Dixon BAYCO 4040RD, BAYCO 4041RD, BAYCO 4041TE, BAYCO 4042RD, BAYCO 4042TE Installation & Operating Instructions Manual

Installation & Operating Instructions

BAYCO 4” SWING CHECK VALVES

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USA:

Mexico:

Asia Pacific:

4040RD — Molded Flapper Seat Swing Check 4” Manifold with Round Flange
4040TE — Molded Flapper Seat Swing Check 4” Manifold with Threaded Ends

4041RD — Metal Seat Swing Check 4” Manifold with Round Flange
4041TE — Metal Seat Swing Check 4” Manifold with Threaded Ends

4042RD — Silicone Seat Swing Check 4” Manifold with Round Flange
4042TE — Silicone Seat Swing Check 4” Manifold with Threaded Ends

Dixon Bayco USA

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

www.dixonbayco.com

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

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

www.dixonvalve.com

Dixon (Asia Pacific) Pty Ltd

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

E-mail: [e-mail]

www.dixonvalve.com.au

For

For Pneumatic Service

Part Numbers:

For Sales & Service Contact

Canada:

Dixon Group Canada Limited

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

www.dixongroupcanada.com

Europe:

Dixon Group Europe Ltd

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

www.dixoneurope.co.uk

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Important: To properly operate and maintain your Bayco 4040 / 4041 / 4042 swing check valve,

the following instructions are provided. Please read with care as improper handling or
maintenance may cause a hazardous condition.

Caution

: Do not modify your Bayco Swing Check Valve for any reason. It could result in a

hazardous condition causing operating difficulties or malfunction. Disassembly or
tampering will void the product warranty.

Installation

: Bayco swing check valves are properly adjusted, tested and ready to use upon
leaving the factory. Swing check valves are designed to be tough and to provide long
service with reasonable care and handling.
Ensure arrow is pointing downstream of product flow when installing. Apply appropriate
gasket for round-flanged model (4040RD / 4041RD / 4042RD).

Temperature

: Bayco 4040 swing check valve is not recommended for direct blower mounted
service. For direct blower mounted service use either the 4041 swing check valve (metal-to­metal seat) or the 4042 swing check valve (silicone-to-metal seat).

INSPECTION / MAINTENANCE

: Swing check valves can fail to operate if not properly

maintained. Frequently check for damage, loose or missing parts.
Swing check valves assure one-way airflow during the off loading or unloading of product.
Swing check valves prevent back flow of product into the blower or piping system. These
safety devises consist of a simple flapper valve that swings clear of the air stream during the
normal off-loading operation, but will immediately close when there is an air stoppage or
airline pressure reversal. Once installed, the valves are often ignored. However, they are a
crucial element in the proper operation of the dry bulk air transfer systems and the protection
of expensive blower equipment.

Swing check valve simplicity and historical durability are probably the reason for
inspection complacency. But, swing checks are subject to temperature extremes and
vibration fatigue that can affect wear and longevity. Wear in particular can result as flapper
and hinge mechanisms vibrate constantly during road travel. Also remember that blowers
raise intake air temperatures by as much as 200F. That means if the outside is 100F, then
airline plumbing (including swing checks) can reach 300F. High temperatures combined
with pulsation stress from the blower and road travel vibration creates a hostile working
environment that warrants performance inspections on a regular basis.

There are two basic ways to inspect swing checks: (a) visual/manual, on the tanker
and (b) removed from tanker, on a test stand.

NOTE: 4041RK1 and 4042RK1 flapper replacement kits will normally not be
compatible with 4040 style bodies that were manufactured prior to March 2007. Any
4040 style bodies manufactured after March 2007 will be compatible with these
4041RK1 and 4042RK1 flapper replacement kits.

To achieve compatibility a sub kit is included in 4041RK1 and 4042RK1 that
includes shorter axial shafts and smaller torsion springs that will enable the 4041 and
4042 style flappers to fit inside 4040 bodies that were manufactured prior to March

2007.

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WARNING: THE SMALLER TORSION SPRINGS WILL NOT ALLOW THE
4041 AND 4042 STYLE FLAPPERS TO FULLY SEAT IF THE VALVE IS
MOUNTED VERTICALLY UPSIDE DOWN. ENSURE THAT THIS MOUNTING
ORIENTATION IS AVOIDED IF THE SMALLER TORSION SPRINGS ARE USED.

Inspection Procedure:

The complete valve assembly may be removed and replaced without
removing the valve body from the system. Please note that the shafts and springs are
designed for left and right orientation, ensure that these components are located correctly.
The colored spring should be used in conjunction with the right hand threaded shaft.

a) Remove the inspection cap/cover and hand operate valve to ensure springs are in good

working order and flapper seats properly without restriction.

b) Whilst pulling the flapper forwards, pull upwards on the valve yoke to withdraw the

complete flapper assembly (take care to ensure that springs are secure during valve
withdrawal).

c) Inspect valve seat and valve for wear or gaps.
d) Inspect for product stuck in flapper assembly or valve seat causing the flapper to hang open.

Should problems be encountered, replace valve immediately.

If springs are replaced, please ensure that, after replacement, the valve assembly is free to
swing to the fully open position (90°) without excessive resistance. If excessive resistance is

felt:

1. Ensure that the springs are fully pressed onto the shaft

2. Reduce spring pre-load by moving torsion spring legs to alternative pre-load stop. The

correct amount of pre-load allows the valve to be freely opened to 90°.

IMPORTANT: Your Bayco 4040 / 4041 / 4042 swing check valve is designed for minimal flow

restriction and low pressure drop during operation. The valve return springs are designed to
provide sufficient pre-load to return the valve to the closed position with only limited pre­load. Excessive pre-loading of the return springs may lead to premature failure.

Inspection Frequency

: Swing check valves should be routinely inspected as part of a
preventative maintenance schedule for dry bulk tankers. The units should be given, at a
minimum, a visual/manual inspection e very 2-3months.
Do not use anything other than genuine Bayco parts in your Bayco swing check valve.
Repair kits are available for all replaceable parts (refer to parts breakdown for details). Use
of non-approved or modified parts can result in a hazardous condition due to operating
difficulties or operation malfunction. Modification or tampering will void the product
warranty.

CAUTION: Do not attempt to inspect the valve while in use; this may result in severe damage

or injury.

DIXON BAYCO WARRANTY: For complete Warranty information, please refer to the inside
back cover of the latest Dixon Catalogue.

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