Dixon 5500 series Operating and maintenance manual

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MAINTENANCE & OPERATING

INSTRUCTIONS

For

DIXON

5500 SERIES

API RACK COUPLER

For Sales & Service Contact

dixonvalve.com

USA:

Dixon Bayco USA

Chestertown, Maryland

Phone: 410-778-2000

Fax: 410-778-4702

Toll Free: 800-355-1991

E-mail: dixonbayco@dixonvalve.com

Canada:

Dixon Group Canada Limited

Mississauga, Ontario

Phone: 905-673-5999

Fax: 905-673-2454

Toll Free: 877-963-4966

E-mail: isales@dixongroupcanada.com

Mexico:

Dixva, S. de R.L. de C.V.

Monterrey, N.L

Phone: 01-800-00-DIXON (34966)

Fax: 01-81-8354-8197

E-mail: contactenos@dixonvalve.com.mx

Europe:

Dixon Group Europe Ltd

Preston, England

Phone: +44 (0)1772 323529

Fax: +44 (0)1772 314664

E-mail: enquiries@dixoneurope.co.uk

Asia Pacific:

Dixon (Asia Pacific) Pty Ltd

Wingfield, South Australia

Phone: +61 8 8202 6000

Fax: +61 8 8202 6099

E-mail: enquiries@dixonvalve.com.au

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5500 Series API Rack Coupler Model Numbers

5500G............ FKM GFLT SEALS, ALUMINUM HANDLE

5500B............ FKM B SEALS, ALUMINUM HANDLE

5500E ............ EPDM SEALS, ALUMINUM HANDLE

5500F............. FLUOROSILICONE SEALS, ALUMINUM HANDLE

5500BL.......... BAYLAST SEALS, ALUMINUM HANDLE

5500K............ FFKM SEALS, ALUMINUM HANDLE

5500H............ HIFLUOR SEALS, ALUMINUM HANDLE

5500G-L ........ FKM GFLT SEALS, ALUMINUM LOCKING HANDLE

5500B-L ........ FKM B SEALS, ALUMINUM LOCKING HANDLE

5500E-L......... EPDM SEALS, ALUMINUM LOCKING HANDLE

5500F-L......... FLUOROSILICONE SEALS, ALUMINUM LOCKING HANDLE

5500BL-L...... BAYLAST SEALS, ALUMINUM LOCKING HANDLE

5500K-L ........ FFKM SEALS, ALUMINUM LOCKING HANDLE

5500H-L ........ HIFLUOR SEALS, ALUMINUM LOCKING HANDLE

5500G-SS ...... FKM GFLT SEALS, STAINLESS STEEL HANDLE

5500B-SS....... FKM B SEALS, STAINLESS STEEL HANDLE

5500E-SS....... EPDM SEALS, STAINLESS STEEL HANDLE

5500F-SS....... FLUOROSILICONE SEALS, STAINLESS STEEL HANDLE

5500BL-SS.... BAYLAST SEALS, STAINLESS STEEL HANDLE

5500K-SS ...... FFKM SEALS, STAINLESS STEEL HANDLE

5500H-SS ...... HIFLUOR SEALS, STAINLESS STEEL HANDLE

5500G-SSL.... FKM GFLT SEALS, STAINLESS STEEL LOCKING HANDLE

5500B-SSL .... FKM B SEALS, STAINLESS STEEL LOCKING HANDLE

5500E-SSL .... EPDM SEALS, STAINLESS STEEL LOCKING HANDLE

5500F-SSL..... FLUOROSILICONE SEALS, STAINLESS STEEL LOCKING HANDLE

5500BL-SSL.. BAYLAST SEALS, STAINLESS STEEL LOCKING HANDLE

5500K-SSL.... FFKM SEALS, STAINLESS STEEL LOCKING HANDLE

5500H-SSL.... HIFLUOR SEALS, STAINLESS STEEL LOCKING HANDLE

5500G-SH...... FKM GFLT SEALS, SHORT ALUMINUM HANDLE

5500B-SH...... FKM B SEALS, SHORT ALUMINUM HANDLE

5500E-SH...... EPDM SEALS, SHORT ALUMINUM HANDLE

5500F-SH ...... FLUOROSILICONE SEALS, SHORT ALUMINUM HANDLE

5500BL-SH.... BAYLAST SEALS, SHORT ALUMINUM HANDLE

5500K-SH...... FFKM SEALS, SHORT ALUMINUM HANDLE

5500H-SH...... HIFLUOR SEALS, SHORT ALUMINUM HANDLE

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5500 SERIES API RACK COUPLER

Item

#

Description

Part #

5500B

5500E

5500F

5500G

5500BL

5500K

5500H

5500B-L

5500E-L

5500F-L

5500G-L

5500BL-L

5500K-L

5500H-L

5500B-SS

5500E-SS

5500F-SS

5500G-SS

5500BL-SS

5500K-SS

5500H-SS

5500B-SSL

5500E-SSL

5500F-SSL

5500G-SSL

5500BL-SSL

5500K-SSL

5500H-SSL

5500B-SH

5500E-SH

5500F-SH

5500G-SH

5500BL-SH

5500K-SH

5500H-SH

1

Body

341933

1

2

Shaft

391876

1

3

Cotter Pin

112307

1

4

Sleeve Assembly

400764

1

5

Valve Assembly

400739

1

6A

Nose Seal Assy -

FKM B

400741

1

-

1

-

1

-

1

-

1

-

6B

Nose Seal Assy -

EPDM

400745

-

1

-

1

-

1

-

1

-

1

-

6C

Nose Seal Assy -

F/SILICONE

400746

-

1

-

1

-

1

-

1

-

1

-

6D

Nose Seal Assy -

FKM GFLT

400742

-

1

-

1

-

1

-

1

-

1

-

6E

Nose Seal Assy -

BAYLAST

400743

-

1

-

1

-

1

-

1

-

1

-

6F

Nose Seal Assy -

FFKM

400767

-

1

-

1

-

1

-

1

-

1

-

6G

Nose Seal Assy -

HIFLUOR

400769

-

1

-

1

-

1

-

1

-

1

7A

Bearing Assembly -

FKM B

400747

1

-

1

-

1

-

1

-

1

-

7B

Bearing Assembly -

EPDM

400751

-

1

-

1

-

1

-

1

-

1

-

7C

Bearing Assembly -

F/SILICONE

400752

-

1

-

1

-

1

-

1

-

1

-

7D

Bearing Assembly -

FKM GFLT

400748

-

1

-

1

-

1

-

1

-

1

-

7E

Bearing Assembly -

BAYLAST

400749

-

1

-

1

-

1

-

1

-

1

-

7F

Bearing Assembly -

FFKM

400766

-

1

-

1

-

1

-

1

-

1

-

7G

Bearing Assembly -

HIFLUOR

400770

-

1

-

1

-

1

-

1

-

1

8

Bearing Washer

112601

1

9

Locking Plate

112589

1

10A

Handle

341937

1

-

1

10B

Handle Lockable

Assy

400740

-

1

-

10C

Stainless Steel

Handle

112627

-

1

-

10D

Handle SS lockable

Assy

400765

-

1

-

10E

Short Handle

341941

-

1

11

Spacer

391142

1

12

Cotter Pin

111563

2

13

Interlocking Cam

112147

5

14

Torsion Spring

112149

6

15

Latch

112240

1

16

Release

391875

1

17

Release Washer

112602

2

18

Bail

341935

1

19

Bail Pin

112619

2

20

Bail Spring

112150

2

21

Shoulder Screw

112621

1

22

Lock Nut

112620

1

23

Comp. Spring

112617

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

1

0

24

Set Screw

112622

2

25

Dust Ring

112173

1

26

Sleeve Lock

112625

1

27

Shoulder Screw

112626

1

28A

O-Ring 208, FKM B

112603

1

-

1

-

1

-

1

-

1

-

28B

O-Ring 208, EPDM

112611

-

1

-

1

-

1

-

1

-

1

-

28C

O-Ring 208,

F/SILICONE

112613

-

1

-

1

-

1

-

1

-

1

-

28D

O-Ring 208, FKM

GFLT

112605

-

1

-

1

-

1

-

1

-

1

-

28E

O-Ring 208,

BAYLAST

112607

-

1

-

1

-

1

-

1

-

1

-

28F

O-Ring 208, FFKM

112643

-

1

-

1

-

1

-

1

-

1

-

28G

O-Ring 208, HIFLUOR

112653

-

1

-

1

-

1

-

1

-

1

29

INSIDE SHAFT

WASHER

112159

1

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API RACK COUPLER –5500 SERIES

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5500 Series API Rack coupler Sub-assembly Components

*Items are optional PTFE U seals. When the U seals are added to the coupler, they isolate the main rubber seals from the liquid being

conveyed, thereby increasing the longevity of the rubber seals. Contact Dixon for kit numbers.

Item #

Description

Part #

Q’ty

4

Sleeve Assembly

400764

-

4.1

Sleeve

-

1

4.2

Sleeve Insert

-

1

4.3

Sleeve Pin

-

3

4.4

Grip Nail

-

2

4.5

Tag

-

1

5

Valve Assembly

400739

-

5.1

Poppet

341934

1

5.2

Bend Link

112151

2

5.3

Bend Link Pin

391141

2

5.4

Washer

112602

2

5.5

Cotter Pin

110721

2

5.6

Drive Link

112148

1

6

Nose Seal Assy

See Dixon website for kit

numbers

-

6.1

Nose Piece

391877

1

6.2

O-Ring 349

See Dixon website for kit

numbers

1

6.3

Nose Seal

See Dixon website for kit

numbers

1

6.4

Dust Felt Ring

112174

1

6.5*

U-Seal 349

See Dixon website for kit

numbers

1

7

Bearing Assembly

See Dixon website for kit

numbers

-

7.1

Bearing

341936

1

7.2

O-Ring 208

See Dixon website for kit

numbers

1

7.3

O-Ring 216

See Dixon website for kit

numbers

2

7.4*

U-Seal 208

See Dixon website for kit

numbers

1

7.5*

U-Seal 216

See Dixon website for kit

numbers

1

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These instructions and recommendations are provided to ensure proper operation and long service

life of the Dixon 5500 API rack coupler. Parts are identified by the item numbers on the assembly

drawing and part list.

SUGGUESTED MAINTENANCE SCHEDULE:

1. MONTHLY INSPECTION

Visual inspection of the API rack coupler operation can be done while the API rack coupler is still

on the loading arm. All safety precautions that apply to the use of the API rack coupler must be

followed.

While the API rack coupler is still on the loading arm, visually examine the API rack coupler for any

worn or damaged parts, such as the body (1), sleeve (4), handle (10), bail (18), poppet (5.1), nose

seal (6.3), interlocking cams (13), latch (15), flange bolts, etc, or any other condition that may affect

the operation of the API rack coupler.

Examine the API rack coupler to make sure that the API rack coupler functions well. See Clause 3

in Section “INSTALL API RACK COUPLER TO LOADING ARM” for procedures.

Check the handle (10) for free and easy movement of the opening and closing cycle. Operation of

the handle (10) normally requires limited effort. If operating the handle (10) involves stronger force,

it implies the need to clean and possibly replace the shaft bearing (7) and the shaft (2).

During service time when the line is filled with liquid product, visually check for evidence of

leakage, especially through the shaft seals (7.2, 7.3, 7.4, 7.5 and 28), nose piece seals (6.2, 6.5),

nose seal (6.3) and the flange gasket. Any evidence of leakage means there is a need for further

maintenance.

2. YEARLY INSPECTION

For yearly inspection, the API rack coupler should be removed from the loading arm. See Section

“DISMANTLE API RACK COUPLER FROM LOADING ARM”for procedures of how to dismantle

the API rack coupler from the loading arm. See Section “DISASSEMBLY” for procedures of how to

disassemble the API rack coupler for further maintenance.

It is recommended that all seals (6.2, 6.3, 6.5, 7.2, 7.3, 7.4,7.5 and 28) should be inspected every

12 months. Replace any worn or damaged seals. See Section “REPLACE SEALS” for

procedures.

It is recommended that the valve assembly should be inspected every 12 months. Check the bent

links (5.2), and poppet (5.1) carefully to make sure that there is no permanent deformation, wear,

cracking, or any other damage. Check the bent link pins (5.3) carefully to make sure there is no

permanent deformation such as bending and cracking. Replace any deformed, worn or damaged

parts in the valve assembly. See Section “REPLACE VALVE ASSEMBLY AND PARTS”for

procedures.

Warning: Deformed bent link pins (5.3), drive link (5.6) and bent links (5.2) may cause leakage

through poppet seals. Further service will lead to cracks and breakage, which will cause a

complete failure of the API rack coupler.

Visually examine the shaft (2) every 12 months for significant dirt accumulation that could cause

shaft seal leakage. Visually examine the shaft (2), bearing washer (8), handle (10) and shoulder

screw (21) for wear and damage. Replace any worn or damaged parts.

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Warning: If the shoulder screws (21 and 27) break, this can cause the poppet to be left in partially

open position which may cause spill. Replace the shoulder screws (21 and 27) when they show

sign of wear or damage.

Visually examine the nose piece assembly every 12 months for significant dirt accumulation that

could cause nose piece seal leakage.

Visually examine the body (1), sleeve (4), interlocking cams (13), latch (15) and torsion springs

(14) for wear or damage every 12 months. Check the interlocking cam groove on the sleeve (4) for

wear and damage. Replace any worn or damaged parts.

Warning: If there is significant wear on the interlocking cam groove of the sleeve (4) or the

interlocking cams (13), replace the sleeve (4) or interlocking cams (13) immediately. Failure to

replace these parts can cause failure to interlock the API rack coupler.

3. SEAL REPLACEMENT

It is recommended that seals should be replaced with appropriate API rack coupler seal kit every 2

years, or at the first evidence of leakage. See Section “REPLACE SEALS” for procedures.

4. OVERHAUL

It is recommended that a complete overhaul of the API rack coupler should be performed every 4

years, or at the first evidence of leakage. Complete overhaul would involve seal inspection and

replacement, valve assembly inspection, inspection of body (1), sleeve (4), shaft (2), interlocking

cams (13), latch (15) and springs (14, 20). Replace any worn or damaged parts immediately. See

corresponding sections for procedures.

CAUTION! WHEN THE API RACK COUPLER POPPET (5.1) IS UNDER PRESSURE, THE

HANDLE (10) OF THE API RACK COUPLER MAY ROTATE VIOLENTLY.

PERSONAL INJURIES MAY RESULT IF THIS PRECAUTION IS NOT TAKEN.

INSTALL API RACK COUPLER TO LOADING ARM:

Warning: Read and understand this instruction manual before starting installation.

1. Check the API rack coupler to make sure that there is no damage.

2. Secure the loading arm. Align the TTMA 4” flange of the API rack coupler to the loading arm

end flange with TTMA 4” gasket. Insert two bolts into the top bolt holes on the flanges and

hand tighten the bolts first. Install the remaining six bolts and tighten all the bolts.

3. Make sure that all other devices for the loading arm are properly installed and ready for use.

Make sure that there is no liquid product in the line. Snap the API rack coupler onto an API

adapter. Check the followings:

•Make sure that the nose ring of API adapter is locked by the five interlocking cams (13) of

the API rack coupler.

•Make sure that the sleeve (4) moves fully forward to the outlet of the API rack coupler.

•If the sleeve (4) is in place, check the interlock by pulling back the API rack coupler or

bending the API rack coupler sideways without triggering the release (16). The API rack

coupler should be locked tightly.

•If the API rack coupler is locked tightly, fully rotate the handle (10) to the open position.

Make sure that the handle (10) can rotate freely and the poppet (5.1) of the API rack

coupler can push the poppet of the API adapter to the open position.

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•When the poppet (5.1) of the API rack coupler is in the open position, try to trigger the

release (16) to make sure that the sleeve (4) is locked by the interlocking cam surface of

the handle (10).

•Rotate the handle (10) to fully closed position. Trigger the release (16). The sleeve (4)

should move back and five interlocking cams (13) should unlock the nose ring of the API

adapter. The API rack coupler should be able to be removed from the API adapter.

•If there are problems with any of the above, see the following section to dismantle the API

rack coupler from the API adapter and remove the API rack coupler from the loading arm.

See Section “DISASSEMBLY”for further instructions of how to disassemble the API rack

coupler to inspect individual parts. Contact the factory if it is a new API rack coupler.

DISMANTLE API RACK COUPLER FROM LOADING ARM:

Warning: Read and understand this instruction manual before starting installation. Make sure that

there is adequate personal protection all the time when dismantling the API rack coupler from the

loading arm.

1. Shut off all working devices. Drain the loading arm. Dismantle the API rack coupler when it

is clean and dry.

2. Secure the loading arm from movement and support the API rack coupler. Make sure that

the API rack coupler is fully closed.

3. Loosen the bolts on the TTMA flange of the API rack coupler. Leave the two top bolts on

and remove the remaining six bolts first. And then remove the two top bolts.

4. Remove the API rack coupler from the loading arm. Remove the TTMA gasket between the

flanges.

REPLACE VALVE ASSEMBLY AND PARTS:

Note: Valve assembly (5) and parts can only be replaced when the API rack coupler is off the rack.

The design of the Dixon API rack coupler shaft (2) makes it easy to remove the valve assembly

from the API rack coupler as a whole. This makes it easy to replace the whole valve assembly (5)

or any individual part of the valve assembly (5). There is NO need to remove the bent link pins (5.3)

from the bent links (5.2) while the valve assembly is still in the API rack coupler.

Warning: Carefully handle the poppet (5.1) without damaging the sealing surface when replacing

valve assembly or parts. Even the smallest scratches on the sealing surface can cause leakage.

1. When the API rack coupler is off the rack, DO NOT remove the handle shoulder screw (21)

and lock nut (22) from the handle (10) yet same as the shoulder screw (27) and lock nut of

sleeve lock (26). When API rack coupler is closed, remove the shaft cotter pin (3) from the

shaft (2) by using pliers.

2. Defeat the interlock manually or use an API adapter nose ring so the sleeve (4) can move

fully forward to the outlet of the API rack coupler.

3. Turn the handle (10) to open the API rack coupler.

4. Pull out the shaft and handle assembly with locking plate (9), dust O-ring (28), bearing

assembly (7), bearing washer (8), while inside shaft washer (29), valve assembly (5) and

spacer (11) will fall free of the shaft (2).

5. Inspect all parts of the valve assembly (5) and replace any damaged parts. When

reassembling the valve assembly, make sure the bent links (5.2) and the drive link (5.6) are

assembled in the same orientation as shown in the valve assembly figure.

6. Assemble the shaft and handle assembly with sleeve lock (26), locking plate (9), dust O-ring

(28), bearing assembly (7) and bearing washer (8) to the body (1). Assemble the inside

shaft washer (29), drive link (5.6) and the spacer (11) before pushing the other end of the

090140 REV5 2021/12/15 877.582.3569 10

shaft (2) into the shaft end pocket on the body (1). Pay attention to the orientation of the

valve assembly.

7. Rotate the handle (10) to fully closed position. Install the shaft cotter pin (3) onto the shaft (2).

8. Check the API rack coupler with an API adapter to make sure all components are

assembled properly.

REPLACE SEALS:

Warning: Carefully remove and install parts without damaging any sealing surfaces when

replacing seals. Even the smallest scratches on the O-Ring groove or other sealing surface will

cause leakage.

REPLACE SHAFT SEALS IN STUFFING BOX

Note: While the API rack coupler is off the rack, shaft seals (7.2, 7.3, 7.4, 7.5 and 28) can be

replaced using the method described here.

1. Follow Step 1 to 4 from “REPLACE VALVE ASSEMBLY AND PARTS”.

2. To remove bearing assembly (7), unscrew the lock nuts (22) and remove the shoulder screw

(21) from the handle (10) and shoulder screw (27) from the sleeve lock (26). Remove the

handle (10) from the shaft (2) followed by the sleeve lock (26), locking plate (9), dust O-ring

(28), the bearing assembly (7) and bearing washer (8).

3. Remove the O-rings (7.2, 7.3) and the u-seals (7.4, 7.5, optional) from the bearing assembly

and make sure not to damage the bearing (7.1) or scratch sealing surfaces.

•If the bearing (7.1) is good, thoroughly clean the bearing (7.1) to remove any debris, oil

and grease. Lubricate NEW O-Rings (7.2 for inside groove and 7.3 for outside groove)

and install into the grooves. If u-seals (7.4, 7.5) are ordered, lubricate NEW u-seals (7.4

for inside groove and 7.5 for outside groove) and install into the grooves. Handle the u-

seals (7.4, 7.5) carefully and make sure not to damage.

•If the bearing (7.1) is already damaged or has scratches on the sealing surfaces, replace

the bearing assembly with a NEW bearing assembly, which includes the bearing (7.1),

the inside O-Ring (7.2), the outside O-Ring (7.3), the inside u-seal (7.4, optional) and the

outside u-seal (7.5, optional).

4. Install bearing washer (8) into the shaft (2) followed by the bearing assembly (7) and dust O-

ring (28) make sure it is greased, locking plate (9), sleeve lock (26) and then the handle

(10). Align the sleeve lock (26) and handle (10) to the shaft (2) holes and insert the shoulder

screws (21 & 27) then tighten the lock nuts (22).

5. Push the end of the shaft to the body through the inside shaft washer (29), drive link (5.6)

and spacer (11). At this instance the bearing assembly is also getting in to the stuffing box of

the body. Push the shaft assemble shaft (2) end to the shaft pocket on the body (1). Pay

attention to the orientation of the valve assembly.

6. Rotate the handle (10) to fully closed position. Install the shaft cotter pin (3) onto the shaft (2).

7. Check the API rack coupler with an API adapter to make sure all components are

assembled properly.

REPLACE THE SEALS ON THE NOSE PIECE

Note: Nose piece seals, including O-Ring (6.2), nose piece dust ring (6.4) and optional u-seal (6.5),

can only be replaced when the API rack coupler is off the rack.

1. Follow Step 1 to 4 from “REPLACE VALVE ASSEMBLY AND PARTS”.

2. Remove the nose piece assembly, which includes the nose piece (6.1), nose seal (6.3), O-

Ring (6.2), nose piece dust ring (6.4), u-seal (6.5, optional). Remove and clean the

compression springs (23).

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•Remove nose seal (6.3), O-Ring (6.2), nose piece dust ring (6.4) and u-seal (6.5, if

applicable) from the nose piece (6.1).

•Inspect the nose piece (6.1) and make sure it is not damaged. Clean seal surfaces

carefully.

•Replace nose seal (6.3), O-Ring (6.2), nose piece dust ring (6.4) and u-seal (6.5, if

applicable) with new ones.

3. Assemble the compression spring (23) and nose piece assembly (6) to the body (1).

4. Follow step 5 to 7 from “REPLACE SHAFT SEALS IN STUFFING BOX”.

DISASSEMBLY:

Warning: Carefully remove parts without damaging any sealing surfaces when disassembling the

API rack coupler. Even the smallest scratches on the O-Ring grooves or other sealing surfaces will

cause leakage.

1. When the API rack coupler is closed, remove the shaft cotter pin (3) from the shaft (2) by

using pliers.

2. Defeat the interlock manually or use an API adapter nose ring so the sleeve (4) can move

fully forward to the outlet of the API rack coupler.

3. Turn the handle (10) to fully open position. Pull out the shaft and handle assembly with

locking plate (9), dust O-ring (28), bearing assembly (7) and bearing washer (8) while the

inside shaft washer (29), valve assembly (5) and spacer (11) will fall free of the shaft (2).

4. To completely disassemble the shaft and handle assembly, remove the handle lock nuts

(22) and shoulder screws (21 & 27). Remove the handle (10), sleeve lock (26), locking plate

(9), dust O-ring (28), bearing assembly (7) and bearing washer (8).

5. To completely disassemble the valve assembly, remove the bent link cotter pins (5.5), bent

link washers (5.4), and bent link pins (5.3).

6. To completely disassemble the bearing assembly, remove O-Rings (7.2, 7.3) and u-seals

(7.4, 7.5, optional) from the bearing (7.1).

7. Remove cotter pins (12) and washers (17) from the release (16) ends. Remove the release

(16) from the bail (18).

8. Remove the set screws (24) from the body (1) to remove the bail pins (19).

9. Turn the API rack coupler upside down and the bail pins (19) will fall out. If the bail pins (19)

do not fall out, move the bail springs (20) until the bail pins (19) fall out.

10.Remove the bail springs (20) and the bail (18).

11.Remove the sleeve (4) from the body (1) by pulling the sleeve (4) to the inlet of the body (1).

12.Remove the five interlocking cams (13) and latch (15) from the body (1). Remove the six

torsion springs (14) and dust ring (25) from the body (1).

13.Remove the nose piece assembly (6) and ten compression springs (23) from the body (1).

14.To completely disassemble the nose piece assembly, remove the O-Ring (6.2), nose piece

(6.1), nose piece dust ring (6.4), nose seal (6.3) and u-seal (6.5, optional) from the nose

piece (6.1).

ASSEMBLY:

Note: Remove any burrs and sharp edges that could damage the seals during reassembly.

1. Assemble the bearing assembly if it is disassembled. See Step 4 “Replace shaft seals

in stuffing box for procedures of how to assemble the bearing assembly.

2. Assemble the valve assembly if it is disassembled. See Section “REPLACE VALVE

ASSEMBLY AND PARTS”for procedures of how to assemble the valve assembly.

3. Assemble the nose piece assembly if it is disassembled. See Section “Replace the

seals on the nose piece”for procedures of how to assemble the nose piece assembly.

090140 REV5 2021/12/15 877.582.3569 12

4. Assemble the shaft and handle assembly if it is disassembled. Install bearing washer (8)

into the shaft (2) followed by the bearing assembly (7, make sure it is greased), dust O-

ring (28), locking plate (9), sleeve lock (26) and then the handle (10). Align the handle

(10) and sleeve lock (26) to the shaft (2) holes and insert the shoulder screws (21 and

27) then tighten the lock nuts (22).

5. Install the body dust ring (25) to the body dust groove.

6. Install the torsion springs (14), the latch (15) and the interlocking cams (13) to the body

(1).

7. Install the compression springs (23) and the nose piece assembly to the body (1).

8. Install the sleeve (4) to the body (1). Push in the five interlocking cams (13) manually so

the sleeve (4) can move fully forward to the outlet of the API rack coupler. Use nose ring

of API adapter or ask others for assistance.

9. Install the shaft and handle assembly with locking plate (9), dust O-ring (28), bearing

assembly (7) and bearing washer (8) to the body (1). Assemble the inside shaft washer

(29), drive link (5.6) of the valve assembly and the spacer (11) before pushing the other

end of the shaft (2) into the shaft pocket on the body (1). Pay attention to the orientation

of the valve assembly.

10.Rotate the handle (2) to fully closed position. Install the shaft cotter pin (3) onto the shaft

(2).

11.Install the bail (18), bail springs (20), bail pins (19) and tighten the set screws (24) to the

body (1).

12.Install the release (16) to the bail (18). Install the washers (17) and cotter pins (12) to the

ends of release (16).

13.Rotate the handle (10) to the open position and closed position several times to verify

proper operation.

14.When the handle (10) is in the closed position, trigger the release (16) so the sleeve (4)

can move fully backward to lock the handle (10). The API rack coupler should not be

able to be opened by rotating the handle (10).

15.Check the API rack coupler with an API adapter to make sure all components are

assembled properly.

Warning: If the sleeve subassembly (4) and interlocking cams (13) are disassembled

and replaced, try coupling and uncoupling the API rack coupler to an API adapter nose

ring a few times making sure the locking mechanism functions well before putting the

API rack coupler back onto the loading arm.

DIXON WARRANTY:

For Warranty Information, please refer to the inside back cover of the latest Dixon

Catalogue.

Dixon 5500 Series Operating and maintenance manual

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