Dixon 5204NGC, 5204NG, 5204NGT, 5204NGTC, 5204BC Maintenance & Operating Instructions

1

Maintenance & Operating Instructions

For

BAYCO 5204 A.P.I. VALVES

Part Numbers

USA:

Dixon Bayco USA

Chestertown, Maryland
Phone: [phone]
Fax: [phone]
Toll Free: 800-355-1991
E-mail: [e-mail]

www.dixonbayco.com

Canada:

Dixon Group Canada Limited

Innisfil (Barrie), Ontario
Phone: [phone]
Fax: [phone]
Toll Free: 877-963-4966
E-mail: [e-mail]

www.dixongroupcanada.com

Mexico:

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

Monterrey, N.L
Phone: [phone]-DIXON (34966)
Fax: [phone]
E-mail: [e-mail]

www.dixonvalve.com

Europe:

Dixon Group Europe Ltd

Preston, England
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]

www.dixoneurope.co.uk

Asia Pacific:

Dixon (Asia Pacific) Pty Ltd

Wingfield, South Australia
Phone: [phone]
Fax: [phone]

E-mail: [e-mail]

www.dixonvalve.com.au

For Sales & Service Contact

5204L ........................ ‘load only’, with sight glass

5204LNG................... ‘load only’, no sight glass

5204LNGV ................ ‘load only’, no sight glass, Poppet O-ring, for B100

Load / Unload

Load only

5204 ....................... fixed handle, with sight glass

5204C .................... detachable handle, with sight glass

5204NG ................. fixed handle, no sight glass

5204NGC .............. detachable handle, no sight glass

5204T .................... fixed handle, with sight glass, PTFE seals, SS spring

5204TC .................. detachable handle, with sight glass, PTFE seals, SS spring

5204NGT............... fixed handle, no sight glass, PTFE seals, SS spring

5204NGTC ............ detachable handle, no sight glass, PTFE seals, SS spring

5204B .................... fixed handle, sight glass, Bayloy nose ring

5204BC ................. detachable handle, with sight glass, Bayloy nose ring

5204BNG .............. fixed handle, no sight glass, Bayloy nose ring

5204BNGC ............ detachable handle, no sight glass, Bayloy nose ring

5204SNG……… …fixed handle, no sight glass, stainless steel main spring
5204NGV…………fixed handle, no sight glass, Poppet O-ring, for B100

5204NGCV ........... detachable handle, no sight glass, Poppet O-ring, for B100

5204BNGV ......... fixed handle, no sight glass, Bayloy nose ring, Poppet O-ring, for B100

5204BNGCV ...... detachable handle, no sight glass, Bayloy nose ring, Poppet O-ring, for B100

5204SNGV …… …fixed handle, no sight glass, stainless steel main spring, Poppet O-ring, for B100

5204P .................... fixed handle, with sight glass, drain plug

090085 Rev 23

IMAGE

ITEM

QTY.

DESCRIPTION

PART NO.

REPAIR KITS

5204K1

5204K2

5204K3

5204K4

5204K5

5204K6

5204K7

5204K8

5204K9

5204K11

5204K12

5204KV1

5204KV2

1

1

1

Body - Pipe End

Body w/ Sight Glass

341614

Body w/ No Sight Glass

341634

Body Load Only w/ S/G

341649

Body Load Only w/ No S/G

341650

2

1

Nose Ring

*

Y

3

1

Shaft

390812

4 1

Handle Pin

*

Y 5 1

Shaft Spacer

390813

6 1

Shaft Bearing

*

Y

Y 7

1

Stop Pin

390814

8

1

Handle * Y

9

1

Poppet Subassembly

341617

Poppet, Subassembly - Load Only

341651

Poppet Subassembly with PTFE

400624

10

1

-Poppet Bearing

*

Y

Y 11

1

Cam

111550

12

1

Sight Glass

*

Y 13

1

-Poppet Roller

*

Y Y

14

1

-Poppet Roller Bearing

*

Y Y

15

1

Retaining Ring

111560

16

1

-O-Ring

*

Y Y Y

Y Y 17

1

O-Ring

111554

Y Y

Y Y Y 18

1

O-Ring * Y Y

Y 19

2

Roll Pin

111567

20

1

-Pin

111566

21

1

Grease Fitting

111561

22

6

Screw

111570

Y 23

8

Screw * Y Y

Y 24

1

O-Ring * Y Y

Y Y 25

5

Washer * Y Y (2) Y

26

1

Cotter Pin

*

Y

27A

1

Main Spring

111564

27B

1

Main Spring – Stainless (for 5204SNG)

111542

28

1

Handle Spring

*

Y

29

1

O-ring * Y

Y 30

14

Lock Washer

111569

Y

Y Y Y 31

1

Washer *

Y Y

Y

32

1

Washer

111574

33

1

Back-up Ring

111579

34

1

U-Cup * Y

Y 36

1

Float Ball

*

Y

2 37

1

Detachable Handle

*

Y

38

1

Bracket * Y

39

1

Clevis Pin

*

Y

40

1

Flat washer

*

Y

41

1

Cotter Pin

*

Y

42

1

Torsion Spring

*

Y

43

1

Pin * Y

3 44

1

Threaded Nose Ring

*

Y

45

1

Wear Ring

*

Y

4 46

1

Sight Glass Delete Kit – Blank Plate

*

Y 47

1

Sight Glass Delete Kit – Gasket

*

Y

*Use Relevant Repair Kit
Repair kit 5204K1: Poppet o-ring
Repair kit 5204K2: Complete rebuild kit; all o-rings and bearings
Repair kit 5204K3: Anodized nose ring with screws
Repair kit 5204K4: Bayloy nose ring with screws
Repair kit 5204K5: Detachable handle assembly
Repair kit 5204K6: PTFE encapsulated seals
Repair kit 5204K7: Fixed handle repair kit
Repair kit 5204K8: Sight glass repair kit
Repair kit 5204K9: Sightglass delete kit
Repair kit 5204K11: Nose ring hardware kit
Repair kit 5204K12: Sight glass hardware kit
Repair kit 5204KV1: Poppet o-ring rebuild-kit for B100
Repair kit 5204KV2: Complete rebuild kit; (including poppet o-rings and bearings for B100)

2 090085 Rev 23

Image 3

Threaded nose ring

* Fixed-handle version only

Image 2

Detachable handle

Image 4

Sight Glass Delete

Kit

3 090085 Rev 23

These instructions and recommendations are provided to ensure proper operation and long service life
of Bayco 5204 API. Parts are identified by the item number on the assembly drawing and part list.

MAINTENANCE AND PART REPLACEMENT FOR BAYCO 5204 API

The following instructions cover both the load/unload and load only API valves. For the load only
versions, please disregard items in italics.

I. SEMI-ANNUAL INSPECTION

1. Visual inspection of the valve operation can be done while the valve is still attached to the tank. All
safety precautions that apply to the use of the valve must be followed and all the lines must be
empty.

Visually examine 5204 API for worn or damaged parts, or any other condition that may affect the
operation of the valve.

Visually examine nose ring (2) for cavities, scratches, or other deformation of the sealing surface.
Visually examine shaft (3) for significant dirt accumulation that could cause shaft seal leakage.

Check that the handle (8) automatically positions at an angle to the valve body (1) with detent end
away from the stop pin (7).

Visually examine stop pin (7) for signs of wear and deformation. When the handle is moved to open
position, it should remain firmly latched on the stop pin (7). If the handle cannot stay securely in the
latched open position due to stop pin (7) wear, stop pin (7) should be replaced. Locking pliers can
be used to unscrew the stop pin (7).

2. To check the handle performance, open and close the API valve a few times. The handle should
move unobstructed and smoothly.

3. When released from the latched (or open) position, the poppet (9) should instantly close and center.

4. Using a non-scratching tool, (piece of wood), push the poppet open without using the operating
handle. Push the poppet to the side and make sure that the poppet reseats and centers itself when
closed slowly.

If any of the checks described above fails, additional maintenance is required.

II. YEARLY INSPECTION AND MAINTENANCE

The 5204 API can be disassembled and the seals may be replaced while the valve is still attached to
the trailer.

It is recommended to draw a line (using a felt-tip pen) across the joint between the pipe end (1) and the
nose ring (2). The line is used later in assembly to rotate the nose ring (2) from the starting position,
which helps balance out wear of the coupling surface.

4 090085 Rev 23

DISASSEMBLY – PART I

CAUTION! THE POPPET IS HELD UNDER CONSIDERABLE SPRING TENSION. WHENEVER

THE NOSE RING (2) OR POPPET (9) ARE REMOVED OR REASSEMBLED, THE
VALVE MUST BE LATCHED IN THE OPEN POSITION OR THE POPPET
OTHERWISE RESTRAINED (LOAD ONLY). PERSONAL INJURIES MAY RESULT IF
THIS PRECAUTION IS NOT TAKEN.

ATTENTION! WHERE POLISHING IS INDICATED, USE NOT LESS THAN 600 GRIT POLISHING

CLOTHS.

Inspect nose ring (2) for scratches on sealing surface. If there are any scratches on the sealing
surface, the nose ring (2) should be replaced to avoid valve leakage. Faces without hard coating
should be polished around the bore and only in circumferential direction.

Poppet (9) should be inspected for scoring or raised metal on the stem. Any raised metal on the
poppet stem should be removed with a fine flat file and polished in axial direction.

Inspect poppet bearing (10) for intrusion of any foreign material on the inside diameter. Any foreign
material on the inside diameter should be carefully removed with a sharp tool and polished.

On completion of poppet (9) and poppet bearing (10) inspection, test the bearing (10) on the poppet (9)
without the spring (27) to make sure that the bearing (10) smoothly slides along the poppet (9) stem. If
this is not the case, the bearing should be replaced.

Test rotation of the poppet roller (13) around the pin (20). If the rotation is difficult, the roller bearing
should be replaced. To access the roller bearing, support the poppet (9) and release the pin (20) using
a ¼” pin punch.

Check the handle (8) for free and easy movement of the opening and closing cycle. Operation of the
handle (8) normally requires limited effort. If operating the handle (8) involves stronger force, it implies
the need to clean and possibly replace the shaft bearing (6) and the shaft (3).

Poppet o’ring (16) and main o’ring (17) should be inspected for cracks, scratches, missing material,

unusual hardness, softness, roughness, and other signs of chemical damage. Do not remove poppet

o’ring from the poppet at this stage.

At this point it may be decided to replace the main o’ring (17) and reassemble the valve if the first part

of the inspection did not reveal any damage or malfunction of the parts, or to continue with Part II of

disassembly and replace all the o’rings if there are any additional concerns regarding the performance

of the valve. Steps 5 through 8 of the Assembly section describe how to assemble the valve from this
point.

DISASSEMBLY – PART II

To remove two roll pins (19), turn the handle until the pin is accessible and drive out each pin in turn

using ¼” pin punch. If this is done with the valve attached to the tank, take precautions to ensure that

the pins (19) do not enter upstream piping. To remove the cam arm roll pin (19), ensure that the
handle is rotated to a position such that the roll pin will be clear of the deflector cone (valve body) as it
is driven out. If the roll pin appears not to drive further than approximately ¼”, check for contact
between the roll pin and deflector cone and slightly adjust the rotation of the handle to allow sufficient
clearance.

Take out handle (8) with shaft assembly, shaft spacer (5) and cam (11).

5 090085 Rev 23