X-4351-D

Revision 02

High Frequency Pulse Generator

Single and Dual Pulse
Installation and Operation Manual

Brodie Meter Co., LLC

19267 Highway 301 North (30461) Phone: (912) 489-0200
PO Box 450 Fax: (912) 489-0294
Statesboro, GA 30459-0450 www.brodiemeter.com

Manufacturers of BiRotors, Oval Gear Meters, and Control Valves

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Essential Instructions
Brodie Meter Co., LLC designs, manufactures and tests its products to meet many national and
international standards. Because these instruments are sophisticated technical products, you must
properly install, use and maintain them to ensure they continue to operate within their normal
specifications. The following instructions must be adhered to and integrated into your safety program
when installing, using and maintaining Brodie Meter Co., LLC products.
• Read all instructions prior to installing, operating, and servicing the product. If this instruction
manual is not the correct manual, telephone 1-912-489-0200 and the requested manual will be
provided. Save this instruction manual for future reference.
• If you do not understand any of the instructions, contact your Brodie representative for clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and maintenance of the
product.
• Install your equipment as specified in the installation instructions of the appropriate instruction
manual and per applicable local and national codes. Connect all products to the proper electrical
and pressure sources.
• To ensure proper performance, use qualified personnel to install, operate, update, program, and
maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts
specified by the manufacturer. Unauthorized parts and procedures can affect the product’s
performance and place the safe operation of your process at risk. Look-alike substitutions may
result in fire, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place, except when
maintenance is being performed by qualified persons, to prevent electrical shock and personal
injury.
• Before opening the flameproof enclosure in a flammable atmosphere, the electrical circuits must be
interrupted.
• It is the customer’s responsibility to provide fire prevention measures and equipment per local
regulations.
• Use of this equipment for any purpose other than its intended purpose may result in property
damage and/or serious personal injury or death.

i
Notice

Brodie Meter Co., LLC (“Brodie”) shall not be liable for technical or editorial errors in this manual or omissions from this
manual. Brodie makes no warranties, express or implied, including the implied warranties of merchantability
and fitness for a particular purpose with respect to this manual and, in no event, shall Brodie be liable for any
special or consequential damages including, but not limited to, loss of production, loss of profits, etc.

Product names used herein are for manufacturer or supplier identification only and may be trademarks/
registered trademarks of these companies.

The contents of this publication are presented for informational purposes only, and while every effort has been made to
ensure their accuracy, they are not to be construed as warranties or guarantees, expressed or implied, regarding the
products or services described herein or their use or applicability. We reserve the right to modify or improve the
designs or specifications of such products at any time.

Brodie does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper
selection, use and maintenance of any Brodie product remains solely with the purchaser and end-user.

Brodie Meter Co., LLC

Statesboro, Georgia, USA
All rights reserved. No part of this work may be reproduced or copied in any form or by any means - graphic,
electronic or mechanical - without first receiving the written permission of Brodie Meter Co., LLC.,
Statesboro, Georgia, U.S.A.

ii
Warranty
1. LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein and except as
otherwise expressly provided herein, Brodie Meter Co., LLC (“Brodie”) warrants that the firmware
will execute the programming instructions provided by Brodie, and that the goods manufactured or
Services provided by Brodie will be free from defects in materials or workmanship under normal use
and care until the expiration of the applicable warranty period. Goods are warranted for twelve (12)
months from the date of initial installation or eighteen (18) months from the date of shipment by
Brodie, whichever period expires first. Consumables and Services are warranted for a period of 90
days from the date of shipment or completion of the Services. Products purchased by Brodie from a
third party for resale to Buyer (“Resale Products”) shall carry only the warranty extended by the
original manufacturer. Buyer agrees that Brodie has no liability for Resale Products beyond making
a reasonable commercial effort to arrange for procurement and shipping of the Resale Products. If
Buyer discovers any warranty defects and notifies Brodie thereof in writing during the applicable
warranty period, Brodie shall, at its option, promptly correct any errors that are found by Brodie in
the firmware or Services, or repair or replace F.O.B. point of manufacture that portion of the Goods
or firmware found by Brodie to be defective, or refund the purchase price of the defective portion of
the Goods/Services. All replacements or repairs necessitated by inadequate maintenance, normal
wear and usage, unsuitable power sources, unsuitable environmental conditions, accident, misuse,
improper installation, modification, repair, storage or handling, or any other cause not the fault of
Brodie are not covered by this limited warranty, and shall be at Buyer’s expense. Brodie shall not be
obligated to pay any costs or charges incurred by Buyer or any other party except as may be agreed
upon in writing in advance by an authorized Brodie representative. All costs of dismantling,
reinstallation and freight and the time and expenses of Brodie’s personnel for site travel and
diagnosis under this warranty clause shall be borne by Buyer unless accepted in writing by Brodie.
Goods repaired and parts replaced during the warranty period shall be in warranty for the remainder
of the original warranty period or ninety (90) days, whichever is longer. This limited warranty is the
only warranty made by Brodie and can be amended only in a writing signed by an authorized
representative of Brodie. Except as otherwise expressly provided in the Agreement, THERE ARE
NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED, AS TO
MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE, OR ANY OTHER MATTER WITH
RESPECT TO ANY OF THE GOODS OR SERVICES. It is understood that - corrosion or
erosion of materials is not covered by our guarantee.

2. Limitation Of Remedy And Liability: Brodie Shall Not Be Liable For Damages Caused By Delay
In Performance. The Sole And Exclusive Remedy For Breach Of Warranty Hereunder Shall Be
Limited To Repair, Correction, Replacement OriiiRefund Of Purchase Price Under The Limited
Warranty Clause In Section 1 Herein. In No Event, Regardless Of The Form Of The Claim Or Cause
Of Action (Whether Based In Contract, Infringement, Negligence, Strict Liability, Other Tort Or
Otherwise), Shall Brodie’s Liability To Buyer And/Or Its Customers Exceed The Price To Buyer Of
The Specific Goods Manufactured Or Services Provided By Brodie Giving Rise To The Claim Or
Cause Of Action. Buyer Agrees That In No Event Shall Brodie’s Liability To Buyer And/Or Its
Customers Extend To Include Incidental, Consequential Or Punitive Damages. The Term
“Consequential Damages” Shall Include, But Not Be Limited To, Loss Of Anticipated Profits, Loss Of
Use, Loss Of Revenue And Cost Of Capital.

iii
Table of Contents

1.0 Introduction .................................................................................................................. 2

1.1 Description ................................................................................................................................................. 2
1.2 Specifications ............................................................................................................................................ 2

2.0 Receipt of Shipment ..................................................................................................... 3

3.0 Storage, Installation And Operation ........................................................................... 3

3.1 General ....................................................................................................................................................... 3
3.2 Installation ................................................................................................................................................. 3
3.3 Electrical Connections .............................................................................................................................. 3
Table 3.1 Recommended Cable Lengths ....................................................................................................... 4
Figure 3.1 Electrical Connection Wiring Diagram ......................................................................................... 4
3.4 Operation ................................................................................................................................................... 4
Figure 3.2 Timing Diagram .............................................................................................................................. 4

4.0 Maintenance .................................................................................................................. 5

4.1 General ....................................................................................................................................................... 5
4.2 Lubrication ................................................................................................................................................. 5
4.3 Standard Unit Part Number and Assembly .............................................................................................. 5
Figure 4.1 Generator Installation .................................................................................................................... 5
Figure 4.2 Nameplate (Input/Output Data) ..................................................................................................... 5
4.4 Changing Generator Output Range ......................................................................................................... 5
4.5 Disassembly (Reference Figure 7.1) ........................................................................................................ 6
Figure 4.3 General Assembly - Exploded View ............................................................................................. 7
Figure 4.4 Type I - Bottom View (Plate Removed) ......................................................................................... 7
Figure 4.5 Type II - Bottom Plate and Adaptor .............................................................................................. 7
Figure 4.6 Type II - Idler Gear Bracket Assembly .......................................................................................... 8
4.6 Reassembly (Reference Figures 7.1) ....................................................................................................... 8
Table 4.1 High Frequency pulse Generator Assembly ............................................................................... 10
Figure 4.7 Gear Train Assemblies - Type I and Type II ............................................................................... 10

5.0 Troubleshooting ......................................................................................................... 11

Table 5.1 Troubleshooting ............................................................................................................................ 11

6.0 Warranty Claim Procedures ......................................................................................

1 11

7.0 Parts List ..................................................................................................................... 12

Figure 7.1 Exploded View of High Frequency Pulse Generator ................................................................. 12
Table 7.1 Parts List - Complete Assembly ................................................................................................... 13
Figure 7.2 Gear Assemblies .......................................................................................................................... 14
Table 7.2 Parts List - Gear Assemblies ........................................................................................................ 14

Appendix A - Customer Problem Report........................................................................ 15

1
1.0 Introduction
250 line discs offered 250, 500, and 1,000
1.1 Description pulses per revolution.
The Brodie High Frequency Pulse Generator is a 256 line discs offer 256, 512, and 1,024 pulses
photo electric device used to provide one or two per revolution.
output signals proportional to unit volume while
maintaining a mechanical meter-to-register link. 1.2 Specifications
Both single and dual output units are available.
Dual signal outputs are electrically 90° out of phase Caution
and are used primarily for pulse security. Although
designed for use in meter proving, the HFPG can Do not operate generator in excess of
be used on any application requiring a high specifications listed below.
resolution signal indicating throughput or rate of
flow. Signals

Phase A and B: Dual Output 90° Electrically

Out of Phase Phase Error: 15° Maximum
Note: Units supplied prior to 1999 utilize
Amplitude: 0 to V+ (500 ohm Internal Pull-up,
100 or 250 line discs. Reference assembly No Load); 0 to 5 Vdc +l- 0.2 Vdc (249 ohm
part number to identify your particular Internal Pull-up, No Load)
generator. High Frequency Pulse Index: Open Collector, 1 Pulse per Revolution
Generators manufactured after January 25 Vdc maximum
1999, utilize 100 or 256 line discs. Part 100 mA maximum
numbers and information contained within Pulse Duration: 90 +1-10% of Shaft Rotation
this service manual will reference 100, 250,
and 256 line discs. Temperature Range:
-40 to 185F (-40 to 85C) Power Requirements
12 to 24 Vdc +l- 10%
It should be noted that units supplied with
88 to 144 mA (Depending on Input Voltage/
256 line discs provide 2.4% more pulses
Output Configuration
per revolution than traditional 250 line
discs, and consequently a 2.4% change in Connections
per unit volume. 1/2" Conduit

Enclosure
Explosion-proof Class C and D, Division 1,
Important: Adjustments MUST BE MADE CSA, UL.
when replacing High Frequency Pulse
Generators utilizing 250 line discs with the 2
Generators using 256 line discs. Load Impedance: 5 k ohms

Maximum RPM
Example: 2222222 Pulser Shaft: 1000 rpm maximum
Gear Changer: 250 rpm maximum
Original HFPG with 250 pulses per revolution
disc.
K-Factor = 123.4 counts per gallon

New HFPG with 256 Pulses per revolution disc

K-Factor is increased by 2.4%
123.4 X 0.024 = 2.9616 (2.4% of 123.4)
123.4 + 2.9616 = 1.26.3616
The new K-Factor is 126.4 counts per gallon
(rounded to 4 digits)
2
2.0 Receipt of Shipment 3.0 Storage, Installation And
When you receive your equipment, inspect the
Operation
outside of the packing case for damage which 3.1 General
may have incurred during shipping.
This section contains specific instructions for
Damage incurred during shipment is the
installation of the High Frequency Pulse
responsibility of the carrier and is not part of
Generator.
the factory warranty.

If the package is in good condition remove the 3.2 Installation

envelope containing the packing list and
carefully remove the equipment and all The High Frequency Pulse Generator is
components included in the shipment from the constructed in two independent units: the
packing case. Inspect for damaged or missing generator assembly, and the gear housing
parts, referring to the packing list, and prior to assembly. The Gear Housing Assembly is
discarding the packing material. If Items are permanently installed in the meter accessory
missing from your shipment, contact your sales stack-up. An adaptor assembly on the gear
representative. Your sales order number will be housing assembly allows the generator to be
required. quickly and easily transferred from one gear
housing assembly to another.
If the packing case is damaged, notify the
local carrier immediately. If the equipment The bottom plate of the generator has four 9/32"
must be returned to the factory for repair or clearance holes for mounting to the meter. The
replacement, a Returned Materials Authorization top of the gear housing is tapped for 1/4 x 1/2"
(RMA) must be included with the equipment or screws in twelve locations to facilitate the
components. RMA forms may be obtained from mounting of impulse contactors, registers, or
your sales representative or from the Product other accessories.
Service Department. In addition to the RMA, a
3.3 Electrical Connections
Material Safety Data Sheet and a
Decontamination Statement must be included 3.3.1 Installation
with items being returned to the factory.
Electrical connections for the generator should
When packing the equipment or components for be made as shown in Figure 3.1.
return to the factory, place the RMA and a copy
of the packing list that was delivered with the For permanent installations where the generator
equipment inside an envelope. Place the is to be located no farther than 700 feet from the
envelope inside the shipping container with the 3 power source, prover counter or other unit,
Item being returned and reference the RMA Belden No.8770, three conductor shielded cable
number on the outside of the shipping container. or equivalent should be used.

Equipment returned to the factory without the If the power supply is to be located within 700
proper documentation will be returned to sender feet of the generator and the unit being pulsed is
at their expense. more than 700 feet from the generator Belden
No. 8760, two conductor shielded cable must be
Ship the container to: used for the output signal. The 12 Vdc power
Brodie Meter Co., LLC would then be supplied to the generator through
Product Service Department its own separate wiring (No.18 AWG - up to 700
19267 Hwy. 301 North feet). Reference Table 3.1 Recommended Cable
Statesboro, GA 30461 Lengths.
Phone: 912-489-0200
Fax: 912-489-0294 The recommended cable lengths are based on
service@brodiemeter.com 18 gauge tinned copper shielded cable with a
load impedance of 5 k ohm (recommended
3
minimum) and cable capacitance of 27 pf/ft. generator. The rate of Pulses is determined by
When other type cables are used the factory the ratio of the gear train between the meter and
should be consulted to determine permissible the pulse generator shaft.
cable lengths. Dual channel signals must be run
in separate cables. Note: The resolution of the Hall Effect Switch
is one pulse/revolution of the rotating disc (one
Table 3.1 Recommended Cable Lengths
contact closure/100 or 256 pulses).

Pulse Output Maximum Recommended

Frequency Cable Lengths A rotating disc with precisely spaced opaque
1,000 Hz 3,700 ft. and transparent slots is located within the pulse
2,000 Hz 1,850 ft. generator. As the disc rotates, it interrupts a light
3,000 Hz 1,185 ft. beam transmitted from a light emitting diode to a
4,000 Hz 925 ft. photo transistor, thus producing a pulsed
5,000 Hz 740 ft. electronic output. The signal is then picked up by
a self-contained amplifier for shaping and
3.3.2 Grounding amplifying. The resulting pulse from the pulse
generator is a positive square wave.
The shielding on the cable must be grounded at
one end only to avoid error readings. It is An integral Hall Effect Switch, mounted at the
recommended that grounding be made at the base of the generator disc, generates one pulse
unit being pulsed. per revolution of the disc. The resulting open
collector signal may be used as a backup, check
Note: Internal moisture will cause failure of or independent system.
the unit. When fixed conduit is used it is
Figure 3.2 Timing Diagram
strongly recommended that a Conduit Seal
be used to prevent moisture from entering
the unit at the conduit connection.

Figure 3.1 Electrical Connection Wiring

Diagram

4444444
3.4 Operation
3.4.1 General

The High Frequency Pulse Generator is

composed of a gear housing assembly and a
pulse generating assembly. An interchangeable
gear train within the housing utilizes change
gears to adjust the ratio between the output shaft
to the register and the shaft of the pulse

4
4.0 Maintenance Figure 4.2 Nameplate (Input/Output Data)

4.1 General
During normal operation, no routine
maintenance or adjustment is necessary. If
generator failure is suspected, refer to Section
5.0 Troubleshooting.

4.2 Lubrication
No lubrication, other than that supplied at the
factory, is required under normal operation.

4.3 Standard Unit Part Number and

Assembly
Information is supplied on the name tag from
which the complete assembly part number may
be derived.

Each unit is supplied with a metal plate (attached

to the accessory block), which contains pertinent
part number information.

To determine your part number:

1. Read the nameplate: 4.4 Changing Generator Output Range
Rev. A (IN lower side) The pulses per revolution of output of any given
Rev. B (OUT far side) standard unit are field changeable to any other
Rev. C (OUT top side) standard pulse output.
2. Match information in Step 1 with information in
Table 4.1. Changing the pulse output requires either a
change in the gearing of the accessory gear
Figure 4.1 Generator Installation housing and/or replacement of the generator
assembly. Once the pulses per revolution of
output desired is located in Table 4.1, the correct
part number for the unit is then read from the
first column.
5
To determine the part number needed to
accurately change output range:
1. Determine the pulses per revolution required.
2. Locate the appropriate part number from
Table 4.1, column 1.
3. Locate this same complete assembly part
number in the row of figures across the top of
Table 7.1. Convert to the proper assembly by
replacing all part numbers that are different
with those listed.
4. Compare accessory gear housing part
numbers and replace as necessary. Proceed
to step 5 and 6 if replacement is required.
5. Locate the new accessory housing part

5
 number from Figure 7.2. 4.5.3 Generator Adaptor, Gear and Shaft
6. Order gear assemblies as required. Assembly
Reference Table 7.2. 1. Remove screws and adaptor from the gear
housing being careful/ not to damage the
4.5 Disassembly (Reference Figure 7.1) shims.
2. Inspect the shaft and gear assembly for
Caution looseness in the bushings. Inspect the bevel
gear, spacer and coupling for wear.
Power must be OFF before performing any
disassembly or reassembly procedures. Failure Note: Certain Assemblies require the use of
to disconnect power could result in serious Spacers. Reference Figure 7.1 Detail A-A.
personal injury and/or damage to the 3. Hold the shaft assembly in by applying light
equipment. pressure to the coupling of the adaptor
housing.
4.5.1 Removal of Generator 4. Press the roll pin from the bevel gear and
1. Loosen seal screws. remove the gear and spacer (if required).
5. Gently remove the shaft and coupling from the
NOTE: The Seal Screws which hold the adaptor housing taking care not to damage
Generator to the Adaptor Assembly are the shims. Replace shims as required.
held by Retaining Rings. Do not attempt to 6. Pull out bushings and replace as required.
loosen more than three (3) revolutions.
4.5.4 Output Coupling - Accessory Gear
2. Remove the generator assembly from the Housing
adaptor by pulling straight out. Gentle prying 1. Remove the cotter pin, coupling, slinger, O-
may be necessary, however do not use force. Ring and spacer from the output shaft.
3. Inspect all wires, O-Rings, shafts and 2. Inspect all parts for wear or damage and
bearings for damage or wear and replace as replace as necessary.
required.
4.5.5 Type I Bottom Plate and Through Drive
4. No further disassembly of the generator
Shaft
should be performed as this is a factory
1. Remove the snap ring holding the through
replaceable item containing no adjustment or
drive shaft adaptor to the bottom plate.
serviceable parts.
2. Remove the four screws and bottom plate
from the gear housing.
Caution 3. Remove the through drive shaft being careful
Under no circumstances should the sealed not to lose or damage shims.
generator housing be opened. There are no 4. Inspect gear, shaft, bushing, shims and
user serviceable components inside. bearing for damage and/or wear.
6
4.5.6 Type II Bottom Plate and Idler Gear
4.5.2 Installation of Generator Bracket Assemblies
(Reference Figures 4.1 and 4.3) 1. Remove the four screws and bottom plate
6666666 from the gear housing.
Be sure that the generator seal screws are 2. Remove the two screws and idler gear
properly aligned in the countersunk slots of the bracket from the bottom plate.
adaptor housing. If the generator will not seat
properly, it may be necessary to rotate the
generator shaft to align with the coupling on the
shaft of the adaptor housing. DO NOT FORCE
the shaft into the coupling as serious damage
could occur. See Figure 4.3.

6
Figure 4.3 General Assembly - Exploded View

Figure 4.4 Type I - Bottom View (Plate Figure 4.5 Type II - Bottom Plate and
Removed) Adaptor
7

7
Figure 4.6 Type II - Idler Gear Bracket 4.5.8 Housing Assembly
Assembly
Inspect all bearings and bushings for wear or
damage and replace as required.

4.6 Reassembly (Reference Figures 7.1)

Shim as required to obtain proper gear mesh,
face alignment and shaft end play.

4.6.1 Output Shaft Assembly

(This section DOES NOT apply to straight

through drive assemblies without idler gear
bracket.)
1. Place shims as required on output end of
shaft.
2. Place output shaft assembly into the bearing
Note: The input gear assembly, shims and in the gear housing.
washer are now loose and should be guarded 4.6.2 Bevel Gear Shaft Assembly
against loss. Inspect the idler gear assembly 1. Place shims on the gear end of the shaft as
(for looseness in the idler gear bracket), gears required.
and shims. Replace as required. 2. Place the shaft into the gear housing, gear
down, making sure that gears mesh properly
3. If further disassembly is required, or to
and that the shaft is fully seated in the
remove idler gears from the assembly:
housing.
a. Drive out the pins holding the gears to the
3. Return shim (if required) to the bushing end of
shafts.
the shaft.
b. Remove gears from the shafts.
c. Remove shims (if required). 4.6.3 Bottom Plate and Drive Through Shaft
d. Remove the shaft from the idler gear
bracket. (This section applies to the straight through drive
4. Remove the input shaft assembly from the assemblies WITHOUT idler gear bracket.)
bottom plate by removing the snap ring. 1. Replace shims (as required) on the square
Inspect the shaft, bearing and bushing for end of the shaft.
wear. 2. Place the through drive shaft into the bearing
in the gear housing making sure that gears
4.5.7 Bevel Gear Shaft Assembly mesh properly.
1. Remove the bevel gear shaft assembly from 3. Align the bottom plate with the locating pin of
the gear housing. Note position of shims (top 8 housing making sure that through
the gear
and bottom) and remove. drive shaft and bevel gear shaft are seated
2. Inspect all gears bushings, shims and shafts properly and secure into position using four
for wear. screws.
8888888
4. Replace the through drive shaft adaptor and
4.5.8 Output Shaft
the retaining ring.
This section does NOT apply to straight through
4.6.4. Bottom Plate and Idler Gear Bracket
drive assemblies without the idler gear bracket.
(This section DOES NOT apply to straight
1. Remove the output shaft.
through drive assemblies without idler gear
2. Note position of shims and remove. bracket.)
1. If previously removed, install the idler gear
3. Inspect all gears, shafts and shims and assembly into the idler gear bracket and shim
replace as required. as required.
8
2. With the idler gear held upside down, place 4. Place shims (as required) over the square end
the washer and shims (as required) over the of the shaft assembly.
bottom bearing in the idler gear bracket and 5. Place the coupling over the square end of the
align the holes. shaft and secure with cotter pin.
3. Gently insert the input gear assembly into the 6. Insert the shaft through the bushings in the
idler gear bracket and align the gear, washer adaptor housing from the generator end.
and shims with the bearing. 7. Return shims (as required) and spacer to the
4. Insert the input gear shaft through the bracket, round end of the shaft.
gears, shims, washer and bearing and align 8. Replace gear and secure in position with the
the pin with the slot in the input gear. roll pin.
5. With the assembly still upside down, insert the
Input shaft through the bottom plate, align the 4.6.7 Installation - Generator Assembly
mounting holes in the bracket with the bottom Align the seal screws of the generator with the
plate and attach with two screws. counter-sunk slots of the adaptor. To properly
6. Install the input shaft adaptor and the retaining seat the generator it may be necessary to rotate
ring into the slotted end of the input shaft. the output coupling on the gear housing while
7. With the output shaft and bevel gear exerting light pressure to the generator
assemblies installed in the gear housing, assembly. When the coupling and shaft of the
place the bottom plate with the idler gear generator assembly line up, a proper seat
bracket onto the gear housing, align with the should be established. Under no circumstances
locating pin and assure that all gears mesh should the shaft be FORCED into the coupling
properly. Rotate the input shaft to assure a as serious damage to the generator could result.
proper seat. DO NOT FORCE the bottom
plate onto the gear housing.
8. Attach the bottom plate to the gear housing
using the four screws previously removed.

4.6.5 Output Coupling

1. Install spacer, O-Ring, slinger and coupling
onto the output shaft.
2. Install Cotter Pin.

4.6.6 Generator Adaptor, Gear and Shaft

Assembly
1. Replace shim (as required ) over adaptor
neck (Gear end).
2. Install the adaptor onto the gear housing
9
taking care not to damage shims. Secure with
screws.
Note: It may be necessary to rotate the output
coupling to obtain proper gear mesh.

Note: Due to specific tolerance dimensions, to

insure proper alignment of the bevel gear “G”
with bevel gear “H” (Figure 4.7), the shaft and
gear assembly must be purchased as a
complete unit.

If the shaft was removed, reassemble following

steps 3 though 8 below.
3. Return bushings to the adaptor.

9
10
Information shown in
Table 4.1 pertains to
both single and dual
output units. Complete
assembly numbers
have been shown using
a place holder of “XX”.
(Reference Table 4.1, Column 2)

If your unit utilizes a

dual output signal “XX”
is replaced by the
number “23”. Single
output units use the
number “13”.

10101010101010
10
Part Number Type Input per/ Ratio Input "A" Output per Pulses per Disc Line Accessory Gear Housing Number of Teeth**
Table 4.1 High Frequency pulse Generator Assembly
Figure 4.7 Gear Train Assemblies - Type I and Type II

(Complete Gear Rev "A" to Output "B" Rev. "B" One (1) Rev. Number "A" Lower "C" Far "B" Top A B C D E F C H
741-XX-622-09 I (1) Unit 1:1 (1) Unit 100 100 1 1 1 31 31 16 16
741-XX-622-10 I (1) Unit 1:1 (1) Unit 250 250 1 1 1 31 31 16 16
741-XX-622-11 I (1) Unit 1:1 (1) Unit 500 250 1 2 1 42 21 16 16
741-XX-622-08 I (1) Unit 1:1 (1) Unit 1,000 250 1 4 1 42 21 32 16
741-XX-622-26 I (1) Unit 1:1 (1) Unit 256 256 1 1 1 31 31 16 16
741-XX-622-27 I (1) Unit 1:1 (1) Unit 512 256 1 2 1 42 21 16 16
741-XX-622-25 I (1) Unit 1:1 (1) Unit 1,024 256 1 4 1 42 21 32 16
741-XX-622-07 II (1) US Gal. 2.67:1 (10) Liters 100 100 2.67 1 1 27 36 21 42 31 31 16 16
741 -XX-622-06 II (1) US Gal. 2.67:1 (10) Liters 1,000 250 2.67 4 1 27 36 21 42 42 21 32 16
741-XX-622-24 II (1) US Gal. 2.67:1 (10) Liters 1,024 256 2.67 4 1 27 36 21 42 42 21 32 16
741-XX-622-05 II (1) US Gal. 4.2:1 (1/10) BBL 100 100 4.2 1 1 20 42 21 42 31 31 16 16
741-XX-622-15 II (1) US Gal. 4.2:1 (1/10) BBL 500 250 4.2 2 1 20 42 21 42 42 21 16 16
741-XX-622-04 II (1) US Gal. 4.2:1 (1/10) BBL 1,000 250 4.2 4 1 20 42 21 42 42 21 32 16
741-XX-622-29 II (1) US Gal. 4.2:1 (1/10) BBL 512 256 4.2 2 1 20 42 21 42 42 21 16 16
741-XX-622-23 II (1) US Gal. 4.2:1 (1/10) BBL 1,024 256 4.2 4 1 20 42 21 42 42 21 32 16
5.0 Troubleshooting
Table 5.1 has been provided to aid in basic troubleshooting. Disassembly procedures are covered
in Section 4.0 Maintenance. If the unitis found to be in need of repair, it is important that servicing
be preformed by trained and qualified service personnel and it is recommended the user contact the
Brodie Meter Co., LLC Repair Department.

Table 5.1 Troubleshooting

Condition Possible Cause

Prover counter not operating properly.
Improper electrical connection.
Gear train turning with NO Insufficient voltage to generator.
output pulse registration. Generator amplifier not operating.
Broken shear coupling between generator and gear housing.
Improper alignment between shear coupling and generator shaft.
Foreign material between gears in the gear train.
Improper gear alignment.
Gear train not turning.
Broken shear coupling below accessory gear housing.
Broken gear teeth.
Shielding on connecting cable grounded at both ends.
Sensitivity control on prover counter not adjusted properly.
Too many counts received at
Excessive vibration on meter stack-up.
the prover counter.
Incorrect gearing.
Incorrect lines on disc.
Too few counts received at Input voltage lower than specified limits.
the prover counter. Sensitivity control on prover counter not adjusted properly.

6.0 Warranty Claim Procedures

To make a warranty claim, you, the Purchaser, must:
1. Provide Brodie with proof of the Date of Purchase and proof of the Date of Shipment of the
product in question.
2. Return the product to Brodie within twelve (12) months of the date of original shipment of the
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product, or within eighteen (18) months of the date of original shipment of the product to
destinations outside of the United States. The Purchaser must prepay any shipping charges. In
addition, the Purchaser is responsible for insuring any product shipped for return, and assumes
the risk of loss or damage of the product during shipment.
3. To obtain Warranty service or to locate the nearest Brodie office, sales, or service center call
(912) 489-0200.
4. When contacting Brodie for product service, the purchaser is asked to provide information as
indicated on the following page entitled “Customer Problem Report” (Appendix B).
5. For product returns from locations outside the United States, it will be necessary for you to obtain
the import consignment address so that Brodie’s customs broker can handle the importation with
the U.S. Customs Service.
6. Brodie Measurement Services offers both on call and contract maintenance service designed to
afford single source responsibility for all its products.
7. Brodie reserves the right to make changes at any time to any product to improve its design and
to insure the best available product.

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7.0 Parts List
This section contains the necessary parts required for routine maintenance and service of the High
Frequency Pulse Generator. Each parts list also contains the recommended spare and replacement
parts denoted by an asterisk. For Items not listed, or additional information, consult factory. When
ordering, the following information must be furnished:
1. Part Number
2. Model Number of the unit
3. Serial Number
4. Quantity required.

Figure 7.1 Exploded View of High Frequency Pulse Generator

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12121212121212

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Table 7.1 Parts List - Complete Assembly

741-13-622-09 741-23-622-09
741-13-622-10 741-23-622-10
741-13-622-11 741-23-622-11
741-13-622-08 741-23-622-08
741-13-622-26 741-23-622-26
741-13-622-27 741-23-622-27
741-13-622-25 741-23-622-25
741-13-622-07 741-23-622-07
741-13-622-06 741-23-622-06
741-13-622-24 741-23-622-24
741-13-622-05 741-23-622-05
741-13-622-15 741-23-622-15
741-13-622-04 741-23-622-04
741-13-622-29 741-23-622-29
741-13-622-23 741-23-622-23
741-13-623-01 741-23-623-01
Dual
Part Number

Single
Item Description Single Output Dual Output Qty.
1 Shear Coupling & Cotter Pin W4125 1 X X X X X X X X X X X X X X X X
3 Spacer 741-12-038-01 1 X X X X X X X X X X X X X X X X
4 Shim 741-12-006-04 1 X X X X X X X X X X X X X X X X
5 Shim 741-12-006-03 A/R X X X X X X X X X X X X X X X X
6 Shim 741-12-006-05 A/R X X X X X X X X X X X X X X X X
7 Shim 741-12-006-00 A/R X X X X X X X X X X X X X X X X
741-12-006-01 A/R X X X X X X X X X X X X X X X X
741-12-006-02 A/R X X X X X X X X X X X X X X X X
8 Bushing 788-14-035-00 2 X X X X X X X X X X X X X X X X
10 Generator Assembly
100 Line Disc w/ 1/2" NPT 228-00-602-37 229-00-602-17 X X X X
Generator Assembly
256 Line Disc w/ 1/2" NPT 228-00-602-46 229-00-602-25 X X X
11 Generator Adaptor 741-12-013-00 X X X X X X X
12 Shim .004 21448 X X X X X X X
Shim .008 21449 X X X X X X X
13 Screw 150533 X X X X X X X
14 Shim 741-12-006-01 X X X X X X X X X X X X X X
15 Shim 741-12-006-00 X X X X X X X X X X X X X X
16 Shim 741-12-006-02 X X X X X X X X X X X X X X
17 Input Shaft Assembly 741-12-325-00 X X X X X X X X X X X X X X
18 Bottom Plate Asssembly 741-12-301-01 X X X X X X X X X X X X X X
19 Housing Assembly 741-12-330-02 X X X X X X X X X X X X X X
20 Idler Gear Assembly 741-12-320-00 X X X X X X X X X X X X X X
21 O-Ring 152064 X X X X X X X X X X X X X X
22 Slinger 4532 X X X X X X X X X X X X X X
23 Washer 741-00-054-00 X X X X X X X X X X X X X X
25 Spacer 741-00-054-60 X X
794-24-067-02 X X X X
26 Shaft and Gear Assembly 741-12-328-00 X X X X X
(Includes gear, roll pin, shaft 741-12-328-01
coupling, and cotter pin) 741-12-328-02
27 Complete Accessory Gear 741-12-502-00 (1.05:4:1)
Housing (Includes Item 1-6 741-12-502-02 (1.05:1:1)
and 13-26 above). 741-12-502-08 (4.2:4:1) X X
See Table 7.2 for Gear 741-12-502-10 (4.2:4:1) X X
Assembly part numbers. 741-12-502-12 (2.67:4:1) X X X
741-12-502-13 (2.67:4:1)13 X
741-12-502-16 (1:4:1) X
741-12-502-18 (1:1:1) X X
741-12-502-25 (1:0.25:1) X
741-12-502-32 (4.2:1:1)

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Figure 7.2 Gear Assemblies

Table 7.2 Parts List - Gear Assemblies

741-12-502-00

741-12-502-02

741-12-502-08

741-12-502-10

741-12-502-12

741-12-502-13

741-12-502-16

741-12-502-18

741-12-502-25

741-12-502-32
Item Description Part Number Qty.
28 Through Drive Shaft Assembly 741-12-341-02 1 X
30 Bevel Gear Shaft Assembly 741-12-327-02 1 X X X X
32 Through Drive Shaft Assembly 741-12-341-01 1 X
33 Bevel Gear Shaft Assembly 741-12-327-01 1 X X X X
34 Input Gear Assembly 741-12-315-00 1 X 14 X X X X X
36 Output Shaft Assembly 741-12-326-02 1 X
37 Output Shaft Assembly 741-12-326-05 1 X X
38 Idler Gear Assembly 741-12-317-03 1 X X X
39 Output Shaft Assembly 14141414141414
741-12-326-04 1 X
40 Output Shaft Assembly 741-12-326-07 1 X
41 Idler Gear Assembly 741-12-317-00 1 X X
42 Input Gear Assembly 741-12-315-02 1 X X
43 Idler Gear Assembly 741-12-317-01 1 X X
46 Bevel Gear Assern. 741-12-327-07 1 X X

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Appendix A - Customer Problem Report

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The contents of this publication are presented for

Brodie Meter Co., LLC informational purposes only, and while every effort has
been made to ensure their accuracy, they are not to be
construed as warranties or guarantees, express or
19267 Highway 301 North (30461) Phone: (912) 489-0200 implied, regarding the products or services described
PO Box 450 Fax: (912) 489-0294 herein or their use or applicability. Brodie Meter Co., LLC
Statesboro, GA 30459-0450 www.brodiemeter.com reserves the right to modify or improve the designs or
specifications of such products at any time without
notice.