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ENGINEERING
19
Drylok
®
Dry Disconnect – 2" Adaptor Maintenance
2" DRYLOK ADAPTORS:
WARNING
OPW ENGINEERED SYSTEMS cannot be held
responsible for the integrity of a Field rebuilt product. To minimize the
possibility of physical injury and obtain the best possible functioning
product after rebuilt, it is strongly recommended that the procedures
outlined be followed to Tear down, Re-assemble and Test the product
before placing the unit back into service. Reference the enclosed illus-
trations to facilitate identification of parts.
RECOMMENDED TOOLS FOR REPAIR:
Adaptor assembly wrench
C20461 (Consult factory), torque wrench with 1/8" hexdriver, small
flathead screwdriver or knife.
TEAR DOWN INSTRUCTIONS:
1.
Clamp the BRIDGE (3) end of the adaptor in vise with
soft jaws. Take care not to mar machined surfaces of
ADAPTOR NOSE (1).
2.
Remove (if applicable) SET SCREW (8) from BRIDGE (3).
3.
Using adaptor nose tool (C20461) or strap wrench,
unthread ADAPTOR NOSE (1) from BRIDGE (3),
exercising care and caution. POPPET in valve is
spring loaded. Exert pressure on POPPET ASS’Y (5)
to relieve spring force against the ADAPTOR NOSE
(1). SPRING force on the 2" Drylok adaptor is
approximately 35 pounds.
4.
Remove POPPET ASS’Y (5), SPRING (2), THREAD
SEAL (6) and BEARING (4). Old THREAD SEAL (6) and
BEARING (4) can be discarded. The POPPET S/A is not
included in the Repair Parts Kit. It will be necessary to
replace the old O-RING (7).
5.
Position POPPET ASS’Y (5) in collet or vise with soft jaws.
Carefully pry O-RING (7) out of the POPPET ASS’Y (5)
groove (be careful not to scratch the groove seat with
the prying tool. This could result in an O-RING leak).
Discard old O-RING.
RE-ASSEMBLE INSTRUCTIONS:
6.
Re-assemble POPPET ASS’Y (5) and new O-RING (7)
in the following manner:
a) Position new O-RING (7) on top of POPPET ASS’Y (5).
b) With your thumb, press a section of the O-RING (7)
into the groove.
c) Press the O-RING (7) around the POPPET ASS’Y (5)
and over the groove lip (it is necessary to slightly
stretch the O-RING (7) to accomplish this).
d) Continue pressing the O-RING (7) around the POPPET ASS’Y
(5) until the O-RING (7) is seated in the groove.
NOTE:
Teflon encapsulated O-RINGS should be heated in hot water for
easier installation.
7.
Lubricate new THREAD SEAL (6) and position on the machined
shoulder on the ADAPTOR NOSE (1). Important: All lubricating
greases must be compatible with seal materials and liquid products
flowing through valve to avoid destruction of elastomeric properties,
or contamination.
8.
Insert new BEARING (4) into BRIDGE (3) with flat, larger diameter
end facing toward poppet end, and cut end toward threaded end.
9.
Install SPRING (2) into deflector cup of BRIDGE (3).
Install rebuilt POPPET ASS’Y (5) with O-RING (7) into
SPRING (2). POPPET shaft should fit into BEARING
(4) bore freely.
10.
Coat threads of ADAPTOR NOSE (1) with suitable heavy grease to
avoid galling of threads during assembly.
11.
Place ADAPTOR NOSE (1) over POPPET ASS’Y (5) and push it into
contact with BRIDGE (3). Spring force will have to be overcome to
get threads started.
12.
Once started, thread ADAPTOR NOSE (1) all the way into BRIDGE (3)
until it stops. Generally, the ADAPTOR NOSE (1) will stop threading
when the THREAD SEAL (6) starts to get squeezed. At this point, it
will be necessary to use the adaptor nose tool (C20461) or a strap
wrench to further tighten adaptor. Tighten adaptor until it abruptly
stops and will tighten no further. Again, take care not to mar ma-
chined surfaces of ADAPTOR NOSE (1). If adaptor uses SET SCREW
(8), apply Loctite
™
242 or 243 to threads of SET SCREW (8). Reinstall
SET SCREW (8) into BRIDGE (3). Tighten SET SCREW (8) using a
torque wrench with 1/8" hex driver. Torque to 60 inch-pounds.
TEST PROCEDURE:
It is recommended that the VALVE be pressure tested utilizing the air
under water method, checking for leaks in the area of the POPPET seat
and around the large threaded joint. Place VALVE under water, tapping
and rotating it to release any trapped air. Pressurize the valve to 2 PSI,
and check inspection points. Then, increase pressure to 80 PSI and
check inspection points again. If pressurized air is not available, low
pressure leaks could be checked by submerging the entire ADAPTOR
face up in a container of clear water. Air trapped inside the VALVE will
bubble through or around the POPPET if the seal is not proper. This test
should be repeated three or four times to ensure that the seal does not
leak. Depress and release the POPPET each time before submerging the
unit into water.