Amerex 488 Application guide

OWNERS SERVICE MANUAL
NO. 05608
INSTALLATION, OPERATING AND SERVICING INSTRUCTIONS
for
AMEREX
STORED PRESSURE
WHEELED & STATIONARY
125/150 POUND
DRY CHEMICAL FIRE EXTINGUISHERS
WHEELED STATIONARY
Model 488 ABC (AMMONIUM PHOSPHATE BASE) Model 476
Model 489 REGULAR (SODIUM BICARBONATE BASE) Model 477
Model 490 PURPLE K (POTASSIUM BICARBONATE BASE) Model 478
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✸✸✸ RECHARGE FIRE EXTINGUISHERS IMMEDIATELY AFTER ANY USE ✸✸✸✸✸✸
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Allfireextinguishersshouldbeinstalled,inspectedandmaintainedinaccordancewiththeNationalFireProtectionAssociationstandardtitled
“PortableFireExtinguishers”,NFPA-10;andtherequirementsoflocalauthoritieshavingjurisdiction.
Whenmaintenanceisindicated,itshouldbeperformedbytrainedpersonshavingproperequipment.Fireextinguishersarepressurevesselsand
mustbetreatedwithrespectandhandledwithcare.Theyaremechanicaldevicesandrequireperiodicmaintenancetobesurethattheyarereadyto
operateproperlyandsafely.Amerexstronglyrecommendsthatthemaintenanceofportablefireextinguishersbedonebyatrainedprofessional-your
localauthorizedAmerexDistributor.
AmerexCorp.makesoriginalfactorypartsavailabletoinsurepropermaintenance-useofsubstitutepartsreleasesAmerexofitswarranty
obligations.Amerexpartshavemachinedsurfacesandthreadswhicharemanufacturedtoexactingtolerances.O-rings,hoses,nozzles,hornsandall
metalpartsmeetprecisespecificationsandaresubjectedtomultiplein-houseinspectionsandtestsforacceptability.Therearesubstitutepartsavailable
whichareincorrectlylabeledasU/Lcomponentparts,someareadvertisedasAmerextype.NoneofthesemeetU/Lrequirementsandallofthemvoid
theAmerexextinguisherwarrantyandU/Llisting.DONOTSUBSTITUTE.
REFERENCES IN THIS MANUAL: AVAILABLE FROM:
NFPA-10 "PORTABLEFIREEXTINGUISHERS” NationalFireProtectionAssoc.,Inc.
BatterymarchPark
Quincy,MA 02269
CGA C-1 "METHODS FOR HYDROSTATIC TESTING CompressedGasAssociation, Inc.
OFCOMPRESSEDGASCYLINDERS" 1235JeffersonDavisHighway
Suite501
CGA C-6 “STANDARDFORVISUALINSPECTION Arlington,VA22202
OFCOMPRESSEDGASCYLINDERS”
AMEREX CORP.AMEREX CORP.
AMEREX CORP.AMEREX CORP.
AMEREX CORP. ❖❖
❖❖
❖ P. O. BOX 81P. O. BOX 81
P. O. BOX 81P. O. BOX 81
P. O. BOX 81 ❖❖
❖❖
❖TRUSSVILLE, ALABAMA 35173-0081TRUSSVILLE, ALABAMA 35173-0081
TRUSSVILLE, ALABAMA 35173-0081TRUSSVILLE, ALABAMA 35173-0081
TRUSSVILLE, ALABAMA 35173-0081
Phone: [phone] ❖❖
❖❖
❖Fax: [phone]
E-Mail: [email protected]
Internet Web Page: http://www.amerex-fire.com
Printed in U.S.A. OM05608Rev.F-7/98T

THIS MANUAL IS ATTACHED TO EVERY NEW EXTINGUISHER OF THIS TYPE, SHIPPED FROM THE
FACTORY. IT CONTAINS VALUABLE INFORMATION WHICH SHOULD BE STUDIED BY EVERYONE
WHO WILL OPERATE OR SERVICE THE EXTINGUISHER. IT SHOULD BE KEPT IN A CONVENIENT
LOCATION FOR EASY REFERENCE.
AMEREX CORPORATION DOES NOT SERVICE, MAINTAIN OR RECHARGE FIRE EXTINGUISHERS.
THIS MANUAL IS PUBLISHED AS A GUIDE TO ASSIST QUALIFIED SERVICE PERSONNEL IN THE
INSPECTION, MAINTENANCE AND RECHARGE OF AMEREX FIRE EXTINGUISHERS ONLY. NO
INSTRUCTION MANUAL CAN ANTICIPATE ALL POSSIBLE MALFUNCTIONS THAT MAY BE
ENCOUNTERED IN THE SERVICE OF FIRE EXTINGUISHERS. DUE TO THE POSSIBILITY THAT
PRIOR SERVICE PERFORMED ON THIS EQUIPMENT MAY HAVE BEEN IMPROPERLY DONE, IT IS
EXTREMELY IMPORTANT THAT ALL WARNINGS, CAUTIONS AND Notes IN THIS MANUAL BE
CAREFULLY OBSERVED.FAILURE TO HEED THESE INSTRUCTIONS COULD RESULT IN SERIOUS
INJURY.
AMEREX ASSUMES NO LIABILITY FOR SERVICE, MAINTENANCE OR RECHARGE OF FIRE
EXTINGUISHERS BY PUBLISHING THIS MANUAL.
INTRODUCTION
The Amerex Models 488 (ABC), 489 (REGULAR) & 490 (PURPLE K) WHEELED and Models 476 (ABC), 477
(REGULAR)and478(PURPLEK)STOREDPRESSUREDRYCHEMICALfireextinguisheraredesignedtoprovidelarge
volumes of dry chemical fire fighting agent for high hazard industrial applications. Wheeled extinguishers can be easily
transported and operated by one person on smooth rolling 16" wheels. The cage type carriage configuration provides
protection for the operating valve, cylinder and hose assembly.
MaximumprotectionfromseverecorrosiveenvironmentisaffordedbytheAmerex“Ultra”metalpreparationandpaint
finish.Theoperatingvalve,handle,gaugeguard,fillcap,hosecouplingsandballtypeshut-offarebrass,orbrass,chrome
plated for years of trouble free use. These Models carry an AMEREX warranty of SIX YEARS -see full wording of the
warranty below.
Fieldrecharging is possible utilizingmaintenance/recharge equipment available throughyour Amerex Distributor. To
provide optimum extinguisher reliability, recharging should be performed by persons trained in fire extinguisher
maintenanceandservicing.Thismanualshouldbeusedasaguideforinstalling,operatingandservicingthisextinguisher.
THE BEST PLACE TO HAVE YOUR EXTINGUISHER SERVICED AND RECHARGED IS YOUR “AUTHORIZED
AMEREX DISTRIBUTOR” WHO HAS THE PROFESSIONAL EXPERIENCE AND EQUIPMENT TO DO IT PROPERLY.
SIX YEAR LIMITED WARRANTY
Amerex warrants its fire extinguishers to be free from defects in material and workmanship for a period of SIX (6)
YEARS from the date of purchase. During the warranty period, any such defects will be repaired or the defective
extinguisher replaced IF THE ORIGINAL GREY LOCKWIRE SEAL IS INTACT AND/OR IF ONLY FACTORY RE-
PLACEMENT PARTS AND RECOMMENDED SERVICE EQUIPMENT HAVE BEEN USED TO SERVICE THE
EXTINGUISHER. This warranty does not cover defects resulting from modification, alteration, misuse, exposure to
unusually corrosive conditions nor improper installation or maintenance. ALL IMPLIED WARRANTIES, INCLUDING,
BUT NOT LIMITED TO, WARRANTIES OF FITNESS FOR PURPOSE AND MERCHANTABILITY, ARE LIMITED
TO THE TIME PERIODS AS STATED ABOVE. IN NO EVENT SHALL AMEREX CORP. BE LIABLE FOR INCIDEN-
TAL OR CONSEQUENTIAL DAMAGES. Some states do not allow limitations on how long an implied warranty lasts
or the exclusion or limitation of incidental or consequential damages, so that the above limitations or exclusions may
not apply to you. Amerex Corp. neither assumes nor authorizes any representative or other person to assume for it
any obligation or liability other than expressly set forth herein. This warranty gives you specific legal rights, and you
may also have other rights which vary from state to state. To obtain performance of the obligation of this warranty,
write to Amerex Corp., P. O. Box 81, Trussville, AL 35173-0081 for instructions.
2.2.
2.2.
2.

PREPARING YOUR NEW EXTINGUISHER FOR USE
1. Examine the extinguisher for evidence of shipping damage. Notify the delivering carrier immediately if any
damage is discovered.
2. Remove all wrappings, straps and pallet retaining bolts.
3. Check to insure that the hose connection to the operating valve and shut-off nozzle to the hose are tight.
4. Check to insure that the shut-off nozzle is in the CLOSED position. The ring (safety) pin should be installed in the
operating valve and the lockwire (tamper) seal intact.
5. Check to make sure that the cap is on the "bleeder valve" (located on the side of the extinguisher operating valve).
The pressure seal is in the cap and it must be in place to prevent leakage.
6. This extinguisher is shipped from the factory fully charged. Visually inspect the pressure gauge - the pressure
should be in the GREEN ZONE (240 psi ± approx. 10 psi range). The most accurate method to determine if the
extinguisher is filled with the proper amount of chemical is to weigh the unit. The gross weight is indicated on
the nameplate (label).
Note: Slight pressure variances in the gauge reading may be found if the extinguisher has been subjected to
extremes of heat or cold. High temperatures can cause high gauge readings and low temperatures, low
readings.Whenindoubt,conditiontheextinguisherto70°F(21°C)forseveralhourstoobtainmoreaccurate
pressure gauge readings.
7. Record the date the unit is being placed into service on the inspection tag and attach it to the extinguisher.
INSTALLATION
Donotplacethisextinguisherclosetoapotentialfirehazard.Amerexrecommendslocationnolessthana50footdistance
from the hazard while leaving an unobstructed access. Avoid placing it in an extremely hot or cold place. The operational
temperature range for this extinguisher is -65° to +120° F (-54° to + 49° C). The extinguisher should be adequately
protected if temperatures outside of this range are anticipated. Keep the extinguisher clean and free from dirt, ice,
chemicals and any contaminants which may interfere with its proper operation. DO NOT FUNCTIONALLY TEST THIS
FIRE EXTINGUISHER. (Testing or any use may cause the extinguisher to gradually lose pressure and become
ineffective.)
3.

OPERATION
CAUTION: PERSONS EXPECTED TO USE THIS EXTINGUISHER SHOULD BE TRAINED IN INITIATING ITS
OPERATION AND IN THE PROPER FIRE FIGHTING TECHNIQUE. “HANDS ON” TRAINING WILL
PREPARE PERSONNEL WITH THE FEEL FOR THIS EXTINGUISHER SO THAT THE MOST
EFFECTIVE APPLICATION CAN BE UTILIZED IN AN EMERGENCY SITUATION. THE BASIC
OPERATING INSTRUCTIONS ARE CONTAINED IN THE PICTOGRAM PORTION OF EVERY
EXTINGUISHERNAMEPLATE(LABEL).THEFOLLOWINGELABORATESONTHESEINSTRUCTIONS.
1. MOVE THE EXTINGUISHER TO WITHIN APPROXIMATELY 50 FEET OF THE FIRE SITE. KEEP
EXTINGUISHER UPRIGHT.
CAUTION:THIS EXTINGUISHER MUST BE OPERATED IN AN UPRIGHT POSITION. IF EQUIPPED WITH AN OPTIONAL TOW
LOOP AND VEHICLE TOWED TO THE FIRE SCENE, REMOVE FROM TOW HITCH AND OPERATE IN AVERTICAL
POSITION.
2. TWIST AND PULL RING PIN. OPEN CYLINDER DISCHARGE VALVE BY ROTATING (PULLING)
THE “T” HANDLE VALVE LEVER TOWARD THE HOSE 90°. THE HOSEIS NOW PRESSURIZED
WITH CHEMICAL. WITH THE HOSE (DISCHARGE) NOZZLE IN THE CLOSED POSITION,
PULL HOSE FROM RACK. START BACK 30 FEET FROM THE FIRE.
3. GRASP NOZZLE AND AIM AT BASE OF FIRE NEAREST YOU.
4. OPEN HOSE (DISCHARGE) NOZZLE BY SLOWLY PULLING THE LEVER FULLY TOWARDS
YOU (BRACE YOURSELF, HOLD THE NOZZLE FIRMLY AND BE PREPARED FOR A DIS-
CHARGE RECOIL). SWEEP SIDE TO SIDE ACROSS THE BASE OF THE FIRE AND PAST
BOTH EDGES. WORK THE FIRE AWAY FROM YOU WHILE BEING ALERT FOR FLASHBACKS.
MOVE CLOSER AS THE FIRE IS EXTINGUISHED BUT NOT SO CLOSE AS TO SCATTER OR
SPLASH THE BURNING MATERIAL. PROGRESSIVELY FOLLOW UP UNTIL THE FIRE IS EXTIN-
GUISHED.
5. WHEN THE FIRE IS OUT, PUSH THE HOSE (DISCHARGE) LEVER FORWARD TO THE CLOSED
POSITION. STAND BY AND WATCH FOR POSSIBLE REIGNITION.
6. EVACUATE AND VENTILATE THE AREA IMMEDIATELY AFTER EXTINGUISHING THE FIRE.
THE FUMES AND SMOKE FROM ANY FIRE MAY BE HAZARDOUS AND CAN BE DEADLY.
DISCHARGE TIME (APPROXIMATE)
488 (476) - 49 SECONDS 489 (477) - 60 SECONDS 490 (478) - 52 SECONDS
EFFECTIVE RANGE OF AGENT THROW - 25 TO 40 FEET
HOSE LENGTH - 50 FEET
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✸✸✸ RECHARGE EXTINGUISHERS IMMEDIATELY AFTER ANY USE ✸✸✸✸✸✸
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SHUTDOWN
BEFORE PERFORMING THE SHUTDOWN PROCEDURE AND PREPARING TO MOVE THE
EXTINGUISHER TO THE RECHARGE LOCATION, MAKE SURE THAT THE FIRE IS
COMPLETELY EXTINGUISHED AND THAT THERE IS NO DANGER OF A FLASHBACK.
1. Tip extinguisher to the horizontal position (resting on the carriage handle) and slowly rotate the CYLINDER
DISCHARGE VALVE LEVER 90° to the OPEN position. Slowly push the HOSE (DISCHARGE) NOZZLE
LEVER to the OPEN position and be prepared for some chemical discharge.
4.

2. Whenallpressurehasbeenevacuatedfromtheextinguisher,returntheHOSE(DISCHARGE)NOZZLE
LEVERandCYLINDERDISCHARGEVALVELEVERtotheCLOSEDPOSITION.
Note: These steps will allow easy depressurization of the extinguisher and clear the hose assembly with a
minimal loss of remaining chemical.
3. Return the extinguisher to the upright position. Coil the hose onto the storage rack and position the nozzle
into the mount in preparation for transport to the recharge location.
INSPECTING THE EXTINGUISHER
INSPECTION [NFPA-10 4-2.1] is a “quick check” that an extinguisher is available and will operate. It is
intended to give reasonable assurance that the extinguisher is fully charged and operable. This is
done by seeing that it is in its designated place, that it has not been actuated or tampered with, and
that there is no obvious physical damage or condition to prevent operation.
PERIODIC INSPECTION PROCEDURES
(Monthly or more often if circumstances dictate)
[NFPA-10 4-3.2] A “quick check” should be made of the extinguisher for the following:
1. Located in designated place.
2. No obstructions to access or visibility.
3. Operating instructions on nameplate and facing outward.
4. Seals and tamper indicators not broken or missing. Bleeder valve cap on operating valve installed.
5. Determine fullness by weighing.
6. Examine for obvious physical damage, corrosion, leakage or clogged nozzle.
7. Pressure gauge reading in the operable area.
MAINTENANCE
MAINTENANCE [NFPA-10 4-4.1 & 4-4.2] At least once a year (or more frequently if indicated by an inspec-
tion), MAINTENANCE should be performed. MAINTENANCE is a “thorough check” of the extinguisher.
It is intended to give maximum assurance that an extinguisher will operate effectively and safely. It
includes a thorough examination and any necessary repair or replacement. It will normally reveal the
need for hydrostatic testing.
MAINTENANCE PROCEDURE
Note: This procedure will be best accomplished with the extinguisher in an upright position and on a level
surface.
1. Clean extinguisher to remove dirt, grease or foreign material. Check to make sure that the instruction name-
plate and U/L manifest are securely fastened and legible. Inspect the cylinder for corrosion, abrasion, dents or
weld damage. If any of these conditions are found and you doubt the integrity of the cylinder, hydrostatically test
5.5.
5.5.
5.

to factory test pressure - 500 psi, [3448 kPa], using the proof pressure method, in accordance with CGA
PamphletC-6and NFPA Pamphlet 10. Seepropermethodof depressurizing and reclaimingchemicalin
RECHARGEprocedures.
Note: Whencleaning,avoiduseofsolvents aroundthepressuregauge. Theycouldseriouslydamage the
plastic gauge face.
2. Inspect the extinguisher for damaged, missing or substitute parts. Only factory replacement parts are
approved for use on Amerex fire extinguishers.
3. Weigh extinguisher and compare with weight printed in the “Maintenance” section on the nameplate (label).
Recharge extinguisher if weight is not within indicated allowable tolerances.
4. Check the date of manufacture stamped on the extinguisher cylinder dome. Cylinder must be hydrostatically
(proof pressure) tested at 12 years (first time), every 7 years thereafter, to the test pressure indicated on the
nameplate - 500 psi, [3448 kPa].
5. Visually inspect the pressure gauge:
a. if bent, damaged or improper gauge, depressurize and replace
b. if pressure is low, check for leaks
c. if overpressurized (overcharged), depressurize the extinguisher and follow recharge instructions
6. Remove and check ring pin for freedom of movement. Replace if bent or if removal appears difficult.
7. Visually inspect, without removing, the agent fill plug for damage or distortion. Replace as necessary ONLY
AFTER PROPER DEPRESSURIZATION PROCEDURES HAVE BEEN PERFORMED (SEE COMPLETE
MAINTENANCE - SIX YEAR TEARDOWN INSTRUCTIONS).
8. Check the nozzle shutoff lever for freedom of movement (open and close several times). If the operation is
impeded, disassemble the nozzle, replace parts and/or properly lubricate as necessary. Make sure that
the nozzle tip is clear and unobstructed.
WARNING: ALWAYS OPEN THE SHUTOFF NOZZLE HANDLE SLOWLY. ANY EVIDENCE OF AGENT
IN THE NOZZLE INDICATES THAT THE UNIT MAY HAVE BEEN USED AND THE USE NOT
REPORTED. BE PREPARED FOR A POSSIBLE DISCHARGE AND NOZZLE RECOIL.
9. After making sure that there is no residual pressure in the discharge hose, disconnect it from the operating
valve. Blow air through the hose and nozzle assemblies to insure that the passage is clear of foreign
material. Check the couplings, hose and hose gasket for damage or deterioration - replace as necessary.
10. Inspect valve assembly for signs of corrosion or damage to hose thread connection. Valve removal and/or
valve part replacement should be made only after following the depressurizing procedures listed in the
COMPLETE MAINTENANCE procedures.
11. Reconnect the hose to the agent cylinder. Properly coil the hose on the rack and install the nozzle (with
the lever in a closed position) on the mount.
Note: When assembling the hose to the agent cylinder or nozzle to the hose, tighten the coupling ¼ turn after
contacting the hose gasket.
12. Wheeled extinguishers - Inspect the wheels to insure they rotate freely. Lubricate as required. Stationary
extinguishers should be checked to assure that all mounting devices are securely fastened.
13. Check carriage assembly for loose nuts, bolts, frame distortion or damage. Check welds for damage or
corrosion. Replace damaged parts or make repairs as necessary.
14. Install new tamper seal and record service data on the extinguisher inspection tag.
15. If the extinguisher has been moved to perform service, it must be returned to its proper location.
6.6.
6.6.
6.

7.7.
7.7.
7.
COMPLETE MAINTENANCE (SIX YEAR TEARDOWN)
COMPLETE MAINTENANCE (SIX YEAR TEARDOWN) [NFPA-10 4-4.1.4] Every six years, stored pres-
sure extinguishers that require a 12 year hydrostatic test shall be emptied and subjected to the
applicable maintenance procedures. When the applicable maintenance procedures are performed
during periodic recharging or hydrostatic testing, the six year requirement shall begin from that
date.
Note: Some States require a Complete Teardown on an annual basis. Check with your Amerex Servicing
Distributor to see if this applies to you. NFPA-10 recommendation requires that a "verification of
service" external collar tag be installed on the extinguisher whenever a "Six Year Maintenance" is
performed. The "verification of service" tag" can only be installed if the operating valve has been
removed. "Six Year Maintenance" service decal must also be attached to extinguisher cylinder.
COMPLETE MAINTENANCE (SIX YEAR TEARDOWN) PROCEDURES
1. Discharge chemical and pressure into a “closed” dry chemical recovery system (Getz Mfg. is recommended).
Make sure that the extinguisher is completely empty and depressurized.
CAUTION: THESE EXTINGUISHERS OPERATE AT 240 PSI. SOME RECOVERY SYSTEMS MAY
REQUIRE THAT THE PRESSURE BE REDUCED TO SAFELY DISCHARGE THE CHEMICAL
AND PRESSURE INTO THE SYSTEM. USE THE PRESSURE BLEEDER VALVE ON THE
EXTINGUISHER VALVE TO REDUCE THE PRESSURE TO A POINT REGISTERING JUST
BELOW THE GREEN OPERABLE AREA ON THE PRESSURE GAUGE. DISCHARGE EXTIN-
GUISHER INTO RECOVERY SYSTEM. RE-PRESSURIZE THE EXTINGUISHER (TO NO
MORE THAN 200 PSI) TO EXHAUST ANY CHEMICAL REMAINING IN THE EXTINGUISHER.
Note: A “closed” recovery system is designed to prevent loss of the chemical “fines”. Loss of the “fines” could
result in reduced extinguisher efficiency.
2. Clean extinguisher to remove dirt, grease or foreign material. Check to make sure that the instruction name-
plate is securely fastened and legible. Inspect the cylinder for corrosion, abrasion, dents or weld damage. If
any of these conditions are found and you doubt the integrity of the cylinder, hydrostatically test to factory test
pressure - 500 psi, [3448 kPa], using the proof pressure method, in accordance with CGA Pamphlet C-6 and
NFPA Pamphlet 10.
Note: When cleaning, avoid use of solvents around the pressure gauge. They could seriously damage the
plastic gauge face.
3. Inspect the extinguisher for damaged, missing or substitute parts. Only factory replacement parts are ap-
proved for use on Amerex fire extinguishers.
4. Checkthedateofmanufactureontheextinguishercylinderdome.Cylindermustbehydrostatically(proofpressure)
testedat12years(firsttime),every7yearsthereafter,tothetestpressureindicatedonthenameplate-500psi, [3448
kPa].
5. Visually inspect the pressure gauge - if bent, damaged or improper type or pressure - replace with Amerex
P/N: 5225 240 psi Gauge.
6. Remove and check ring pin for freedom of movement. Replace if bent or if removal appears difficult.
7. VERIFY THAT NO PRESSURE REMAINS IN THE EXTINGUISHER (Operating valve and nozzle shutoff in
open position and there is no discharge). Remove and inspect the agent fill cap for damage or distortion.
8. Checkthenozzleshutoffleverforfreedomofmovement(openandcloseseveraltimes).Iftheoperationisimpeded,
disassemblethenozzle,replacepartsand/orproperlylubricateasnecessary.Makesurethatthenozzletipisclear
andunobstructed.
9. Disconnectthedischargehosefromtheoperatingvalve.Blowairthroughthehoseandnozzleassembliestoinsure
thatthepassageisclearofforeignmaterial.Checkthecouplings,hoseandhosegasketfordamageordeterioration,
replaceasnecessary.Thedischargehoseshouldbehydrostaticallytestedto300psi(2068kPa)everytwelveyears.

10. Inspect the wheels to insure they rotate freely. Lubricate as required.
11. Check carriage assembly for loose nuts, bolts, frame distortion or damage. Check welds for damage or
corrosion. Replace damaged parts or make repairs as necessary.
12. Remove operating valve assembly. Inspect for corrosion or damage to hose thread connection.
WARNING: VALVE REMOVAL AND/OR VALVE PART REPLACEMENT SHOULD BE MADE ONLY
AFTER COMPLETING THE DEPRESSURIZING PROCEDURES LISTED IN STEP 1 OF THE
COMPLETE MAINTENANCE PROCEDURES.
13. Complete steps 2 thru 15 of RECHARGE PROCEDURE.
RECHARGE
RECHARGING [NFPA-10 4-2.3] is the replacement of the extinguishing agent and also includes the
expellant for this type of extinguisher.
WARNING:
A.BEFORE ATTEMPTING TO RECHARGE BE SURE THE EXTINGUISHER IS COMPLETELY DEPRESSURIZED.
B.NEVER HAVE ANY PART OF YOUR BODY OVER THE EXTINGUISHER WHILE REMOVING THE VALVE ASSEMBLY
OR FILL PLUG.
C.USE APROTECTIVE SHIELD BETWEEN YOU AND THE PRESSURE GAUGE WHILE CHARGING AN EXTINGUISHER.
DO NOT STAND IN FRONT OF THE GAUGE IF ASHIELD IS NOT AVAILABLE.
D.USE AREGULATED PRESSURIZING SOURCE OF DRY NITROGEN ONLY WITH AMINIMUM DEW POINT OF
MINUS 70°F ( MINUS 57°C). SET THE REGULATOR TO NO MORE THAN 265 PSI ( 1827 KPA) .
E.CHECK AND CALIBRATE REGULATOR GAUGE AT FREQUENT INTERVALS. THE REGULATOR GAUGE SHOULD BE
USED TO DETERMINE WHEN THE INTENDED CHARGING PRESSURE HAS BEEN REACHED. DO NOT USE THE
EXTINGUISHER GAUGE FOR THIS PURPOSE.
F.NEVER LEAVE AN EXTINGUISHER CONNECTED TO AREGULATOR OF AHIGH PRESSURE SOURCE FOR AN
EXTENDED PERIOD OF TIME. ADEFECTIVE REGULATOR COULD CAUSE THE CYLINDER TO RUPTURE DUE TO
EXCESSIVE PRESSURE.
G.DO NOT MIX TYPES OF DRY CHEMICALS IN EXTINGUISHERS, RECHARGE OR RECOVERY SYSTEMS. MIXING
ABC (ACIDIC BASE) WITH REGULAR, PURPLE K, SUPER-K OR MONNEX (ALKALINE BASE)
DRY CHEMICALS MAY RESULT IN ACHEMICAL REACTION CAPABLE OF DEVELOPING ADANGEROUS PRES-
SURE BUILDUP.
RECHARGING PROCEDURE
1. Perform steps 1 thru 12 of the “COMPLETE MAINTENANCE (SIX YEAR TEARDOWN)” section.
2. Remove downtube, spring and valve stem assembly from the operating valve and thoroughly clean all parts
with a soft bristle brush or soft cloth. Blow the valve, downtube and "Bleeder" valve (if used to depressurize
the extinguisher) out with air or nitrogen. Inspect the collar o-ring, valve stem, spring and downtube ass’y -
replace parts if worn or damaged. Lubricate the collar o-ring, and small o-ring on the valve stem with Visilox
V-711 (do not lubricate the valve stem seal).
3. Reassemble the valve assembly, including downtube and set aside.
4. Remove agent fill cap and place to the side. Remove any chemical remaining in the cylinder and check the
condition. Properly dispose of any chemical that is contaminated or caked.
8.8.
8.8.
8.

9.
5. InspectthecylinderinteriorfollowingCGA Visual InspectionStandard,PamphletC-6.
6. Clean cylinder collar o-ring seat and collar threads with a small brush and then wipe off surfaces with a clean
damp cloth to remove dust. Lightly brush the collar o-ring seat with Visilox V-711. Install operating valve/
downtube assembly, HAND TIGHT.
Note: A "verification of service" external collar tag must be installed BEFORE installing the operating valve/
downtube assembly.
7. Stand the extinguisher upright on an accurate scale of sufficient size and capacity (400 lb. minimum).
Remove agent fill cap. Remove agent fill cap o-ring. Clean cap and cylinder threads with a small brush and
wipe surfaces with a clean damp cloth to remove dust. Inspect o-ring and replace if damged or deformed.
Install o-ring and lightly brush it and all threads with Visilox 711.
8. Fill cylinder through chemical agent fill hole with the correct amount and type of dry chemical specified on the
label (nameplate). Use AMEREX chemical which has been kept free of moisture and contamination.
CAUTION: FILLING BY EYE ALONE COULD CAUSE POTENTIALLY DANGEROUS OVER-FILLING
ALWAYS USE A SCALE.
9. After the extinguisher has been filled to the proper weight, install the agent fill cap, HAND TIGHT.
10. Attach the nitrogen charging adapter to the male hose connector on the operating valve.
11. With the extinguisher properly secured in an upright position, connect your nitrogen pressurizing line with
a quick connect to the nitrogen charging adapter. Rotate the extinguisher operating valve lever to the
OPEN position and pressurize extinguisher with dry nitrogen to 240 psi. When the desired pressure has
been reached, rotate the operating lever to the CLOSED position. Shut off nitrogen supply and remove the
quick connect.
CAUTION: PRESSURIZING THE EXTINGUISHER IN THIS MANNER WILL ALLOW FOR PROPER
AERATION OF THE CHEMICAL THROUGH THE DOWNTUBE. DO NOT USE THE
“BLEEDER” VALVE TO PRESSURIZE THE EXTINGUISHER.
12. Remove the nitrogen charging adapter. Check extinguisher for leaks by applying leak detecting fluid or a
solution of soapy water to the male hose connector orifice, around the collar o-ring sealing areas of valve and
fill cap, cylinder welds, gauge and "Bleeder" valve. Remove leak detecting fluid from valve assembly by
blowing out with air or nitrogen. Wipe exterior of extinguisher to remove any remaining residue.
13. Reconnect the hose to the operating valve. Properly coil the hose on the rack and install the nozzle (with
the lever in a closed position) on the mount.
CAUTION: WHEN ASSEMBLING THE HOSE TO THE AGENT CYLINDER OR NOZZLE TO THE HOSE,
TIGHTEN THE COUPLING ¼ TURN AFTER CONTACTING THE HOSE GASKET.
14. Install ring (safety) pin and lockwire (tamper) seal. Record recharge date and attach new recharge tag.
15. Weigh assembled extinguisher and confirm that the toal weight is within the allowable tolerances indicated in
the "Maintenance" section of the nameplate (label).

10.
TROUBLESHOOTING GUIDE
WARNING: BEFORE ATTEMPTING TO CORRECT ANY LEAKAGE PROBLEM, BE SURE THAT THE
AGENT CYLINDER AND HOSE ARE COMPLETELY DEPRESSURIZED.
Note:Check to determine the source of a leak before the extinguisher is depressurized. Leakage repairs will
require depressurization and removal of the valve assembly or chemical agent fill cap. Depressurize by
removing bleeder valve cap (“bleeder” valve is mounted on the side of the operating valve assembly),
depress valve stem to relieve the dome pressure, with the extinguisher in an upright position. After
depressurizing the extinguisher and correcting the problem, it will be necessary to clean all valve and cap
parts thoroughly.
PROBLEM CORRECTIVE ACTION
1. Leak at operating valve collar o-ring 1. Remove valve assembly, clean collar thoroughly and
install new collar o-ring. Lubricate o-ring with Visilox V-711.
2. Leak at agent fill cap 2. Remove cap, clean threads thoroughly and install new
o-ring. Lubricate o-ring with Visilox V-711.
3. Leak through valve. 3. Install new valve stem assembly. Check valve seat for
scratches or foreign matter.
4. Leak at “bleeder” valve. 4. Remove and reinstall valve using Teflon tape on threads.
Note: “Bleeder” valve cap must be installed to prevent
leakage.
5. Leak around gauge threads. 5. Remove gauge*and reinstall using Teflon tape on the
gauge threads.
6. Defective gauge. 6. Remove defective gauge*and install new P/N: 5225
240 psi gauge using Teflon tape on the gauge threads.
7. Leak in the cylinder. 7. Contact Amerex if under warranty, otherwise - mark
“Rejected” and remove from service or return to owner.
*Pressure gauge threads are coated with a special epoxy at the factory. For easy removal, soak
the valve assembly in hot water (180°F.) for two to four minutes. Remove gauge with a 7/16"
open end wrench.

11.
PROPER METHOD FOR COILING DISCHARGE HOSE
ON 125/150 LB. WHEELED AND STATIONARY
STORED PRESSURE DRY CHEMICAL EXTINGUISHERS
(If instructions are followed, the hose will uncoil without kinks.)
1
Connecthosecouplingto extinguisher valve.
Lay hose straight out on ground to its full 50
ft. length. Start first regular loop counter-
clockwise by placing between side brackets
and over top bracket.
2
The second loop is a REVERSE loop. Notice
that the hose passes behind the loop on this
REVERSEloop.
3
The next loop is a regular “HOSE IN FRONT”
loop. Succeeding loops are alternated: RE-
VERSE, FRONT for a total of five loops.
4
Adjust the loops so that the nozzle fits into
the nozzle mount. Loops should be approxi-
mately the same size.
HOSE
BEHIND
LOOP

1
2
3
45
6
7
8A
8B
9
10 17
11 18
12
13
14
15
16 20
21
22
23
24
25
26
27
PARTS LIST
for
125 / 150 LB. WHEELED / STATIONARY Stored Pressure
DRY CHEMICAL Extinguishers
WHEELED MODELS 488 125 LB. ABC 489 150LB.REGULAR 490 125 LB.PURPLE K
STATIONARY MODELS 476 125 LB. ABC 477 150LB.REGULAR 478 125 LB. PURPLE K
ITEM
NO. PART NO. DESCRIPTION STD. PKG.
1 5197 Valve Ass'y Complete with Downtube 1
2 4938 Downtube/Retainer Ass'y 1
3 9300 Fill Cap 1
4 8392 Gasket, Fill Cap 1
5 10431 Carriage Ass'y without Wheels - New Style 1
⌧6624 Old Style 1
6 10430 Hose Support with Mounting Hardware -
New Style 1
⌧6129 Old Style 1
⌧6225 Nozzle Clips with Mounting Hardware -
Old Style (2 required) 2
⌧6376 Nozzle Mount with Hardware (Old Style) 1
75194 Cylinder with Mounting Brackets -Old Style 1
10467 New Style 1
8A Nameplate (Mylar Label) Non U/L
SPECIFY MODEL NO. AND YEAR
OF MFG. OF THE EXTINGUISHER
1
8B 7481 Pictogram - 488, 476 1
7483 489, 490, 477, 478 1
9 7751 Wheel Ass'y, 16" with Hub Cap, Washer
and Retaining Pin (Semi-Pneumatic) 1
10 4945 Hub Cap 1
11 6059 Valve Lever with Screws 1
12 3562 Gauge Guard Ass'y 1
13 5225 Gauge - 240 PSI 1
14 6100 Ring Pin, Stainless Steel with Wire 12
15 0155 Pressure Valve and Cap Ass'y 12
16 1387 Lock Wire Seal (Yellow) 500
17 3678 Valve Body 1
18 6060 Cam Ass'y with O-Rings 1
19 5239 Collar O-Ring 12
20 5067 Valve Stem Ass'y 6
21 3556 Spring 6
22 3501 Hose Ass'y, 50 ft. 1
23 3877 Gasket, Hose/Nozzle 6
24 6279 Ball Valve Ass'y 1
25 6470
6208 Nozzle Tip - 488, 489, 476, 477 (.344) 490, 478 (.328) 1
26 5191
7432
Nozzle Ass'y (Ball Valve & Tip)
488, 489, 476, 477
490, 478
1
27 9857 Fill Adpater 1
28 5152 Hydrotest Adapter (Cylinder) 1
NOTE: Replacement Valve Assemblies include New
Valve Body, Gauge, Gauge Guard, Safety Disc
Ass'y, Cam, Pressure Valve & Cap, Lever, Valve
Stem Ass'y, Spring, Downtube/Retainer Ass'y
⌧PART NOT PICTURED 28
12.
19