REPAIR KIT INSTRUCTIONS (PISTON RELAY VALVE)
DISASSEMBLY PROCEDURE:
1.
Mark the cover (1) and body (15), for proper location for reassembly.
2.
Remove 4 cap screws (20), rotate the cover 45º, then pull off cover while
holding body (15).
3.
Remove the retaining ring (13) using snap-ring pliers. Remove washer (12),
exhaust valve body (8), modulation tube (16), and spring (6) from body (15).
4.
Place wooden dowel against head of screw (2) in the bottom of piston (19), as
shown in Fig. 2.
Note: If the unit has the anti-compounding feature, shown
in (Fig. 3) or biased primary feature shown in (Fig. 4), remove valve seat
(22) from cover (1) and remove the valve disc (23), and spring (24), if
included. Remove screw (11) from exhaust valve body (8).
5.
Remove spring (5).
CLEANING PROCEDURE:
1.
Remove and discard all rubber components.
2.
Clean all metal components with cleaning solvent and dry thoroughly.
REASSEMBLY PROCEDURE:
1.
Lubricate new rubber parts and all mating surfaces with grease provided.
2.
Assemble inlet seal (18), seal retainer (17) and O-Ring (14) onto modulation
tube (16).
3.
Assemble exhaust seal (3) and screw (2) to piston (19). Torque screw (2) to
43-53 in. lbs.
4.
Install diaphragm (9), washer (10) and screw (11) to exhaust valve body (8).
Torque screw (11) to 15-20 in. lbs.
5.
If unit was equipped with valve disc (23), install new disc and spring (24) as
required in cover (1).
NOTE: Do not put valve disc (23) or spring (24) in
cover if unit was not originally equipped with disc.
6.
Place O-Ring (21) on valve seat (22) and assemble into cover. Torque valve
seat (22) to 360-480 in. lbs. Assemble seal (4) on piston (19). Select correct
replacement spring (5). Install piston and spring (5) as shown in Fig. 1.
7.
Apply grease provided onto bore (A) in cover (1). Place seal (4) onto cover
(1). Align marks made prior to disassembly and press cover (1) into valve
body (15).
8.
Insert 4 bolts (20) and torque to 110-160 in. lbs. Insert modulation tube (16)
into body (15). Place new spring (6) over modulation tube so that it rests on
seal retainer (17).
9.
Place O-Ring (7) on exhaust valve body (8). Align spring (6), modulation
tube (16) and exhaust valve body (8). Press exhaust valve body over
modulation tube and into body (15). Place washer (12) on exhaust valve body.
Install retaining ring (13) into groove of body (15).
10
11
12
13
14
15
16
17
18
19
20
A
1
2
3
4
5
6
7
8
9
Figure 1
Strike dowel in
direction shown.
23
22
21
1
Figure 3
Figure 4
1
22
24
23
21
Wood dowel
place over screw as shown.
Figure 2
