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JC Carter LLC LNG Couplings

1. the system is free from any leakage Be careful not to exceed the rated pressure of the fueling system when doing leak test 11 JC Carter 671 West 17t Street e Costa Mesa CA 92627 3605 USA www jccarternozzles com Manual P N C01340 JC Carter aes Nozzles designed to fuel tomorrow s clean energy vehicles Operating Instructions Caution The operator must wear the protective clothing outlined in the Warnings and Safety Instructions on page three 3 of this manual Failure to do so may result in injury Never point the nozzle directly at yourself or others at anytime Step 1 Put on the following protective clothing e Full face shield e Thermal gloves rated for cryogenic use e Cryogenic smock e Solid shoes capable of withstanding cryogenic spillage Step 2 If this is the first fueling of the day check to be sure no fuel pressure is present at the nozzle Then wipe out the mating end of the nozzle using a clean dry cloth Step 3 Remove the receptacle dust cap Step 4 With the nozzle handles completely retracted toward the operator which allows the locking latches to open insert the nozzle into the receptacle far enough for the locking mechanism to engage Step 5 To start the flow push both handles forward simultaneously toward the receptacle Pushing on the handles will cause them to rotate forward and will lock the nozzle as well as engage the poppet assembly 12 JC Carter 671 West 17t Street e Cos
2. 0 is the mating receptacle portion of the LNG fueling coupling The receptacle mounts to the vehicle as described on pages 10 12 of this manual The receptacle contains an independent primary shut off valve 5 JC Carter 671 West 17t Street e Costa Mesa CA 92627 3605 USA www jccarternozzles com JC Carter Manual P N C01340 Rev E Nozzles designed to fuel tomorrow s clean energy vehicles Installation Tools and Accessories Tools Torque Wrench 120 130 Ft Lb range 1 Ea Adjustable Wrench 2 Ea Accessories 50 GPM Nozzle Installation Kit Model Number B91546 1 Consists of 1 Silver Plated Boss Seal and 1 37 Degree Flared Large Hex Fitting 4 20 Stainless Steel Bolts 4 Ea 1 4 Stainless Steel Lock Washers 4 Ea 4 Stainless Steel Nuts 4 Ea 6 JC Carter 671 West 17t Street e Costa Mesa CA 92627 3605 USA www jccarternozzles com JC Carter Manual P N C01340 Rev E Nozzles designed to fuel tomorrow s clean energy vehicles Specifications Caution Failure to adhere to the specification limits of this coupling may result in injury Fluid Compatibility LNG Methane and LN gt Maximum Refueling Pressure 250 psig Maximum Working Pressure 500 psig Burst Pressure 1500 psig Rated Flow 50 Gallons per Minute Receptacle Weight 4 Lbs Nozzle Weight 12 Lbs Operating Temperature 320 F to 120 F Storage Temperature 60 F to 120 F Spillage on De Mating lt Icc Lea
3. Manual P N C01340 JC Carter tend Nozzles designed to fuel tomorrow s clean energy vehicles JC Carter LLC LNG Couplings USER MANUAL 50 GPM Quick Disconnect Liquefied Natural Gas Coupling Models 50E701 1 Nozzle and 62050 Receptacle User s Manual and Installation Guide Rev E Warning Read the User s Manual and Installation Guide Follow all warning and safety instructions Failure to do so may result in serious injury l JC Carter 671 West 17t Street e Costa Mesa CA 92627 3605 USA www jccarternozzles com Manual P N C01340 JC Carter m Nozzles designed to fuel tomorow S clean energy vehicles Introducing the JC Carter LNG Couplings Thank you for selecting JC Carter LNG Couplings JC Carter Couplings offer the following features Attention No nitrogen purging is required for proper operation Primary valve vehicle half eliminates the need for manual valve operation during each fueling Built in compression fittings allow simple inexpensive vehicle installation Patent pending self cleaning diametric sealing prevents liquid leakage while fueling Couplings are easy to use and maintain Unique Freeze On Free feature allows removal of nozzle from the receptacle under most weather conditions Safety features prevent fuel flow while couplings are disconnected Durable design protects against damage in the field Extensive cycle life testing has shown the coupling to be reliable and lon
4. P N C01340 Rev E Nozzles designed to fuel tomorrow s clean energy vehicles Contents Title Page Description 5 Installation Tools and Accessories 6 Specifications 7 Nozzle Installation 8 Receptacle Installation 9 Operating Instructions 12 Maintenance Schedule 14 4 JC Carter 671 West 17t Street e Costa Mesa CA 92627 3605 USA www jccarternozzles com Manual P N C01340 JC Carter cts Nozzles designed to fuel tomorrow s clean energy vehicles Description The Refueling Nozzle JC Carter model 50E701 1 is the nozzle half of the liquefied natural gas LNG coupling The nozzle comes in two versions the first being 50E701 which has shorter handles their length is 6 inches The second offers a slightly longer handle at 8 inches and is designated as SOE701 1 The quick disconnect single line nozzle is intended for use in NO VENT top fill LNG fuel systems A key feature of this nozzle is the independent shut off valve located in the flow path within the nozzle The operator mates the nozzle 50E701 1 to the receptacle model 62050 by pushing the two handles forward toward the LNG powered vehicle The nozzle is locked on by way of the three 3 latches and fueling can now be started When fueling is complete the operator simply returns the handles back by pulling away from the vehicle to their original position This will stop the flow and the nozzle will unlock from the receptacle The Refueling Receptacle JC Carter model 6205
5. d to fuel tomorrow s clean energy vehicles 2 12 12 31 NOZZLE ASSEMBLY MODEL NC 50E701 RECEPTACLE ASSEMBLY MODEL NQ 62050 The following figure shows the mounting footprint of the receptacle The circular cutout in the middle of the figure shows the clearance necessary for the fuel line When choosing the mounting location be sure that the mounting surface on the vehicle gives solid support to the bolt locations shown in the figure RECEPTACLE FOOTPRINT 10 JC Carter 671 West 17t Street e Costa Mesa CA 92627 3605 USA www jccarternozzles com Manual P N C01340 JC Carter aes Nozzles designed to fuel tomorrow s clean energy vehicles Step 3 Mount the receptacle on the vehicle using the four 4 20 stainless steel bolts lock washers and nuts Place the bolts washers and nuts as shown in the figure below with the bolt heads toward the outside of the mounting surface Torque nuts to 75 In Lb Step 4 Insert the 4 tubing into the receptacle fitting Make sure that the tubing is firmly against the shoulder of the fitting Finger tighten the fitting nut Scribe the nut to note a location then tighten the nut one full revolution and go past 1 4 turn Step 5 Caution This step is critical in assuring safe performance of the LNG coupling Leak testing should be performed monthly Perform initial leak test of the LNG receptacle by pressurizing the fueling system with Nitrogen gas and verify
6. g lasting Model 50E701 Short Handle and 50E701 1 Long Handle This symbol will be used to point out important safety instructions Please read this manual carefully before using couplings 2 JC Carter 671 West 17t Street e Costa Mesa CA 92627 3605 USA www jccarternozzles com Manual P N C01340 JC Carter gt Nozzles designed to fuel tomorrow s clean energy vehicles Warnings and Safety Instructions i Operator Safety 1 Always wear protective clothing consisting of the following Full face shield Thermal gloves rated for cryogenic use Cryogenic smock Solid shoes capable of withstanding cryogenic spillage 2 Read the User s Manual and Installation Guide completely before operating coupling 3 Keep area of operation clear of all persons other than operator 4 Use coupling only as described in this User s Manual failure to do so may result in Serious injury 5 Do not use any attachments or accessories with coupling not supplied by JC Carter 6 Do not operate coupling if damage has occurred If damage has occurred use only JC Carter or JC Carter s approved source for repairs 7 Maintenance and repairs should be done only by trained personnel using genuine JC Carter supplied replacement parts Failure to comply will void the JC Carter warranty and exclude JC Carter from any responsibility 3 JC Carter 671 West 17t Street e Costa Mesa CA 92627 3605 USA www jccarternozzles com JC Carter Manual
7. kage While Fueling None 7 JC Carter 671 West 17t Street e Costa Mesa CA 92627 3605 USA www jccarternozzles com Manual P N C01340 JC Carter ia Nozzles designed to fuel tomorrow s clean energy vehicles Nozzle Installation Step 1 Caution Open nozzle package only in a dry protected area Do not allow water or other contaminants to enter the internal mechanism of the coupling Remove the nozzle from the sealed packaging and pull the shipping plug from the nozzle port Using installation kit B91546 1 position the nozzle upright with the poppet assembly facing downward Place the boss seal in the nozzle port and thread the 37 degree flared fitting until bottomed Be careful to not allow the threads of the flared fitting contact the boss seal Once the flared fitting is bottom visually inspect to ensure an even alignment of the boss seal around the nozzle port Torque the flared fitting to between 120 and 130 Ft Lbs using the 1 2 flats Step 2 Purge the hose from the filling station to remove any contaminants and moisture that may have entered the lines Caution Failure to remove contaminants or moisture may affect the performance of the LNG coupling Step 3 Connect the line from the LNG filling station to the straight thread connector installed in step 1 Torque the filling station hose to between 120 and 130 Ft Lbs Step 4 Caution This step is critical in assuring the safe performance of the LNG coup
8. ling Perform leak test of the LNG coupling filling hose and adapters by pressurizing the upstream side of the filling station hose to 250 psig with Nitrogen gas Verify the system is free from any leakage 8 JC Carter 671 West 17t Street e Costa Mesa CA 92627 3605 USA www jccarternozzles com Manual P N C01340 JC Carter toni Nozzles designed to fuel tomorrow s clean energy vehicles Receptacle Installation Step 1 Caution Open receptacle packaging only in dry protected area Do not allow water or other contaminants to enter the internal mechanism of this coupling Remove the receptacle from the sealed packaging and remove the shipping plug from the receptacle outlet port Step 2 Select an appropriate location on the LNG fueled vehicle to mount the receptacle based on the following envelope definition figures The following two figures illustrate clearance needed to allow a proper nozzle to receptacle connection The three inch radius shown about the top handle in the figure below depicts the recommended clearance to grip the handle during operation MOUNTING SURFACE NOZZLE ASSEMBLY MODEL NO 50E701 RECEPTACLE ASSEMBLY MODEL NO 62050 t m The following side view figure shows the overall dimensions of a mated nozzle and receptacle 9 JC Carter 671 West 17t Street e Costa Mesa CA 92627 3605 USA www jccarternozzles com Manual P N C01340 JC Carter e Nozzles designe
9. r directly at 1 949 764 2200 Daily Maintenance At the start of each fueling day e Check to be sure no pressure is present in the nozzle e Clean out the mating end of the nozzle with a clean dry cloth Each Fueling Before each fueling e Clean out the cup of the receptacle with a clean dry cloth 3 Months or 5 000 Fuelings Remove and replace the nozzle retaining rings nozzle seals and nozzle seal retainers Use only JC Carter Nozzle Seal Replacement Kit part number B91548 1 20 000 Fuelings Perform 5 000 fuelings repair as well as replacing all nozzle linkage bushings Use only JC Carter parts 14 JC Carter 671 West 17t Street e Costa Mesa CA 92627 3605 USA www jccarternozzles com
10. ta Mesa CA 92627 3605 USA www jccarternozzles com Manual P N C01340 JC Carter o Nozzles designed to fuel tomorow S clean energy vehicles Step 6 Caution Before removing the nozzle from the receptacle the LNG supply should be turned off Once the LNG supply has been stopped pull the control handles away from the receptacle While pulling back the operator should first stop at the intermediate stop point in order to relieve any line pressure This is done to prevent damage to the nose seal and to protect the operator from blow off Once pressure is relieved the operator should continue to pull the handles until the mechanical hard stop point the locking mechanism will be disengaged and the nozzle can be removed from the receptacle Step 7 Replace the dust cap to the receptacle Step 8 Store the nozzle in a protected location free from moisture and debris Preferably in the Handles Up orientation 13 JC Carter 671 West 17t Street e Costa Mesa CA 92627 3605 USA www jccarternozzles com Manual P N C01340 JC Carter aes Nozzles designed to fuel tomorrow s clean energy vehicles Maintenance Schedule Please note that JC Carter recommends the following maintenance schedule be followed to ensure trouble free operation and maximum life Failure to follow the schedule may result in less than optimal performance or reduced operating life All kits described in this section may be ordered by contacting JC Carte

JC Carter LLC LNG Couplings

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