steel

19 2 ● ● ● ● Spring Pin 561852 Stainless Steel

20 4 ● ● ● ● Hitch Pin 560489 Stainless Steel

21 1 ● ● ● ● Wave Spring 564090 Stainless Steel

22 2 ● ● ● ● Link Pin 408252 Stainless Steel

23 5 ● ● ● ● Locking Claw 674213 Stainless Steel

24 1 ● ● ● ● Safety Lug 674190 Stainless Steel

25 6 ● ● ● ● Roll Pin 470078 Stainless Steel

26 4 ● ● ● ● M8 Thin Washer 671270 Stainless Steel

27 1 ● ● ● ● Safety Lug Spring 674191 Stainless Steel

28 2 ● ● ● ● Retractor Guide 673241 Stainless Steel

29 2 ● ● ● ● Retractor Spring 577205 Stainless Steel

30 1 ● ● O-Ring 672741 Viton - PTFE Treated

30 1 ● ● O-Ring 672551 Buna

31 5 ● ● ● ● Locking Claw Spring 673269 Stainless Steel

32 8 ● ● ● ● M4 x 10 C’Sunk Screw 617025 Stainless Steel

33 2 ● ● ● ● Cotter Pin 234131 Stainless Steel





Sheet:

SS

J0

45

2P

, 1

7/0

4/1

2,

Rev:

2

A

s a

part

of

a c

ontinu

ous c

om

mitm

ent

to p

rod

uct

de

velo

pm

ent

the c

om

pa

ny r

eserv

es t

he r

ight to

alter

the s

pecific

atio

n o

f its p

roducts

witho

ut

prio

r n

otice

API Coupler Return Pump

ITEM QTY DESCRIPTION PART No. MATERIAL

34 2 Packing 516046200 Felt

35 1 Star Retaining Ring 244008001 Stainless Steel

36 1 Retaining Ring 518092210 Zinc Plated Steel

37 1 Cover 513170200 Nylon

38 2 Plug 302123204 Zinc Plated Steel

39 2 ¼” Ball Bearing 510201200 Stainless Steel

40 2 Check Valve Spring 517000203 Stainless Steel

41 1 Roll Pin 470029 Stainless Steel

42 1 Pump Body 500052200 Aluminum 356-T6

43 2 Check Valve Housing 500073204 Aluminum 6061-T6

44 1 Filter 306050200 Foam

45 1 Washer 240803801 Aluminum 6061-T6

46 1 Orifice Cap 240816802 Aluminum 6061-T6

47 1 Sleeve 532120200 Stainless Steel

48 1 Piston 541010205 Delrin

49 1 Bearing Disc 510031200 Delrin

50 1 Push Rod 504083200 Stainless Steel

51 1 Pump Spring 401006 Stainless Steel

52 1 U Cup Seal 512050212 Viton

53 3 O-Ring 405968 Viton

54 2 O-Ring 522011234 Viton

55 2 O-Ring 522011233 Viton

56 1 Gasket (not shown) 577362 Buna

57 2 Socket Screw O-ring (not shown) 566306 Buna

58 2 Lock Washer (not shown) 577693 Stainless Steel

59 2 Mounting Screw (not shown) 673280 Stainless Steel

60 2 Mounting Screw (not shown) 673281 Stainless Steel

46 37 43 40 53 45 35 36

49 50

51 48

54

34

41

52 47 38

42

55 39

44

Fig. 2





Sheet:

SS

J0

45

2P

, 1

7/0

4/1

2,

Rev:

2

A

s a

part

of

a c

ontinu

ous c

om

mitm

ent

to p

rod

uct

de

velo

pm

ent

the c

om

pa

ny r

eserv

es t

he r

ight to

alter

the s

pecific

atio

n o

f its p

roducts

witho

ut

prio

r n

otice

J0452 Pump Variants

• J0452-051 – Side Lever, Viton Seals & Pump

• J0452-052 – Side Lever, Buna Seals & Pump

• J0452-151 – Top Lever, Viton Seals & Pump

• J0452-152 – Top Lever, Buna Seals & Pump

Spares Kits

Viton Seal Kit – Part No. 494529

Item Qty Description Part No.

8 1 Nose Seal 672213

11 1 Bearing 560594

12 1 Bearing 560595

13 1 O-Ring 407433

15 1 O-Ring 561320

19 2 Spring Pin 561852

21 1 Wave Spring 564090

25 2 Roll Pin 470078

30 1 O-Ring 672741

Buna Seal Kit – Part No. 494530



11 1 Bearing 560594

12 1 Bearing 560595

13 1 O-Ring 564769

15 1 O-Ring 561320



25 2 Roll Pin 470078

30 1 O-Ring 672551

LT Viton Seal Kit – Part No. 494531



11 1 Bearing 560594

12 1 Bearing 560595

13 1 O-Ring 672548

15 1 O-Ring 561320



25 2 Roll Pin 470078

30 1 O-Ring 672549

Nose Piece & Poppet Kit – Part No. 674227


4 1 Nose Piece 673991

10 1 Poppet 673992

20 2 Hitch Pin 560489

22 2 Link Pin 408252

J0452-05*P Variant J0452-15*P Variant

Fig. 3 Fig. 4





Sheet:

SS

J0

45

2P

, 1

7/0

4/1

2,

Rev:

2

A

s a

part

of

a c

ontinu

ous c

om

mitm

ent

to p

rod

uct

de

velo

pm

ent

the c

om

pa

ny r

eserv

es t

he r

ight to

alter

the s

pecific

atio

n o

f its p

roducts

witho

ut

prio

r n

otice

To Change Nosepiece Seal – Kits 494529, 494530 & 494531

1. Once fully drained, remove coupler from loading arm at flange.


2. Depress the 5 Locking Claws (23) and the Interlock

Lug (24) to allow the sleeve to move forward under spring pressure.

3. Turn the Lever (3) to open the coupler to allow access to the poppet linkage assembly. (Poppet linkage assembly consists of the Poppet (10), Bent Links (18) and Link Pins (22).

Claws & Interlock Lug Kit – Part No. 673293



20 2 Hitch Pin 560489

23 5 Locking Claw 674213

24 1 Interlock Lug 674190

25 5 Roll Pin 470078

27 1 Interlock Spring 674191

31 5 Locking Lug Spring 673269

33 2 Cotter Pin 234131

J0452 Lever Kit – Part No. 673295


3 1 Lever 673259

15 1 O-Ring No. 312 561320

25 1 Roll Pin 470078

Nose Ring Kit – Part No. 673294


7 1 Nose Ring 673265

32 8 Screw 617025

J0451/J0452 Shaft Kit – Part No. 672869


9 1 Shaft 672319

16 1 Ret. Ring 408169


25 1 Roll Pin 470078

Pump Viton Seal Kit– Part No. 673951 Item Qty Description Part No.

34 0.83' Felt Packing 516046200

36 1 Star Retaining Ring 244008001

44 1 Filter 306050200

52 1 U-Cup Seal 512050212

53 3 O-Ring EW-405968

54 2 O-Ring 522011234

55 2 O-Ring 522011233

24

23

Fig. 5

Fig. 6 Fig. 7

3

Fig. 8 Fig. 9





Sheet:

SS

J0

45

2P

, 1

7/0

4/1

2,

Rev:

2

A

s a

part

of

a c

ontinu

ous c

om

mitm

ent

to p

rod

uct

de

velo

pm

ent

the c

om

pa

ny r

eserv

es t

he r

ight to

alter

the s

pecific

atio

n o

f its p

roducts

witho

ut

prio

r n

otice

4. With no tension on the poppet assembly, use needle nose pliers to remove one set of the Hitch Pin (20), Link Pins (22) and Washers (26). (Fig. 11)

5. After the pin set has been removed, remove

poppet assembly from the body bore. Carefully remove the Nosepiece (4) and Wave Spring (21). Do not nick the bore in the process. (See Fig. 12)

6. If replacing O-Ring (30) & Nose Piece Seal (8).

Without scratching the seal seats on the Nosepiece (4), use a pick to carefully remove Nose Seal (8) and the O-Ring (30). If not replacing O-Ring & Nose Piece Seal Move to step 8.

7. Using a solvent, thoroughly clean the bore and

nosepiece seal grooves. Make sure all grit is removed. Carefully assemble New O-Ring (30) & Nose Piece Seal (8) into the Grooves. Apply Parker Super Lube (or equivalent) to outside of Nose Piece Seal once assembled.

8. If shaft seal needs replacing, go to steps 9-12 before reattaching poppet and

bent links. If not then reassemble, reversing the above steps. Once Coupler is fully reassembled pull back Retractor Handle (6) pulling the Coupler Sleeve back into the Uncoupled Position (Fig. 6). The Coupler is now ready for use.

To Change Shaft Seals - Kits 494529, 494530 & 494531

9. With Lever still open, use a hammer and punch

to remove roll pin (25) from lever (3). Slide lever off the end of the shaft. (See Fig. 13)

10. Remove dust seal (15) with picking tool. Discard

dust seal. Remove retaining ring (16) with retaining ring pliers. (See Fig. 14)

11. Slide shaft out to expose spacer (14) and O-

Ring (13). Remove spacer and O-Ring discard O-Ring. Thoroughly clean the bore. If Replacing Bearings (11&12) go to step 13.

12. Lubricate New O-Ring (13) with Parker Super Lube (or equivalent) and

assemble in reverse order. Lubricate new dust seal (15) before installation. Replace Lever (3) and using a hammer & punch install New Roll Pin (25). (See Fig. 13) Return to step 8.

22

26

20

Fig. 10 &11

18 30 4 10 8 22 21

Fig. 12

25

Fig. 13

15 16 14 13 9

Fig. 14





Sheet:

SS

J0

45

2P

, 1

7/0

4/1

2,

Rev:

2

A

s a

part

of

a c

ontinu

ous c

om

mitm

ent

to p

rod

uct

de

velo

pm

ent

the c

om

pa

ny r

eserv

es t

he r

ight to

alter

the s

pecific

atio

n o

f its p

roducts

witho

ut

prio

r n

otice

13. Use a hammer and punch to remove roll pin (19) to free link (17) on shaft. Slide shaft (9) out of Body and link off shaft. (See Fig. 15)

14. Remove Top Bearing (12) and Bottom Bearing

(11) (Fig. 16) and discard.

15. Thoroughly clean the bores, replace Top and Bottom Bearings (11 &12). 16. Lubricate Shaft (9) with Parker Super Lube (or equivalent) as indicated in Fig.

17 and replace into bore with Link (19), push shaft all the way in. Use New Spring Pin (19) to secure link to shaft with hammer. Return to step 12.

To Change Claws & Interlock Lug – Kit 673293


17. Follow steps 1 & 2 to move sleeve forward. 18. Remove Screws (59 & 60, 2 Off Each) O-Rings

(57) and Lock Washers (58) with 3/16 Allen Key. Carefully remove Pump and Gasket from Coupler Body (See Fig. 18). Be careful not to loose Ball Bearing (39), Spring (40), Orifice Cap (46) and O-Ring (53) from inside of pump (See Fig. 19).

17 19

Fig. 15

9

11 12

Fig. 16

Fig. 17

Lubricate Here Lubricate Here

Fig. 18 60 57 59 58

53 Fig. 19 39 40 46





Sheet:

SS

J0

45

2P

, 1

7/0

4/1

2,

Rev:

2

A

s a

part

of

a c

ontinu

ous c

om

mitm

ent

to p

rod

uct

de

velo

pm

ent

the c

om

pa

ny r

eserv

es t

he r

ight to

alter

the s

pecific

atio

n o

f its p

roducts

witho

ut

prio

r n

otice

19. Follow steps 3 to 13 to strip down coupler without discarding or replacing any parts. Keep removed parts to one side for re-assembly.

20. Remove Cotter Pins (33) (discard) and washers

(26) from either side of Coupler. (See Fig. 20)

21. Pull Retractor Handle (6) out of Retractor Bale (5). (See Fig. 20)

22. Remove Hitch Pins (20) (discard) from Retractor

Guide (28) on both sides of Coupler. (Fig 21)

23. Use Pliers inside of Retractor Spring (29), depress retractor spring, grip Retractor Guide (28) and slide guide out of the Coupler. Once retractor guide removed, remove retractor spring. Repeat process to remove spring and guide on the other side of the Coupler. Warning, be careful whilst completing this step as the mechanism is highly sprung. The Retractor Bale (5) will now fall away from the Coupler. (Fig. 22)

24. The Coupler Sleeve (2) is now free to be slide off the back of the Coupler Body (1). (Fig. 23)

25. Use a punch and hammer to remove Roll Pin

(25) from Body (1). The Locking Claw (23) will now be free to remove. Repeat process for the other 4 locking claws. Discard locking claws and roll pins. (Fig. 24)

26. Insert New Locking Claw (23) into the slot in the

Body (1). Secure locking claw to body with New Roll Pin (25) with a hammer. Repeat process for other 4 Claws. (Fig. 24)

33 Fig. 20

26

5

6

Fig. 22

29

28

5

1 Fig. 23 2

Fig. 24

23

1

25

Fig. 21

20

Note: Hitch Pin pulled all the way through when re-assembling





Sheet:

SS

J0

45

2P

, 1

7/0

4/1

2,

Rev:

2

A

s a

part

of

a c

ontinu

ous c

om

mitm

ent

to p

rod

uct

de

velo

pm

ent

the c

om

pa

ny r

eserv

es t

he r

ight to

alter

the s

pecific

atio

n o

f its p

roducts

witho

ut

prio

r n

otice

27. Use a punch and hammer to remove Spring Pin (19) from Body (1). The Safety Lug (24) and Spring (27) will now be free to remove. Discard safety lug, spring and spring pin. (Fig. 25)

28. Insert New Safety Lug (24) into the slot in the

Body (1). Secure interlock lug to body with New Spring Pin (19) with a hammer. Insert New Spring (27). (Fig. 25)

29. Slide Coupler Sleeve (2) over Coupler Body (1) (Fig. 23).

30. Depress 5 x Locking Claws (23) and Safety Lug (24) (Fig. 5) to allow the sleeve to slide forward (Fig. 7).

31. Reassemble Coupler & pump reversing steps 18 to 23 using existing parts except for New Cotter Pins (33) and New Hitch Pins (20) to retain Retractor Guide (28). Pull Hitch Pins all the way through (Fig. 21). N.B. Apply a small amount of Parker Super Lube (or equivalent) to the top of the orifice cap o-ring (53) to help retain the check valve assembly whilst reinstalling the pump to the coupler. (Fig.19)

32. Once Coupler is fully reassembled pull back Retractor Handle (6) pulling the

Coupler Sleeve back into the Uncoupled Position (Fig. 6). The Coupler is now ready for use.

To Change the Nose Ring – Kit 673294

33. Undo the 8 screws (32) on the front of the coupler using a 2.5mm allen key. (Fig. 26)

34. Remove the nose ring (7) and discard. If the

nose ring is difficult to remove, use a screwdriver to lever the ring off. (Fig. 26)

35. Replace nose ring and fit new retaining screws.

Use one drop of a medium strength thread locking compound such as loctite 241/2/3, on each screw. (Fig. 26)

To Change the Lever– Kit 673295

36. Follow steps 1 to 3 to open Coupler.

37. Using a hammer and punch, remove roll pin (25) from lever (3). Slide lever off the end of the shaft. (See Fig. 13)

Fig. 26

32 7

Fig. 25 24 19

27





Sheet:

SS

J0

45

2P

, 1

7/0

4/1

2,

Rev:

2

A

s a

part

of

a c

ontinu

ous c

om

mitm

ent

to p

rod

uct

de

velo

pm

ent

the c

om

pa

ny r

eserv

es t

he r

ight to

alter

the s

pecific

atio

n o

f its p

roducts

witho

ut

prio

r n

otice

38. Remove dust seal (15) with picking tool. Discard dust seal. Lubricate New Dust Seal (15) with Parker Super Lube (or equivalent) before replacing. (See Fig. 14)

39. Replace New Lever (3) and using a hammer & punch install New Roll Pin (25).

(See Fig. 13)

40. Turn Lever (3) back to the closed position and pull back Retractor Handle (6) pulling the Coupler Sleeve back into the Uncoupled Position (Fig. 6). The Coupler is now ready for use.

To Change shaft – Kit 672869 41. Follow steps 1 to 13 to remove current Shaft (9) without discarding any

parts except for the Retaining Ring (16). 42. Lubricate New Shaft (9) with Parker Super Lube (or equivalent) as

indicated in Fig. 17 and replace into bore with Link (17), push shaft all the way in. Use New Spring Pin (19) to secure link to shaft with hammer.

43. See Fig. 14: Lubricate O-Ring (13) with Parker Super Lube (or

equivalent) and assemble in reverse order, use New Retaining Ring (16) before assembling Dust Seal (15). Lubricate dust seal before installation. Return to step 8.

To Change Seals on the Pump – Kit 673951

44. Follow steps 17 & 18 to remove Pump from

Coupler. 45. Using a small pick, remove from the pump to

body connection the following items: Orifice Cap (46) and O-Ring’s (53), Spring (40), Ball (39), Check Valve Housing (43), and O-Ring Seat (55). Discard both O-Rings. (Fig. 27)

46. Remove Plug (38) from one side of pump before

removing Filter (44), discard filter. (Fig. 28)

47. Remove the rear Vinyl Cover (37). (Fig, 29)

48. Using Retaining ring pliers remove the pump piston Retaining Ring (36) from its grove and slide rearward while extracting the push rod assembly. (Fig. 29)

Fig. 27 39 40 53 53 43 55 46

Fig. 28 44 38

36 37 Fig. 29

Push Rod Ass.





Sheet:

SS

J0

45

2P

, 1

7/0

4/1

2,

Rev:

2

A

s a

part

of

a c

ontinu

ous c

om

mitm

ent

to p

rod

uct

de

velo

pm

ent

the c

om

pa

ny r

eserv

es t

he r

ight to

alter

the s

pecific

atio

n o

f its p

roducts

witho

ut

prio

r n

otice

49. Remove from the Push Rod Assembly the Bearing Disk O-Ring (54), U-Cup Seal (52), and 2 off Felt Packing (34). Discard. (Fig. 30)

50. Using a pick pry out the Star Retaining Ring (35)

from the bottom of the piston bore inside the pump body. (Fig 31.)

51. With the star retaining ring removed pick out the Washer (45), O-Ring (53),

Spring (40), Ball (39), Check Valve Housing (43), and O-Ring Seat (55). Discard o-rings and star retaining ring. (Fig. 31)

52. Clean all remaining items thoroughly.

To Rebuild the Pump

53. Reassemble the check valve in the bottom of the piston bore by inserting the components in this order: New O-Ring Seat (55), Check Valve Housing (43), Ball (39), Spring (40), New O-Ring (53), Washer (45), and New Star Retaining Ring (35). Using a punch ensure that the star retaining ring is pushed firmly against the washer. (Fig. 31)

54. Install two pieces of New Felt (34) (pre-soaked

in silicone oil) onto the first and last groves of the pump piston. (Fig. 32)

55. Install the New U-Cup Seal (52) with the cup

facing the flat end of the pump piston onto the centre grove of the pump piston. (Fig. 32)

56. Install the New O-Ring (54) onto the bearing disk of the push rod assembly.

Lubricate the u-cup and o-ring with Parker Super O lube. (Fig. 32)

57. Insert the Pushrod Assembly and Retaining Ring (36) into the piston bore until the retaining ring fits into the retention grove. Reinstall the Rear Vinyl Cover. (37) (Fig. 29)

58. Insert New Foam Filter (44) and reinstall Plug (38) (Fig. 28)

Fig. 30

54

34

52

34

Fig. 31 55 43 39 40 53 45 35

34 Fig. 32

52 34 54





Sheet:

SS

J0

45

2P

, 1

7/0

4/1

2,

Rev:

2

A

s a

part

of

a c

ontinu

ous c

om

mitm

ent

to p

rod

uct

de

velo

pm

ent

the c

om

pa

ny r

eserv

es t

he r

ight to

alter

the s

pecific

atio

n o

f its p

roducts

witho

ut

prio

r n

otice

59. Reassemble the Check Valve in the pump to body connection by inserting the components in this order: New O-Ring Seat (55), Check Valve Housing (43), Ball (39), Spring (40), New O-Ring (53), Orifice Cap (46), and New Orifice Cap O-Ring (53). (Fig. 27). Apply a small amount of Parker Super Lube (or equivalent) to the top of the new orifice cap o-ring to help with retaining the check valve assembly whilst reinstalling the pump to the coupler. (Fig. 27)

60. Install O-Rings (57) onto the socket head cap screws for the front of the pump

assembly, and align the Pump Gasket with front mounting holes of the pump assembly. (Fig. 18)

61. With Coupler Sleeve still in the forward position. Mount the pump assembly to

the coupler body ensuring that all seals remain in place. (Fig. 18)

62. Torque the mounting screws to 2.5 Nm.

service sheet ssj0452p j0452 coupler with pump ... - emco ike · emco wheaton uk limited, channel...

Documents