Roughneck 24923 User manual

MECHANICAL FUEL METER
OWNER’S MANUAL
WARNING: Read carefully and understand all INSTRUCTIONS before operating.
Failure to follow the safety rules and other basic safety precautions may result in
serious personal injury.
Item # 24923

Page 1of 6
Thank you very much for choosing a Roughneck™ Product! For future reference, please complete the
owner’s record below:
Model: _______________ Purchase Date: _______________
Save the receipt, warranty and these instructions. It is important that you read the entire manual to become
familiar with this product before you begin using it.
This fuel meter is designed for certain applications only. The distributor cannot be responsible for issues
arising from modification. We strongly recommend this fuel meter is not modified and/or used for any
application other than that for which it was designed. If you have any questions relative to a particular
application, DO NOT use the fuel meter until you have first contacted the distributor to determine if it can or
should be performed on the product.
For technical questions, please call 1-800-222-5381.
WARNING: Read carefully and understand all INSTRUCTIONS before operating. Failure to follow
the safety rules and other basic safety precautions may result in serious personal injury.
Save these instructions in a safe place and on hand so that they can be read when required. Keep
these instructions to assist in future servicing.
INTENDED USE
This Mechanical Fuel Meter is designed for use only with thin viscosity fuels such as diesel fuel and kerosene.
Do not use this equipment for dispensing any fluids other than those for which it was designed. Otherwise, it
may damage the meter and will void the warranty.
TECHNICAL SPECIFICATIONS
Item No.
24923
Meter mechanism
Nutating disk
Flow rate range
5-32 GPM
Operating pressure
Max. 50 PSI
Storage humidity
Max. 95%
Working temperature range
14–140°F
Accuracy
±1%
Inlet/Outlet connection
1in. NPT
Includes two 1in. male to 3/4in. female adapters for versatility.
Weight
4 lbs.
GENERAL SAFETY REGULATIONS
WARNING: Read and understand all instructions. Failure to follow all instructions listed below may
result in electric shock, fire and/or serious injury.
WARNING: The warnings, cautions, and instructions discussed in this instruction manual cannot
cover all possible conditions or situations that could occur. It must be understood by the operator that

Page 2of 6
common sense and caution are factors that cannot be built into this product, but must be supplied by the
operator.
1. Keep the work area clean and dry. Damp or wet work areas can result in injury.
2. Keep children away from work area. Do not allow children to handle this product.
3. Store idle equipment. When not in use, tools and equipment should be stored in a dry location to
inhibit rust. Always lock up tools and equipment, and keep out of reach of children.
4. Use the right tool for the job. Do not attempt to force small equipment to do the work of larger
industrial equipment. There are certain applications for which this equipment was designed. It will do the
job better and more safely at the capacity for which it was intended. Do not modify this equipment, and
do not use this equipment for a purpose for which it was not intended.
5. Check for damaged parts. Before using this product, carefully check that it will operate properly and
perform its intended function. Check for damaged parts and any other conditions that may affect the
operation of this product. Replace damaged or worn parts immediately.
6. Do not overreach. Keep proper footing and balance at all times to prevent tripping, falling, back injury,
etc.
7. DO NOT use the equipment when tired or under the influence of drugs, alcohol, or medication.
A moment of inattention while operating this equipment may result in serious personal injury.
8. Industrial applications must follow OSHA requirements.
SPECIFIC OPERATION WARNINGS
To ensure safe and efficient operation, it is essential to read each of these warnings and precautions, and to
follow all instructions listed in this manual.
Improper use or installation of this product can cause serious bodily injury or death.
DO NOT smoke near meter or use meter near an open flame when dispensing flammable fluids. Fire
could result.
Do not exceed 50 PSI line pressure.
CAUTION: DO NOT INSTALL ADDITIONAL FOOT VALVE OR CHECK VALVE DURING
INSTALLATION WITHOUT PRESSURE RELIEF VALVE. CRACKING MAY RESULT.
This product is not suited for use with fluids for human consumption, including potable water.
Observe precautions against fire or explosion when dispensing fuel. Do not operate the meter in the
presence of any source of ignition including running or hot engines, lighted cigarettes, gas or electric
heaters.
Any components such as hose, nozzle, or pump added to the meter must be statically grounded.
Avoid prolonged skin contact with fuels. Use protective goggles, gloves, and aprons in case of accidental
splashing or spillage. Change saturated clothing and wash skin contact areas promptly with soap and
water.
INSTALLATION
1. The meter can be installed in any position, directly on rigid pipelines or flexible hoses, or directly on
pumps or tanks.
2. The meter flow direction is fixed and indicated by an arrow. The meter is supplied in the standard
configuration (Figure A).
3. The counter and the cover can be rotated around the body in order to carry out the different

Page 3of 6
configurations (Figures B, C & D).
4. The meter body is equipped with 4 blind holes which can be threaded for a possible fastening. If solid
particles enter the measuring chamber the correct working of the nutating disk may be affected.
5. Always filter the fluid by installing a filter (included) on the meter inlet.
CALIBRATION
The meter is accurately pre-calibrated in factory for use with kerosene. Due to differences in viscosity and
flow rates, the meter may require recalibration to measure other fuels or to adjust for inaccuracies. Calibration
is required upon installation, after disassembly, after significant wear or when metering a different viscosity
fluid.
Meter calibration can be easily changed by following the calibration procedure. A container of KNOWN
volume will be needed for the calibration procedure. For this fuel meter, a five-gallon container or larger
should be used.
CALIBRATION PROCEDURE
1. Unscrew the plug (#26, see diagram).
2. Purge the system (pump, pipelines and meter) of air by dispensing fuel into a container until the flow
stream is full and steady — no bubbles of interruptions in flow should be evident.
3. Stop the flow by shutting off the nozzle, but let the pump continue to run.
4. Reset the batch register with the reset knob (#2).
5. Pump into a graduated calibration container to a specified quantity. For the greatest accuracy, be sure the
container is placed on a level surface and a consistent flow rate is used. When topping off the calibration
container, use a quick-open and quick-close method until the mark is reached.
6. Compare the indication of the calibrated container (real value) with the meter’s indicated value.
a) If the indicated value is higher than the real value, loosen the screw (#24).
b) If the indicated value is lower than the real value, tighten the screw (#24).
7. Repeat the steps 4 to 6 until satisfactory accuracy is achieved.
8. Tighten the plug (#26) again. The O-ring (#23) provided with the calibration screw will hold the new
calibration position to avoid accidental loosening of the adjustment screw, but does not seal the unit, so it
is always necessary to properly fix the plug (#26) with the sealing gasket (#25).
OPERATING INSTRUCTIONS
After installation and calibration, the meter is ready for use.
Turn the reset knob (#2) clockwise if it is mounted on the left of the meter and counterclockwise if it is
mounted on right, until the batch register is completely reset. The total register cannot be reset in any way.
WARNING: Make sure that during use the pressure does not exceed 50 PSI.

Page 4of 6
GRAVITY-FED SYSTEMS
The meter can also be used in gravity-fed fuel units where the flow is generated by the difference in fuel level
between the tank and the nozzle outlet. As a general rule, a gravity-fed system, which is composed of a tank
off the ground, a meter installed at the bottom of the tank, and a 9.8-ft. long 1in. flexible pipe, guarantees a
flow rate of approximately 8 GPM if the height difference is greater than 5 feet. Longer pipes or nozzles
producing higher pressure losses will reduce the flow rate.
NOTE: Use of this meter for gravity-fed systems with level differences less than 3 feet is not recommended
because the reduced flow rate causes the meter to work outside its guaranteed accuracy range. Onsite
calibration is required in any gravity-fed installation.
MAINTENANCE
No ordinary maintenance is required if the meter is properly installed and used according to recommendations.
An incorrect filtering on the meter inlet may block or wear out the measuring chamber, thus affecting the
meter accuracy. If this happens, meter should be thoroughly cleaned (see instructions below). Disassemble
the measuring chamber, as shown in section ASSEMBLY/ DISASSEMBLY, and evaluate the filter’s condition.
CLEANING INSTRUCTIONS:
Run a flushing fluid through meter. For a more thorough cleaning, disassemble meter per “ASSEMBLY
/DISASSEMBLY” section, “Meter Chamber Assembly” subsection. Rinse all meter components.
User should carry out periodic cleaning of the unit with a soft brush or small tool (i.e. a screwdriver). During
cleaning, be careful not to damage the chamber or the disk. Carefully check the meter and replace any
damaged parts. Only use the original spare part kits shown in DIAGRAM AND PART LISTS.
NOTE: A new calibration is always necessary after cleaning or replacing the meter parts.
STORAGE: Clean thoroughly if meter is to be stored for a period of time. This will help protect meter from
damage.
WARNING: Before disassembling the meter, always make sure that all fluid is drained from the meter and
pipes connected with the meter.
ASSEMBLY/ DISASSEMBLY
The meter can be disassembled easily into its primary components without removing the body from the pipes.
Meter unit
Disassemble the meter unit as follows:
1. Remove the reset knob by firmly pulling it straight out.
2. Loosen four retaining screws (#22).
3. Loosen two screws (#5).
To reassemble the unit, reverse the above procedure.
Measuring chamber
To enter the measuring chamber, operate as follows:
1. Disassemble the meter unit following the above steps 1-3.
2. Loosen the eight screws (#7).
3. Remove the body cover (#6), together with the gear unit.
WARNING: Be careful not to damage the sealing gasket (#16).
4. Remove the whole measuring chamber (#27) by lifting it from the meter body and at the same time pulling

Page 5of 6
it back towards the inlet in order to remove the O-ring (#17) from its seat at the outlet.
5. Remove the O-ring (#17) and divide the measuring chamber (#27) into two halves to check the inside of
the chamber containing the nutating disk.
To reassemble the chamber, reverse the above procedure. Be sure to:
1. Verify that the nutating disk rotates freely in the assembled chamber.
2. Install the gaskets (#16, #17) properly after inspecting and lubricating them with grease.
3. Make sure that when reattaching the cover to the body of the meter, the nutating disk needle does not hit
the driving lever (#14), which must remain free to be moved by the disk needle.
4. Tighten the screws (#7) completely.
Gear unit
To reach the gear unit components:
1. Remove the cover Assembly (#28).
2. Loosen the screws (#13).
3. Remove the plate (#12). Now all gears can be reached for inspection.
4. Should the gasket (#10) be replaced, remove the bevel gear (#8) from the shaft by pulling straight out,
and then remove the gear unit (#11) together with the shaft.
To reassemble, reverse the above described procedure paying particular attention to:
1. Lubricating the O-ring with grease before installation.
2. Checking that the gear unit can rotate freely before reattaching the cover.
TROUBLE SHOOTING
Problem
Possible Cause
Corrective Action
1. Broken counter assembly.
Replace counter.
2. Foreign material in counter
assembly or nutator assembly.
Remove and clean counter assembly or
nutator assembly.
3. Broken nutator disc pin or defective
nutator assembly.
Install new nutator assembly.
Meter counter does not
operate. (Normal fuel
delivery)
4. Jammed or broken gear train.
Push reset to free number wheels.
1. Clogged strainer in meter.
Clean or replace strainer.
2. Other system components
malfunctioning.
Check all system components from tank
to nozzle for clogs and/or malfunctions.
Repair as necessary.
Meter counter does not
operate. (Little or no fuel
flow)
3. Foreign material in nutator
assembly.
Remove and clean nutator assembly.
1. Leakage at counter drive shaft.
Replace cover plate assembly.
2. Leakage between cover plate and
housing.
Remove cover plate and inspect for
damaged, missing or incorrectly seated
seal. Replace as required.
3. Leakage at fittings.
Remove fittings and inspect for damaged,
missing or incorrectly seated seals.
Replace as required.
Fuel leakage
4. Leakage at threads.
Remove meter and reseal all threaded
connections with thread tape or pipe
thread sealing compound approved for
use with flammable liquids.

Page 6of 6
DIAGRAM & PARTS LIST
No.
Description
Quantity
No.
Description
Quantity
1
Name plate
1
16
O-ring 110.72x3.53
1
2
Reset knob
1
17
O-ring 23.47x2.62
1
3
External cover
1
18
Measuring chamber
1
4
Meter
1
19
Measuring tray
1
5
Screws 4x20
2
20
Measuring chamber
1
6
Body cover
1
21
Cylinder spring
4
7
Screws 5x16
8
22
Screws 4x20
4
8
Bevel pinion
1
23
O-ring 4.47x1.78
2
9
O-ring 3.62x2.62
1
24
By-pass adjusting screw
1
10
Cover sealing
1
25
O-ring 9.25x1.78
1
11
Gear kit
1
26
Bypass plug
1
12
Gear plate
1
27
Measuring chamber
assembly
1
13
Screws 3x10
4
28
Body cover assembly
1
14
Driving lever
1
29
Adapter
2
15
Meter body
1
For replacement parts and technical questions, please call 1-800-222-5381.
WARRANTY
One-Year Limited Warranty
Distributed by
Northern Tool + Equipment Co., Inc.
Burnsville, MN 55306
NorthernTool.com
Made in China