Instruction Manual
D103366X012
81000 Valve
May 2012
5
2. Remove the bolts (key 13) and lift the bonnet yoke assembly (key 2) with the diaphragm (key 5) and O-ring (key 15)
from the valve body (key 1). Lift out the spring (key 6).
3. Remove the O-ring (key 15) and diaphragm (key 5). Wipe with a clean soft cloth and examine for wear.
4. Inspect the valve body sealing surfaces. Refer to the Lapping the Valve Seat procedure in this instruction manual.
Lapping the Valve Seat
If valve seat leakage becomes excessive, it may be necessary to lap the valve seat.
1. Use a good quality lapping compound with a mixture that contains 280 to 600 grit. Apply at several spots around
theplugseatingsurface(refertofigure5).
2. Thoroughly lap the valve body on a flat, preferably cast iron, surface plate.
3. Clean the seats thoroughly after lapping.
4. Inspect the diaphragm (key 5) and replace if necessary.
Bonnet Maintenance
1. Remove the actuator by unscrewing the yoke drive nut (key 9) and lifting off the complete actuator assembly. Hold
the flattened portions of the bonnet yoke (key 2) in a vise and unscrew the v alve bonnet (key 8) using a 2-1/4 inch
wrench. Remove and inspect the bearing cartridge assembly (key 4) and O-ring (key 49).
2. Reinsert the parts, O-ring (key 49) and bearing cartridge assembly (key 4), ensuring the bearings extend below the
side plate of the bearing cartridge assembly (key 4) and contact the piston subassembly (key 3). With the plunger
(key 10) removed, screw the bonnet (key 8) onto the yoke (key 2). There should be no binding or galling. Tighten
the bonnet with a wrench until there is metal-to-metal contact.
3. Insert the plunger (key 10) and push it in and out. The piston subassembly (key 3) should travel easily up and down.
Calibration
1. Reassemble the valve by inserting the spring (key 6), O-ring (key 15), and diaphragm (key 5) into the valve body.
2. Replace the bonnet yoke assembly (key 2) and install the bolts (key 13) and tighten. Add t he jam nut (key 27) and
travel indicator disk (key 58) to the plunger (key 10). Line up the plunger (key 10) in the bearing cartridge assembly
(key 4). Screw the actuator onto the plunger (key 10) until the actuator yoke touches the bonnet (key 8). Lock the
actuator with the drive nut (key 9).
3. Topreventdamagetotheplunger(key10)orthebearingcartridgesubassembly(key4),besurethehexjamnut
(key 27) is not tightened against the travel indicator (key 58).
CAUTION
To prevent damage to the plunger (key 10) or bearing cartridge subassembly (key 4), be sure the hex jam nut (key 27) is not
tightened against the travel indicator (key 58).
Do Not Attempt to Rotate the Plunger (key 10)
1. For an air-to-retract actuator (air-to-open). Apply 6.9 bar (100 psi) air pressure (or N2) to the normal valve inlet.
Apply 0.2 bar (3.2 psi) air signal to the actuator. Use 0.07 bar (1 psi) signal to the actuator if the inlet pressure
exceeds 6.9 bar (100 psi). If the valve leaks, slowly turn the actuator stem counterclockwise. This will move the
plunger (key 10) down until leakage is below 1 cc/min. Lock the plunger (key 10) in position with the jam nut (key
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