CHERNE AIR-LOC User manual

INSTRUCTIONS
AIR - LOC
SLEEVELESS JOINT TESTERS
42" THROUGH 120"
1100 mm THROUGH 3000 mm
CHERNE INDUSTRIES INCORPORATED
5700 LINCOLN DRIVE
MINNEAPOLIS, MN 55436 - 1695
1
-
800
-
THE
-
PLUG
(1 - 800 - 843 - 7584)
FAX: 1 - 800 - 843 - 7585
www.cherneind.com

SLEEVELESS JO INT TESTERS
2
TABLE OF CONTENTS
Introduction ............................................................... Page 2
Packing List .............................................................. Page 3
Safety ........................................................................ Page 3
Frame Assembly ....................................................... Page 4 -6
End Element Installation Procedure .......................... Page 7
Control Panel & Wheel Assembly Installation .......... Page 8
Operation ................................................................... Page 9
Air and Water Testin g Procedure .............................. Page 10
Maintenance .............................................................. Page 11
Daily Checklist .......................................................... Page 11
Replacement End Elements ....................................... Page 11
Trouble Shooting Guide ............................................ Page 12
Joint Tester Control Panel Parts List ......................... Page 13
Joint Tester Wheel Assembly Complete ................... Page 15
Wheel Assembly Parts Li st ....................................... Page 16 - 17
Component Parts List ................................................ Page 19
Manhole Safety Procedures ...................................... Page 21
Warranty ................................................................... Page 22
INTRODUCTION
The Joint Tester measures leaks in pipeline joints. End elements create a sealed
cavity along a joint into which either air or water can b e pumped. A control panel
monitors pressure within the cavity. Standard Joint Testers are made specifically
for reinforced concrete pipe. Consult the factory for Joint Testers to be used in
pother types of pipe.
Cherne Industries manufactures joint te sters ranging in size from 21 " (525 mm) through 120" (3,000 mm) . This manual
provides information on how to assemble, operate, trouble shoot, and maintain Large Diameter Sleeveless Joint Testers.
NOTE: Custom sizes are available upon request in a wide v ariety of sizes and test pressures.

ITEM QUANTITY PART NUMBER DESCRIPTION
1 1 Refer to page 19 Joint Tester Weld Assembly
2 3 010 - 628 Gasket - Straight Leg, 42" - 54" JT
or
010 - 638 Gasket - Tapered Leg, 60" - 120" JT
3 2 Refer to page 19 End Elemen t
5 4 104 - 132 Bulkhead, 1/4 Long neck
6 4 006 - 290 Washer -Flat, .75 D, .06" Thick
7 4 067 - 415 Washer, 3/4 Flat
8 4 006 - 282 Washer, 3/4 Rubber - 3/16" Thick
9 3 251 - 623 Nipple, 1/4 QD x 1/4 MPT
10 1 002 - 690 Reducer - 1/4MPT x 1/8FPT
11 1 055 - 948 Nipple - 1/8FPT
12 1 003 - 808 Valve - 1/8FPT
13 2 251 - 607 Plug - Brass, 1/4 NPT
15 2 067 - 008 Wheel Assembly, 39" - 54" JT or
093 - 661 Wheel Assembly, 60 -95 JT or
024 - 358 Wheel Assembly, 9 6" - 120" JT
16 17 068 - 136 Bolt, Carriage, 3/8 - 16 x 1.25 SS
17 8 118 - 974 Washer, 3/8 Bolt, Neoprene
18 17 000 - 051 Washer, 3/8 Flat
19 8 000 - 159 Washer, 3/8 Lock
20 8 000 - 884 Nut, 3/8 - 16 Hex
21 1 010 - 048 Control Panel
22 1 013 - 008 Hose Assy, 12' JT I nflation
24 2 000 - 361 Bolt, MHH, 1/4 - 20 x 1/2"
25 2 000 - 132 Washer, Lock, 1/4
26 1 017 - 914 Disc, Red
27 1 017 - 922 Disc, Blue
28 1 017 - 930 Disc, Yellow
29 9 000 - 892 Nut, 3/8 - 16 Self Locking SS
30 5.3 oz. 016 - 808 Grease, Silicone
3
SLEEVELESS JOINT T ESTERS
PACKING LIST
(Refer to FIGURE 10, Page 20)
Inspect your Joint Tester for damage upon arrival. If damage is found the delivery carrier must be notified immediately so
that you may file a claim. If the ca rrier is not notified immediately, they are within their rights to refuse any claims. When
unpacking, care should be taken to be sure that all items are accounted for and that none are discarded with the
packaging. Check the parts list for part numbers.
SA FETY
1. Observe all state and federal regulations when entering pipelines or manholes.
2. Follow the Manhole Safety Procedure at the end of this manual.
3. Wear a hard hat, safety glasses & ear protection during operation.
4.
Before you connect the air
-
input hose to the control panel, make sure both valves on the panel are OFF
(counter - clockwise).
5. Never inflate the end elements above ground or inside pipe that is larger than the design size of the Joint Tester.
6. Inflate end elements to 80 psig (5.5 Bar), but DO NOT OVER - INFLATE.
7. Inflate the test cavity to 50 psig (3.4 Bar), but DO NOT OVER - INFLATE.

SLEEVELESS JOINT TESTERS
4
The only assembly required on Joint Testers is hooking up the control panel and installing the wheel assemblies.
How ever, it may be necessary at some point to take apart and re - construct the frame and end elements. If so, carefully
follow the FRAME ASSEMBLY and END ELEMENT installation instructions in this manual. Improper assembly will
cause your joint tester to leak d uring operation.

SLEEVELESS JOINT TESTERS
5
2. Lay the three sections of the frame on a flat surface in the form of a circle. Make sure the stamped
identification marks on the outside edge of the frame match as shown in FIGURE D.
3. Place the gasket (coated with silicone) on the end of one frame section as shown in FIGURE E.
4. Slide the ends of the frame sections together to secure the sealing gasket as shown in FIGURE F.
NOTICE: Proper gasket installation is critical! Make sure the sealing gasket i s installed as shown in
FIGURE F; NOT as shown in FIGURE G.

6
5. Refer to FIGURE H. Fasten the sections together by
installing the 3/8 carriage bolts, flat washers and
self locking nuts. Only hand tighten the hardware at
this time.
6. Repeat Fram e Assembly steps 1 through 5 for the
two remaining sections to be joined.
7.
Refer to FIGURE 1. Tighten the
center
carriage bolt
and
self
-
locking nut
on each of the three brackets with a
wrench.
8. After each center bolt and nut is fully tightened, tight en the top and bottom carriage bolts and self Locking nuts
on each bracket. While tightening with the wrench, press the gasket against the outer channel of the frame with
your hand to make sure it stays in place. See FIGURE J.
9. Repeat Frame Assembly ste ps 7 and 8 to make sure each gasket is evenly compressed.
10. Wipe off any excess grease from the gaskets and frame.

SLEEVELESS JOINT TESTERS
7
INSTALLING THE END ELEMENTS
(You will need two people)
1. Insert eight 3/8 - 16 x 1 - 1/4" carriage bolts and 3/8 rubber washers into the frame's wheel bracket mounting
holes. (Make sure the threads of the carriage bolts are on the inside of the frame.) Install the 3/8 lock washers
and thread the 3/8 hex nuts onto the carriage bolts. Only hand tighten the hex nuts at this time. This hardware
will be used to later mount the wheel assemblies.
2. Refer to FIGURE 3. On the outside of the frame, insert the brass end element inflation fitting through
the hole in the top channel of the frame.
On the inside of the f rame, secure the brass end element inflation fitting using the star washer and hex
nut supplied with the end element.
3. Refer to FIGURE 4. Carefully stretch the end element over the joint tester (by hand or with
the aid of pry bars) and into the top ch annel section of the frame. Corn starch, silicone, or soapy water
may be used if desired.
NOTE: Make sure the outer strip of the gasket doesn't become pinched under the end element. If it does, carefully
pry the end element away from the joint tester fra me and press the gasket back into it's original position.
4. Turn the joint tester over and repeat steps 2 and 3 for the second end element.
NOTE: If pry bars are used, the edge of the joint tester frame must be filed smooth if it has nicks or sharp edge s.

SLEEVELESS JOINT TESTERS
8
CONTROL PANEL HOOK - UP AND WHEEL ASSEMBLY INSTALLATION
1 . Refer to FIGURE 5. Using the 1/4 - 20 x 1/2" bolts and 1/4 lock washers, mount the control panel on the control
panel mounting pad located at the bottom of the joi nt tester frame. A bracket is also included at the top of the weld
assembly as an optional location for the control panel.
2. Connect the hoses on the hose assembly from the control panel to the joint tester center cavity and end element
inflation fitting s. Make sure the hoses are connected between fittings with the same colored disc markers.
3. Refer to FIGURE 5. Fasten the wheel assemblies to the joint tester using the hardware pre - installed in step 1 on
page 7.
NOTE: It is very important that the rubb er washer remains properly seated on the carriage bolt, and that the square
neck of the carriage bolt is properly seated in the square holes of the joint tester frame. Leakage may occur if an
improper fit exists. After sliding the wheel assembly base onto the bolts, check the bolt for a proper fit. To
make sure the bolt remains properly seated, apply pressure to the end element directly above the bolt until the
lock nut is fully tightened.
CAUTION: NEVER STAND THE JOINT TESTER IN AN UPRIGHT POSITION WHERE IT IS NOT SUPPORTED
BY THE WHEEL ASSEMBLIES. NEVER RELOCATE THE JOINT TESTER BY ROLLING IT ON
END (ESPECIALLY OVER ROUGH SURFACES). EXTREME AMOUNTS OF PRESSURE ARE
PLACED UPON THE JOINT TESTER IN BOTH OF THESE SITUATIONS WHICH MAY RESULT IN
DAMAGING THE EN D ELEMENTS.

SLEEVELESS JOINT TESTERS
9
OPERATION
NOTE: Before joint testing begins, an air compressor or ample water supply (depending on the type of test media
you're using) should be located above ground with a sufficient length of air hose capabl e of reaching all
joints to be tested.
CAUTION: BEFORE OPERATING, BE SURE THAT THE 3 - WAY VALVES ON THE CONTROL PANEL ARE
IN THE "OFF"POSITION, AND THAT THE TEST PRESSURE AND END ELEMENT AIR
REGULATORS ARE TURNED FULLY COUNTERCLOCKWISE.
1 . Once completel y assembled and inside the pipe, roll the joint tester to the first joint to be tested.
2. Refer to FIGURE 6. Place the joint tester in its upright position so that each end element straddles the joint
being tested.
3. Adjust the wheel assemblies so ther e is approximately a 1" space between the joint tester and the pipe wall.
Adjust the height of the joint tester by turning the adjustment handles on the wheel assembly.
Note: Offset pipe joints require different wheel settings to compensate for pipeline i rregularities. Extra care must
be taken when positioning the joint tester over this type of joint.

SLEEVELESS JOINT TESTERS
10
AIR TESTING PROCEDURE
1. Attach the air hose leading from the air compressor to the AIR IN connection on the control panel a nd turn the air
compressor on.
CAUTION: WEAR EAR PROTECTION WHEN INFLATING THE END ELEMENTS AND PRESSURIZING THE
PIPE JOINT.
2. Place the end element inflation valve in the "FILL" position, and adjust the end element regulator by turning it in a
clockwis e direction until 80 PSI reads on the end element pressure gauge. Following this adjustment, place the end
element 3 - way valve in the OFF position.
CAUTION: DO NOT EXCEED 80 PSIG (5.5 BAR).
3. To pressurize the pipe joint, place the test pressure inflati on valve in the "FILL" position. Turn the test pressure
regulator dial in a clockwise direction until the specified test pressure is indicated on the test pressure gauge.
Place the test pressure 3 - way valve in the OFF position.
CAUTION: DO NOT EXCEED 15 P SIG ( 1.0 BAR).
NOTE: The end element and test pressure control regulators are now adjusted to their correct settings. All
operational control adjustments hereafter are to be made using the 3 - way control valves.
4. Monitor the test pressure gauge to dete rmine the amount of time it takes to drop 1 PSIG.
NOTE: Refer to your City, County and/or State Municipal Inspection Codes to determine the minimum allowable air
loss/time ratio.
5. If the joint holds its pressure for the specified amount of time, it pas ses. If there is a loss of air pressure in excess of
1 PSIG during the required test period, the location of the joint should be noted and future repair will be necessary.
6. Relieve the test pressure by placing the test pressure 3 - way valve into the "EXH AUST" position.
7. Deflate the end elements by placing the end element 3 - way valve into the "EXHAUST"' position.
8. When the end element pressure gauge reads "0", disconnect the air hose, and roll the joint tester to the next joint to
be tested. Repeat o peration procedures.
CAUTION: ALWAYS DEFLATE THE CENTER CAVITY BEFORE DEFLATING THE END ELEMENTS.
WATER TESTING PROCEDURE
1. Attach the hose leading from the water supply to the WATER IN connection on the control panel. Attach the air
supply to the pane l as directed in step 1 of the AIR TESTING PROCEDURE.
CAUTION: WEAR EAR PROTECTION WHEN INFLATING THE END ELEMENTS AND PRESSURIZING THE
PIPE JOINT.
2. Place the END ELEMENT inflation valve in the "FILL" position, and adjust the END ELEMENT regulator by
t urning it in a clockwise direction until 80 psig reads on the END ELEMENT PRESSURE GAUGE. Following this
adjustment, place the END ELEMENT 3 - way valve in the OFF position.
CAUTION: DO NOT EXCEED 80 PSIG (5.5 BAR).

SLEEVELESSJOINT TESTERS
11
3. To press urize the pipe joint, place the CENTER CAVITY valve in the OFF position. Turn the water supply
on.
NOTE: Make sure the 1/8 inch female valve on the bulkhead assembly (located at the top of the joint tester) is in
the open position before performing step 4 .
4. Place the TEST MEDIA SELECT and the TEST GAUGE SELECT valves in the WATER TEST position. Water
will slowly begin to enter the test chamber.
5. When a steady stream of water is bleeding from the 1/8 inch female valve on the bulkhead, place the
CENTER CAVITY valve in the "OFF" position, and close the 1/8 inch female valve.
6. Slowly return the CENTER CAVITY valve to the ON position and adjust the water test pressure to the desired
setting by monitoring the CENTER CAVITY WATER PRESSURE gauge.
CAUTION: DO NOT EXCEED 50 PSIG (3.4 BAR) WATER.
7. Place the CENTER CAVITY valve in the "OFF" position when the desired water test pressure is achieved.
NOTE: Refer to State/Federal municipal pipeline testing specifications regarding the correct test pressure.
8. Monitor the water test pressure gauge to determine the amount of time it takes for the water pressure to drop 1 PSIG.
NOTE: Refer to your City, County and/or State Municipal Inspection Specifications to determine the
minimum allowable water loss/time r atio.
9. If the joint holds its pressure for the specified amount of time, it passes. If there is a loss in water pressure, the
location of the joint should be noted for future repair.
10. To relieve the pressure, place the CENTER CAVITY valve on the con trol panel in the EXHAUST position.
Water will then drain from the CENTER CAVITY exhaust port.
11. To deflate the end elements, place the END ELEMENT 3 - way valve in the "EXHAUST"' position.
12. When the END ELEMENT PRESSURE GAUGE reads "0", roll the Join t Tester to the next joint to be tested.
Repeat Operation Procedures.
CAUTION: ALWAYS DEFLATE THE CENTER CAVITY BEFORE DEFLATING THE END
ELEMENTS.
MAINTENANCE
1 . Clean and inspect the entire unit at the end of each day.
2. The inflatable end elements an d hoses should be checked for excessive wear and damage that may
lead to possible leaks.
DAILY CHECK LIST
1 . Pressure regulators checked for proper settings?
2. All fittings and hoses checked for leaks?
3. Air compressor checked for proper operation?
RE PLACEMENT END ELEMENTS
Joint Tester replacement end elements are available upon request from CHERNE INDUSTRIES INCORPORATED.
After receiving your replacement end elements, install them according to the installation procedures on page 7.
Consult the compone nts parts list for the appropriate part number.

SLEEVELESSJOINT TESTERS
12
TROUBLE - SHOOTING GUIDE
IF END ELEMENTS DON'T INFLATE...
Connect the hose leading to the end elements.
Connect the hose from your air compressor.
Turn on your air compres sor.
Fix or replace an end element.
Turn your end element regulator dial clockwise and to the right.
Fix or replace the end element regulator.
Fix or replace the end element 3 - way valve.
IF THE END ELEMENT PRESSURE GAUGE READS THE WRONG PRESSURE...
C heck the hose leading to the end elements for kinks.
Test and replace gauge if necessary.
IF END ELEMENTS LOSE PRESSURE WHEN VALVE IS TURNED TO "OFF"...
Fix or replace an end element.
Fix or replace the hose leading to the end elements.
Tighten the hose connections.
Fix or replace the 3 - way valve.
IF THE TEST PRESSURE GAUGE WON'T READ ANY PRESSURE...
Have you found a leaking pipe joint.
Connect or tighten the hose leading to the cavity. Fix
or replace the hose going to the cavity.
Verify that the te st pressure regulator is on.
Fix or replace the test pressure regulator.
Fix or replace the 3 - way valve.
Test and replace gauge if necessary.
IF THE TEST PRESSURE READING ON THE GAUGE DROPS TOO QUICKLY...
Have you found a leaking pipe joint?
Replace the hose leading to the cavity.
Tighten the hose connections.
Clear debris off the pipe wall so no air leaks out between the wall and the end elements.
Wet the pipe wall to see if air is leaking through the wall.
Use epoxy or latex paint on pipe walls to seal the porous pipe.

SLEEVELESS JOINT TESTERS
JOINT TESTER CONTROL PANEL PARTS LIST
(Refer to FIGURE 7)
P/N OTY PART NUMBER DESCRIPTION
13
1 1 010-038 CONTROL PANEL, RAW
2 1 017-358 GAUGE, LIQ FILLED, 0 - 15 PSI
3 1 087-602 GAUGE, 0 - 60 PSI
4 1 014-838 GAUGE, 0 - 100 PSI
5 3 002-615 ELBOW 90,1/4 FPT X 3/8 POLY
6 6 050-466 SCREW, BUM 10 - 32 X 3/8 SS
7 6 068-470 WASHER, #10 TOOTH LOCK, SS
8 6 050-512 NUT - HEX, #10 - 32 SS
9 17 002-593 ELBOW 90,1/4 MIT X 3/8 POLY
10 4 007-892 VAL VE, 3 - WAY
11 4 251-623 NIPPLE, 1/4 QD X 1/4 MPT
12 1 017-922 DISC, BLUE
13 1 017-914 DISC, RED
14 1 017-930 DISC, YELLOW
15 1 251-690 ELBOW 90,1/4 STREET
16 4 003-492 TEE, 1/4 STREET
19 6.25 FT 014-796 TUBING, 3/8 POLY
20 2 296-643 REGULATOR, 0 - 100 PSI OU TLET
21 2 002-518 BULKHEAD, 1/4
22 1 035-653 ADAPTER, 1/4 MPT X F GARD HSE
23 1 035-688 WASHER, GARDEN HOSE
24 1 012-978 MUFFLER, 9/16 DIA
28 1 024-848 LABEL - INFO. TO ZERO GAUGE

16
ITEM QUANTITY PART NUMBER DESCRIPTION
1 1 066 - 583 Wheel Mount Supports
2 1 066 - 575 Wheel Mounts
3 2 000 - 620 Bolt, NIM 1/2 - 13 x 3.50
4 2 000 - 957 Nut, 1/2 - 13 UNC Self Lo cking
5 1 066 - 850 Shaft, Crank Support Upper
6 2 004 - 944 Ring, Snap - l" Ext.
7 1 066 - 834 Crank Assembly, IT
8 1 018 - 368 Sleeve, Crank Handle
9 1 001 - 848 Ring, Snap - 5/8" Ext.
10 1 002 - 062 Grip, Large
11 1 066 - 869 Shaft, Crank Support - Lower
12 2 044 -9 70 Bushing, Oilite Flange - 3/8" ID
13 2 001 - 856 Ring, Snap - 3/4" Ext.
14 1 001 - 503 Cotter Pin, 1/8" x 1 1/2"
15 2 000 - 078 Washer, 1/2" Flat
16 1 066 - 842 Wheel, 5" OD x 1/2" ID
19 4 050 - 709 Bolt, MHH, 5/16 - 18 x 1.25
20 4 000 - 140 Washer, 5/16 Lock
21 4 000 - 930 Nut, 5/16 - 18 UNC Self Locking
22
2
000
-
043
Washer, 5/16 Flat
SLEEVELESS JOINT TESTERS
WHEEL ASSEMBLY PARTS LIST
(P.N.004
-
000)
(SEE FIGURE 9A)
SLEEVELESS JOINT TESTERS
SLEEVELESS JOINT TESTERS

ITEM QUANTITY PART NUMBER DESCRIPTION
1 1 024 - 338 Wheel Mount Supports
2 1 024 - 378 Wheel Mounts
3 2 000 - 620 Bolt, NIM 1/2 - 13 x 3.50
4 2 000 - 957 Nut, 1/2 - 13 UNC Self Lockin g
5 1 066 - 850 Shaft, Crank Support Upper
6 2 004 - 944 Ring, Snap - l" Ext.
7 1 066 - 834 Crank Assembly, IT
8 1 018 - 368 Sleeve, Crank Handle
9 1 001 - 848 Ring, Snap - 5/8" Ext.
10 1 002 - 062 Grip, Large
11 1 066 - 869 Shaft, Crank Support - Lower
12 2 044 - 970 B ushing, Oilite Flange - 3/8" ID
13 2 001 - 856 Ring, Snap - 3/4" Ext.
14 1 001 - 503 Cotter Pin, 1/8" x 1 1/2"
15 2 000 - 051 Washer, 3/8" Flat
16 1 024 - 478 Wheel, 6" OD x 3/8" ID
17 2 000 - 043 Washer, 5 \16 Flat
19 4 050 - 709 Bolt, MHH, 5/16 - 18 x 1.25
20 4 000 - 140 Washer, 5/16 Lock
21 4 000 - 930 Nut, 5/16 - 18 UNC Self Locking
22 2 000 - 043 Washer, 5/16 Flat
23 1 301 - 469 Bolt - MHH, 3/8 - 16 x 3.50 Lg
24 2 000 - 892 Nut - 3/8 - 16, Self Locking
17
SLEE
VELESS JOINT TESTERS
WHEEL ASSEMBLY PARTS LIST
(P.N. 024
-
348)
(SEE FIGURE 9B)

SLEEVELESS JOINT TESTERS

19
JOINT
TESTER
SIZE
JOINT
TESTER
PART #
PLAIN
JOINT
TESTER
WELD
ASSEMBLY
PART #
END
ELEMENT
PART #
42 009 - 088 012 - 088 009 - 618 063 - 363
46 504 - 098 NA 057 - 058 057 - 068
48" 009 - 098 012 - 098 009 - 628 063 - 371
54 009 - 108 012 - 148 009 - 638 063 - 398
60 009 - 118 012 - 118 009 - 648 063 - 401
66" 009 - 128 012 - 128 009 - 658 063 - 428
72 009 - 138 012 - 138 009 - 668 063 - 436
78 009 - 158 012 - 158 009 - 678 070 - 444
84" 009 - 168 012 - 168 009 - 688 063 - 452
90 009 - 178 012 - 178 009 - 698 063 - 460
96 009 - 188 012 - 188 009 - 708 063 - 479
102 009 - 198 012 - 198 009 - 718 063 - 487
108" 009 - 208 012 - 208 009 - 728 063 - 495
114 009 - 218 012 - 218 009 - 738 063 - 509
120 009 - 228 012 - 228 009 - 748 063 - 517
1200 MM 009 - 348 N/A 009 - 848 063 - 592
1300 MM 009 - 358 N/A 009 - 858 063 - 606
1700 MM 009 - 348 N/A 009 - 898 063 -6 49
1800 MM 009 - 408 503 - 628 009 - 908 063 - 657
1900 MM
1950 MM N/A 502 - 708 039 - 238 039 - 278
2000 MM
2088 MM 504 - 038 N/A 056 - 388 056 - 398
2100 MM 501 - 398 N/A 031 - 178 031 - 168
2800 MM 503 - 718 N/A 009 - 998 063 - 762
3200 MM 500 - 158 N/A 024 - 118 019 - 268
3450 MM 500 - 128 N/A 024 - 088 024 - 108