Apollo 40-100 Series (2-1/2

Page: 21 / 26

Customer Service

(704) 841-6000

backflow.apollovalves.com

ES1595 REV A.

BFMMDC4S00

40-100 DOUBLE CHECK BACKFLOW PREVENTER

ITEM NO.

DESCRIPTION

QUANTITY

PART NO.

2-1/2”

3”

4”

Shut-Off Valve (OS&Y)

W-6825-00

W-6826-00

W-6859-00

Shut-Off Valve (NRS)

W-6744-00

W-6827-00

W-6858-00

Shut-Off Valve (Ball)

6Q-20C-01

6Q-20E-01

N/A

Brass Nipple

K-3412-40

K-3412-00

Test Cock

70-104-10

Stud

N/A

B-2036-00

Body

Consult Factory

Body

Consult Factory

C.V. Seat O-Ring

D-2576-00

D-2589-00

D-2588-00

C.V. Seat

L-4644-05

L-4653-05

L-4759-05

C.V. Stem

G-3246-00

G-3273-00

G-3305-00

C.V. Stem O-Ring

D-2578-00

D-2587-00

Retainer Nut/Bolt

***

C-1760-00

B-1754-00

Retainer Washer

E-2205-00

E-2208-00

E-2229-00

C.V. Seat Disc

D-2575-00

D-2586-00

D-2649-00

Seat Disc Holder

F-3002-05

F-3008-05

F-3019-05

1st Check Spring

A-1746-00

A-1748-00

A-1779-00

2nd Check Spring

A-1746-00

A-1748-00

A-1779-00

Spring Retainer

E-2203-05

E-2207-05

E-2228-05

Jam Nut

C-1706-00

C-1763-00

Cap O-Ring

D-2577-00

D-2588-00

D-2651-00

C.V. Cap

Q-4537-19

Q-4545-19

Q-4574-19

Cap Bolt

****

B-1800-00

B-1690-00

B-1881-00

Test Cock

70-804-10

N/S

Seat Bolt

N/A

B184900

*** 6” QTY = 2 / 8” & 10” QTY = 8
**** 6” QTY = 12 / 8” & 10” QTY = 24

PARTS LIST - 6” - 8” - 10” DCV

REPAIR KITS

KIT

PARTS INCLUDED

PART NO.

2-1/2”

3”

4”

1st Check Valve

Repair Kit

(12, 13, 14, 15, 16, 17, 18, 20, 21,

22), n/s packet lube

40-009-02

40-00A-02

Seal

Repair Kit

(10, 11, 22), n/s packet lube

40-009-03

40-00A-03

Rubber Repair Kit 2 each (10, 13, 16, 22), n/s packet lube

40-009-04

40-00A-04

Summary of Contents for 40-100 Series (2-1/2" - 10")

Page 1: ...INSTALLATION OPERATION MAINTENANCE MANUAL 40 300 Series 1 2 4S 100 Series 1 2 40 100 Series 3 4 2 40 100 T Series 3 4 2 40 100 Series 2 1 2 10 40 600 Series 3 10 ES1594 IOM BFMM4001 rev b ...

Page 2: ... and Operation 3 II Installation 3 III Troubleshooting Guide 5 IV Maintenance Instructions 1 2 40 103 5 V Maintenance Instructions 1 2 4S 103 6 VI Maintenance Instructions 3 4 2 7 VII Maintenance Instructions 2 1 2 10 7 VIII Testing Procedures 1 2 10 8 11 PARTS LIST 40 300 1 2 12 4S 103 1 2 13 40 100 3 4 2 14 17 2 1 2 10 18 21 3 10 DCDA 22 25 TABLE OF CONTENTS ...

Page 3: ...N II INSTALLATION 1 The DCV must be installed in an accessible location to facilitate periodic field testing and maintenance 2 Flush all upstream piping thoroughly to remove foreign matter prior to installing the device 3 The device should be installed horizontally for ease of maintenance and testing A clearance between the lower most portion of the device and flood grade or floor should be provid...

Page 4: ...CV assembly and water meter Each device is equipped with test cocks for periodic field testing and is normally supplied with inlet and outlet shut off valves For information on operation installation trouble shooting testing refer to Installation Instruction Booklet I476700 furnished with each DCDA unit For maintenance instructions see pages 4 6 For parts list see pages 21 24 FIGURE 5 NO FLOW COND...

Page 5: ...y opening 2 3 and 4 test cocks CAUTION Caps are spring loaded and should be removed carefully to avoid personal injury 3 Unscrew cap using hex head provided 4 Remove spring and poppet assembly from the body 5 Remove the seat disc from the poppet B INSPECTION 1 All parts should be carefully inspected for any damage or excessive wear and thoroughly rinsed in clean water prior to reassembly Replace w...

Page 6: ...laced in the groove provided will aid removal Be sure test cock 4 is open as to prevent hydraulic lock B INSPECTION 7 All parts should be carefully inspected for any damage or excessive wear and thoroughly rinsed in clean water prior to reassembly 8 Replace all worn parts as necessary NOTE Check valve modules are not user serviceable In the event of check failure replacement modules are sold indiv...

Page 7: ...ver spring and poppet stem and tighten cap A DISASSEMBLY CHECK VALVES 1 Close 2 shut off valve then close 1 shut off valve 2 Bleed pressure from the assembly by opening 2 3 and 4 test cock 3 Remove cover bolts and cover NOTE The spring load on the cover will be removed when the cover bolts are backed off approximately 3 8 4 Remove the complete check assembly straight out of the valve body being ca...

Page 8: ...heck valve disc compresses fully the required high side pressure of 2 psi below the low side should be obtainable If this pressure differential can be maintained then check valve 1 is reported as tight or okay Proceed to test no 2 However if this pressure differential cannot be maintained proceed to step no 6 6 Open 1 shut off valve to repressurize the device 7 Loosely attach the vent hose to test...

Page 9: ...E DURING TEST 1 HIGH SIDE CONNECT TO TC 2 FOR TEST 1 TC 3 FOR TEST 2 LOW SIDE CONNECT TO TC 3 FOR TEST 1 TC 4 FOR TEST 2 TEST COCK 1 TEST COCK 2 TEST COCK 3 TEST COCK 4 TC CHECK 2 SHUT OFF VALVE 1 SHUT OFF VALVE 2 CHECK 1 B P 1 DRAIN HOSE B P 2 HYDRAULIC HOSE BYPASS B P VALVE TEST COCK DUPLEX GAUGE OR TWO BOURDON TUBE GAUGES VIII TESTING PROCEDURES FIGURE 6 ...

Page 10: ...10 Customer Service 704 841 6000 www apolloflowcontrols com Apollo Flow Controls INSTALLATION OPERATION MAINTENANCE MANUAL FIGURE 7 VIII TESTING PROCEDURES ...

Page 11: ... from test cock No 3 then a leaky shut off valve is evident and should be repaired or bypassed before testing continues If the water recedes from the test cock opening then move the gauge to a point level with the centerline of the check seat area and record the gauge reading as the static pressure differential across check No 1 TEST NO 2 PURPOSE TO DETERMINE THE STATIC PRESSURE DROP ACROSS CHECK ...

Page 12: ...12 Customer Service 704 841 6000 www apolloflowcontrols com Apollo Flow Controls INSTALLATION OPERATION MAINTENANCE MANUAL FIGURE 9 VIII TESTING PROCEDURES ...

Page 13: ... SHUT OFF VALVE BYPASS CHECK NO 1 CHECK NO 2 INLET SHUT OFF VALVE BYPASS LOW SIDE HOLD OPEN END AT SAME LEVEL AS GAUGE DURING TESTING HIGH SIDE CONNECT TO TC NO 2 FOR TEST NO 1 MAINLINE DCV TC NO 3 FOR TEST NO 2 MAINLINE DCV TC NO 6 FOR TEST NO 1 BY PASS DCV TC NO 7 FOR TEST NO 2 BY PASS DCV FIGURE 6 IV TESTING PROCEDURES V TROUBLESHOOTING SYMPTOM CAUSE CORRECTIVE ACTION Check valve fails to hold ...

Page 14: ...3 Spring 2 A 1750 00 4 Poppet 2 K 3404 00 5 Seat Disc 2 D 2600 00 6 Cap O Ring 2 D 2501 00 7 Test Cock 3 78 257 01 8 Union Nut 1 C 1778 06 9 Tail Piece 1 L 5226 06 10 Seal 1 D 2607 00 PARS LIST 1 2 BRONZE REPAIRS KITS MAJOR REPAIR KIT 40 300 02 Kit includes items 3 2 6 2 part no W 6759 06 2 n s packet lube RUBBER REPAIR KIT 40 300 01 Kit includes items 5 2 6 2 n s packet lube 2 3 6 4 5 8 9 10 7 1 ...

Page 15: ...O Ring 1 D 2422 00 5 Check Spacer 1 L 6104 00 6 Cap 1 F 3206 05 7 Cap O Ring 1 D 2568 00 REPAIRS KITS 4S 003 01 Kit includes items 1 2 3 4 7 n s packet lube PARTS LIST 1 2 4S 103 DOUBLE CHECK VALVE INLET AND OUTLET SHUT OFF VALVES VALVE TYPE 1 2 Inlet Shut Off Valve 7B80301 Inlet Shut Off Valve w Union 7B30301 Outlet Shut Off Valve 7B80331 Outlet Shut Off Valve w Union 7B30331 Replacement Handles ...

Page 16: ...16 Customer Service 704 841 6000 www apolloflowcontrols com Apollo Flow Controls INSTALLATION OPERATION MAINTENANCE MANUAL PART NUMBER DIAGRAM 3 4 2 BRONZE TOP ENTRY ...

Page 17: ...T plug needed for units without top mounted test cocks PARTS LIST 3 4 2 BRONZE TOP ENTRY REPAIR KITS KIT PARTS INCLUDED PART NO 3 4 1 1 1 4 1 1 2 2 Major Repair Kit 4 2 5 2 6 2 7 2 8 2 10 2 11 2 n s packet lube 40 004 A5 40 007 A5 Check Valve Repair Kit 4 5 6 7 8 10 11 n s packet lube 40 004 A2 40 007 A2 Rubber Repair Kit 5 2 8 2 11 2 n s packet lube 40 004 A6 40 007 A6 Replaceable Seat Kit 10 2 1...

Page 18: ...18 Customer Service 704 841 6000 www apolloflowcontrols com Apollo Flow Controls INSTALLATION OPERATION MAINTENANCE MANUAL PARTS NUMBER DIAGRAM 2 1 2 10 DUCTILE IRON ...

Page 19: ...Retainer Washer 2 E 2199 00 E 2199 00 E 2204 00 16 C V Seat Disc 2 D 2560 00 D 2560 00 D 2572 00 17 Seat Disc Holder 2 F 3000 05 F 3000 05 F 3001 05 18 1st Check Spring 1 A 1741 00 A 1741 00 A 1744 00 19 2nd Check Spring 1 A 1741 00 A 1741 00 A 1744 00 20 Spring Retainer 2 E 2198 05 E 2198 05 E 2202 05 21 Jam Nut 2 C 1589 05 C 1589 05 C 1589 05 22 Cap O Ring 2 D 2566 00 D 2566 00 D 2574 00 23 C V ...

Page 20: ...20 Customer Service 704 841 6000 www apolloflowcontrols com Apollo Flow Controls INSTALLATION OPERATION MAINTENANCE MANUAL PARTS NUMBER DIAGRAM 6 8 10 DCV ...

Page 21: ...t Bolt C 1760 00 B 1754 00 B 1754 00 15 Retainer Washer 2 E 2205 00 E 2208 00 E 2229 00 16 C V Seat Disc 2 D 2575 00 D 2586 00 D 2649 00 17 Seat Disc Holder 2 F 3002 05 F 3008 05 F 3019 05 18 1st Check Spring 1 A 1746 00 A 1748 00 A 1779 00 19 2nd Check Spring 1 A 1746 00 A 1748 00 A 1779 00 20 Spring Retainer 2 E 2203 05 E 2207 05 E 2228 05 21 Jam Nut 2 C 1706 00 C 1763 00 C 1763 00 22 Cap O Ring...

Page 22: ... apolloflowcontrols com Apollo Flow Controls INSTALLATION OPERATION MAINTENANCE MANUAL NOTES 1 USE P N W 7062 00 FOR METER IN CUBIC FEET REGISTER USE P N W 7094 00 FOR METER IN GALLONS REGISTER 2 N S NOT SHOWN PART NUMBER DIAGRAM 3 4 DCDA ...

Page 23: ...W706200 W706200 9 Water Meter in Gallons 1 W709400 W709400 10 3 4 DCV 1 W378905 W738905 11 Elbow Street K350200 K350200 12 By Pass Shut Off Valve 1 7B10431 7B10431 13 Swivel Nut 1 N A C186705 N S Washer Meter 1 N A D261000 15 Coupling 1 N A K379106 16 3 4 Coupling 2 N A K350400 17 Nipple Close K337000 K337000 18 Test Cock 1 7010310 7010310 22 Cap 2 Q453019 Q453319 23 Cap Bolt 12 B179700 B180100 24...

Page 24: ...polloflowcontrols com Apollo Flow Controls INSTALLATION OPERATION MAINTENANCE MANUAL NOTES 1 USE P N W 7062 00 FOR METER IN CUBIC FEET REGISTER USE P N W 7094 00 FOR METER IN GALLONS REGISTER 2 N S NOT SHOWN PART NUMBER DIAGRAM 6 8 10 DCDA ...

Page 25: ...00 K351100 9 Coupling Water Meter 2 K350500 K350500 K350500 10 Water Meter in Cubic Feet 1 W706200 W706200 W706200 10 Water Meter in Gallons 1 W709400 W709400 W709400 11 Coupling 3 4 1 K350400 K350400 K350400 12 3 4 DCV 1 W738905 W738905 W738905 13 Elbow 3 4 NPT 1 K350100 K350100 K350100 14 By Pass Shut Off Valve 1 7B10431 7B10431 7B10431 15 Nipple 3 4 NPT 2 K350900 K352700 K356000 16 Ball Valve 1...

Page 26: ...1 rev b 8 17 www apolloflowcontrols com Regional Management List now available online at http conbra co rmlist Phone 704 841 6000 Fax 704 841 6020 Check our website for the most up to date information on all our products ...

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Apollo 40-100 Series (2-1/2" - 10"), Installation, Operation & Maintenance Manual

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