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RELIEF VALVE REASSEMBLY
1.
Install new pipe plugs (item 32, fi gure 3) into relief valve body
(item 31, fi gure 3) and torque to 10-12 ft-lbs [13-16 Nm].
2.
Install copper gasket (item 30, fi gure 3) onto seat (item 29,
fi gure 3), with round edges facing away from the seat.
3.
Place seat (item 29, fi gure 3) onto the bottom counter
bore in the relief valve body, with the gasket side down.
Note: make sure that the seat is fi rmly seated and not
crooked.
4.
Install spacers, back-up rings and O-ring (item 19, 20, 21
fi gure 4) onto piston (item 14, fi gure 4).
5.
Grease spacers, back-up rings and O-ring (items 19, 20, 21,
fi gure 4) and insert the piston (item 14, fi gure 4) into the body
(item 16, fi gure 4).
6.
Insert guide (item 15, fi gure 4) over piston and force spacers,
back-up rings, and O-ring up against the bottom of the bore
in the body (item 16, fi gure 4).
7.
Install spring and spring guide (items 22, 23, fi gure 4) into
bore in the opposite end of the body.
8.
Apply Loctite 242 onto the threads of the cap (item 25, fi gure
4) and thread cap into end of body (item 16, fi gure 4). Torque
to 10-12 ft-lbs [13-16 Nm].
9.
Install back-up ring (item 18, fi gure 4) and O-ring (item 17,
fi gure 4) onto the body.
10. Grease O-ring (item 17, fi gure 4) and insert relief valve
subassembly (item 28, fi gure 3) into cavity in the relief valve
body (item 31, fi gure 3).
11. Torque relief valve subassembly (item 28, fi gure 3) to 32-39
ft-lbs [43-53 Nm].
12. Install O-rings (item 49, fi gure 3) onto relief valve assembly
(item 47, fi gure 1).
13. Install relief valve assembly (item 47, fi gure 1) onto control valve
body (item 34, fi gure 1) using six socket head cap screws (item
48, fi gure 1) and torque to 10-12 ft-lbs [13-16 Nm].
POPPET VALVE REASSEMBLY
Repeat the following steps for each poppet valve:
1.
Electric valves only: Install solenoid stem (item 6, fi gure 2)
into body (item 2, fi gure 2). Turn stem in until bottomed out,
then unscrew 1.5 turns.
2.
Lubricate the inside bore of the body and valve stack
components with oil.
3.
Assemble poppet set (item 1G, fi gure 2) by installing O-rings
(item 1H) fi rst then Glyd Rings (item 1E, fi gure 2) on both
ends of poppet set (item 1G, fi gure 2). Allow the valve to sit
approximately 10 minutes to allow each Glyd Ring to return
to its original position.
4.
Insert bushing (item 1A, fi gure 2) into cavity, taking care not
to misalign the part in the bore. Be sure that orientation of
bushing is as shown in fi gure 2.
5.
Insert O-ring (item 1C, fi gure 2).
6.
Insert seat spacer (item 1F, fi gure 2) into cavity taking care
not to misalign the part in the bore.
7.
Insert O-ring (item 1C, fi gure 2).
8.
Insert poppet set assembly (item 1G, fi gure 2).
9.
Insert O-ring (item 1C, fi gure 2).
10. Insert seat spacer (item 1F, fi gure 2) into cavity taking care
not to misalign the part in the bore.
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11. Insert O-ring (item 1C, fi gure 2).
12. Insert bushing (item 1A, fi gure 2) into cavity, taking care not
13. Insert spring (item 1D, fi gure 2) into valve plug (item 3, fi gure 2).
14. Screw valve plug (item 3, fi gure 2) into cavity using a 7/8"
15. Insert set screw (item 9, fi gure 2) using a 5/32" Allen wrench.
16. Electric valves only: Torque solenoid stem to 15-20 ft-lbs
17. Air actuated valves only (follow steps a through g):
18. Torque valve plug (item 3, fi gure 2) to 32-35 ft-lbs
19. Install three O-rings (item 13, fi gure 2).
20.
CONTROL VALVE REASSEMBLY
1.
2.
3.
4.
5.
6.
6
to misalign the part in the bore. Be sure that orientation of
bushing is as shown in fi gure 2.
socket wrench until bottomed out. Then, loosen 1.5 turns.
Tighten until fl ush with valve plug (item 3, fi gure 2), then
tighten 1.5 turns.
[20-27 Nm].
a. Install cylinder housing (item 19, fi gure 2) prior to installing
plug (item 18, fi gure 2). Torque plug (item 18, fi gure 2) to
15-20 ft-lbs [20-27 Nm].
b. Insert pin (item 22, fi gure 2) into plug (item 18, fi gure 2).
c. Apply Loctite 222 to threads of spring guide (item 25,
fi gure 2) and install into cylinder (item 20, fi gure 2).
d. Install spring (item 23, fi gure 2) over pin (item 22, fi gure 2).
e. Install cylinder (item 20, fi gure 2) to cylinder housing (item
19) and secure with capscrews (item 24, fi gure 2) Torque
capscrews to 5-6 ft-lbs [6-8 Nm].
f. Install fi tting and breather vent (items 27 and 28, fi gure
2) into cylinder (item 20, fi gure 2) and torque to 6-8 ft-lbs
[8-10 Nm].
g. Install two set screws (item 26, fi gure 2) into cylinder
housing (item 19, fi gure 2) and torque to 6-8 in-lbs
[,70-,90 Nm].
[43-47 Nm].
Mount the poppet valve (item 41, fi gure 1) in the orientation
shown in fi gure 1. Before installing socket head cap screws
(item 42, fi gure 1), apply a small amount of grease to threads.
Torque to 6-10 ft-lbs [8.1-13.6 Nm].
Mount the multi-port assembly (if equipped - items 50-56
and 61-62, fi gure 1) using fi ve socket head cap screws (item
53, fi gure 1). Torque to 10-12 ft-lbs [13-16 Nm].
On older versions without externally adjustable "B" side
relief valve, install ball, guide and spring (items 36, 37, 38,
fi gure 1) through the bottom of the body (item 34, fi gure 1).
On newer versions with externally adjustable "B" side relief
valve, install ball, guide and spring (items 36, 37, 38, fi gure
1) through the top of the body (item 34, fi gure 1). Then install
set screw (item, 75, fi gure 1), copper gaskets, jam nut and
acorn nut (items 70, 71, 76, fi gure 1).
Install O-rings (items 44, 45) and mount the manifold (item
33, fi gure 1) to the bottom of the body (item 34, fi gure 1).
Before installing socket head cap screws (item 40, fi gure 1),
apply a small amount of grease to threads. Torque to 10-12
ft-lbs [13-16 Nm].
Reinstall the return tube and gasket (not shown).
Mount the valve assembly onto the pump using four socket
head cap screws (item 176, fi gure 1).
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