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Tokheim TQM Manual

Tokheim TQM Manual

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TQM Manual
(Inc. Ethanol Grades)
Document Ref 942175-001
Rev - 3
10/2010

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Summary of Contents for Tokheim TQM

  • Page 1 TQM Manual (Inc. Ethanol Grades) Document Ref 942175-001 Rev - 3 10/2010...
  • Page 2 Tokheim shall not be liable for damage to the product, nor for personal or third party injury, caused by incorrect use of the product or by attempts to maintain or to repair the product by parties other than those fully trained by Tokheim or by its accredited third party representatives.
  • Page 3 3.6.1 Added Flushing and Calibration flowchart Piston meter. New graphic and parts list TQM meter. New graphic and parts list Cylinder cover assemblies. New graphic and parts list Collector assembly.New graphic and parts list Piston assembly. New graphic and parts list Crankshaft assembly.
  • Page 4 TQM for Fuel Dispensers Component Technical Manual This page is intentionally blank Document Ref 942175-001 Rev 3...

  • Page 5: Table Of Contents

    Electrical Description ................2-3 Piston Meter Operation ..................2-6 Dimensions ......................2-8 Hydraulic Performance Ranges and Tolerances ...........2-8 Environmental Conditions ..................2-8 MOUNTING, CONNECTING & ADJUSTING THE TQM .........3-2 Front View ......................3-2 Plan View......................3-2 Correct Sealing Application (W&M) ..............3-3 Pulser Connections (MPT1) .................3-3 Mechanical Adjustment ..................3-4 Flushing and Calibration Instructions (Non MID Dispensers) .......3-6...
  • Page 6 TQM for Fuel Dispensers Component Technical Manual This page is intentionally blank Document Ref 942175-001 Rev 3...
  • Page 7 Component Technical Manual TQM for Fuel Dispensers CONTENTS INTRODUCTION ......................1-2 How to Use this Manual ..................1-2 Product Scope ...................... 1-2 Authorised Technicians ..................1-2 Contact Information ....................1-2 Health & Safety ....................1-3 1.5.1 Safety Checklist ...................1-3 1.5.2 Duties of the Employees ..............1-3 1.5.3...

  • Page 8: Introduction

    Section 5 lists the assembly drawings and part identification lists for the TQM. Product Scope This manual is designed to cover the TQM metering unit in Quantium 10 series dispensers. Authorised Technicians Only qualified technicians familiar with the contents of this manual should carry out the procedures contained herein.

  • Page 9: Health & Safety

    Component Technical Manual TQM for Fuel Dispensers Health & Safety 1.5.1 SAFETY CHECKLIST • It is obligatory that this checklist be fully complied with during all work at the petrol station, particularly construction or repair work. • It is the duty of the contractor to ensure that all workers employed by him obey each and all of the relevant laws, directives and other regulations.

  • Page 10: Hazards

    TQM for Fuel Dispensers Component Technical Manual 1.5.3 HAZARDS Prior to starting work, the dispenser must be isolated (i.e. entirely disconnected from the mains supply) and the mains supply switch locked in the OFF position. The submerged pump (if applicable) and control signals from the dispenser must also be isolated.

  • Page 11: Personal Protective Equipment (Ppe)

    Component Technical Manual TQM for Fuel Dispensers Do not spill fuel on the Visible from both ground sides of dispenser Smoking forbidden Visible from both sides of dispenser Stop vehicle engine Visible from both sides of dispenser At Diesel high speed...

  • Page 12: Standards & Certificates

    The TQM with the pulser MP-T1(CW), MPE or MPL is constructed for use in fuel dispensers in a Zone 1 area. All components used within the TQM are selected in accordance with the European Standard EN BS 60079-0 (Electrical Apparatus for explosive gas atmospheres) and the supplementary Standards listed therein.
  • Page 13 Component Technical Manual TQM for Fuel Dispensers CONTENTS PRODUCT INFORMATION..................2-2 Functional Description ..................2-2 The Piston Meter....................2-2 The Pulser ......................2-3 2.3.1 Mechanical Description ..............2-3 2.3.2 Electrical Description ................. 2-3 Piston Meter Operation ..................2-6 Dimensions ......................2-8 Hydraulic Performance Ranges and Tolerances ..........

  • Page 14: Product Information

    Fuel flow The Piston Meter The TQM is a twin piston meter. The pistons are activated by the flow of fuel from the pumping unit (suction or submersible type) and are mounted in parallel cylinder bores. Both pistons transmit their reciprocating movement to separate crank shafts mounted perpendicular to the piston stroke.

  • Page 15: The Pulser

    TQM for Fuel Dispensers The Pulser 2.3.1 MECHANICAL DESCRIPTION The pulser is mounted in the pressure moulded TQM control housing, which has three integrated chambers: • Control Valve Chamber - the control valve opens and closes the four chambers for the piston movement •...
  • Page 16 TQM for Fuel Dispensers Component Technical Manual HALL EFFECT SENSORS (DIRECTION) Two sensors (sensors A and B) are placed above the outer ring of the disc. They are used to indicate the direction of the disc. The diagram above indicates the output of the two sensors when the disc rotates clockwise.
  • Page 17 Component Technical Manual TQM for Fuel Dispensers OUTPUT DRIVER The output driver is required to supply the current needed for the inputs of the calculator. It also delays the low-to-high transition of the cl pulses on the output lines A and B. This delay is designed to prevent cross-talk between the two pulse lines and interference on other lines.

  • Page 18: Piston Meter Operation

    TQM for Fuel Dispensers Component Technical Manual Piston Meter Operation The following phases of the piston meter can be identified as shown in the following diagram:- Inlet/fuel entry Inlet/fuel entry Outlet/fuel exit Outlet/fuel exit PHASE 1 PHASE 2 Inlet/fuel entry...
  • Page 19 Component Technical Manual TQM for Fuel Dispensers Phase 1: • The right hand (RH) piston is against the front stop • The channels to chamber C and D are closed by the control valve • The fuel flows into chamber A •...

  • Page 20: Dimensions

    TQM for Fuel Dispensers Component Technical Manual Dimensions Width x height x length 169 x 201 x 184 mm Entrance flange - adjustment By 30° Drive shaft diameter 10 mm Piston - quantity - diameter 65 mm - stroke 39 mm...
  • Page 21 Component Technical Manual TQM Meter for Fuel Dispensers CONTENTS MOUNTING, CONNECTING & ADJUSTING THE TQM .........3-2 Front View ......................3-2 Plan View......................3-2 Correct Sealing Application (W&M) ..............3-3 Pulser Connections (MPT1) .................3-3 Mechanical Adjustment ..................3-4 Flushing and Calibration Instructions (Non MID Dispensers) .......3-6 3.6.1...

  • Page 22: Mounting, Connecting & Adjusting The Tqm

    TQM Meter for Fuel Dispensers Component Technical Manual MOUNTING, CONNECTING & ADJUSTING THE TQM The piston meter must be mounted inside the dispenser in such a way to allow unrestricted access to the adjustment devices and seals. NOTE : To allow the flamepath to function correctly there must be a minimum clearance of 300mm around the pulser housing.

  • Page 23: Correct Sealing Application (W&M)

    Component Technical Manual TQM Meter for Fuel Dispensers Correct Sealing Application (W&M) Tote Port Cap Meter Housing Sealing Wire Meter Housing Pulsar Sealing Seal Wire Tote Port Seal Tote Port Seal Wire Calibration Sealing Calibration Sealing Wire Pulser Connections (MPT1) •...

  • Page 24: Mechanical Adjustment

    Component Technical Manual Mechanical Adjustment For the TQM meter to function correctly, the control valve must fill the front and rear chambers in a specific sequence in relation to the pistons. This is dependent upon the position of the control valve relative to the crank shafts.
  • Page 25 Component Technical Manual TQM Meter for Fuel Dispensers This page is intentionally blank Page 3-5 Document Ref 942175-001 Rev 3...

  • Page 26: Flushing And Calibration Instructions (Non Mid Dispensers)

    Component Technical Manual Flushing and Calibration Instructions (Non MID Dispensers) Tokheim dispensers are accurately calibrated before leaving the factory using a test liquid with viscosity and density properties between diesel and gasoline. Any meter error caused by these viscosity and density differences is minimal, however during initial field calibration, meter errors can go above the acceptable limits and would therefore require a meter adjustment.

  • Page 27: Flushing And Calibration Flowchart

    Component Technical Manual TQM Meter for Fuel Dispensers 3.6.1 FLUSHING AND CALIBRATION FLOWCHART. The flowchart below illustrates the flushing and calibration instructions. Start Run FP until Calibration 3 Calibration 3 fuel comes out of nozzle Clean pump nozzle filter 2 = 3...

  • Page 28: Metrological Adjustment

    TQM Meter for Fuel Dispensers Component Technical Manual Metrological Adjustment The scale is based upon 100% of the metering gauge. The deviation (+ and -) is related to the calculator display. 100.60 Check the piston meter (refer to section 4.2) 100.50...
  • Page 29 Component Technical Manual TQM Meter for Fuel Dispensers CONTENTS TROUBLESHOOTING ....................4-2 Blocked Piston Meter ..................4-2 Display Faults ....................4-3 External Leakage ....................4-4 Page 4-1 Document Ref 942175-001 Rev 3...

  • Page 30: Troubleshooting

    TQM Meter for Fuel Dispensers Component Technical Manual TROUBLESHOOTING Blocked Piston Meter Pressure in front of Check the pump piston meter Meter Check the nozzle exit Check the solenoid valves line? Meter Gear out of adjustment correct? Adjustment screw fouls piston...

  • Page 31: Display Faults

    Component Technical Manual TQM Meter for Fuel Dispensers Display Faults Positive display fault: 100.90 Stops out of adjustment Piston seized (check the piston 100.80 and piston seals) 100.70 100.60 100.50 100.40 100.30 100.20 100.10 Adjust the meter (see section 3.7) 100% 99.90...

  • Page 32: External Leakage

    TQM Meter for Fuel Dispensers Component Technical Manual External Leakage The following are common symptoms and possible solutions relating to external leakage problems:- • Leakage through drive shaft - replace drive shaft seal • Leakage through adjustment screw - replace adjustment screw O-ring •...
  • Page 33 Component Technical Manual TQM Meter for Fuel Dispensers CONTENTS SPARE PARTS ......................5-2 Piston Meter Exploded View ................5-2 TQM Meter Assemblies ..................5-4 Cylinder Cover Assembly ................... 5-5 Collector Assembly ..................... 5-6 Piston Assembly ....................5-7 Crankshaft Assembly ..................5-8...

  • Page 34: Spare Parts

    TQM Meter for Fuel Dispensers Component Technical Manual SPARE PARTS Piston Meter Exploded View Page 5-2 Document Ref 942175-001 Rev 3...
  • Page 35 900008-039 O-Ring 84 x 3 Joint Torique 84 x 3 900050-059 MID Compliant Typeplate TQM MID Conforme Etiquette TQM 901689-170 TQM Typeplate + Temp Comp TQM plaque + Temp Comp 901689-220 Temp.Compensation Gear Wheel 20T Pignon 20 Dents 903220 Special Beta Pin...

  • Page 36: Tqm Meter Assemblies

    Mes TQM MPE-EC en ligne asm 948475-021 Meter TQM MPE-TC in-line assy Mes TQM MPE-TC en ligne asm 948475-024 Meter TQM MPE-TC TW in-line assy Mes TQM MPE-TC TW en ligne asm 948475-031 Meter TQM MPL in-line assy Mes TQM MPL en ligne asm...

  • Page 37: Cylinder Cover Assembly

    Component Technical Manual TQM Meter for Fuel Dispensers Cylinder Cover Assembly Item No Description Désignation Français Part No Comments O-Ring 9.12 x 3.53 Joint Torique 9.12 x 3.53 900050-091 Adjustment Spring Ressort de Vis Relage 908165 TQM Adjustment Bolt Vis D'ajustement TQM...

  • Page 38: Collector Assembly

    Pulser MPC-TC + Cable Emetteur MPC-TC + Cable 943360 Pulser CP1 + Cable Emetteur CP1 + Cable 908702 Bearing Bush Comp. Lapped Bague Collecteur Asm - Rode 941519 TQM Control Housing Machine TQM Collecteur Usine 945701-001 Page 5-6 Document Ref 942175-001 Rev 3...

  • Page 39: Piston Assembly

    Component Technical Manual TQM Meter for Fuel Dispensers Piston Assembly Item No Description Désignation Français Part No Comments Circlip Seeger Type AL48 Segment Seeger type AL48 908169-001 Holding Ring Bague de Maintien Piston 941941 Piston Seal TQM Joint Piston TQM...

  • Page 40: Crankshaft Assembly

    Pignon 36 Dents 908058 Lip Seal 10x16x4 Joint Zoggel 908077-001 Disc Spring Rondelle Ressort 908167 TQM Parallel Pin L=22.5mm Goupil Paral L=22.5mm 908721 Crank Shaft TQM Vilebrequin TQM 940635 Key :- TC = Temperature Compensation Page 5-8 Document Ref 942175-001 Rev 3...
  • Page 41 Component Technical Manual TQM Meter for Fuel Dispensers This page is intentionally blank Document Ref 942175-001 Rev 3...
  • Page 42 For Technical manual enquiries, contact: author@dundee.tokheim.com...

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