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[SGML Version See Change Record ] TECHNICAL MANUAL OPERATION AND MAINTENANCE INSTRUCTIONS WITH PARTS LIST PNEUMATIC PRESSURE REGULATING MANIFOLD DISTRIBUTION STATEMENT B: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES ONLY: THIS PUBLICATION IS REQUIRED FOR OFFICIAL USE OR ADMINIS- TRATIVE OR OPERATIONALPURPOSES: (DATE OF PUBLICATION). OTHER REQUEST FOR THIS DOCUMENT MUST BE REFERRED TO THE NAVAL SEA SYSTEMS COM- MAND (SEA-09T) WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C., SEC. 2751, ET SEQ.) OR EXECUTIVE ORDER 12470. VIOLATION OF THESE EXPORT LAWS ARE SUB- JECT TO SEVERE CRIMINAL PENALTIES. DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLO- SURE OF CONTENTS OR RECONSTRUCTION OF THIS DOCUMENT. THIS MANUAL SUPERSEDES NAVSEA 0983-LP-013-0010, DATED 20 NOVEMBER 1975 AND ALL CHANGES THERETO. S6434-AF-MMO-010 0910-LP-048-7000 Change B TITLE-1 / (TITLE-2 Blank)@@FIpgtype@@TITLE@@!FIpgtype@@ @@FIpgtype@@TITLE@@!FIpgtype@@ PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND 1 OCT 1981 CHANGE B 15 JUN 1991

Marotta Valve Tech Pub

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[SGML Version See Change Record ]TECHNICAL MANUAL

OPERATION AND MAINTENANCEINSTRUCTIONS

WITH PARTS LIST

PNEUMATIC PRESSUREREGULATING MANIFOLD

DISTRIBUTION STATEMENT ″B″: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENTAGENCIES ONLY: THIS PUBLICATION IS REQUIRED FOR OFFICIAL USE OR ADMINIS-TRATIVE OR OPERATIONAL PURPOSES: (DATE OF PUBLICATION). OTHER REQUESTFOR THIS DOCUMENT MUST BE REFERRED TO THE NAVAL SEA SYSTEMS COM-MAND (SEA-09T)

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT ISRESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C., SEC. 2751, ETSEQ.) OR EXECUTIVE ORDER 12470. VIOLATION OF THESE EXPORT LAWS ARE SUB-JECT TO SEVERE CRIMINAL PENALTIES.

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLO-SURE OF CONTENTS OR RECONSTRUCTION OF THIS DOCUMENT.

THIS MANUAL SUPERSEDES NAVSEA 0983-LP-013-0010, DATED 20 NOVEMBER 1975AND ALL CHANGES THERETO.

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PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

1 OCT 1981CHANGE B 15 JUN 1991

TITLE-2 Change B@@FIpgtype@@BLANK@@!FIpgtype@@

RECORD OF REVISIONS

CHANGE DESCRIPTION DATEAPPROVED

BY

CHANGE A TECHNICAL MANUAL CHANGED TOREFLECT ADDITION OF PNEUMATIC PRES-

SURE REGULATING MANIFOLD, MODEL RM21FA-1, PART NUMBERS 281166-0002 AND

281166-0003.

8 AUG. 1990 W. GLOSS

CHANGE B TO REPLACE AIR DRY CORPORATIONMANIFOLDS WITH NEWLY-DESIGNED

MAROTTA MANIFOLDS AND UPGRADEEXISTING MAROTTA MANIFOLDS TO NEW

DESIGN SPECIFICATIONS.

6 JUN. 1991 S. NGUYEN

NOTE

THIS TECHNICAL MANUAL (TM) HAS BEEN DEVELOPED FROM AN INTELLIGENT ELECTRONICSOURCE KNOWN AS STANDARD GENERALIZED MARKUP LANGUAGE (SGML). THERE IS NOLOEP. ALL CHANGES, IF APPLICABLE, ARE INCLUDED. THE PAGINATION IN THIS TM WILL NOTMATCH THE PAGINATION OF THE ORIGINAL PAPER TM; HOWEVER, THE CONTENT ISEXACTLY THE SAME. ANY CHANGES RECEIVED AFTER RECEIPT OF THIS TM WILL ONLY FITIN THIS PAGINATED VERSION.

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FOREWORD

Ships, training activities, supply points, depots, Naval Shipyards and Supervisors of Shipbuilding arerequested to arrange for the maximum practical use and evaluation of NAVSEA technical manuals. All errors,omissions, discrepancies, and suggestions for improvement to NAVSEA technical manuals shall be reported tothe Commanding Officer, Naval Ship Weapons Systems Engineering Station (Code 5H00), Port Hueneme, CA93043-5007 on NAVSEA Technical Manual Deficiency/Evaluation Report, NAVSEA Form 9086/10. To facilitatesuch reporting, a copy of NAVSEA Form 9086/10 is included at the end of each bound part of each technicalmanual. All feedback comments shall be thoroughly investigated and originators will be advised of action result-ing therefrom. Extra copies of NAVSEA Form 9086/10 may be requisitioned from the Naval Publications andForms Center (NPFC), Philadelphia, PA 19120-5099 (S/N 0116-LF-090-8651).

MACHALT 551-48019 (ECP-346) replaced Air Dry Corporation manifolds with newly-designed Marottamanifolds and upgraded the existing Marotta manifolds to new design specifications.

This technical manual is applicable to pneumatic pressure regulating manifold Model RM21FA-1, PartNumber 281166-0004. Disregard all references to Part Number 281166-0001.

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TABLE OF CONTENTS

Chapter/Paragraph Page

1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2.1 Part Number 281166-0004. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2.2 Part Number 281166-0002. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2.3 Part Number 281166-0003. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2.3.1. Operating Pressure Setting (Low). . . . . . . . . . . . . . . . . 1-21.2.3.2. Operating Pressure Setting (High). . . . . . . . . . . . . . . . . 1-2

1.3 Special Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5 REMOVAL & DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Removal of the Entire Manifold from the System. . . . . . . . . . . . . . . . . . . . 5-1

5.2 Removal and Disassembly of the Filter Element (2 ; and ).. . . . . . . . . . . . . . 5-2

5.3 Removal and Disassembly of a Pressure Reducing Valve (See ; and Item 4, ).. . . . 5-2

5.4 Removal and Disassembly of the Pressure Relief Valve Assembly. . . . . . . . . . 5-3

5.5 Removal and Disassembly of the Inlet Handvalve. . . . . . . . . . . . . . . . . . . 5-4

5.6 Removal and Disassembly of the By-Pass Handvalve. . . . . . . . . . . . . . . . . 5-5

5.7 Removal and Disassembly Needle Valves (Gage bleed, gage shut-off (2, and ). . . . 5-5

5.8 Removal and Disassembly of Needle Valves: Filter/Reducer Bleed (1, and ). . . . . 5-6

6 INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 Cleaning Methods for Metallic Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

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7.2 Cleaning Method for Non-Metallic Parts and Coated Parts. . . . . . . . . . . . . . . 7-2

7.3 Cleaning Method for Synthetic Rubber Parts (o-rings). . . . . . . . . . . . . . . . . 7-3

7.4 Quality Assurance (Cleaning). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

8 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9 ASSEMBLY AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1 Assembly and Installation of the Inlet Handvalve. . . . . . . . . . . . . . . . . . . . 9-1

9.2 Assembly and Installation of the By-Pass Valve. . . . . . . . . . . . . . . . . . . . . 9-2

9.3 Assembly & Installation of the Filter Element. . . . . . . . . . . . . . . . . . . . . . 9-4

9.4 Assembly and Installation of the Pressure Reducing Valve. . . . . . . . . . . . . . . 9-4

9.5 Assembly and Installation of the Pressure Relief Valve. . . . . . . . . . . . . . . . . 9-6

9.6 Assembly and Installation of Needle Valves. . . . . . . . . . . . . . . . . . . . . . . 9-7

9.7 Final Assembly and Installation of the Manifold into the System. . . . . . . . . . . 9-8

10 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.1 Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.2 Reducer Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

11 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11.1 Pressure Regulating Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11.2 Reducer Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

11.3 Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

11.4 By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

11.5 Reducer and Filter Bleed Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

11.6 Gage Shut-Off and Gage Bleed Valve. . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

11.7 Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

11.8 Inlet Handvalve - (7, ; and ) and Outlet Handvalve (8, ; and ). . . . . . . . . . . . . 11-5

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TABLE OF CONTENTS - Continued

Chapter/Paragraph Page

12 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

12.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

13 STORAGE AND PREPARATION FOR RESHIPMENT . . . . . . . . . . . . . . 13-1

13.1 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

13.2 Preparation for Reshipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

14 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

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LIST OF TABLES

Table Title Page

General Data, Part Number 281166-0004. . . . . . . . . . . . . . . . . . . . . . . . 1-1

General Data, Part Number 281166-0002. . . . . . . . . . . . . . . . . . . . . . . . 1-1

Operating Pressure Setting (High). . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Pressure Regulating Manifold Troubleshooting. . . . . . . . . . . . . . . . . . . . . 11-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

Parts List for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

Parts List for and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

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LIST OF ILLUSTRATIONS

Figure Title Page

1 PRESSURE REGULATING MANIFOLD (REF. 281166-0001) SHEET 1 OF 3 . . . 14-5

1A PRESSURE REGULATING MANIFOLD (REF. 281166-0002) (SHEET 1 OF 3) . . 14-11

1B PRESSURE REGULATING MANIFOLD (REF. 281166-0003) (SHEET 1 OF 3) . . 14-17

2 FILTER (REF233032) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-25

2A FILTER ASSEMBLY (P/N 236285-0002) . . . . . . . . . . . . . . . . . . . . . . . . 14-27

3 PRESSURE REDUCER (REF 280038). . . . . . . . . . . . . . . . . . . . . . . . . 14-31

3A PRESSURE REDUCING VALVE ASSEMBLY (P/N 283371-0002). . . . . . . . . 14-33

4 RELIEF VALVE (REF280039) SHEET 1 OF 2. . . . . . . . . . . . . . . . . . . . . 14-37

4A PRESSURE RELIEF VALVE ASSEMBLY(P/N 2800397-0003). . . . . . . . . . . . 14-41

5 BYPASS HANDVALVE (REF 280566) . . . . . . . . . . . . . . . . . . . . . . . . . 14-45

6 INLET HANDVALVE (REF 233188) . . . . . . . . . . . . . . . . . . . . . . . . . . 14-49

7 OUTLET HANDVALVE (REF. 233695) . . . . . . . . . . . . . . . . . . . . . . . . . 14-51

8 NEEDLEVALVE (REF. 233029) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-55

9 OPERATIONAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-57

10 O’RING PICK (T10723) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-58

11 SEAT PULLER (T10722) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-58

12 TEST FIXTURE (T11293) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-59

13 TEST FIXTURE (T11392) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-60

14 TEST FIXTURE (T11294) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-61

15 TEST FIXTURE (T11298) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-62

16 TEST FIXTURE (TF-1813). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-63

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CHAPTER 1

GENERAL INFORMATION

This manual provides maintenance and overhaul instructions for a Pressure Regulating Manifold, Part Num-ber 281166-000; Model Number RM21FA-1, as manufactured by Marotta Scientific Controls, Inc., Montville,New Jersey.

MACHALT 551-48019 (ECP-346) replaced Air Dry Corporation manifolds with newly-designed Marottamanifolds and upgraded the existing Marotta manifolds to new design specifications.

This technical manual is applicable to pneumatic pressure regulating manifold Model RM21FA-1, Part Num-ber 281166-0004. Disregard all references to Part Number 281166-0001.

1.1 Description

The RM21FA-1 pressure regulating manifold consists of a pressure reducer and a downstream relief. Hand-valves provide alternate flow paths, enabling the system to be operated without interruption, should servicing ofthe filter or pressure reducer be required. A gauge port connection with independent shut-off and bleed valves isprovided to permit monitoring.

1.2 General Data

1.2.1 Part Number 281166-0004

General Data, Part Number 281166-0004

Operation Pressure Regulating Manifold

Operating Pressures:1. Inlet = 900-3000 psi Range2. Reducer = 20-250 psi Range (Set to Lockup at 175 psi)3. Relief = 150-255 psi Range (Max Accumulation 245 psi, set to crack at approx. 225 psi with Min.Reseat at 190 psi).Proof Pressure 4500 psi at inletBurst Pressure 9000 psi at inletService Air or NitrogenOperating Temperature (Ambient) +20°F to +140°FWeight 83 Pounds without fittings

1.2.2 Part Number 281166-0002

General Data, Part Number 281166-0002

Operation Pressure Regulating Manifold

Operating Pressures:1. Inlet = 1000-3000 psi Range2. Reducer = 20-250 psi Range (Set to Lockup at 175 psi)3. Relief = 150-255 psi Range (Max. Accumulation 240 psi, set to crack at approx. 200 psi with Min.Reseat at 185 psi).Proof Pressure 4500 psi at inlet

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General Data, Part Number 281166-0002 - Continued

Service Air or NitrogenOperating Temperature (Ambient) +20°F to +140°FWeight 83 Pounds without fittings

1.2.3 Part Number 281166-0003

NOTE

The equipment pressure settings concerning configuration 281166-0003 are asfollows:

1.2.3.1. Operating Pressure Setting (Low)

1. Inlet = 1000-3000 psig Range

2. Reducer = 175 psi (Lockup pressure)

3. Relief = 150 psi (max. accumulation 300 psig) 195 psi (cracking pressure) 185 psi (reseat pressure)

1.2.3.2. Operating Pressure Setting (High)

1. Inlet = 1000-3000 psig Range

2. Reducer = 225 psi (Lockup pressure)

3. Relief = 255 psi (max. accumulation 300 psig) 240 psi (cracking pressure) 232 psi (reseat pressure)

Operating Pressure Setting (High)

Proof Pressure 4500 psi at inlet

Service Air or NitrogenOperating Temperature (Ambient) +20°F to +140°FWeight 83 Pounds without fittings

1.3 Special Equipment

The following special tools and fixtures are recommended for the maintenance and overhaul of the unit:

Part No. Figure No Description Function Reference Paragraph

T10723 (Fig. 10) O-ring Pick O-ring Removal 5.2D; 5.3J; 5.4F; 5.5A;5.3A; 5.6G; 5.6J

T10722 (Fig. 11) Seat Puller Seat Removal 5.3H; 5.4B 5.6H1/4 20 UNC Bolt - Reducer Disassembly

and Assembly2, 3, 6.4

1/4 inch dia. rodHex-socket wrenches,Assorted sizes

General Assembly andDisassembly

5.3D

T11298Fig. 15 Test Fixture Testing and Adjust. ofrelief valve

6.5

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Part No. Figure No Description Function Reference Paragraph

T11294Fig. 14 Test Fixture Testing and Adjust. ofreducer valve

6.4

T11392Fig. 13 Test Fixture Testing and Adjust. ofinlet handvalve

6.1

T10238Fig. 16 Test Fixture Testing and Adjust. ofoutlet handvalve

6.1

T11293Fig. 12 Test Fixture Testing and Adjust. ofbypass handvalve

6.2

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CHAPTER 2

INSTALLATION

No adjustments are necessary for installation. Connections for operation are as follows:

A. Mounting:

Six threaded mounting holes, 5/8-11UNC-2B x 1.12 min. thread are provided.

B. Fittings:

Part Number: 281166-0001

Inlet - 1/4 IPS per Buships 810-1385884, Linear Adj.

Outlet - 3/8 IPS per MIL-F-1183, Linear Adj.

Vent - 3/8 IPS per MIL-F-1183

Gauge - Threaded port per MS16142-4 (1/4″ TS)

Part Number: 281166-0002 and 281166-0003

Inlet - 3/8 IPS per Buships 803-1385943 Linear Adj.

Outlet - 1/2 IPS per Buships 803-1385943 Linear Ajd.

Vent - 1/2 IPS per Buships 803-1385943

Gauge - Threaded port per NS16142-4 (1/4″ TS)

NOTE

Manifold is supplied with gauge port plugged with a fitting comprised of com-ponents: MS21902-4C MS21921-4J and MS 21922-4C.

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CHAPTER 3

OPERATION

NOTE

Refer to the Operational Schematic (Figure 9) as an aid to the following func-tional description of the operation of the pressure regulating manifold.

Note that the RM21FA-1 manifold incorporates two identical flow paths. Both flow paths have inlet and out-let handvalves, a filter and a pressure reducing valve. The two flow paths are connected to the common inlet andoutlet ports, gauge port and pressure relief valve.

Fully close the inlet and outlet handvalve for one flow path or side. With the bypass handvalve fully closedand the inlet and outlet handvalves fully open, inlet line fluid enters the manifold and is directed to the open inlethandvalve and the closed manual bypass valve. Fluid flowing at inlet pressure through the inlet handvalve is fil-tered and reduced to the preset outlet pressure by a spring referenced reducer assembly. The reduced line fluidthen passes through the outlet handvalve and out of the manifold at a reduced pressure.

The outlet system is connected to a spring referenced pressure relief valve, which senses any pressurechanges, and vents all excess pressure above the preset pressure level. A gauge connection is connected to theoutlet system through a shut-off valve and permits a check of the downstream pressure conditions at all times.Normally only one flow path is in use, the alternate flow path is used when maintenance or the filter or reduceris required, and uninterrupted service must be maintained. This may be accomplished as follows:

A. Slowly open the alternate inlet and outlet handvalves until the outlet pressure just starts to exceed the presetvalve. If a gauge is used at the gauge port to check the downstream pressure, wait for it to stabilize beforeproceeding. The relief valve may temporarily vent until the pressure has stabilized. Fully close the inlet andoutlet handvalves in the″side″ or flow path to be serviced. Slowly open the filter/reducer bleed valve to ventthe trapped pressure.

B. Both of the flow paths may be isolated simultaneously by slowly opening the bypass valve until the outletpressure just starts to exceed the preset valve. If a gauge is used at the gauge port to check downstream pres-sure, wait for it to stabilize before proceeding. The valve may temporarily vent until the pressure has stabi-lized. Close all the inlet and outlet handvalves for both paths and adjust the bypass valve until the outlet pres-sure equals the preset outlet pressure level. Slowly open the filter/reducer bleed valve to rent the trappedpressure. The filter and reducer have been isolated from the system.

WARNING

Make certain the trapped pressure has been vented through the bleed valvebefore attempting any disassembly.

The manual bypass valve may also be used to check the cracking pressure of the relief valve. This may beaccomplished as follows:

With inlet pressure applied, and the outlet handvalve either opened or closed, slowly crack the bypass hand-valve. Note the pressure at which leakage is first observed from the relief vent. This is the cracking pressure.

C. The outlet side of the bypass valve may be vented through the gauge bleed when the gauge shut-off is open.

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NOTE

This will vent any pressure downstream of the manifolds.

D. To monitor outlet pressure, proceed as follows:

Close the gauge shut-off and install desired gauge into the gauge port. (SeeParagraph 12.1Cfor gaugeinformation).

For operation, open the gauge shutoff.

For removal, shut the gauge shut-off and vent pressure through the gauge bleed.

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CHAPTER 4

MAINTENANCE

At time of overhaul, the manifold should be disassembled and inspected. All o-rings and damaged partsshould be replaced and all parts should be cleaned and properly lubricated before assembly. Refer toparagraph6.0, ″Inspection and Repair″; paragraph 7.0″Cleaning″ andparagraph 8.0″Lubrication″ for proper maintenanceprocedures. The filter element may require periodic replacements due to contamination by the line fluid. Thecontamination will be indicated by the differential pressure indicator button popping out. Before replacing theelement, verify the indication by resetting the indicator button and observing whether or not it pops out again. Toreplace the filter element, proceed as perparagraph 3.0 (A).

4.1 Suggested Maintenance Schedule

Maintenance is largely corrective and is performed when required by: Troubleshooting (Paragraph 11.0); byvisual inspection; as a result of the leakage and functional tests (Paragraph 12.0) or as part of an overhaul.

(A) Overhaul every (2) years or when o-ring cure dates have expired.

(B) Monthly visual inspection for visible signs of leakage using a bubble fluid.

(C) Servicing of filter element as indicated by indicator button popping up.

NOTE

Functional and leakage tests (Paragraph 12.0) are to be performed after anymajor reassembly of the valve, or as an aid to″Troubleshooting″ (Paragraph11.0).

WARNING

Follow all caution and warning notes before attempting any maintenance onthe equipment. Otherwise personal injury and/or equipment damage mayresult.

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CHAPTER 5

REMOVAL & DISASSEMBLY

The following disassembly procedures are divided into paragraphs describing all the phases of complete dis-assembly. Each paragraph describes a complete and particular phase of the disassembly that is independent ofany other phase unless otherwise stated. To disassemble any component of the manifold, it is necessary to referto the paragraph describing the disassembly of that particular component only. DO NOT PERFORM UNNEC-ESSARY DISASSEMBLY. The assembly drawings (Figures 1 - Figure 8) and other figures as indicated, are tobe used in conjunction with the following procedure for the disassembly of the manifold. During disassembly,cut only the lockwire required and assort all disassembled parts.

WARNING

Make certain that all the pressure is bled from in and around the compo-nent to be disassembled as described in each paragraph before attemptingany disassembly. SeeParagraph 3.0, A.

NOTE

Item numbers and other callouts regardingFigure 1, Figure 2, Figure 3, or Figure4 also apply toFigure 1A, Figure 1B, Figure 2A, Figure 3AandFigure 4A.

5.1 Removal of the Entire Manifold from the System

WARNING

Remove all line pressure and open all handvalves, needle valves and bleedvalves before removing the manifold from the system.

NOTE

Cut lockwire before assembly.

A. Unscrew the fitting nuts (91 and 92,Figure 1from the inlet and outlet and vent fittings, and slide nuts overthe tailpieces (93 and 94,Figure 1).

B. Unscrew the (6) mounting screws, and carefully remove the manifold from the mounting brackets.

C. Unscrew the eight socket head cap screws (68,Figure 1) from the adapters (19,Figure 1) and remove withassembled components.

D. Remove o-ring (62,Figure 1) and retainer (21,Figure 1) and from the inlet and outlet fittings (12, 13,Figure1).

E. Unscrew inlet and outlet fittings (12, 13,Figure 1out of adapters (19,Figure 1).

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F. Unscrew the vent fitting (14,Figure 1) from the body (9,Figure 1) and remove o-ring (63,Figure 1) from thevent fitting.

G. Do not remove the fitting nuts (91, 92,Figure 1) or tailpieces (93, 94,Figure 1from the system piping unlessit is necessary.

H. Remove the instruction plates (16 or 17,Figure 1) from its location only if it is damaged or the lettering isobliterated.

I. Remove O-rings (64, 65,Figure 1) and rings (20,Figure 1) from the inlet, outlet, and vent tailpieces (93, 94,Figure 1).

J. Unscrew nut (84,Figure 1) from union (83,Figure 1). Unscrew union (83,Figure 1) from body (9,Figure1). Remove o-ring (61,Figure 1).

5.2 Removal and Disassembly of the Filter Element (2Figure 1; and Figure 2).

A. Isolate the filter and bleed the pressure through the reducer bleed valve (1,Figure 1) as perpara. 3.0 A.

B. Unscrew cap screws (67,Figure 1) and remove housing (91,Figure 2) from body (9,Figure 1).

C. Gently pull element (90,Figure 2) from body (9,Figure 1). Remove orifice (15,Figure 1) from body (9,Figure 1).

D. Remove o-ring (83, 84,Figure 2) from disassembled parts using o-ring pick (Figure 10). Remove ring (82,Figure 2).

CAUTION

Do not attempt to further disassemble the filter assembly.

5.3 Removal and Disassembly of a Pressure Reducing Valve (SeeFigure 3; and Item 4, Figure 1).

A. Isolate the pressure reducing valve assembly (seePara. 3.0.A) and bleed the pressure through the filter bleedvalve (1,Figure 1).

B. Cut the lockwire (82,Figure 1) and unscrew the four socket head cap screws (66,Figure 1). Carefully pullthe reducer assembly (4,Figure 1) out of the body and pin assembly (9,Figure 1).

C. Remove the two set screws (81,Figure 3) and back the screw (21,Figure 3) out with a 3/8 Allen wrench.

D. Unscrew the nut (22,Figure 3) by the two-inch flats and carefully remove spring (24,Figure 3), guide (25,Figure 3), o-ring (69,Figure 3), bearing (92,Figure 3), and two races (91,Figure 3). Unscrew the screw (21,Figure 3) from the nut (22,Figure 3) with a 3/8 Allen wrench.

NOTE

Do not remove the decal (26,Figure 3), as it is permanently affixed with epoxyglue.

E. Screw a 1/4 - 20 UNC bolt into the piston (20,Figure 3) and pull the piston out of the body (23,Figure 3).Unscrew the bolt from the piston.

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F. Unscrew the end nut (15,Figure 3) with a 15/16 wrench and remove the spring (14,Figure 3) and the guide(12, Figure 3).

G. Carefully push the poppet (19,Figure 3) and the internal parts out from the piston end of the body (23,Figure3) with a blunt brass rod.

H. Carefully remove the seat support (17,Figure 3) and the seat (18,Figure 3) from the body (23,Figure 3)with the seat support puller (Figure 11).

I. Separate the seat (18,Figure 3) from the seat support (17,Figure 3). Take care not to damage the criticalsealing surface of the seat support.

J. Remove all the o-rings (61, 62, 63, 64, 67, 68, 70, 71, 72,Figure 3) and the three slugs (11 and 13,Figure3) from the disassembled parts with the o-ring pick (Figure 10).

5.4 Removal and Disassembly of the Pressure Relief Valve Assembly

(SeeFigure 4; and Item 5,Figure 1).

WARNING

Before attempting any disassembly of the pressure relief valve, close bothoutlet handvalves and the bypass valve. Remove the outlet line pressure andopen the gage shut-off gage bleed valve (2,Figure 1) to make certain that theoutlet system is fully vented.

A. Bend up the tab on the washer (17,Figure 4) and unscrew the valve by the 2-3/8 inch hex on the housing(22, Figure 4).

B. Remove the seat (24,Figure 4) from the body (16,Figure 1) with the seat support puller (Figure 11).

C. Unscrew the set screw (81,Figure 4) and carefully back the cap (23,Figure 4) off the housing (22,Figure 4).

NOTE

Do not remove the decal (20,Figure 4) from the cap as it is permanently affixedwith epoxy glue.

D. Disassemble the race (91,Figure 4), bearing (90,Figure 4), ring (15,Figure 4) and the spring assembly (1,Figure 4).

NOTE

Do not perform any further disassembly of the spring assembly (1,Figure 4)after it has been removed from the valve.

E. Remove the piston (16,Figure 4) and poppet (21,Figure 4) from the housing (22,Figure 4) by carefullypushing on the poppet.

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NOTE

Do not disassemble the piston and poppet unless they are damaged. If disassem-bly is required, carefully remove the Spiral pin (92,Figure 4) with an arbor pressand disassemble the poppet, piston, and spring (11,Figure 4).

F. Remove o’rings (64, 65 & 66,Figure 4) and the slug (12,Figure 4) from the disassembled parts with theo’ring pick (Figure 10).

5.5 Removal and Disassembly of the Inlet Handvalve

(7, Figure 1; and Figure 6) and Outlet Handvalve (8,Figure 1; and Figure 7). Refer toFigure 6for disas-sembly of both inlet and outlet handvalves.

WARNING

Before attempting any portion of disassembly, the following precaution mustbe taken:

Inlet handvalve: Close both outlet handvalves and the by-pass handvalve. Remove the inlet line pressureand slowly open the inlet handvalves and filter bleed valves to fully vent the manifold inlet section.

Outlet handvalve: Close both inlet and the by-pass handvalves. Vent the outlet line pressure and slowlyopen the outlet handvalves and filter bleed valves to fully vent the manifold outlet section.

A. Unscrew the inlet and outlet handvalves (7, 8,Figure 1), from the body (9,Figure 1) by the large hex on thevalve bonnet (2,Figure 6) and remove o’ring (13,Figure 6) using the o’ring pick (Figure 10).

NOTE

The handvalve assembly has a lefthand thread and must be turned in a clockwisedirection to remove.

B. While holding the handle (1,Figure 6), unscrew the nut (15,Figure 6).

Remove the lockwasher (14,Figure 6) and the handle (1,Figure 6) from the valve assembly.

C. Slide the handle (1,Figure 6) back onto the stem (3,Figure 6) and while holding the bonnet (2,Figure 6)with a wrench, turn the handle (1,Figure 6) in a clockwise direction. This will disengage the seat (6,Figure6) from its press fit into the bonnet (2,Figure 6) while holding the bonnet (2,Figure 6) with a wrench.

D. While holding the bonnet (2,Figure 6) with a wrench, unscrew the gland nut (7,Figure 6) from the bonnet(2, Figure 6).

E. Push the stem (3,Figure 6) with its assembled components from the bonnet (2,Figure 6).

CAUTION

When pushing the stem through the bonnet, be careful not to damage thepacking (10,Figure 6) with the threads on the stem.

F. Carefully remove the retainer (8,Figure 6) and the packing (10,Figure 6).

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G. Unscrew the stem retainer (9,Figure 6) and disassemble the stem (3,Figure 6) and the guide (4,Figure 6).

H. Remove the o-rings and back-up ring (11 & 12,Figure 6) from the disassembled parts with the o-ring pick(Figure 10).

5.6 Removal and Disassembly of the By-Pass Handvalve

(6, Figure 1; andFigure 5).

WARNING

Before attempting any portion of disassembly of the by-pass valve, vent theinlet and outlet line pressures and open the inlet and outlet handvalves toinsure the manifold is fully vented.

A. Unscrew the by-pass valve from the body (9,Figure 1), utilizing the hex on the retainer screw (13,Figure 5).

B. Remove slug (11,Figure 5) from the screw (13,Figure 5).

C. Remove set screw (81,Figure 5) and slug (12,Figure 5) from the retainer screw (13,Figure 5).

E. Screw the screw (14,Figure 5) into the retainer screw (13,Figure 5) until the stem (15,Figure 5) can beremoved by sliding out of the slot in the screw (14,Figure 5).

F. Unscrew the handle (20,Figure 5) from the screw (14,Figure 5) by first loosening the nut (22,Figure 5).

G. Pull cage (17,Figure 5) from body (9,Figure 1) and remove o’ring (63,Figure 5) utilizing o’ring pick.(Figure 10).

H. Remove o’ring (61,Figure 5) from the stem (15,Figure 5).

I. Utilizing the seat support puller (Figure 11), remove the seat (16,Figure 5), seat support (19,Figure 5) fromthe body (9,Figure 1).

J. Remove o’ring (62,Figure 5) from the seat support (19,Figure 5) utilizing an o’ring pick (Figure 10).

5.7 Removal and Disassembly Needle Valves (Gage bleed, gage shut-off (2,Figure 1 and Figure 8).

WARNING

Before attempting any portion of disassembly of the gage valves, close all theinlet, outlet and bypass handvalves.

Remove outlet line pressure and open the outlet handvalve, gage bleed andgage shut-off needle valves to assure the manifold is fully vented.

A. Snap out retainer ring(s) (81,Figure 1), utilizing retaining ring pliers and remove washer(s) (11,Figure 1).

B. Unscrew the screw(s) (12,Figure 8) and remove o’ring(s) (61,Figure 8) and slug(s) (11,Figure 8).

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5.8 Removal and Disassembly of Needle Valves: Filter/Reducer Bleed (1,Figure 1 and Figure 8)

WARNING

Before attempting disassembly of the filter/reducer bleed valve, isolate theflow path per paragraph 3.0.A and open the filter reducer bleed valve to ventthe pressures.

A. Snap out the retaining ring (81,Figure 1), using retaining ring pliers and remove washer (11,Figure 1).

B. Unscrew the screw (12,Figure 8), and remove slug (11,Figure 8).

NOTE

The filter/reducer bleed valve (1,Figure 1) does not use an o-ring (61,Figure 8).

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CHAPTER 6

INSPECTION AND REPAIR

6.1 Inspection

(A) Check all parts for damage.

(B) Check sliding surfaces for freedom of movement.

(C) Check parts for contamination (dirt, dust, etc.).

(D) Check for scratches, nicks, etc., on sealing surfaces that could cause leakage.

(E) Check for clogged flow paths.

(F) Check for filter contamination.

(G) Check for stripped or broken threads.

6.2 Repair

A. Clean any parts found to be contaminated with dirt, dust, grease, etc., prior to reassembly. Refer toParagraph7.0 ″Cleaning″ for proper cleaning procedures.

B. Replace with new parts found to be worn or damaged as a result of inspection. Use the following rejectioncriteria.

Nicks, scratches, etc., on seating/sealing surfaces that can be seen with the unaided eye or felt with a finger-nail shall be cause for replacement.

Any damages such as cracks, breaks, stripped threads, roughness shall be cause for replacement.

Any wear on parts surfaces which can be seen with the unaided eye or felt with a fingernail shall be causefor replacement.

C. Parts should be lubricated before reassembly. SeeParagraph 8.0″Lubrication″ for proper procedures.

NOTE

O-rings are easily damaged during disassembly. Replace all o-rings removedduring disassembly.

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CHAPTER 7

CLEANING

NOTE

Select one or a combination of the following cleaning methods to achieve visualcleanness.

7.1 Cleaning Methods for Metallic Parts

A. Detergent Cleaning:

Clean ultrasonically in detergent at 140°F (±10°F) for three minutes.

Rinse thoroughly in tap water.

Dry and wipe clean utilizing lint free cloth.

B. Trichloroethane Cleaning:

WARNING

Hazardous substance. Follow all instructions carefully. Do not use the fol-lowing procedures in a collective protection HVAC system environment.Trichloroethane Cleaning Solvent

General Precautions: Handle with reasonable care. Avoid breathing vapors. Store ina cool place. Keep container tightly closed.

Ventilation: Limit concentration in air to 350 PPM (1974 Data).

Respiratory Protection: Below 350 PPM - None. Respiratory protection required inthe absence of environmental control. For levels up to 2% for 1/2 hour or less, a suit-able full-face mask with organic canister should be used. Above 2% and for emergen-cies, use a self-contained breathing apparatus.

Protective Clothing Suitable leak proof gloves.

Eye Protection Safety glasses. Eye wash stations and safety showers should bereadily available.

Conditions to Avoid: Open flames, welding arcs or other high temperature sourceswhich induce thermal decomposition.

Incompatibility: Water - slow hydrolysis produces corrosive acid.

Hazardous Decomposition Products: Hydrogen chloride and very small amounts ofphosgene and chlorine.

Fire Extinguishing Media: Water fog Special Fire Fighting Equipment and Hazards:Self-contained respiratory equipment. Not considered a flammable liquid under normalindustrial use conditions.

Cleaning Procedure

(1) Clean ultrasonically in trichloroethane for three minutes.

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(2) Dry and wipe clean utilizing a lint free cloth.

(3) Rinse thoroughly in tap water. Make sure all surfaces are rinsed.

(4) Dry and wipe clean utilizing a lint free cloth.

C. Trichlorotrifluoroethane Cleaning

WARNING

Hazardous substance. Follow all instructions carefully. Do not use the fol-lowing procedures in a collective HVAC system environment. Trichlorotrif-luoroethane Cleaning Solvent

General Precautions: Handle with reasonable care. Avoid breathing vapors. Store incool dry place. Keep container tightly closed.

Ventilation: Limit concentration in air to 1000 PPM (Tentative).

Respiratory Protection: Below 1000 PPM - None. Respiratory protection required inthe absence of environmental control. For higher levels and for emergencies, use a self-contained breathing apparatus.

Protective Clothing Rubber apron and suitable leak proof gloves.

Eye Protection Safety glasses, eye wash stations and safety showers should be readilyavailable.

Conditions to Avoid: Open flames, welding arcs or other high temperature sourceswhich induce thermal decomposition.

Incompatibility: Hot reactive metal such as molten aluminum, barium, lithium.

Hazardous Decomposition Products: Halogens, halogen acids and carbonyl halides.

Fire Extinguishing Media: Water spray to knock down vapors and cool container

Special Fire Fighting Equipment and Hazards: Self-contained respiratory equip-ment. Not considered a flammable liquid under normal use conditions.

Cleaning Procedure

(1) Clean ultrasonically in Trichlorotrifluoroethane for three minutes.

(2) Dry and wipe clean utilizing a lint free cloth.

NOTE

For parts too large to clean in ultrasonic cleaner, proceed as follows:

Dry an wipe clean utilizing a lint free cloth.

7.2 Cleaning Method for Non-Metallic Parts and Coated Parts

Detergent Cleaning

(1) Clean ultrasonically in detergent at 70°F (±10°F) for a maximum of two minutes.

(2) Rinse thoroughly in tap water.

(3) Dry and wipe clean utilizing a lint free cloth.

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NOTE

For parts too large to clean in ultrasonic cleaner, proceed as follows:

Clean in detergent and rinse thoroughly. Dry and wipe clean utilizing a lint free cloth.

7.3 Cleaning Method for Synthetic Rubber Parts (o-rings)

Clean in detergent and rinse thoroughly. Dry and wipe clean utilizing a lint free cloth.

7.4 Quality Assurance (Cleaning)

Parts cleaned per these processes shall be free from particulate contamination as verified by visual inspectionwith the unaided eye.

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CHAPTER 8

LUBRICATION

NOTE

If cleaned and lubricated parts are not to be immediately installed or assembled,the parts should be stored in a clear, sealed plastic bag.

After cleaning, and prior to reassembly, lubricated as follows:

Lubricants

Lubricant: Manufactured By:

A. Halocarbon Grease 25-5-S orKrytox 240AC

Halocarbon Products Co.Hackensack, New JerseyE.I. DuPont DeNemours & Co.Organic Chemicals DepartmentDyes & Chemical DivisionWilmington, Delaware 19899

B. Jetlube #MP50 Jetlube Co.Houston, Texas

WARNING

#MP50 is a petroleum based lubricant and dieselization may occur if it isexposed to high pressure line media. Only utilize MP50 lubricant in areas asrequired.

Amount of Lubricant: Apply sparingly.

Items to be lubricated:

A. All o-rings and sliding surfaces. (25-5-S)

B. All races and bearings (Jetlube #MP50)

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CHAPTER 9

ASSEMBLY AND INSTALLATION

The following assembly procedures are divided into paragraphs describing all the phases of complete assem-bly. Each paragraph describes a complete and particular phase of the assembly that corresponds to a phase of thedisassembly. The assembly drawings (Figure 1 - Figure 8) and other figures, as indicated, are to be used in con-junction with the following procedure for the assembly of the manifold.

NOTE

Item numbers and other callouts regardingFigure 1, Figure 2, Figure 3, andFigure 4also apply toFigure 1A, Figure 2A, Figure 3A, andFigure 4A.

9.1 Assembly and Installation of the Inlet Handvalve

(7, Figure 1; and Figure 6) and Outlet Handvalve (8,Figure 1; and Figure 7). Refer toFigure 6 duringassembly of both the inlet and the outlet handvalve.

A. Insert the flanged end of the stem retainer (9,Figure 6) into the guide (4,Figure 6) and screw the stemretainer (9,Figure 6) down over the stem into the guide (4,Figure 6).

B. Carefully push the stem (3,Figure 6) with the attached parts, threaded end first, into the bonnet (2,Figure6) until it bottoms.

C. Lubricate the threads on the stem (3,Figure 6) and the packing (10,Figure 6) per Paragraph 8.0and care-fully push the packing over the stem down into the bonnet (2,Figure 6). Make certain the grooved end ofthe packing is facing down in the bonnet.

D. Push the retainer (8,Figure 6) small end first, down into the bonnet (2,Figure 6) against the packing (10,Figure 6).

E. Screw the gland nut (7,Figure 6) onto the stem (3,Figure 6) and engage the external threads on the glandnut with the threads in the bonnet (2,Figure 6). Continue turning in on the gland nut until the packing (10,Figure 6) is pushed into the bonnet recess. Tighten the gland nut to approximately 150-inch pounds of torque.

F. Temporarily assemble the handle (1,Figure 6), to the stem (3,Figure 6), and turn the handle in a counter-clockwise direction until the stem is raised to the full open position.

G. Push the seat (6,Figure 6), into the bonnet (2,Figure 6) groove, tap lightly with a block of wood or plastic.

H. Assemble the handle (1,Figure 6), to the stem (3,Figure 6). Place the washer (14,Figure 6) on the stem and,while holding the handle, screw on and tighten the nut (15,Figure 6) with a 9/16 socket wrench.

I. Position the back-up ring (11,Figure 6) and the o-ring (12,Figure 6) on the bonnet (2,Figure 6).

NOTE

Use test fixture (Figure 13) for inlet handvalve (Figure 6). Use test fixture(Figure 16) for outlet handvalve (Figure 7).

J. Place the o-ring (13,Figure 6) into the groove in the test fixture (Figure 13or 16).

K. Screw the valve into the test fixture by the hex on the bonnet (2,Figure 6). Tighten to 45 - 60 foot poundsof torque.

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NOTE

The bonnet thread is left-handed and must be turned counterclockwise to tighten.

L. Set-up the test fixture (Figure 13or 16), as shown in the following figure. Close the handvalve and slowlyapply 3000 psig to the inlet port. Check for leakage at the outlet port. If leakage persists, refer toparagraph11.8, open and close the valve several times and recheck for leakage.

M. Remove the handvalve from the test fixture (Figure 13or Figure 16).

N. Remove the o-ring (13,Figure 6) and seat from the test fixture (Figure 13or Figure 16) and insert all itemsinto the body (9,Figure 1).

O. Screw the valve into the body (9,Figure 1) by the hex on the bonnet, (21,Figure 6). Tighten to 45 - 60 footpounds of torque.

NOTE

The bonnet thread is lefthand and must be turned counter-clockwise to tighten.

9.2 Assembly and Installation of the By-Pass Valve

(6, Figure 1; andFigure 5).

A. Install o-ring (62,Figure 5) onto the support seat (19,Figure 5) and insert into the test fixture (Figure 12).

NOTE

Assemble the support seat (19,Figure 5) with the larger diameter hole positioneddown.

B. Insert the seat (16,Figure 5) into the test fixture (Figure 12) on top of the support seat (19,Figure 5).

Test Fixture Setup, Inlet Handvalve

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NOTE

Assemble the seat (16,Figure 5) so that the side with the larger diameter hole isseated against the support seat (19,Figure 5).

C. Assemble o-ring (63,Figure 5) onto the cage (17,Figure 5) and assemble o-ring (61,Figure 5) onto the stem(15, Figure 5).

D. Carefully slide the stem (15,Figure 5) into the cage (17,Figure 5)

E. Assemble components, as completed perStep Dabove, into the slot of the screw (14,Figure 5).

F. Generously lubricate the internal threads of the retaining screw (13,Figure 5) and the large threads on thescrew (14,Figure 5) per 8.0 and screw the retaining screw onto the screw (14,Figure 5) until it bottoms.

G. Press the slug (12,Figure 5) into the threaded hole in the retaining screw (13,Figure 5). Screw in the setscrew (81,Figure 6) and tighten just enough to keep the screw (14,Figure 5) from turning.

H. Screw the nut (22,Figure 5) onto the screw (14,Figure 5) and thread the handle (20,Figure 5) onto the screwabout half the screw length. Tighten the nut (22,Figure 5) snugly against the handle (20,Figure 5).

NOTE

Final positioning of the handle may be performed after the valve has beeninstalled in the manifold.

I. Set-up the test fixture (Figure 12) as shown in the following figure. Close the handvalve and slowly apply3000 psig pressure to the inlet port. Check for internal leakage at the outlet port. If leakage is observed, verifythat the valve is fully closed. If the leakage persists, refer toparagraph 11.4, Troubleshooting. Open and closethe valve several times and recheck for leakage.

J. Remove the by-pass valve from the test fixture (Figure 12).

K. Remove the seat (16,Figure 5), o-ring (62,Figure 5) and support seat (19,Figure 4) from the test fixture(Figure 12) and insert orifice (18,Figure 5) into the body (9,Figure 1).

NOTE

Install components inStep L in the proper direction as stated inStep 9.2 A&Step B

Test Fixture Setup, By-Pass Valve

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L. Press the slug (11,Figure 5) into the thread in the retaining screw (13,Figure 5) and screw the retaining screwwith the attached parts into the body (9,Figure 1) by the hex. Tighten securely.

9.3 Assembly & Installation of the Filter Element

(Figure 2; and Item 3,Figure 1).

A. Insert orifice (15,Figure 1) into body (9,Figure 1) cavity.

B. Assemble o-rings (83,Figure 2) on element (90,Figure 2). Assemble o-ring (84,Figure 2)

C. Insert element (90,Figure 2) onto body (9,Figure 1). Assemble housing (91,Figure 2) over element andinstall four cap screws (67,Figure 1) in body (9,Figure 1).

Tighten and secure cap screws (67,Figure 1) using lockwire (82,Figure 1.)

9.4 Assembly and Installation of the Pressure Reducing Valve

(SeeFigure 3; and Item 4,Figure 1).

NOTE

A pressure reducing valve may be assembled and installed with the manifold inservice if the reducer has been properly isolated perparagraph 3.0 A.

A. Assemble the seat (18,Figure 3) and the seat o-ring (63,Figure 3) to the seat support (17,Figure 3) andcarefully insert the seat support into the body (23,Figure 3).

B. Insert the retainer o-ring (64,Figure 3) into the groove in the body (23,Figure 3).

C. Insert the poppet o-ring (61,Figure 3) into the groove in the retainer (16,Figure 3) and assemble the otherpoppet o-ring (68,Figure 3) to the poppet (19,Figure 3).

D. Slide the retainer (16,Figure 3) over the poppet (19,Figure 3) and carefully position this assembly in thebody (23,Figure 3).

E. Place the spring guide (12,Figure 3) on the end of the poppet (19,Figure 3).

F. Insert the retainer o-ring (62,Figure 3) into the end of the retainer (16,Figure 3).

G. Press the slug (13,Figure 3) into the threads of the end nut and position spring (14,Figure 3) into the endnut (15, Figure 3). Screw the end nut into the body (23,Figure 3) and tighten to approximately 50 inch-pounds of torque.

H. Insert the piston o-ring (67,Figure 3) into the body (23,Figure 3).

I. Carefully push the piston (20,Figure 3) into the body (23,Figure 3).

J. Lubricate the threads on the screw (21,Figure 3) perParag. 8.0and screw the screw into the nut (22,Figure3) with a 3/8 Allen wrench until it bottoms.

K. Position the valve, as assembled throughStep J, in a vertical position so that the piston (20,Figure 3) is ontop.

Place the spring (24,Figure 3) on the piston (20,Figure 3).

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L. Generously lubricate the bearing (92,Figure 3) and the two races (91,Figure 3) per Paragraph 8with thelubricant (93,Figure 3). Assemble the bearing with a race on each side, to the spring guide (25,Figure 3)and position the guide on the spring (24,Figure 3).

M. Carefully screw the nut (22,Figure 3) by the two inch flats, into the body (23,Figure 3), positioning thespring guide (25,Figure 3), and bearing (92,Figure 3) inside the screw (21,Figure 2). Tighten securely.′

N. Press one slug (11,Figure 3) into the hole in the nut (22,Figure 3) and screw a set screw (81,Figure 3), butdo not tighten. Press the remaining slug into the hole in the body (23,Figure 3), screw in and tighten the setscrew.

O. Slide the nut o-ring (69,Figure 3) over the nut (22,Figure 3), and position it against the body (23,Figure3). Secure the decal (26,Figure 3) to the nut (22,Figure 3), if previously removed with the. epoxy glue (94,Figure 3).

P. Assemble the three body o-rings (70, 71, and 72,Figure 3), to the body (23,Figure 3) and position the valvein the test fixture (Figure 14). Secure in place with the four socket head cap screws (66,Figure 1).

Q. Setup the test fixture (Figure 14) with the gauges and the downstream handvalve, as shown in the followingfigure. Close the handvalves and slowly apply the proper inlet pressure (900-3000 psig) for Part Number281166-0001; (1000-3000 psig) for Part Numbers 281166-0002 and 281166-0003 to the test fixture. Set therequired outlet pressure (20-200 psig) for Part Number 281166-0001; (150-250 psig) for Part Numbers281166-0002 and 281166-0003 by adjusting the screw (21,Figure 3) with a 3/8 inch allen wrench. Allow ashort period of time for the system to stabilize and check for leakage at the seat. Seat leakage would be indi-cated by a gradual and steady increase in the lockup pressure shown on the downstream gauge. If leakage isdetected, refer toParagraph 11.2in Troubleshooting.

R. With the system in the same condition as described inStep Q, verify that the lock-up pressure is as required.

NOTE

The lock-up or″no flow″ pressure is equal to the outlet pressure.

Test Fixture Setup, Pressure Reducing Valve

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Change B 9-5

If the lock-up pressure is not as required, readjust (seePara. 10.2), screw (21,Figure 3) and repeat thelock-up pressure check.

S. Create a downstream flow by opening the downstream handvalve. Slowly close the handvalve and allow thesystem to stabilize. Verify that the lock-up pressure is as required.

T. Tighten the set screw (81,Figure 3).

Check for any external leakage. If external leakage is detected, refer toparagraph 11.2in TROUBLESHOOT-ING.

Remove the valve from the test fixture (Figure 14) and reinstall it in the body and pin assembly (9,Figure1).

9.5 Assembly and Installation of the Pressure Relief Valve

(SeeFigure 4; and Item 5,Figure 1).

A. Position the spring (11,Figure 4) in the piston (16,Figure 4) and slide the poppet (21,Figure 4) into the pis-ton over the spring. Align the hole in the poppet with the slot in the piston and press the Spirol Pin (92,Figure4) into the hole in the poppet with an arbor press. Make certain that the ends of the pin do not protrude outof the piston.

B. Assemble the o-ring (65,Figure 4) to the piston (16,Figure 4) and carefully insert the piston with the attachedparts into the housing (22,Figure 4).

Position the spring assembly (1,Figure 4) on the piston (16,Figure 4).

C. Generously lubricate the bearing (90,Figure 4), race (91,Figure 4), and ring (15,Figure 4) per Paragraph 8with lubricant and position the race, bearing and ring in the cap (23,Figure 4).

D. Carefully screw the cap (23,Figure 4) onto the housing (22,Figure 4), until a slight force is exerted on thepiston (16,Figure 4).

NOTE

Make certain that the ring (15,Figure 4) is properly aligned with the springassembly (1,Figure 4).

E. Press the slug (12,Figure 4) into the hole in the cap (23,Figure 4) and screw in the set screw (81,Figure 4),but do not tighten.

Assemble the o-ring (66,Figure 4) to the cap (23,Figure 4).

F. Secure the decal (20,Figure 4) if previously removed, to the cap (23,Figure 4) with the epoxy glue (93,Figure 4).

G. Assemble the o-ring (63,Figure 4) to the seat (24,Figure 4) and carefully insert the seat into the test fixture(Figure 15).

H. Setup the test fixture (Figure 15) with the gauges and the downstream handvalve, as shown in the followingfigure. Crack the handvalve and slowly apply the proper outlet pressure (200 psig) for Part Numbers 281166-0001 and 281166-0002; (195 psig or 240 psig) for Part Number 281166-0003 (seeParagraph 1.2.3.1andParagraph 1.2.3.2) to the test fixture inlet port. Turn in on the cap (23,Figure 4) until no flow is observedcoming from the handvalve. Close the handvalve and check for leakage at the seat. Seat leakage would beindicated by a gradual and steady increase in pressure as shown by the downstream gauge. If leakage isdetected refer toParagraph 11.3in Troubleshooting.

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9-6 Change B

I. Gradually increase the pressure at the inlet port until the valve cracks and starts venting. Verify that thecracking pressure is within the specification limits. If the cracking pressure is not as required, readjust the cap(23, Figure 4), perparagraph 10.1, and recheck the cracking pressure.

NOTE

Valve cracking pressure shall conform to the requirements of MIL-V-24272.

J. After completingStep I, gradually decrease the pressure at the inlet port until the poppet reseats. Verify thatthe reseat pressure is as required and recheck the downstream gage for seat leakage.

Check for any external leakage. If external leakage is detected, refer toparagraph 11.3in TROUBLESHOOT-ING.

K. Remove the valve from the test fixture (Figure 15) and assemble the washer (17,Figure 4) to the housing(22, Figure 4). Reinstall the valve in the body and pin assembly (9,Figure 1) and bend down a tab on thewasher (17,Figure 4).

9.6 Assembly and Installation of Needle Valves

(SeeFigure 8& item 1 & 2, Figure 1)

A. Press the slug (11,Figure 8) into the threads on the screw (12,Figure 8).

B. Slide the o-ring (61,Figure 8) onto the screw (12,Figure 8), and turn the screw into the body (9,Figure 1).

NOTE

The filter/reducer bleed valve assembly (1,Figure 1), does not include o-ring (61,Figure 8). Make certain that the needle valves are installed in the proper cavities.

C. Place the washer (11,Figure 1) on top of the screw (12,Figure 8) and snap in the retaining ring (81,Figure1) with retaining ring pliers.

Test Fixture Setup, Pressure Relief Valve

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Change B 9-7

9.7 Final Assembly and Installation of the Manifold into the System

NOTE

The following procedure is to be performed after all components have beenassembled and installed onto the manifold. (Paragraph 9.1 - Paragraph 9.6).

A. Install o-ring (61,Figure 1) onto the union (83,Figure 1) and screw into the body (9,Figure 1).

B. Insert sleeve (85,Figure 1), into the nut (84,Figure 1) and screw the nut onto the union (83,Figure 1).

C. Install o-ring (62,Figure 1) and retainer (21,Figure 1) onto the inlet and outlet fittings (12, 13,Figure 1).

D. Screw the inlet and outlet fittings as assembled inStep Cinto the adapter (19,Figure 1).

E. Install inlet and outlet fittings (12, 13,Figure 1) into the body (9,Figure 1) and secure utilizing screws (68,Figure 1).

F. Install o-ring (63,Figure 1) onto the vent fitting (14,Figure 1) and screw into the body (9,Figure 1).

G. Install rings (20,Figure 1) and o-rings (65,Figure 1) onto the outlet and vent tailpieces (94,Figure 1).

H. Install o-ring (64,Figure 1) onto the inlet tailpiece (93,Figure 1).

I. Carefully align the manifold up to the existing piping and connect by screwing the nuts (91, 92,Figure 1)onto the fittings (12, 13, 14,Figure 1).

NOTE

The inlet fitting (12,Figure 1) and outlet fitting (13,Figure 1) are linear adjust-able by screwing the fittings in or out (as necessary) of the adapter (19,Figure1).

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9-8 Change B

CHAPTER 10

ADJUSTMENTS

The manifold is preadjusted and should not require any readjustments during operation.

Adjustments are to correct malfunction port for reassembly and are as follows:

NOTE

Item numbers and other callouts regardingFigure 1, Figure 3, andFigure 4alsoapply toFigure 1A, Figure 3A, andFigure 4A.

10.1 Relief Valve

(5, Figure 1; andFigure 4)

Loosen Screw (81,Figure 4).

Turn cap (23,Figure 4) in a clockwise direction to increase the relief cracking pressure or counterclockwiseto decrease the relief cracking pressure.

Retighten screw (81,Figure 4).

10.2 Reducer Valve

(4, Figure 1; andFigure 3)

A. Loosen screw (81,Figure 3).

B. Turn screw (21,Figure 3) in a clockwise direction to increase outlet pressure or counterclockwise to decreasethe outlet pressure.

C. Retighten screw (81,Figure 3).

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CHAPTER 11

TROUBLESHOOTING

Use discretion in any maintenance disassembly to prevent unnecessary removal, isolate problem area beforeattempting any disassembly.

Locate the problem are in the″PROBLEM″ column. The″PROBABLE CAUSE″ column will indicate thecause of the faulty condition and the″CORRECTIVE ACTION″ column lists the prescribed action to be taken.

(See Chart on following pages)

NOTE

Item numbers and other callouts regardingFigure 1, Figure 2, Figure 3, andFigure 4also apply toFigure 1A, Figure 2A, Figure 3A, andFigure 4A.

11.1 Pressure Regulating Manifold

(Figure 1)

Pressure Regulating Manifold Troubleshooting

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

External Leakage Loosened fasteners Retighten fasteners as necessary.Damaged o-rings (61, 62, 63, 64, 65,Fig. 1).

Examine o-ring(s) and adjacent sealingsurfaces for nicks, scratches, etc., thatcould cause leakage. Replace defectiveparts.

Defective reducer valve (4,Fig. 1). SeeParagraph 11.2Defective relief valve (5,Fig. 1). SeeParagraph 11.3Defective inlet handvalve (7,Fig. 1). SeeParagraph 11.8Defective outlet handvalve (8,Fig. 1). SeeParagraph 11.8Defective bypass valve (6,Fig. 1). SeeParagraph 11.4Defective needle valve (1, 2,Fig. 1). SeeParagraph 11.5, 11.6Defective filter element (3,Fig. 1). SeeParagraph 11.7

Internal Leakage Outlet handvalve (8,Fig. 1). SeeParagraph 11.8Inlet handvalve (7,Fig. 1). SeeParagraph 11.8By-Pass Handvalve (6,Fig. 1) SeeParagraph 11.4Gage Bleed, Gage Shutoff, ReducerBleed (needle valve) (1, 2,Figure 1).

SeeParagraph 11.5& Paragraph 11.6

Excessive venting of Relief Valve Faulty relief valve or improper setting(cracking pressure setting too low).

SeeParagraph 11.3

Excessive outlet pressure due toimproper reducer valve setting. (4,Fig.1).

SeeParagraph 11.2(Also see Internalleakage bypass valve,Parag. 11.4B)

Outlet pressure too high. Defective reducer valve. Internal Leak-age Bypass.

SeeParagraph 11.2SeeParagraph11.4B

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Change B 11-1

Pressure Regulating Manifold Troubleshooting - Continued

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

Outlet pressure too low. Defective reducer valve Filter elementcontamination.-

SeeParagraph 11.2Contamination ofthe filter is indicated by the red indica-tor button in the up position. This canbe verified by pushing the button downto reset. If the button returns to the upposition, remove and disassemble perparag. 5.2. Replace the element (3,Figure 1) and reassemble perparag.9.3.

Supply pressure to pressure regulatingmanifold too low

Verify that proper pressure is supplied.

Flow path restricted. Inspect flow path for any foreign mat-ter, (dust, etc.) which may cause block-age & remove.

11.2 Reducer Valve

(4, Figure 1; andFigure 3)

A. Problem: External Leakage

Probable Cause: Damaged o-rings (64, 70, 71, 72,Figure 3)

Corrective Action: Examine o-rings and adjacent sealing surface for nicks, scratches, etc., that could causeleakage. Replace defective parts.

B. Problem: High outlet pressure

Probable Cause: Damaged parts or incorrect adjustment

Verification of faulty reducer operation is as follows: (one flow path at a time).

1. Close the bypass valve (6,Figure 1) (and alternate flow path handvalves).

2. Loosen the screw (81,Figure 3) and adjust the screw (21,Figure 3) until the proper outlet pressure isattained.

3. Isolate the reducer and switch to the by-pass valve (Seeparagraph 3.0 A).

4. If correct outlet pressure is not achieved, refer toparagraph 11.4for bypass corrective procedures.

5. If correct outlet pressure is achieved, proceed to Corrective Action below.

Corrective Action: Remove the faulty unit from the manifold and install it in the test fixtures (Figure 14)as set-up perparagraph 9.4. Apply inlet pressure and allow the valve to lock-up. Verify that the outlet pressureis too high and readjust the screw perparagraph 10.2. If the pressure is still too high, proceed with the follow-ing examination and replace all damaged parts.

1. Examine all the sliding surfaces of the poppet (19,Figure 3), piston (20,Figure 3) and the attached partsfor dirt, burrs, or misalignment that could cause binding.

2. Examine the seating and sealing surfaces of the poppet, (19,Figure 3), support (17,Figure 3), and the seat(18, Figure 3), for nicks, scoring, or scratches that could cause leakage.

3. Examine the critical sealing surface of the support (17,Figure 3) for dirt or damage that could cause leak-age.

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11-2 Change B

4. Make certain that the sensing hole in the body (23,Figure 3) beneath the piston (20,Figure 3) is notobstructed,

C. Problem: Low outlet pressure

Probable Cause: Incorrect adjustment or supplied pressure

Corrective Action: Verify that the manifold inlet pressure is greater than the required outlet. Readjustreducer valve setting as perparagraph 10.2until the proper outlet pressure is achieved.

11.3 Relief Valve

(5, Figure 1; andFigure 4)

A. Problem: External leakage

Probable Cause: Damaged o-rings (63, 67,Figure 4).

Corrective Action: Examine o-ring and adjacent sealing surfaces for nicks, scratches, etc., that could causeleakage. Replace defective parts.

B. Problem: High cracking pressure

Probable Cause: Damaged parts or incorrect adjustment

Verification of faulty relief operation is as follows:

1. Close the bypass valve (6,Figure 1) and the inlet handvalve (7,Figure 1).

2. Open the gage bleed valve (2,Figure 1) as pressure escapes. Verify that the relief valve is not venting. Ifventing occurs, proceed as follows:

Corrective Action: Remove the faulty unit from the manifold and install it in the test fixture (Fig. 15) asset-up perparagraph 9.5. Gradually apply pressure to the test fixture inlet port until the valve cracks. Verify thatthe cracking pressure is too high and readjust the relief valve as perparagraph 10.1. If the cracking pressure isstill too high, proceed with the following examination and replace all damaged parts.

Examine the sliding surfaces of the piston (16,Figure 4) for dirt, burrs or misalignment that could causebinding.

C. Problem: Low cracking pressure

Probable Cause: Incorrect adjustment

Corrective Action: Readjust the relief valve as perparagraph 10.1until the proper cracking pressure isachieved.

11.4 By-Pass Valve

(6, Figure 1; andFigure 5)

A. Problem: External leakage

Probable Cause: Damaged o-ring(s) (61, 63,Figure 5)

Corrective Action: Examine o-rings (61, 63,Fig. 5) and adjacent sealing surfaces for nicks, scratches, etc.,that could cause leakage. Replace defective parts.

B. Problem: Internal leakage

S6434-AF-MMO-010

Change B 11-3

Probable Cause: Damaged parts

Corrective Action: Remove the faulty unit from the manifold and install it in the test fixture (Fig. 12) asset-up perparagraph 9.2. Close the handvalve and gradually apply pressure to the test fixture and check if leak-age persists.

1. If leakage persists, proceed with the following examination and replace all damaged parts.

2. Examine the seating surfaces of the o-ring (62,Figure 5), seat (16,Figure 5), stem (15,Figure 5) and sup-port (19,Figure 5) for nicks, scratches, etc. that could cause leakage.

11.5 Reducer and Filter Bleed Valve

(1, Figure 1; andFigure 8)

Problem: External leakage

Probable Cause: Damaged parts or valve open

Corrective Action: Verify that the valve is closed.

1. Torque the screw (12,Fig. 8) for better seating.

2. Examine the seating area of the screw (12,Fig. 8) for nicks, scratches, etc. that could cause leakage.

3. Examine the seating area of the body (9,Figure 1) for nicks, scratches, etc. that could cause leakage.

11.6 Gage Shut-Off and Gage Bleed Valve

(2, Figure 1& Figure 8)

A. Problem: External leakage

Probable Cause: Damaged parts

Corrective Action: Examine o-ring (6 1,Figure 8) and adjacent sealing surfaces for nicks, scratches, etc.that could cause leakage.

B. Problem: Internal leakage

Probable Cause: Damaged parts or valve open

Corrective Action: Verify that the valve is closed.

1. Torque the screw (12,Figure 8) for better seating.

2. Examine the seating area of the screw (12,Figure 8) for nicks, scratches, etc., that could cause leakage.

3. Examine the seating area of the body (9,Figure 1) for nicks, scratches, etc. that could cause leakage.

11.7 Filter Element

(3, Figure 1; andFigure 2)

A. Problem: External leakage

Probable Cause: Damaged parts

Corrective Action: Examine o-ring (84,Figure 2) and adjacent sealing surfaces for nicks, scratches, etc.that could cause leakage.

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11-4 Change B

B. Problem: Filter contamination

Probable Cause: Clogged filter element

Verify contamination as follows:

Contamination of the filter is indicated by the red indicator button (located on the filter) in the up position.This can be verified by pushing the button down to reset. If the button returns to the up position, the filter isclogged.

Corrective Action: Remove and disassemble perparagraph 5.2

Replace the element (90,Figure 2) and reassemble perparagraph 9.3.

11.8 Inlet Handvalve - (7,Figure 1; and Figure 6) and Outlet Handvalve (8,Figure 1; and Figure 7)

A. Problem: External leakage

Probable Cause: Defective parts

Corrective Action: Examine o-ring (12,Figure 6) and adjacent sealing surfaces for nicks, scratches, etc.that could cause leakage. Replace parts that are damaged. Examine the packing (10,Figure 6) and adjacent seal-ing surfaces for nicks, scratches, etc. that could cause leakage. Replace any damaged parts.

B. Problem: Internal leakage

Probable Cause: Defective parts

Corrective Action: Examine o-ring (13,Figure 6) and adjacent sealing surfaces for nicks, scratches, etc.that could cause leakage.

Examine the seating areas of the seat (6,Figure 6) and the disc and guide assembly (4,Figure 6).

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CHAPTER 12

TESTING

Testing of the manifold should be performed:

A. When the performance of the manifold is in question.

B. After any reassembly of the manifold which involves readjustment of components.

C. When problems arise such as those described inparagraph 11.0, TROUBLESHOOTING, the following testsmay help to isolate the probable cause.

NOTE

The proof pressure test should be performed only if the structural integrity of themanifold is in question.

12.1 General Information

A. Standard Testing Conditions:

Test Fluid: Clean air or nitrogen gas unless otherwise indicated for specified tests.

Test Temperature: Room Ambient

Allowable Leakage: Bubble Tite internal and external (except as indicated).

Pressure Rating: 3000 psi max.

B. Descriptive Terms used in Testing

Lock-up Pressure The outlet pressure delivered when the regulator’s flow rate is equal to or less than theallowable leakage rate.

Stabilization A condition due to temperature variances of the line fluid thus causing slight pressurechanges.

C. Utilize gauges with a scale of 1-1/2 times min. to 4 times max. of the required pressure, and accurate to 1/4of 1% of the full scale.

(See Charts on following pages)

Testing

TEST NO.EXAMINATION &TESTS TEST CONDITIONS

PURPOSE OF EXAMI-NATIONS AND TESTS

ACCEPTANCE CRI-TERIA

12.2 Proof Test, Perform onlyif the structural integrityof the equipment is inquestion.

Water, nitrogen, or air atthe pressure of 4500 psigapplied to the manifoldinlet with the outlethandvalve(s) closed.

To test strength and sound-ness of pressure containingenvelope.

No external leakage,permanent distortion orstructural failure.

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Change B 12-1

Testing - Continued

TEST NO.EXAMINATION &TESTS TEST CONDITIONS

PURPOSE OF EXAMI-NATIONS AND TESTS

ACCEPTANCE CRI-TERIA

12.3 Seat Tightness Handvalve seating andunseating with a torquenot to exceed 70 inch/pounds and a runningtorque not to exceed 35inch/pounds. Check forleakage at the outlet withbubble fluid or by immers-ing the outlet, or a linefrom the outlet, underwater. Regulators andrelief valves shall be testedat lockup pressure.

To verify seat tightness No visible leakage overa 5-minute period. If theregulators or reliefvalves cannot meet thisrequirement, they shallbe tested using theallowable leakage crite-ria of 15 SCIH (max.)per inch of seat diam-eter.

12.4 External Leakage Test Air at maximum ratedpressure applied to eachsection of manifold. Leak-age checked by eitherusing bubble fluid or bysubmerging manifold inwater.

To check for external leak-age.

No visible leakage overa 5 minute period.

12.5 Filter operational test. operating conditions. To test operation of differ-ential indicator.

Filter indicator nominal″trip″ value 50 psid.

12.6 Relief Valve reseat test.(Reducer)

Maximum inlet pressureapplied to inlet, regulatingvalve set far enough abovethe relief valve accumula-tion pressure or blockedopen to ensure that theregulating valve is openwide during this test.Reduce pressure until therelief valve reseats. Max.inlet pressure is 3000 psi.

To verify relief valvecapacity, and demonstrateability to reseat at min.pressure of:1) 190 psig for Part No.281166-0001 configuration(Ref. Paragraph 1.2.1).2) 185 psig for Part No.281166-0002 configuration(Ref. Paragraph 1.2.2).3A) 185 psig for Part No.281166-0003 configuration(Ref. Paragraph 1.2.3.1,cracking pressure 195 psi)3B) 232 psig for Part No.281166-0003 configuration(Ref. Paragraph 1.2.3.2,cracking pressure 240 psi)

1) For Part No. 281166-0001 configuration;minimum reseat 190psig2) For Part No. 281166-0002 configurationminimum reseat 185psig.3A) For Part No.281166-0003 configura-tion; minimum reseat185 psig (Ref.Paragraph 1.2.3.1195psig cracking pressure).3B For Part No.281166-0003 configura-tion; minimum reseat232 psig (Ref.Paragraph 1.2.3.2240psig cracking pressure).

12.7 Relief Valve reseat test(bypass handvalve)

Maximum inlet pressure of3000 psi applied to inlet.

To test reseat pressure ofrelief valve.

1) For Part No. 281166-0001 configuration;minimum reseat 190psig.

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12-2 Change B

Testing - Continued

TEST NO.EXAMINATION &TESTS TEST CONDITIONS

PURPOSE OF EXAMI-NATIONS AND TESTS

ACCEPTANCE CRI-TERIA

Manual bypass valve wideopen.

2) For Part No. 281166-0002 configurationminimum reseat 185psig.3A) For Part No.281166-0003 configura-tion; minimum reseat185 psig (Ref.Paragraph 1.2.3.1195psig cracking pressure).3B) For Part No.281166-0003 configura-tion; minimum reseat232 psig (Ref.Paragraph 1.2.3.2240psig cracking pressure).

12.8 Handvalve pressurizationrate test.

Max. inlet pressure of3000 psi upstream ofvalve, zero pressure down-stream initially.Handvavles operated inaccordance with operatinginstructions affixed tomanifold. A volume nogreater than that corre-sponding to 30 pipe diam-eters downstream.

All isolation valves,including regulator isola-tion and bypass and gageisolation, shall be tested todemonstrate that they canbe operated in a manner tolimit pressure build-up rateto a safe value.

Operating personnelshall be capable of eas-ily limiting the down-stream pressure build-uprate to a value notexceeding 200 psi persecond.

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CHAPTER 13

STORAGE AND PREPARATION FOR RESHIPMENT

13.1 Storage

Items as packaged should be stored in an area that protects all components from the following:

A. Contamination

B. Extreme temperature variations (store at 40° to 120°F)

C. Relative humidity (store in area with relative humidity between 20% to 70%).

13.2 Preparation for Reshipment

A. All items with openings leading to internal surfaces shall be covered with protective caps, plugs, or otherapplicable closures, and of a material that will not cause corrosive action between the item and the protectiveclosure.

B. Containers for reshipment shall be of sufficient size and strength to protect the enclosed items and markedwith proper identifying part numbers and nomenclature.

C. Dunnage, cushioning and/or fillers shall be used to minimize shock, dampen vibrations and to protect itemsagainst damage. They shall be of a quality suitable for the purpose of the items being protected and selectedin relation to the weight and size of the item.

D. Holding devices such as bolts, nails, strapping, etc. shall be of adequate strength, size and length to suffi-ciently contain the item(s).

E. Shipment can be by commercial carrier or whatever method the owner warrants.

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CHAPTER 14

PARTS LIST

The following is a list of parts required to assemble one Model RM21FA-1, Part Number 281166-0004, pres-sure regulating manifold.

The item numbers in the first column correspond to the item numbers shown onFigure 1. The quantitiesshown are for one (1) unit.

Parts List forFigure 1

ITEM NO.(FIG. 1)

QTY PERUNIT MAROTTA PART NO. NOMENCLATURE

1 2 233029-1 Needle valve assembly2 2 233029-0004 Needle valve assembly3 2 233032-0006 Filter assembly4 2 283371-0002 Reducer assembly5 1 2800397-0003 Relief assembly6 1 280566-5331 By-pass valve7 2 233188-0007 Inlet valve8 2 233695-0002 Outlet valve9 1 234877-0001 Body & pin assembly10 3 180784-1 & 2 Decal11 4 120002-48 Washer12 1 189790-0130 Fitting - inlet13 1 189791-0213 Fitting - outlet14 1 189945-0013 Fitting - vent15 2 180339-0009 Orifice16 1 4001543-0101 Instruction plate17 1 4001542-0101 Nameplate18 1 180708-2 Decal19 2 189649-0113 Adapter20 2 4790911-0006 Ring - retainer21 2 189787-0130 Retainer61 1 4410571-9040 O-ring - gauge62 2 4410571-1170 O-ring - in & out63 1 4410571-9120 O-ring - vent64 1 4410571-1140 O-ring65 2 4410571-0190 O-ring66 8 4201511-1302 Socket head cap screw67 8 4201611-0301 Socket head cap screw68 8 4201511-2301 Socket head cap screw81 4 4190101-1037 Ring-retainer82 AR - Lockwire83 1 4722102-0404 Union84 1 4781013-0004 Nut85 1 4780902-0004 Sleeve91 1 4760313-6004 Nut92 2 4781311-0006 Nut93 1 4760424-0004 Tailpiece

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Change B 14-1

Parts List forFigure 1- Continued

ITEM NO.(FIG. 1)

QTY PERUNIT MAROTTA PART NO. NOMENCLATURE

94 2 4781411-0006 Tailpiece95 4 4230000-1001 Drive screws

The following is a list of parts required to assemble one Model RM21FA-1 Part numbers 281166-0002 and281166-0003, Pressure Regulating Manifold.

The item numbers in the first column correspond to the item numbers shown onFigure 1AandFigure 1B.The quantities shown are for one (1) unit.

Parts List forFigure 1AandFigure 1B

ITEM NO.(FIG. 1A/FIG.

1B)QTY. PER

UNIT MAROTTA PART NO. NOMENCLATURE

1 2 233029-1 Needle Valve Assembly2 2 233029-2 Needle Valve Assembly3 2 236285-0002 Filter Assembly,4 2 283371-0002 Reducer Assembly5 1 2800397-0003 Relief Assembly6 1 280566-5531 Bypass Valve7 2 233188-1 Inlet Valve8 2 233695 Outlet Valve9 1 234877-0002 Body and Pin Assembly

10 3 192802-0028 Decal11 4 120002-48 Washer12 1 189790-0230 Fitting - Inlet13 1 194697-0013 Fitting - Outlet14 1 * 182149-0013 Fitting - Vent15 2 180339-0009 Orifice16 1 4001543-0101 Instruction Plate17 1 4001542-0101 Nameplate18 1 180708-2 Decal19 2 189649-0113 Adapter21 2 189787-0130 Retainer61 1 4410571-9040 O-Ring - Gauge62 2 4400571-1170 O-Ring - In and Out63 1 4410571-9120 O-Ring - Vent64 1 4400571-2100 O-Ring65 2 4400571-2120 O-Ring66 8 4201511-1302 Socket Head Cap Screw67 8 4201611-0301 Socket Head Cap Screw68 8 4201511-2301 Socket Head Cap Screw69 3 192802-0027 Nameplate81 4 4190101-1037 Ring - Retaining82 AR - Lockwire83 1 4722102 Union84 1 4781013-0004 Nut

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14-2 Change B

Parts List forFigure 1AandFigure 1B- Continued

ITEM NO.(FIG. 1A/FIG.

1B)QTY. PER

UNIT MAROTTA PART NO. NOMENCLATURE

85 1 4780902-0004 Sleeve86 AR 4990005 Scotch Held91 1 4762413-3006 Nut92 2 4762413-3008 Nut93 1 4762311-0006 Tailpiece94 2 4762311-0008 Tailpiece95 4 4230000-1001 Drive Screws

*Optional Part No. 182149-0061

CORRECTION PAGE FOR FIGURE 1

MACHALT 551-48109 (ECP-346) REPLACED AIR DRY CORPORATION MANIFOLDS WITH NEWLY-DESIGNED MAROTTA MANIFOLDS AND UPGRADED THE EXISTING MAROTTA MANIFOLDS TONEW DESIGN SPECIFICATIONS. ACCORDINGLY, THIS MACHALT ADDED THE FOLLOWING PARTNUMBERS TO THE PARTS LIST OF MATERIAL FOR USE WITH THE MODEL RM21FA-1, PART NUM-BER 281166-0004, PRESSURE REGULATING MANIFOLD:

ITEM NO. UNIT QTY PART NO. NOMENCLATURE

2 2 233029-0004 NEEDLE VALVE ASSEMBLY3 2 233032-0006 FITLER ASSEMBLY4 2 2883371-0002 REDUCER ASSEMBLY5 1 2800398-0003 RELIEF ASSEMBLY6 1 280566-5331 BY-PASS VALVE7 2 231188-0007 INLET VALVE8 2 233695-0002 OUTLET VALVE61 1 4410571-9040 O-RING GAGE, MIL-G-23652,

VITON62 2 4410571-9120 O-RING - IN AND OUT, MIL-

G-23652, VITON63 1 4410571-9120 O-RING - VENT, MIL-G-23652,

VITON64 1 4410571-1140 O-RING, MIL-G-23652, VITON65 2 4410571-0190 O-RING, MIL-G-23652, VITON

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Figure 1 PRESSURE REGULATING MANIFOLD (REF. 281166-0001) SHEET 1 OF 3

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Figure 1 PRESSURE REGULATING MANIFOLD (REF. 281166-0001) SHEET 2 OF 3

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Figure 1 PRESSURE REGULATING MANIFOLD (REF. 281166-0001) SHEET 3 OF 3

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Figure 1A PRESSURE REGULATING MANIFOLD (REF. 281166-0002) (SHEET 1 OF 3)

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Figure 1A PRESSURE REGULATING MANIFOLD (REF. 281166-0002) (SHEET 2 OF 3)

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Figure 1A PRESSURE REGULATING MANIFOLD (REF. 281166-0002) (SHEET 3 OF 3)

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Figure 1B PRESSURE REGULATING MANIFOLD (REF. 281166-0003) (SHEET 1 OF 3)

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Figure 1B PRESSURE REGULATING MANIFOLD (REF. 281166-0003) (SHEET 2 OF 3)

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Figure 1B PRESSURE REGULATING MANIFOLD (REF. 281166-0003) (SHEET 3 OF 3)

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CORRECTION PAGE FOR FIGURE 2

MACHALT 551-48109 (ECP-346) REPLACES THE FOLLOWING ITEMS IN THE PARTS LIST:

ITEM NO. UNIT QTY PART NO. NOMENCLATURE

83 2 4400571-0260 O-RING, MIL-G-23652, VITON84 1 4400571-1280 O-RING, MIL-G-23652, VITON

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Figure 2 FILTER (REF233032)

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Figure 2A FILTER ASSEMBLY (P/N 236285-0002)

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CORRECTION PAGE FOR FIGURE 3

MACHALT 551-48109 (ECP-346) ADDED THE FOLLOWING ITEMS TO THE BILL OF MATERIALFOR USE WITH THE MODEL RM21FA-1, PART NUMBER 281166-0004, PRESSURE REGULATINGMANIFOLD:

ITEM NO. UNIT QTY PART NO. NOMENCLATURE

14 1 186776-0057 SPRING18 1 235324 SEAT19 1 191782-0030 POPPET61 1 4400571-0120 O-RING, MIL-G-23652, VITON62 1 4400571-0140 O-RING, MIL-G-23652, VITON63 1 4400571-0150 O-RING, MIL-G-23652, VITON64 1 4400571-1160 O-RING, MIL-G-23652, VITON67 1 4400571-1340 O-RING, MIL-G-23652, VITON68 1 4400571-0050 O-RING, MIL-G-23652, VITON69 1 4400571-1390 O-RING, MIL-G-23652, VITON70 1 4400571-1240 O-RING, MIL-G-23652, VITON71 1 4400571-1270 O-RING, MIL-G-23652, VITON72 1 4400571-1300 O-RING, MIL-G-23652, VITON

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Figure 3 PRESSURE REDUCER (REF 280038)

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Figure 3A PRESSURE REDUCING VALVE ASSEMBLY (P/N 283371-0002)

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CORRECTION PAGE FOR FIGURE 4

MACHALT 551-48109 (ECP-346) ADDED THE FOLLOWING ITEMS TO THE PARTS LIST FOR USEWITH THE MODEL RM21FA-1, PART NUMBER 281166-0004, PRESSURE REGULATING MANIFOLD:

ITEM NO. UNIT QTY PART NO. NOMENCLATURE

63 1 4400571-0160 O-RING, MIL-G-23652, VITON65 1 4400571-0230 O-RING, MIL-G-23652, VITON66 1 4400571-1240 O-RING, MIL-G-23652, VITON67 1 4400571-1300 O-RING, MIL-G-23652, VITON

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Figure 4 RELIEF VALVE (REF280039) SHEET 1 OF 2

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Figure 4 RELIEF VALVE (REF 280039) SHEET 2 OF 2

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Figure 4A PRESSURE RELIEF VALVE ASSEMBLY(P/N 2800397-0003)

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CORRECTION PAGE FOR FIGURE 5

MACHALT 551-48109 (ECP-346) ADDED THE FOLLOWING ITEMS TO THE PARTS LIST FOR USEWITH THE MODEL RM21FA-1, PART NUMBER 281166-0004, PRESSURE REGULATING MANIFOLD:

ITEM NO. UNIT QTY PART NO. NOMENCLATURE

61 1 4400571-0100 O-RING, MIL-G-23652, VITON62 1 4400571-0120 O-RING, MIL-G-23652, VITON63 1 4400571-0160 O-RING, MIL-G-23652, VITON

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Figure 5 BYPASS HANDVALVE (REF 280566)

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CORRECTION PAGE FOR FIGURE 6.

MACHALT 551-48109 (ECP-346) ADDED THE FOLLOWING ITEMS TO THE PARTS LIST FOR USEWITH THE MODEL RM21FA-1, PART NUMBER 281166-0004, PRESSURE REGULATING MANIFOLD:

ITEM NO. UNIT QTY PART NO. NOMENCLATURE

12* 1 4405592-2230 O-RING, MIL-G-23652, VITON13* 1 4405592-1150 O-RING, MIL-G-23652, VITON12** 1 4405592-2220 O-RING, MIL-G-2365213** 1 4405592-1140 O-RING, MIL-G-23652, VITON

*FOR 233188-2, -4, -6, AND -8 OUTLET HANDVALVE.

** FOR 233188-1, -3, -5, AND -7 INLET HANDVALVE

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Figure 6 INLET HANDVALVE (REF 233188)

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Figure 7 OUTLET HANDVALVE (REF. 233695)

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CORRECTION PAGE FOR FIGURE 8

MACHALT 551-48109 (ECP-346) ADDED THE FOLLOWING ITEM TO THE PARTS LIST FOR USEWITH THE MODEL RM21FA-1, PART NUMBER 281166-0004, PRESSURE REGULATING MANIFOLD:

ITEM NO. UNIT QTY PART NO. NOMENCLATURE

61 1 4400571-0060 O-RING, MIL-G-23626, VITON

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Figure 8 NEEDLEVALVE (REF. 233029)

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Figure 9 OPERATIONAL SCHEMATIC

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Figure 10 O’RING PICK (T10723)

Figure 11 SEAT PULLER (T10722)

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Figure 12 TEST FIXTURE (T11293)

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Figure 13 TEST FIXTURE (T11392)

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Figure 14 TEST FIXTURE (T11294)

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Figure 15 TEST FIXTURE (T11298)

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Figure 16 TEST FIXTURE (TF-1813)

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