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S A G IT Subsidiary of

This manual provides dperational and service'information . . for the Skagit Mddel DMW-15.0 ... , . . . . ,

Mooring Winch, Serial Nos. A29 and A30. he& units weie manufa+ured unde? P"rc.haS&' '" Order 7C-13-1617 of Brown & Root, Inc. for use:oii tlie barg< Atlas I.

; . " . >E. i " .. The manual is organized'.in the following:madnep! .~ebtir i i ; I &ovide$. a general d@s&piion

. , . - . . ~ of the winch and its component assemblies. Section; I I 6b~ers.the physical describtion;

. . . , ,. , : . .. function, and location of the co'ntrols and inditaW~s: . . ~ection"'11l contains oierating' iri-

1 1 . : structions for the winch and the pawl.'Section IV contacns the necessary inspections for preventive maintenance. section V contains lubrication recbmmendations. section V'l provides recommended maintenance adjustments and corrective kainjenance tro"b1e- shooting. Section VI I contains the Illustrated Parts List an& gives parts ordering iriforma- tion. Section V l l l contains purchased components data.

TABLE OF CONTENTS

SECTION PAGE

Foreword . ......................................................... Tableofcontents . . . . . . . . . . . . ....................................... List of Illustrations ..................................................... ListofTables .......................................................

I GENERAL DESCRIPTION

1.1 . Introduction ............................................... 1.3 . Unit Description ........................................... 1.5 . Power Unit . . .......................................... 1-7 . Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 . Drum Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 . Drum Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . 1-15 . Ratchet Installation (Drum Pawl) 1-17 . Levelwind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 . Controls .......................................... . . . 1-21 . Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II CONTROLS AND INDICATORS

2.1 . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .... .. ... . . . . . . . 2-1 2.3 . Remote Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.. 1 2.5 . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.7 . Lower lntra Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.. 1 2.9 . Winch Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2- 10 . Junction Box Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2- 12 . Air Valve Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2- 14 . Control Valve Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.. 7 2- 16 . Engine Sender Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2-18 . Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2-20 . Pawl Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2-22 . Customer-Furnished Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Ill OPERATION

3-1 . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . ... ... . . . . . . . . . . . . 3-1 3-3 . Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.. 1 3-5 . Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-7 . Payout Procedure.. Motor Controlled . . . . . . . . . . . . . . . . . . . . . 3-2 3.9 . Payout Procedure-Brake Controlled . . . . . . . . . . . . . . . . . . . . . . . 5-3 3-11 . Inhaul Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3- 13 . Ratchet Pawl Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3-15 . Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

SECTION

TABLE OF CONTENTS (Continued)

PAGE

I V INSPECTIONS

............................................... . 4.1 Introduction 4-1 4.3 . Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4..1 4.5 . Weekly Inspections . . ......................................... 4-1

......................................... 4.7 . Monthly Inspections 4-2 4-9 . Semi-Annual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

V LUBRICATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Introduction 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 DMW.150 Lubrication 5-1

VI MAINTENANCE

6.1 . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.4 . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-5 . Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-7 . Drum Band Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . - 4 6-9 . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6- 1 1 . Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6-13 . Levelwind Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6-15 . Air Line Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 6-17 . Multiple-Feed Chain Oiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 6- 19 . Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 6-21 . Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 6-23 . Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

VII ILLUSTRATED PARTS LIST

7.1 . lnstn~ctions for Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.3 . Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

V l l l PURCHASED COMPONENTS DATA

8- 1 . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 . Vendor Inserts 8-1

LIST OF ILLUSTRATIONS

Fig . No . Title Page

General Arrangement DMW-150 Mooring Winch . . . . . . . . . . . . . . . . . . . . 1-2 DMW-150 Remote Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 DMW-150 Remote Control Console Panel . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Lower lntra Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Air Valve Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Control Valve Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 DMW-150 Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-. 2 Valve Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Control Valve Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Drum Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Drum Brake Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 6-6 Drive Chain Adjustment . . . . . . . . . . . . . . . . . . . . ... .. . . ... ..... ... 6.. 8 Chain Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Levelwind Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

LIST OF TABLES

Table No. Title Page

1-1. DMW-150 Mooring Winch Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 2-1. DMW-150 Control Console Controls and Indicators . . . . . . . . . . . . . . . . . . . . . 2-4 2-2. Air Valve Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 2-3. Control Valve Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . "2-12 6-- 1. Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13 8-1. Vendor Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

SECTION I GENERAL DESCRIPTION

1-1. INTRODUCTION.

1-2. This section provides a general discription of the Model DMW-150 Mooring

Winch, It contains functional and physical characteristics of the component parts in addi-

tion to specifications on this double drum machine.

1-3. UNIT DESCRIPTION. (Reference Figure 1-1.)

1-4. The DMW-150 Mooring Winch is a two side-by-side drum, underwinding, diesel

engine powered unit designed specifically for mooring applications in offshore service. It has a spooling capacity of 3,250 feet of 2 inch diameter wire rope. Each drum is equipped

with a single diamond screw, sheave-type levelwind. Power is transmitted from a power shift transmission by a drive roller chain to the drive shaft. The frame i s reinforced

structural steel, line-bored to provide accurate gear mesh and alignment, and designed for welding to the deck. Winch control is accomplished a t the electric-over-air operated Remote

Control Panel.

1-5. Power Unit.

1-6. The winch is powered by a General Motors 6V-71 diesel engine equipped for air- starting. Heat exchanger cooling has been provided. The engine cooling water requirements have been combined with the torque converter and transmission cooling requirements in the power train section. A 65 gallon fuel tank is supplied. Exhaust piping, mufflers (if required), and starting air are customer-furnished.

1-7. Power Train.

1-8. The engine drives through an Allison TC-550 torque converter and power shift

transmission Model CRT-5631. The transmission has three speeds forward and three speeds

reverse with a selector switch located on the Remote Control Console panel. The trans-

mission oil is cooled in an oil to water heat exchanger, completely piped for connection to

the vessel's cooling system. At 110 degrees F. cooling water temperature, the engine and

transmission combined require 185 GPM.

1-9. The drive from the transmission to the drive shaft is by a four-strand, splash-

lubricated, one and onequarter pitch roller chain. The two gearsets between the drive shaft and the main drums are heavily guarded and grease lubricated.

1-10, A hydraulic actuated 26 x 7 0. F. Goodrich expander-type friction clutch transmits the power from the intermediate shaft to the pinion of the final gearset. The clutch permits drum selection on the two-drum DMW-150 unit and facilitates the fast payout of wire-rope

li. Levelwind Sheave 6. Valve Panel 2. Band Brake 7 Junction Box 3. Drum 8. Ai r Tank 4 Manual Ratchet Lever 9. Fuel Tank

-! EL Drum Clutch 10. Control Valve Panel

11. Chain Case 12. Power Unit

13. Driveshaft 14. Intermediate Shaft

FIGURE 1-1. General Arrangement DMW-150 Mooring Winch

1-2

from the winches. It has a service factor of 1.35 a t stall of the converter with the trans-

mission in first gear.

1-1 1. Drum Assembly.

1-12. Each drum assembly is of alloy cast-steel construction and mounted on anti-

friction roller-type bearings on a fixed, non-rotating drumshaft which acts as a structural member giving additional strength to the winch frame. The assemblies are balanced to

reduce vibration during high-speed operation of the winch. The underwinding drum is 46.0

inches long with a barrel diameter of 30.0 inches and a flange diameter of 74.0 inches. I t

has a spooling capacity of 3,250 feet of 2-inch diameter wire rope.

1-13. Drum Brake.

1-14. Each 8.0 inch wide drum brake has a diameter of 66.0 inches with linings 314 inch

thick by 8.0 inches wide. Each one is an external contracting, self-energking, band-type Make mounted on the drum flange. Each brake is spring-set and air-released with a holding capacity of 300,000 pounds when the drum is filled to the first layer of 2-inch diameter wire rope.

1-15. Ratchet Installation. (Drum Pawl.)

1-16. Each drum is provided with a manually actuated ratchet drum pawl which acts

on the pockets i n the brake flange. The drum pawl holding capacity is 400,000 pounds on

the average layer, and is only operable a t the winch.

1-17. Levelwind.

1-18. A powered sheave-type levelwind i s mounted on the winch frame a t the front of

each drum. It is equipped with a single diamond screw shaft and a heavy guide shaft. Each

levelwind is chain driven from the drum and is complete with a manual disconnect clutch for phasing with the drum. The maximum lead angle with 2-inch diameter wire rope is 45 degrees and the maximum fleeting angle is 6 degrees to the fleeting or guide sheave.

1-19. Controls.

1-20. Control assemblies for the DMW-150 Mooring Winch installations consist of two

remote consoles. Controls for individual operation of the two winches are mounted in each

of two Remote Control Consoles, (one for the forward winch and one for the aft winch).

Each remote console contains the controls and indicators necessary to direct, monitor, and

operate its respective winch assembly. Pawl operation is accomplished manually a t the winch itself.

1-21. Air System.

1-22. An air tank with automatic drain, safety valve, filter, lubricator check valve, and pressure regulator is installed on each DMW-150 Mooring Winch frame. The ai r supply for

the controls and diesel engine starting is obtained from the vessel a i r supply. The normal air requirement i s 15 SCFM at 125 PSI.

1-23. SPEC1 FICATIONS.

1-24. General Specifications and Performance data for the DMW-150 Mooring Winch are presented in Table 1-1 included in this section.

TABLE 1-1. DMW-150 Mooring Winch Specifications. (Sht. 1 of 2.)

I Drum Dimensions:

1 Flange Diameter

I Barrel Diameter

Drum Length

Drum Spooling Capacity:

Drum Brake [Xnensions:

Diameter

Width

Linings

I Drum Brake Holding Power:

( Ratchet Pawl Holding Power:

I Levelwind:

Maximum fleeting angle permissible

1 Maximum lead angle

Overall Dimensions:

I Width

1 Height

Weight (without wire rope)

Specification

74 inches

30 inches

46 inches

3,250 feet of 2-inch wire rope.

66 inches

8 inches

314-inch thick x 8 inches wide.

300,000 pounds on the first layer. - 400.000 oounds on the averaae laver.

6 degrees to the fleeting or guide sheave.

45 degrees below horizontal.

General Motors 1 3 - 7 1 diesel engine with a Startmastel SM-19000 air starter. Transmission drive is through an Allison TC-550 torque converter and power shift trans

mission Model CRT-5631. -

181.5 inches

88.2 inches

182.0 inches

Approximately 60,500 pounds.

TABLE 1-1. DFAW-150 Mooring Winch Specifications. (Sht. 2 of 2.)

Performance

The following performance can be obtained with the engine and power

train described in paragraph 1-5, in single drum operation:

Stall 31.000 0 42,900 70 Percent Eff. 17,300 22 1 24,000 Max. Eff. 10,000 485 13,900 Max. Speed 5,300 704 7,400

First Gear - Stall

70 Percent Eff. Max. Eff. Max. Speed

AVG DRUM FULL DRUM

7

FULL DRUM AVG DRUM - BARE DRUM - Second Gear .-- Pounds FPM Pounds FPM Pounds FPM - Stall 61,600 0 85,300 0 138,600 0 70 Percent Eff. 34,400 111 47,700 80 77,500 49 Max. Eff. 20,000 244 27,700 176 45,000 109 Max. Speed 10,600 354 14,700 256 23,900 157

FULL DRUM AVG DRUM BARE DRUM

Pounds

171,800 96,000 55,700 29,600

Pounds

124,000 69,300 40,200 21,400

BARE DRUM

Third Gear

FPM

0 40 88

127

FPM

0 55

121 176

Pounds

279,200 156,000 90,000 48,200

Pounds I FPM I Pounds 1 FPM I Pounds 1 FPM

FPM - 0

25 54 78

SECTION II CONTROLS AND INDICATORS

2-2. This section contains descriptions and illustrations covering the functions and opera-

tion of the Remote Control Consoles and the winch electrical installation.

NOTE

Before operating the DMW-150 Mooring Winch, the

operator should become thoroughly familiar with this

section.

2-3. REMOTE CONTROL CONSOLE. (Reference Figure 2-1.)

2-4. Each of the Remote Control Consoles incorporates the electric-over-air controls,

indicators, and readouts necessary to operate and monitor i t s respective winch. (One for the

forward winch and one for the aft winch.)

2-5. Control Panel.

2-6. The Control Panel arrangement is shown in Figure 2-2, and the control functions are described in Table 2-1, in the numerical order illustrated in Figure 2-2.

2-7. Lower Intra Panel.

2-8. The Lower lntra Panel contains the 12 volt D.C. power supply, relays, fuses and

diodes that provide the necessary logic to operate both drums of the winch. A 150-watt

space heater is also included in this panel. Reference Figure 2-3.

2-9. WINCH ELECTRICAL INSTALLATION.

2- 10. Junction Box Enclosure.

2-1 1. The winch junction box is a NEMA-4 enclosure mounted on the frame. A

"Lockout Switch", mounted in the cover, is a coin-operated, two-position rotary switch. The

"Lockout" position opens the common side of the controls which disables the control

operation from the remote controls. The "Operate" position on the switch allows operation from the Remote Control Console.

FIGURE 2-1. DMW-150 Remote Control Console

2 -2

FIG1.IRE 2-2. DMW-150 Remote Control Console Panel

2-3

TABLE 2-1. DMW-150 Control Console Controls and Indicators. (Sht. 1 o f 2.)

Fig. 2-2 1 lrem NO. / Control or Indicator Function

1 / TRANSMISSION Drive Oil Pressure I lndicates the transmission drive oil pressure

-.- gauge, 0-300 PSI.

2 TRANSMISSION Oil Temperature Indicates the transmission oil temperature.

aauae. 100-325 deqrees F.

SYSTEM P R ESSure gauge, Indicates air system pressure. Should read

125 PSI for normal operation.

engine coolant temperature.

.- 100-230 degrees F.

ENGINE Oil Pressure gauge, Indicates the pressure of the lubricating 0-80 PSI. oi l in the ensme.

Engine Tachometer gauge, Indicates the speed of the engine in rev-

olutions per minute (RPM).

ENGINE OFF-ON-START rotary Used to start and stop engine. switch.

Drum B pawl is fully

--. - DRUM B PAWL OUT indicator Illuminates when Drum B pawl is fully

disengaged.

10 DRUM B CLUTCH OUT indicator Illuminates when Drum B clutch is

lamp. fully disengaged., .- - ---

11 DRUM B CLUTCH IN indicator Illuminates when Drum B clutch i s ful ly

lamp. engaged.

l2 I DRUM B CLUTCH OUT-IN rotary Used in OUT position to disengage Drum switch. B clutch and in IN position to engage

Drum B clutch. - 13 DRUM B BRAKE SET Used to modulate control for Drum B

Potentiometer. brake actuation. Below 2 brake fully set and above 10 brake fuily released.

TRANSMISSION 1ST-2ND-3RD

rotary switch.

DRUM B BRAKE PRESSure gauge, 0-200 PSI.

Three position switch used for selecting

desired speed range of transmission. - lndicates Drum B brake air pressure. A t

0 PSI brake fully set and a t 120 PSI brake fully released.

TABLE 2-1. DMW-150 Control Console Controls and Indicators. (Sht. 2 of 2.)

20 I TRANSMISSION REV-NEUT-FWD

rotary switch.

=ig. 2-2 tern No.

16

17 P

18

19

DRUM A CLUTCH OUT-IN rotary " L i t c h "

Control or Indicator

PRESS TO TEST pushbutton switch.

-- THROTTLE SET potentiometer - PANEL PAWER OFF-ON rotary

switch.

DRUM A BRAKE PRESSure gauge,

0-200 PSI.

2 1

- - 23 / DRUM A CLUTCH IN indicator

Function

When pushbutton is depressed, a l l indica-

tor lamps on the console are illuminated- lamp testing only.

Used to modulate control for engine speed.

Used to provide control power to the control panel when switch is in ON position.

Indicates Drum A brake air pressure. A t 0 PSI brake fully set and a t 120 PSI

brake fully released.

DRUM A BRAKE SET

Potentiometer

/ lamp.

Three positon switch used for selecting

desired rotation direction of the trans-

mission-reverse, neutral or forward. - Used to modulate control for Drum A

brake actuation. Below 2 brake fully set

and above 10 brake fully released.

Used in OUT position to disengage Drum

A clutch and IN position to engage Drum A clutch. -- -- "- Illuminates when Drum A clutch is fully

engaged.

24 1 DRUM A CLUTCH OUT indicator Illuminates when Drum A clutch is fully lamp. disengaged.

NOTE: Item 27 indicates location of the Lower lntra Panel a t the Remote Control

Console. (Reference Figure 2-1.)

25

26

DRUM A PAWL IN indicator lamp.

DRUM A PAWL OUT indicator lamp.

Illuminates when Drum A pawl is fully

engaged.

Illuminates when Drum A pawl is fully

disengaged.

1. 12VDC Power Supply 2. Diode Term Strip 3. Resistor R-?A-Drum A Brake

Control Service Adjustment 4. Fuse Block 5. Resistor A-2A - Drum B

Brake Control Service Adjustment

6. Resistor R-3A - Throttle 11. Relay E - Transmission Control Service Adjustment 2ND Speed Range

7. Relay A - Panel Power 12. Relay D - Transmission 8. Relay B - Transmission 3RD Speed Range

Forward Direction 13. DC 'Terminal Board 9. Relay C - Transmission 14. AC Terminal Board

Neutral Position 10. Relay F - Transmission

IST Speed Range

FIGURE 2-3. Lower lntra Panel

2 -6

The "Lockout" position does not assure the operator

that all electrical voltages are off. For electrical serv-

icing, lock out the disconnect switch supplying control voltage t o the Remote Control Console.

2-12. Air Valve Panel.

2-13. The air valve panel assembly is located in front of the intermediate shaft. Figure

2-4 illustrates the panel and Table 2-2 describes and gives the function of the components

in the numberical order shown on Figure 2-4.

2-14. Control Valve Panel.

2-15. 'The control valve panel assembly is mounted on the power unit frame. I t i s illustrated in Figure 2-5. Table 2-3 gives the description and function of the valves in the numerical order shown on Figure 2-5.

2-16. Engine Sender Installation.

2-17. This installation contains the engine water temperature, engine oil pressure, and tachometer senders necessary to operate the engine readouts.

2- 18. Transmission Installation.

2-19. This installation contains the transmission drive oil pressure and the transmission drive oil temperature senders necessary to operate the transmission readouts.

2-20. Pawl Limit Switches.

2-21. The "Pawl Out", "Pawl In" switches are rotary-actuated, watertight switches

mounted on the winch and operated by the pawl. They close a set of contacts when the

pawl is either fully engaged or fully disengaged.

2-22. CUSTOMER-FURNISHED ITEMS.

2-23. All interconnecting cables and stuffing tubes necessary for interconnecting the major items will be sized and furnished by the customer. The Martin-Decker Dynaline tension system is to be supplied by the customer. (Panel space is provided in the Remote

Control Console for an analog tension meter.) Al l disconnect switches and equipment necessary to supply voltage are customer-furnished.

FIGURE 2-4. Air Valve Panel

Fig. 2-4.

Item No.

1

TABLE 2-2. Air Valve Panel Components. (Sht. 1 of 2.)

Component Function

Adjustable Ratio Relay Used to set air pressure ratio wherein low pressure

(Throttle) input variations determine high pressure output variations. Set a t 1:6 ratio.

-, - Transducer (Throttle) Electrically operated air valve used for control of

Adiustable Ratio Relav (item 1) . --

Adjustable Ratio Relay I Used to set air pressure ratio wherein low pressure

(Drum B Brake) input variations determine high pressure output variations. Set a t 1:8 ratio.

Transducer Electrically operated air valve used for control of (Drum B Brake)

Solenoid Valve Electrically operated air valve used to control the

(Drum B Clutch) engagement or disengagement of Drum B clutch.

Pressure Switch

(Drum B Clutch)

Air pressure switch used to close contacts a t 80 PSI and above to illuminate DRUM B CLUTCH IN indi-

cator lamp and to close contacts at 10 PSI or below to illuminate DRUM B CLUTCH OUT indicator lamp.

Adjustable Ratio Relay Used to set air pressure ratio wherein low pressure

(Drum A Brake) input variations determine high pressure output vari-

ations. Set a t 1:8 ratio.

Transducer Electrically operated air valve used for control of

(Drum A Brake) Adjustable Ratio Relay (item 7). .- Solenoid Valve Electrically operated air valve use to control the

(Drum A Clutch) 1 enqasernent or disensaqement of Drum A clutch

Pressure Switch

(Drum A Clutch)

Air pressure switch used to close contacts a t 80 PSI and above to illuminate DRUM A CLUTCH IN indi-

cator lamp and to close contacts a t 10 PSI or below

to illuminate DRUM A CLUTCH OUT indicator lamo.

Air Regulator with Used to regulate air supply pressure for the Trans- gauge. ducers (items 2, 4, and 8) and the engine-shutdown

solenoid valve. Set at 20 plus or minus 2 PSI. .- the air from the air tank to the system

air regulator (item 13).

Air Regulator with Used to regulate the operating air pressure into the gauge. winch air system. Set at 125 PSI.

3 TABLE 2-2. Air Valve Panel Components. (Sht. 2 of 2.)

Fig. 2-4 Item No.

14

Transducer (System Pressure gauge)

Component

Air Lubricator

15

Transducer (Drum A Brake Pressure

gauge)

Transducer (Drum B Brake Pressure

gauge)

Air Regulator with guage

Function

Used to provide lubrication to air supply.

Used to regulate air supply pressure for the Solenoid

Valves (items 5 and 9). Set a t 90 to 95 PSI.

Used to convert air pressure variations to electrical signals for use by the electrically-operated SYSTEM PRESS gauge.

Used to convert air pressure variations to electrical signals for use by the electrically-operated DRUM A BRAKE PRESS gauge.

Used to convert air pressure variations to electrical

signals for use by the electrically operated DRUM B

BRAKE PRESS gauge.

FIGURE 2-5. Control Valve Panel

2-1 1

TABLE 2-3. Control Valve Panel Components

I I / mission direction cvlinder. 1

Item No.

1

1 2 1 Air Regulator (Reverse) I Used to regulate air supply pressure for the trans- 1

Component

Air Regulator (Forward)

I I I engine air starter. I

Function

Used to regulate air supply pressure for the trans-

3

4

1 5 / Air Regulator Oiigh) Used to regulate air supply pressure for the transmission speed range cylinder. I

regulate air supply pressure for the transmission speed range cylinder.

-"

Air Regulator (Low) Used to regulate air supply pressure for the trans-

Solenoid Valve

Air Regulator

I 1 \ mission speed range cylinder. I

mission direction cylinder. .-

Electrically operated air valve engine air starter.

Used to regulate the operating air pressure to the

SECTION Ill OPERATION

3-1. INTRODUCTION.

3-2. This section of the manual provides instructions for preparing the DMW-150 Mooring Winch for starting, operating, and shutdown. I t is recommended that the operator carefully review the instructions provided before operating the winch.

3-3. START-UP PROCEDURE.

3-4. To prepare the winch for operation:

Perform daily inspections as outlined in Section IV, paragraph 4-3 of this manual. Check to ensure that both drum ratchet pawls are in the desired operational position. Check to ensure that both drum brakes are set. DRUM A and DRUM B BRAKE SET potentiometer turned in full counterclockwise position. Check to ensure that both drum clutches are in the desired operational position. Check to ensure that ENGINE OFF-ON-START switch is in OFF position.

Check to ensure that TRANSMISSION REV-NEUT-FWD switch is in NEUT position. Check to ensure that THROTTLE SET potentiometer is in full counter. clockwise position. Check to ensure "Lockout" switch on junction box is in "operate" position. Check to ensure that clean lubricated air is available a t 125 PSI. Assure that vessel electrical power is available. Turn PANEL POWER switch to ON position. Check to ensure that a l l gauge lamps are illurninated. Should any lamp fail to illuminate, refer to Section VII of this manual for corrective action. Check operating condition of the indicator lamps for the ratchet pawls and drum clutches by depressing the PRESS TO TEST pushbutton. All indicator lamps should illuminate. Should any lamp fail to illuminate, refer to Section VI1 of this manual for corrective action. Check to ensure that indicator lamps are illuminated for the desired operational position of the ratchet pawls and drum clutches. I f the correct lamp is not illurninated, refer to Section VII of this manual for corrective action. The engine can now be started by placing the ENGINE OFF-ON-START switch in START position. The ENGINE switch will return to ON Position when released.

p. After the engine has started, the gauges should show the following indications:

TRANSMISSION DRIVE OIL PRESS-Should be 130 to 140 PSI a t 1500 engine RPM when the output is stalled.

TRANSMISSION OIL TEMP-Normal operating temperature range is 180 to 200 degrees F. The temperature should never be allowed to exceed 250 degrees F.

SYSTEM PRESS-Should read 125 PSI for normal operation.

ENGINE WATER TEMP-Normal engine coolant temperature i s 160 to 185 degrees F.

ENGINE OIL PRESS-Minimum pressure a t 1200 RPM is 25 PSI and a t 2100 RPM it is 30 PSI. The pressure should not fall below these pressure levels and normal operating pressure should be higher.

3-5. OPERATING PROCEDURES.

3-6. The following information relates the proper procedures for operation of the winch. Motor controlling operation is available in three speeds in both inhaul and payout

directions. Operation of either drum on the winch is similar. Therefore these procedures detail operation of a single drum ( D n m A) only. Simultaneous operation of the drums is

) the operator's prerogative as is mooring strategy, and is therefore no$ included in this manual.

NOTE

Should indications other than those detaiied in these procedures be noted, refer to Section VII for corrective action.

3-7. Payout Procedure-Motor Controlled.

3-8. To operate the winch with motor controlling in payout direction:

NOTE

Do not exceed normal inhaul line speeds when paying out under control of the diesel engine.

a. Assure that Start-up Procedure has been performed. b. Select operating speed by placing TRANSMISSION 1ST-2ND-3RD switch in

desired gear range position. c. Engage the d ~ m clutch by placing DRUM A CLUTCH switch in IN positon.

When clutch is fully engaged. DRUM A CLUTCH IN indicator lamp will

illuminate.

I f ratchet pawl is engaged (Pawl IN indicator lamp illuminated), release

drum pawl. (Refer to paragraph 3-13 for details.)

CAUTION

Do not attempt to select forward or revers transmission direction while drum is turning.

Place TRANSMISSION REV-NEUT-FWD switch in FWD position.

Increase throttle by turning THROTTLE SET potentiometer clockwise and release drum brake by turning DRUM A BRAKE SET potentiometer clockwise until desired payout speed is reached. After desired length of wire rope has been payed out, decrease throttle by turning THROTTLE SET potentiometer to full counterclockwise position and set brake by turning DRUM A BRAKE SET potentiometer to full counterclockwise position. Place TRANSMISSION REV-NEUT-FWD switch in NELJT position. Disengage drum clutch by placing DRUM A CLUTCH switch in OUT position. When clutch is fully disengaged, DRUM A CLUTCH OUT indicator lamp will illuminate.

3 3-9. Payout Procedure-Brake Controlled.

3-10. To operate the winch with brake controlling in payout direction:

CAlJTION

Do not exceed 2400 FPM payout under brake control.

a. Assure that Start-LJp Procedure has been performed.

b. I f ratchet pawl is engaged (PAWL IN indicator lamp illuminated), release pawl. (Refer to paragraph 3-13 for details.)

c. Disengage drum clutch by placing DRUM A CLU'TCH wi tch in OUT position. When clutch is fully disengaged, DRUM A CLUTCH OlJT indicator lamp will illuminate.

d. Release drum brake by slowly turning DRUM A BRAKE SET potentiometer clockwise until wire rope is paying out at desired speed.

e. After desired length of wire rope has been payed out, set brake by turning DRUM A BRAKE SET potentiometer to full counterclockwise position.

3-1 1. lnhaul Procedure.

3 3-12. 'To operate the winch in inhaul direction:

a. Assure that Start-up Procedure has been performed. b. Select operating speed by placing TRANSMISSION 1ST-2ND-3RD switch

in desired gear range position.

c. Engage the drum clutch by placing DRUM A CLUTCH switch in IN position. When cl i~tch is fully engaged, DRUM A CLUTCH IN indicator lamp will illuminate.

d. If ratchet pawl is engaged (PAWL IN indicator lamp illuminated), release drum pawl. (Refer to paragraph 3-13 for details.)

CAUTION

Do not attempt to select forward or reverse transmission direction while drum is turning.

e. Place TRANSMISSIQN REV-NEUT-FWD switch in REV position. f. Increase throttle by turning THROTTLE SET potentiometer clockwise and

release drum brake by turning DRlJM A BRAKE SET potentiometer clockwise until desired inhaul speed is reached.

g. After desired length of wire rope has been hauled in, decrease throttle by turning THROTTLE SET potentiometer to full counterclockwise position and set the drum brake by turning DRUM A BRAKE SET potentiometer to full counterclockwise position.

h. Place TRANSMISSION REV-NEUT-FWD switch in NEUT position. i. Disengage drum clutch by placing DRUM A CLLJTCH switch in OUT position.

When clutch is fully dkengaged, DRUM A CLUTCH OUT indicator lamp will illuminate.

3-73. Ratchet Pawl Operation.

3-14. To operate the ratchet pawl:

NOTE

This procedure requires two people-one at the winch and one at the control console.

a. With the drum stationary, set the drum ratchet pawl by manually engaging pawl using the lever provided on the winch. To fully engage pawl, inhaul slightly until pawl drops into flange lug pocket. Payout slightly until pawl face contacts the flange lug face and the PAWL IN indicator lamp illuminates.

b. Release the pawl manually by using the lever provided on the winch. Inhaul slightly until the pawl fully disengages and the PAWL QUT indicator lamp illuminates.

9 3-15. SHUTDOWN PROCEDURE.

3-16. Operating conditions, maintenance, lubrication or other purposes may require that

the winch be secured from operation. Shutdown may be performed as follows:

Set drum brakes. Verify that clutches are disengaged. CLlJTCH OUT indicator lamps should

illuminate. For added security during shutdown, ratchet pawls may be engaged. Refer to paragraph 3-13 for Ratchet Pawl Operation. Position the THROTTLE SET potentiometer in full counterclockwise position. Place the TRANSMISSION REV-NEUT-FWD switch in NEUT position. Place the ENGINE OFF-ON-START switch to OFF position. Turn PANEL POWER switch to OFF position. Turn "Lockout" switch on junction box to "lockout" position.

SECTION I V INSPECTIOI\LS

4-1. INTRODUCTION.

4--2. This section covers those inspections necessary to ensure that the equipment remains in optimum working order. Inspections wil l be divided into daily, weekly, monthly

and semi-annual frequencies. Severe operating conditions or long duty cycles may warrant

conducting these inspections more frequently than specified.

WARNING

Before performing these inspections, isolate the winch from the Remote Control Console operation by setting the "Lockout" switch a t the junction box to "Lockout" position. Also, lock out the customer-furnished disconnect switch supplying control voltage t o the

Remote Control Console.

4-3. DAILY INSPECTIONS.

4-4. Perform the following inspections on a daily basis:

Lubricate as specified in Section V.

Make a "walk around" inspection. Check for obvious misalignment of rods,

arms, and pivots. Check for rubbing of wiring and piping.

Check engine and transmission coolant supply.

Check engine fuel supply.

Check engine and transmission oil level.

lnspect the engine and transmission for signs of oi l leakage.

Inspect all gears for a protective grease coating.

lnspect the clutches per vendor instructions in Section VIII.

4- 5. WEEKLY INSPECTIONS.

4-6. Perform the following inspections on a weekly basis:

a. Lubricate as specified in Section V.

b. Check piston rods on the clutch actuator, transmission actuators, throttle actuator, and brake actuator for signs of scoring or pitting. Refer to Section Vl I1 for applicable vendor data.

c. lnspect clutch lining per vendor instructions in Section VIII.

3 4-7. MONTHLY INSPECTIONS.

4-8. Perform the following inspections on a monthly basis:

a. Lubricate as specified in Section V. b. Check brake lining for excessive wear. Adjust or replace worn linings as

required. Refer to Section VI, paragraph 6-6 for adjustments. C. Inspect a l l air system actuators, valves, lines and connections for air leakage.

Repair or replace as required. Refer to Section V l l l f o r applicable vendor data. d. Check hydraulic lines and fittings for leakage. Repair or replace as required. e. Perform inspections of the engine as specified in the engine manual. f. lnspect Deublin Union on clutch per vendor instructions in Section VIII.

g. Inspect clutch actuators per vendor instructions in Section VIII.

4-9. SEMI-ANNUAL INSPECTIONS.

4-10. Perform the following inspections afzer the first 100 hours of operation, at a maximum of every 500 hours thereafter or semi-annually:

a. Perform inspections of the engine as specified in the engine manual. b. Perform inspections of the transmission as specified in the transmission

manual. c. Check space heaters for proper operation, security of mounting and terminal

condition. Repair or replace as required. d. Check for loose or corroded terminals and connections and frayed or damaged

wire. Repair or replace damaged wire, wire connectors and tighten all loose connections. Remove corrosion and repair or replace terminal blocks.

SECTION V LUBRICATION

5-1. INTRODUCTIQN.

5-2. Lubrication a t prescribed intervals is one of the most important preventive maintenance procedures for the winch. Components receiving inadequate lubrication or improper lubricants are more apt to cause problems and subsequent downtime for the equipment. This section will provide instructions for keeping the winch properly lubricated.

WARNING

Before performing these lubricating procedures, isolate the winch from remote control operation by setting the "Lockout" witch a t the junction box to "lockout" position. Also, lock out the customer- furnished disconnect switch supplying control voltage to the Remote Control Console.

5-3. DMW-150 LUBRICATION.

5-4. Figure 5-1 locates the lubrication points on the DMW-150. I t also describes the location, theifrequency of application recommended for normal operating usage, and the type of lubricant to be used.

5-5. Recommended lubricants for the winch are Standard Oil Products. However, if other products are more readily available, or preferred by the user, equivalents may be used.

5-6. Lubricants recommended are based on ambient operating temperatures of 20 to 125 degrees F.

FIGURE 5-1. DMW-150 Lubrication Diagram

5-2

SECTION VI

MAINTENANCE

6-1. INTRODUCTION.

6-2. This section of the manual furnishes instructions for preventive and corrective maintenance. Preventive maintenance adjustments should be made whenever indications have

been noted that a system or component is not functioning normally or is out of adjustment.

Additionally, this section contains guidelines for accomplishing corrective maintenance,

6-3. For adjustment and repair information on systems and/or components not manufactured by Skagit Corporation, refer to Section V l l l of this manual for the applicable

vendor data.

6-4. ADJUSTMENTS.

6-5. Air System.

6-6. Refer to Figure 6-1, Valve Panel Assembly, and Figure 6-2, Control Valve Panel Components; Air Schematic, dwg. no. 5564505, and Winch Wiring Diagram, 5564503.

The air tank safety valve should be set a t 175 plus or minus 5 PSI. See Bendix-Westinghouse insert.

Winch air supply regulator (item 13 on Figure 6-1) should be set a t 125 PSI.

See Wabco insert. Clutch air supply regulator (item 15 on Figure 6-1) should be set a t '

90-95 PSI. See Wabco insert.

Throttle and brake air supply regulator (item 1 1 on Figure 6-11 should be

set a t 20 plus or minus 2 PSI. See Wabco insert. Throttle adjustable ratio relay valve (item 1 on Figure 6-1) should be set a t

1:6 ratio. See Fairchild insert.

Drum B brake adjustable ratio relay valve (item 3 on Figure 6-1) should be

set at 1:8 ratio. See Fairchild insert. Drum A brake adjustable ratio relay valve (item 7 on Figure 6-1) should be

set a t 1:8 ratio. See Fairchild insert. Engine starter air regulator (item 4 Figure 6-2) should be set a t 120 PSI. See Wabco insert. Transmission gear range pressure regulators (items 5, 6, and 7 on Figure 6-2) should be set a t 20 PSI. See Wabco insert. Transmission direction pressure regulators (items 1 and 2 on Figure 6-2) should be set a t 56 PSI. See Wabco insert.

1. Adjustable Ratio Relay 7. Adjustable Ratio Relay 13. Air Regulator 2. Transducer 8. Transducer 14. Air Lubricator 3. Adjustable Ratio Relay 9. Solenoid Valve 15. Air Regulator 4. Transducer 10. Pressure Switch 16. Transducer 5. Solenoid Valve 11. Air Regulator 17. Transducer 6.. Pressure Switch 12. Air Filter 18. Transducer

FIGURE 6-1 Valve Panel Assembly

6-2

"I. Air Regulator ? Air Regulator

3. Solenoid Valve 4. Air Regulator

5. Air Regulator

6. Air Regulator 7. Air Regulator

FIGURE 6-2. Control Valve Panel Components

6-3

NOTE

The following adjustments must be made with the

component removed from the winch and tested sepb

rately using a closely-controlled air source and a re-

sistance measuring meter. Refer to Winch Wiring

Diagram 5564503 and Custom Components vendor

insert for switch contact locations and adjustment

procedures.

k. Drum B clutch dual pressure switch (item 6 on Figure 6-1) should be set

a t 10 PSI for the low l imit (2PSW-18 position on l imit switch for Clutch

Out) and 80 PSI for the high limit (2PSW-1A positon on l imit switch for Clutch In).

I. Drum A clutch dual pressure switch (item 9 on Figure 6-1) should be set a t 10 PSI for the low l imit (IPSW-1B position on l imit switch for Clutch Out) and 80 PSI for the high l imit (1PSW-1A position on l imit switch for

Clutch In).

6-7. Drum Band Brake.

6-8. To compensate for normal brake lining wear, brake lining replacement and/or

brake actuating cylinder or brake spring replacement:

a. Check band brake contact clearance.

NOTE

Two persons will be required-one a t the winch and one at the control console-to make this maintenance

check.

1. Engage the ratchet pawl. (Refer to Section I l l , paragraph 3-13 for

Ratchet Pawl Operation.)

2. Place the ENGINE OFF-ON-START switch in OFF position.

3. Release drum brake.

4. Check clearance between brake wheel and lining around complete contact surface. Clearance should be 1/16 to 1/8 inch.

5. I f clearance is not within specified tolerance, refer to Figure 6-3 and

adjust by loosening outside jam nut (4) and tightening inside jam nut

(3) to take up excess clearance between the lining and the brake wheel.

b. Check brake spring length. Reference Brake Installation P/L and dwg. no.

5564338, Section VI I.

1. After brake clearance has been set, refer to Figure 6-4 and check

length of compression brake spring (3).

1. Brake Band Assembly 2. Adjusting Rod

3. Jam N u t 4. Jam Nut

F I G U R E 6-3. Drum Brake Adjustment

FIGURE 6-4. Drum Brake Spring Adjustment

2. Measure brake set spring length between the inside faces of the spring keepers. This should be 19.8 plus or minus 114 inch. I f not within specified tolerance, turn spring keeper (2) and hex nut (1) to bring spring to tolerance length. Lock in place with hex nut (1).

6- 9. Clutch.

6-10. I f inspection or performance indicates that the clutch is out of adjustment, refer to vendor insert in Section V l l l for operation, maintenance and pans replacement information.

6-1 1. Drive Chain.

6--12. The drive chain, when properly adjusted, should have approximately 518 inch of slack. For drive chain adjustment, refer to Figure 6-5 and proceed as follows:

a. Remove inspection cover (1) to'check amount of slack in chain. Refer to Figure 6-6 for procedure to use in determining proper slack in chain.

b. I f there is excessive chain slack, loosen jam nuts (3) and loosen the six clamps holding the power unit frame to the main frame.

c. Turn adjusting bolts (2) equally until approzimately 518 inch of slack remains in the chain.

d. Tighten jam nuts and the six clamps holding the frames together and replace the inspection cover.

6- 13. Levelwind Mechanism.

6-14. For correct chain adjustment refer to Figure 6-6. I f the levelwind sheave and the spooling of the wire rope on the drum are out of phase, refer to Figure 6-7 and proceed as follows:

a. Pay out line until the fleeting angle is nearly zero degrees and side loads on the levelwind sheave have been reduced.

b. L.oosen lock nut (2) on end of worm shaft.

WARNING

Be careful to avoid the spinning clutch handles when wire rope is a t an angle of more than 1 degree with the centerline of levelwind sheave.

c. Disengage the clutch by pulling on clutch handles (1).

1. Inspection Cover

2. Adjusting Bolt

3. Jam Nut

FIGURE 6-5.. Drive Chain Adjustment

6-8

Accurate alignment, proper chain tension, good lubrication, and periodic inspection are required to obtain maximum chain and sprocket life. Chains may be easily and accurately installed and sprockets checked in the following manner:

DETAIL 1 -. Sprocket Alignment Check

Sprocket Alignment - Sprockets must be in axial alignment for correct chain and sprocket tooth engagement. Apply a straight edge or heavy cord to the mach- ined sprocket surfaces as shown in Detail 1. When a shaft i s subject to end float, the sprocket should be checked for alignment in the normal running position. Repair or replace sprockets out of alignment.

DETAIL 2 -- Inserting Connecting Link

Chain Installation .- Inspect chain to make sure it i s free from dirt or grit before installing. Fit the chain around both sprockets before bringing the free ends together on one sprocket as shown in Detail 2. Insert connecting link and secure in place.

Sag in inches based on 2% of sprocket centers

Shaft centers, / 20 1 30 1 40 150 ( SO 170 'vc inches I I I I I I I Sag. inches 1 112 1 518 1 718 ( 1 / 1.1141 1..5/8) 1.5/8/ 1..7/8

DETAIL 3 - Determining Chain Sag

Shaft csnrerr, inches

Chain Tension - Normally, horizontal and inclined drives should be installed with an initial sag equal to approximately 2 per cent of sprocket center distance. Vertical center drives and those subject to shock loading, reversal of rotation, or dynamic braking, should be operated with both spans of chain, almost taut. Periodic inspection of such drives should be made to avoid operation with excessive slack and to maintain proper chain tension. 1 To determine the amount of sag, pull one side of the chain taut allowing a l l the excess chain to accumulate in the opposite span. As illustrated in Detail 3, place a straight edge over the slack span and, pulling down a t the center, measure the amounr of sag. If necessary, adjust chain for proper chain tension by removing or inserting links in the chain. The table in Detail 3 provides proper sag informatior for horizontal or inclined drive chains.

100

On double reduction type drives where two drive chains are used, the center sprockets are mounted in an adjustable pillow block mount. The pillow block position may be adjusted to provide equal tautness in both drive chains. When removing links from one chain, adjust the pillow block position to compensate for any differences in tautness between the two drive chains.

Sag, inches

FIGURE 6-6. Chain Adjustment 6-9

125 150 2 2.'112 3

CAUTION

Do not attempt to align levelwind by means of the handwheel. Use the square end-plate on the levelwind

driveshaft end for alignment.

d. Rotate the worm shaft, by using retainer (3) a t the end of the shaft, until the

levelwind sheave and wire rope are aligned.

e. Re-engage clutch. f. Tighten lock nuts (2).

6--15. Air Line Lubricator. (Refer to Figure 6-1 .)

6-16. The air line lubricator (item 14) should be adjusted for a flow rate of 2 drops of

oil per actuation of the largest air user on the machine (such as the band brake). This will be adequate to lubricate other items satisfactorily. To adjust, refer to vendor insert in

Section VI I l and adjust as required.

6-17. Multiple Feed Oiler.

6-78. The multiple feed oiler should be adjusted for a flow rate of one drop per minute. To adjust, refer to vendor insert in Section V l l l and adjust as required.

6-19; Electrical System. (Refer to drawing 5564422, Section VII.)

6-20. Assure that the output voltage of the power supply a t the Lower lntra Panel (Figure 2-3) is 12 VDC. Set the voltage for the Drum B Brake Control, Drum A Brake Control and Throttle Control to 9V by adjusting resistors R-IA, R-2A, and R.3A with con-

sole controls R-10, R-20, and R-30 in fully clockwise position.

6-21. CORRECTIVE MAINTENANCE.

6-22. Isolate the trouble to a specific component or system with the help of the

Troubleshooting Guide, Table 6-1. Remove faulty part and repair or replace it. Replacement parts data are provided by the Illustrated Parts List, Section VII and Purchased Components

Data, Section VIII.

WARNING

Before removing a faulty part for repair or replace-

ment, isolate the winch from remote control operation by setting the "Lockout" switch a t the junction

box to "lockout" position. Also, lock out the customer-furnished disconnect switch supplying control voltage to the Remote Control Console.

-. . . - . - - - . . - - -

1. Handles 2. Lock Nuts 3. Retainer

FIGURE 6-7: Lwelwind Clutch Assembly

6-1 1

3 6-23. Troubleshooting Guidelines.

6-24. See Table 6-1 for aid in determining, isolating and correcting equipment malfunc. tions.

6 2 5 . Where electrical circuits, components or interconnections are a t fault, troubleshooting and repair should be performed only by qualified personnel familiar with Ladder

Logic circuit diagrams. Electrical schematics, wiring diagrams and interconnections are illustrated in Section VII.

6-26. The following items should always be checked before proceeding with further troubleshooting:

a. Check for correct air pressure input of 125 PSI to the winch air tank. b. On winch junction box cover, check that Lockout switch is positioned for

normal operation.

TABLE 6--1. Troubleshooting Guide. (Sht. 1 of 3.)

Malfunction

Engine operating but transmission is

lo t .

Transmission run- ing hot or irregular.

- Transmission out-

put shaft operating but driveshaft is not.

Driveshaft turning but intermediate shaft is not. - Drum. does not rotate or is erratic.

Corrective Action

a. Engage transmission. b. Check transmission actuating cylinders for damage, leakage, and

condition. Repair or replace per vendor insert in Section Vl l l . c. Check transmission pressure regulators for proper setting. Refer

to Section VI, paragraph 6-4 for adjustments. d. Check transmission solenoid valves for proper operation, condition

and security of electrical connections. Repair or replace per

vendor insert in Section VIII. e. Troubleshoot transmission electrical circuits. Refer t o Section VI I

for electrical schematic and wiring diagrams. f. Refer t o transmission manual.

a. Add oil to proper level. b. Engage transmission. c. Check transmission direction actuating cylinder for damage, leak-

age, and condition. Repair or replace per vendor insert in Section VIII.

d. Check transmission direction pressure regulators for proper set: ting. Refer to Section VI, paragraph 6-4 for adjustments.

e. Check transmission direction solenoid valves fpr proper operation, condition and security of electrical connections. Repair or replace per vendor insert in Section V l I I.

f. Troubleshoot transmission electrical circuits. Refer to Section VI I for electrical schematic and wiring diagrams.

g. Refer to transmission manual. - ---. - a. Replace sheared key. b. Repair broken chain. c. Replace faulty sprocket.

a. Replace sheared key. b. Replace faulty pinion.

c. Replace faulty gear.

a. Adjust clutch per vendor instructions in Section VI I I. b. Check clutch actuator for proper operation, hydraulic fluid level,

and damage. Repair or replace as required per vendor insert in Section VIIl,and/or f i l l hydraulic reservoir per instruction in Section V.

c. Check air and hydraulic lines for breaks, leaks, and damage. Re- pair or replace as required.

6-13

TABLE 6-1. Troubleshooting Guide. (Sht. 2 of 3).

Malfunction

)rum does not otate or is rratic.

)rum brake, :lutch ahd throttle ill not operate.

4ir pressure avail- ible but drum brake Nill not operate

- 4ir pressure avail- ible but drum :lutch wil l not lperate properly.

Corrective Action

j. Check clutch pressure regi~lator and pressure switch for proper

setting. Refer t o Section VI, paragraph 6-4, for adjustments.

. Check clutch solenoid valve for proper operation, condition, and security of electrical connections. Repair or replace per vendor insert in Section Vi l I.

f. Troubleshoot clutch electrical circuits. Refei t o Section V I I for electrical schematic and wiring diagrams.

3. Replace sheared key. il. Refer to transmission manual. i. Refer to engine manual.

a. Check air and hydraulic lines for breaks, leaks and damage. Re- pair or replace as required.

b. Replace system air filter. c. Troubleshoot electrical circuits. Refer to Section VI I for

electrical schematic and wiring diagrams. -- a. Check brake linings for clearance, condition and foreign material.

Adjust or replace as required. Refer to Section VI, paragraph 6-6 for adjustmenp.

b. Check air lines for breaks, leaks and damage. Repair or replace as required.

c. Check brake setting spring and rod for damage. Repair or replace as required.

d. Check brake release actuating cylinder for leakage, damage and condition. Repair or replace per vendor instructions in Section VIII.

e. Check brake pressure regulator and adjustable ratio relay for proper setting. Refer t o Section VI, paragraph 6-4, for adjustments.

f. Check quick release valve for leakage, damage and condition. Re- pair or replace as required per vendor instructions in Section VIII.

g. Troubleshoot brake electrical circuits. Refer t o Section V I I for electrical schematic and wiring diagrams. -

a. Adjust clutch per vendor instructions in Section VIII. b. Check clutch actuator for proper operation, hydraulic f luid level,

and damage. Repair or replace as required per vendor insert in Section V l l I, and/or f i l l hydraulic reservoir per instructions in Section V.

9 TABLE 6 ' 1 . Troubleshooting Guide. (Sht. 3 of 3.)

Malfunction Corrective Action

Air pressure avail- c. Check a i r and hydraulic lines for breaks, leaks and damage. Re- - _ _ = _ _ = = $ - = = able but drum

clutch wi l l not

operate properly.

pair or replace as required

d. Check clutch pressure regulator and pressure switch for proper

setting. Refer to Section Vl, paragraph 6-4 for adjustments.

e. Check clutch solenoid valve for proper operation, condition and security of electrical connections. Repair or replace per vendor

insert in Section VI I I. f. Troubleshoot clutch electrical circuits. Refer to Section V I I for

electrical schematic and wiring diagrams.

Air pressure avail-

able but engine

RPM does not increase properly.

a. Check throttle actuator for 2roper operation and damage. Repair

or replace as required. Refer to vendor insert in Section VIII.

b. Check air lines for breaks, leaks and damage. Repair or replace as required.

c. Check throttle pressure regulator and adjustable ratio relay for proper setting. Refer to Section VI, paragraph 6-4 for adjustments.

d. Check throttle solenoid valve for proper operation, condition and security of electrical connections. Repair or replace per vendor insert in Section VI'II.

e. Troubleshoot throttle electrical circuits. Refer to Section VI I for electrical schematic and wiring diagrams.

f. Refer to transmission manual.

g. Refer to engine manual.

I Levelwind wil l not I a. Engage levelwind clutch.

I operate. b. Replace sheared key. c. Replace or repair drive chain.

Repair or replace damaged levelwind shuttle. --- - Winch functions a. Troubleshoot indicator electrical circuits. Refer to Section V11

I operate normally for electrical schematic and wiring diagrams.

but indicator

1 lamps do not. 1 Equipment will function but indicator lights at

a. Replace faulty lamp. (See note.) b. Replace faulty sender.

1 Remote Control I NOTE: To replace console lamps, remove eight screws holding con- panel fail to illuminate.

. trol panel in place, tilt panel outward for access to bulbs and replace faulty bulb. Qbserve caution to align bulb pins with socket. Replace panel and screws.

SECTION VII ILLUSTRATED PARTS LIST

7-1. INSTRUCTIONS FOR PARTS ORDERING.

7-2. When ordering parts for this mooring winch, be sure to specify the model and serial number of your machine. It is-suggested that you write the model and serial number in the following spaces so that they will be readily available when needed:

MODEL NO.

SERIAL NO.

Be sure to indicate part number, pan name, and quantity desired of each part ordered.

To ensure prompt delivery, be sure to identify the correct name, address, town and state to which the parts are to be shipped. Also indicate the type of shipment to be made. Address al l parts inquiries to the nearest Skagit dealer. I f unknown, send inquiries to the following:

Skagit Corporation P. 0. Box 151 Sedro-Woolley, Washington 98284 Telephone: (206) 855-1 141 Telex: 32-881 5

7-3. PARTS LISTS.

7-4. The following pans lists are included in this section. Refer to drawing of same number for pictorial record.

List Number Title

General Arrangement DMW-150 Frame Air Piping Installation Air Tank Assembly Brake Installation Control Console Installation Control Panel lntra Panel Drum Installation Frame Installation Guard Installation

SECTION V l l l PURCHASED COMPONENTS DATA

8-1. INTRODUCTION.

8-2. This section of the manual contains vendor data. on components purchased by Skagit Corporation for' use in the manufacture of the- DMW-150 Mooring Winch.

8-3. VENDOR' INSERTS.

8-4. A list of the- data included is arranged alphabetically by manufacturer per Table 8-1, Vendor Insem, as, follows:

Manufacrurer 1 Skag~t PIN 1 Vendor PIN Item Descr~ption - .-

A C S~ark Plus Co. 1 5554654 I 6463661 I Transduce:

Air-Maze A14132 I / A15347 I Breather Filter a Breather Filter

Deublin

Bellows-Valvair

Bendix-Westinghouse

Cash Acme

Rotorseal

Fairchild 1 5554655 / T-5109 I Transducer

5568552

5553066

5557660 5557696

5568555

Yibco 1 5567139 1 T-211-% I Globe Valve

i 120 PSI

N325-71-947-115VAC

281923

Mawel

3hmite / 5554650 1 WO-112 I Potentiometer

Solenoid Valve

PV-2 Automatic Reservoir Drain Valve

'arker Hannifin 1 5553073 / ::,203PB-20 I Check Valve 1 5554601 Solenoid Valve

5554656

5555042

Insert I. D. I

221154 Safety Valve 279414 Throttle Cylinder

i 232130 M O ~ J 21 i Adjustable Ratjo Relay

A - l X-50 1 Filter

Cat. sht. 700-425 & 7QO-101

I I

Type "E" Ser 3 1 %

Manual GI Manual 6

Sht. C-3 and C-4

Cat. Sht 9D1 & SD-52 i Regulator

Cat. Sht. 401 Cqt. Sht. 12A1

Bulletin R E G 4

Engr. Dwg. No. 20

PfL for Model 20 Bulletjn No. 8-9-68

4 p. Brochure dwgs. EA-11597 & ED-11189 Cat. Sht. 22760 & 22127

Manufacturer

Rundel

Startmaster

Thermal Products

Trico

Wabco

TABLE 8-1. Vendor Inserts. (Stit. 2 Of 2)

I tem Description

Switch Cat. CU2-74 Switch Cat. CU2-74

Heat exchanger 1 2 Sheets

L ight L ight sw i t ch

Lubricator Air Starter

Oiler 1 5 Sheets

Cat. W?-74 Cat. CU2-74 Cat. CU2-74

Sheet 1420-1 , Sheer 1410-1

Fi l ter Regulator Regulator Lubricator Check Valve Quick Release Ualve Solenoid Valve Solenoid Valve Cylinder Cyl inder Cyl inder Cyl inder

Cat. A6-115.01 Cat. A6-115.01 Cat. 46-1 15.01 Cat. A6-115.01 Cat. Sht. 86-10?.01 Cat. Sht. $5-87.03 Cat. 04-78.00 Cat. $4-78.00 Cat. 83-41 .O1 Cat. Sht. 83-49.16 Cat. Shr. 83-49.21 Cat. S h t A3-36.00

Gate Valve Single Sheet

. . 2 . , SECT~ON.: BREATHERS. , . .. . '

.. . . . : . a . , -

. ' . . PAGE:- 700-425 ' . , . D A T ~ : . . . . FEBRU'ARY 15; 1963 ,, - : .. , . .

.. . - SUPERSEDES. ~ B R U A R Y , 1956, > ; . . , .,

. . . .. L :

, . ". -. .. .

SERVICING: INSTRUCTIONS , "

FOR 01 L-WETTED TYPE: BREATHER F l LTERS

Tb OPERATE E F F I C I E N T L Y AND WITH. M I N I HUM- R E S I S T A N C E TO A I R FLOW, AN, O I L

WETTED ~ Y P E DUEATHER, FILTER MUST BE CLEANED AND RECHARGED WITH 01 L AT

REGULAR. INTERVALS DETERMINED B Y OBSERVATION., WHEN THE OUTSIDE SURFACE . .--

OF THE ELEMENT APPEARS TO BE EVENLY COATED WITH DIRT, IT SHOULD. BE:

CLEANED AND RECHARGED AS. FOLLOWS: '. ' 4 1 .. WHERE POSSIBLE, REMOVE HOOO AND ELEMENT... (SOME: TYPES-

ARE ONE PIECE. CONSTRUCTION. AND THEREFORE CANNOT BE. D I SASSEMBL~D. 1

2. WASH CLEMENT (OR COMPLETE UNIT) I N A D f T E R G E N T AND WATER

SOLUTION, ANY COMMERCIAL GREASE SOLVENT OR KEROSENE.

3 . SHAKE OR BLOW O F T EXCESS WATER AND ALLOW TO DRY.

4. DIP IN ENOINC o i ~ S A E 3 0 TO SAE50,

5. DRAIN OFF E X C E S S O I L AND REASSEMBLE.

SECTION: BREATHER PAGE: 700-101 DATE: August 15; 1974. SUPERSEDES: 10.15-73

For crankcases o f engines and compressors, gear cases, hydraulicequipment, liquid storage tanks, machinery housings, etc..

Efficient and economical protection fo r air vents against dust . . every housing that has.an air vent should have. the protection of an Air-Maze. Breather Filter. Dusf- or other foreign maner in

,.:m ,,.. nd.rd,l,ril,c.d the air is removed, thus preventing dirt from entering the vented case . . . All-weather Hoodsare- 0. ~ b i * y.m Othrd.-=-ll-- available for outside installation . . . A wide range o f sizes is available along with various typesand

.bI*O" rrquolt, sizes of connections.

Advantages of Air-Maze Breather Filters include:

1. Cylindrical design affords large filter surface area.

2. Filter media is vibration proof

3. Breather filters quickly cleaned by washing.

4. Low-profile models available.

5. Dry type and Oil-wetted models available.

OILWETTED BREATHER FILTERS Dust or foreign matter impinges on oil coated wire baffles and is retained, thus preventing dirt from entering the vented case. . These all-metal models also prevent oil loss from the equipment

VENT SIZE

(Inches)

114MPT 318 MPT' 318 MPT' 318 MPT' 112 MPT 112 MPT 314 MPT 314 MPT 1 MPT 1 MPT 1-114 MPT 1-114 MPT 1.112 MPT 1-112 MPT 1-112 O.D. --

MODEL NO.

A15981 A14132 A 15962 GFOHS A 15349 GCOHS A 15347 GBOHS GAOHS 8 16056 GJOHS 8 17583 GKOHS 816744 8 15800

llustration No.

3 1 3 2 3 2 3 2 2 5 2 5 2 5 5

DIMENSIONS (Inches)

ROTECTED

YES

1-,114 1.114 1.114. 1.114

YES 1-114

YES YES

YES YES YES YES YES

LOW PROFILE BREATHER

114 112

1.114 112

1 114

This "squat type" button breather, similar in design to our model A14132, features a low, compact silhouette. This breather is especially adaptable where compactness is desired or where close clearance requirements are encountered.

(over)

MODEL NO.

(Inches)

( ie. 819929GH)

WEATHER PROTECTED

YES YES YES YES YES

APPROX. SH\k'GT" 114 114 114 114 1 I 4

Illustration No.

1 1 1 1 1

DIMENSIONS [Inches)

A

2.318 2.318 2-318 2.48 2.418

8

112 1.31 1.31 1.44 1.38

Not.gCb1, a o n d d .I=. Il~d; m thJ. p . Othsulrr.nl1-

OIL BATH BREATHER FILTERS (With Automatic Oil Return) ah?. bn r q u n r .

R'ecommendedwheredi~rrconcentration~ is unusually high. Outsideair- is first washed by theoil andfinedirt irremovedby theelement mediabeforeitenten theaankcaseor housing: Oil in the breather forms a positiveseal against outsidedust entering, when the equipment is not operating;

Air-Maze Division Rockwell International

1'

p- A.-i Provides a high degree of filtration of extremely fine dirt particles. Media is suitable! for contin- uous operation a t temperatures ranging from -65O to +25Q°F Easily serviced by washing in a. water and detergent solution.

25000 Miles Road Cleveland. Ohio 44128

r '

Pnnred in U S A

i HIGH EFFICIENCY DRY TYPEBREATHER FILTERS.

-- VENT SlZE (Inches).

318 MPT 112MPT 314 M PT 1 to-ZMPT 1 to 2-112 MPT 1-114 to 3MPT 1-112to 4 MPT

.-- VENT SlZE

(Inches)

118 MPT 114MPT 318 MPT 112MPT 314MPT

MODEL NO.

F8A.OBGF FBA.08GC FBA.OBG8 F88QS FB.140S FB250S F8350S

rn

-- CORROSION RESISTANT BREATHER FILTERS

Corrosive atmospheres and marine applications call for special material. Air.Maze manufactures a wide variety of brass, bronze and plastic breathers for such requirements.

MODEL NO'.

DMGHL DMGGL DMGFL DMGCL DMGBL

318 MPT 112 MPT 318 MPT

illustration (Inches'

- Illustration

No..

3 3 3 3' 3

20071T A17001 200916

WEATHER' PROTECTED

YES YES YES YES YES YES YES

No.

4- 4. 4 4. 4 4- 4-

Sim. to 1 1-1 1/16

Sim.

. APPROX.

SHI:bFFr 1-112 1-11T 1-112 4. 8

12 15

A.

3~13116 3.13116 3-13/16 6 7-5/16 10-11116' 11-112

DIMENSIONS (inches)

I3 4-15/16 4-15/16 4-15/16' 5.518 6-9/16 8.118 9-318

, WEATHER PROTECTED

YES YES YES YES YES

A.

2-318 2-318 2-318 2.318 2-318

APPROX. SHIP. WGT.

(Ibs.)

112' 1 12 112~ 112. 314

B

2 2-118 2-1 I 8 2-1 14- 2-518

ED: INLlME 2-WAY' & 3-W&y'

POPPET-TYPE PILOT..OPERATED LANES. - . INTERNM w0.r SUPPLY 2 . ', , .' ,., . >

' . E:wOUGH; 1-1 /2 IN;. N?lF .C-' . .>..

NORMALLY-CLOSED NORMALLY-OPEN

A S A . SYMBOL i A.S.A. SYMBOL

The Inl ine Poppel Type-Valve-is ideal lor applications whereexlremely rapid re:;ponse IS mandalary. such as brake-and clulch-applications. I t gives l u l l l low pt , I mtl l lsxonds alter aclualion: I t can. also be. used where equipment must

ti111 sde ' '

FUNCTION: 2.WAY-For o n o l l control of I l o w Available- "normally closed" or 'normally.open" lo supply when dewerg ized. Valve shins when ralenoid is ilnergized

3 WAY-Used la operale a s~ngle.actlng cyltnder. NORMALLY CLOSED VALVE hal)intet clorcd to cylinder and cyltnder open to exhaust In deaerg l zed posllion. lnlpt opens to cyltnder and exhaust i s blocked when energized. NORMALLY- OPEN VALVE l!as mlet open lo cylinder(exhaust blocked) In the de.energtzed po!illlon When energized wlet i s blacked. cyllnder open lo exhaust.

PRESSURE LIMITATIONS: AIR. VACUUM OTHER

CURRENT CONSUMPTION: at 115 V-60 cycle:

INRUSH HOLDING.

.. 48 amp. 28 amp.

HClW TO ORDER. . . . - .. -. -- - - - ., ., .- - - - . . - - -- - -. - - . ., ,- - - , Select lhe hasx valve model num- 0. BASIC MODEL NUMBERS i NORMALLY-CLOSED T"--~RMALLY-OPEN ber lram lahlenumber Q l a the i f l v l ~ t Conlplclethecenler and l ina l elc~ncnts o l !he model number (in. 2.WAY VALVE : N 3 2 5 - - 0 1 e W 8 1 P I , [email protected]

d m l c d hv thecolored blocks) wl lh 3.WAY VALVE i N 3 6 5 - ~ & - m H m . I N385--~-.... the correct numbers laken tram (he. . L-.. - - ... . . .- --

?!en t ~ ~ l o w

-.e:f;-- . ., -. . . -- .. . . - ----- -. .. . , - -- 7--..-.--- ' - - 1%" BASIC

Cocipletc Ihe-cenler lwo dtpits o l !

tl!e model nuniber by replacing the @ P I L O T VALVE OPTIONS 1%" EXH. I 16" EXH. 1 Ibj" EXH. two blue hlocks rill! !he lwo d ~ g ~ l s shorn in table number 0 lor the V : OTHER PORTS!OTHER PORTS'OTHER PORTS desired valve sire lapping and ( 1' NPTF 1%" NPTF 1%'' NPTF pllqt opttons 1 i

BASIC PILOT VALVE -91- -5IICb-

., . BASIC PILOTVALVE w/NON-LOCKING 0VER.RIDE - -82- ' -92-

Com~tn le ihe model number by 18. BASIC PILOT VALVE wILOCXING OVERRIDE P~;~I:I~R tne I I ~ I three black blocks JUNCTION BOX PILOT VALVE -74- j -4- -M-. wll l l the threed! $1 ru l f ix shown in lahlc number (!J lor the derired lUNCTlON BOX PILOT VALVE w/NON'LOCKING OVER.RIOE ! -1% -8% : -95- YAII!~ lunction and p,lot a p l m

JUNCTION BOX PILOT VALVE w/LOCKING OVER..RIDE 1 -76- ! -86- ' 46- SPECIFY "VOLTACE AN0 CYCLV .. -. . .---.---- 1 ------ ! FOLLO\YI1IC THE MODEL MUM.. BE&. tor Example: Order "Model 11325 71 047 wdlh 115 V. €4 cycle - .- -- - salcnotd ' PILOT

For best perlormanee and service @ FUNCTION ' " use clean, motsturelree. lu.

.ated air See pages F.9 and INTERNAL PILOT SUPPLY. SEPARATE I Ill lor proper slze Lubr!.A~r@ PILOT EXHAUST Ittlw teculalar, lubr~calor unil. , - . , ,. _ _ -_ -- .

25-125 PSI

B.F.GQODRICH AEROSPACE & DEFENSE PRODUCTS A Division o f TheB.F.Goodrich Company

Wheel and Brakeplant Troy, Ohio

MANUAL GI

OPERATION, MAINTENANCE, AND OVERHAULOF 6.F.GOODRICH EXPANDER TUBEBRAKES FOR

INDUSTRIAL EQUIPMENT

ISSUED: 2 4 A ~ r i l 1957 REVISED: 19 March 1975

THIS MANUAL IW'IACES THE KEVISION OF 26. OCTOUER 1972 AND IS TO BE USED WITH THE B.F.GQODKICH PARTS CATALOG FOR

THE SPECIFIC MODEL BRAKE BEING MAINTAINED.

Manual GIH

4 2

LlSTQF REVISED PAGES ISSUED b

.. Insert 1.atwt Rsised Pagcs. Destroy Snperseded Pagea.

NOTE: The portion of t h e text affected. by the current rcvimon in indicated by a vertical line in the. 1 outermargin of the page.

f:

PqcNo. Date of Latest Revision -,

"Title.. . . . . . . . . . . . . . . . . . . . . I0 March 1975 *ii . . . . . . . . . . . . . . . . . . . . ., . . .. I9 March 1975

1 . . . . . . . , . . . . . . . . . .. . . . . . . 6 January 1971 2 . . . . . . .7.. . . . . . . . . . . . . . . . 1 May 1967 3 . . . . . . . . . . . . . . . . . . . . . . . 1 November 1963 4 . .. . . . . . . . . . . . . . . . . . , . . . . 1 November 1963 5 . . . . . . . . . . . . . . . . . . . . . ... 1 May 1967 6 . . . . . . .,. . . . . . . . . . . . . .. . I May 1967 7 . . . . . . .. . . .. . . . . . . . . . . . . 24 October 1972. 8 . .. . . . . gF-. . ... . . . . . . . . . . . . 24 October 1972 8 A . . . . . . . . . . . . . . . . . . . . . . . 24 October1972 9 . . . . . . . . . . . . . . . . -. . . . . . . 18 December 1967

'1 10 . . . . . . . . . . . . . . . . . . . . . . . . 1 May 1967 *1 I . . . . .. . . . . . . . . . . . . . . . . . . . 19 March 1975

The aatrria indicltes pagcs reviscd, d~dded, or deleted Ly the current revision. 8

** The letter,G denutes grwnd vehicle publications as distiWlislred fwnl otilers. This typographic change has beenmade (11' all pages.

bviaed: 19 March 1975

Figure 1 . Expunder Tube Bmke

1 DESCRIPTION

The expander tube brake is of the- 360' segmented, shoe type, actuated by an expander tube. Its components include a cast torque plate (10) upon which the expander tube (7) is mounted and an inlet connection (&)- into which the nozzle of theexpander tube is inserted. Steel side frames with welded steel torque bars (6) are attached to both sides of the torquc plate Brake linings mounted on stccl shocs (2) are inserted between the torque bars and side frames and held in position by revacting springs (I). Steel shields ( 3 ) are used to briiige the gap between shoes and protect the expander tube. The springs inserted under the center of the linings and over the steel brake shoes withdraw the block and. shoeassemblies from the surface of the- brake drum after the actuation pressure has been released.

CAIlTIQN The inlet connection must bt: in the 12 o'clock positio~~ with inlet port facing veliicle when installed.

2 OPERATION

The brake is actuated by hydraulic pressure which enters thrwgh the hole oi the inlet connection (8) and llows through the nozzle into the expander tube (7) Pressure is exerted 360' around the expander tubc, forcing the block and shoe assemblies (Z), which are hearing against the expander tube, to move radially against the inside diameter oi the brake drum. At the release of actuation pressure, the retracting springs ( I ) force the hydraulic h i d from the expander tube and insure fast positive retraction oi the block and shoe assemblies 1

Kcvised: 6 January 1971 I

........ -. . . . . . . . . . . . . . . . .----- --

Manual GI "

CAUTION, Use only approved oils. See paragraph 4 Z for information about hydraulic oils.

3 ASSEMBLY

Unless o~herwise noted, t h e brake is shipped from the factory completely assembled and ready to install on the vehicle Assemble the brakes in reverse order of the applicable exploded view and parts breakdown. -

CMI TI ON Do not apply pressure to the brake when it is not in a drum

4. MAINTENANCE

4.1 PREVEN'I'IVE MAINl'LtNANCE:

4.1.1 Inspect daily to assure that visible frame holts have not loosened, retractor springs +re not broken, and that brakes are not overheating. If brakes arr overheating, refer to trouble shooting

1 chart paragraph 4 . 3 for corrective action.

4.1.2 Frequent inspection should also be made to check lining wear. To check wear, apply brakes and look into the spring openings in the brake frames If the brake shoes tend to shear the springs at a point between the frame and s h w s (approximately 1/8 in space between the top of the spring opening and the ledge or the shoe upon which the spring rests), travel is at a maximum. Replace linings and springs belore t h i s condition is reached Continued operation in this condition will damage rhe brake suucture.

4.2 HYDRAULIC 011.: Ilse only mineral oils to specilications outlined below to actuate B.F. Goodrich expander tube brakes.

WARNING Do not u s e otller fluids, especially avoid using automotive btake fluid a s it is destr~tctive m brakes, master cylinders, and adjusters.

---- -- FIlYSICAL PROPERTIES --

Mote: The aniline point m u s t be- 200°1; minimum. Saybolt llnivcrsal Viscosity at 210°F.. .......... 43 seconds, minimum Saybolt Universal Viscosity at 100°F ............... 145 to 155 seconds Viscosity Index (Dcan and Davis) . . . . . . . . . . . . . . . . . . . . . . . .90 minimum Pour Point (ASTM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-2S°F min' Color (ASTM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . no^ 2 or Lighter Neuualization Number (ASTM) ........................... . O . 10 or less Copper Strip Tes t (Corrosion) 3 Hours . . . . . . . . . . . . . . . . . . . . . . . . 'Negative

at 21Z°F

. *. i z * 'I6 Revised: 1 May 1967

r"3 ;!

. . . . . . . . .___... ..-............. , .............. ........ .....

-

PIIYSICAL PKOP1;.R'l'lLS (Continncd)

Ihulsion T e s t . ~ t 1?O0F, Ilistilled Wnccr: Tiine for Complctc Separation;. ................ .30 m i m ~ ~ c s , maximum

Rust Test (ASTM) Distilled Watcr ........................... No RUSL Oxidation. Tes t (ASTM):

Time to Neutralization' Number 2.0 . . . . . . . . . . . . ,1500 hours, mininwnr I. oam. Tes t (ASTM):

Sequence I, 2. 5 ML Foam After 10.. ........................ .None Minutes Standing

Flash. Point .................................. .:. ..... 370°F minimum Additives: .................................... Additives harmful to

Buna N and neoprene rubber com- pounds will not be

- used.

4.3 TROUBLE SHOOTING:

Note This chart covers trouble shooting for master cylinders and in-line adjusters used with expander tube brakes as well as the expander tube brakes covered in this manual.

Brakes dragging or

I I

IUR OVER HYDRAULIC ACTUATING SYSTEM

POSSIBLE CAUSE CORRECTION - Air trapped in hydraulic actuating Bleed system and brake in accordance

system. with paragraph 4 4.

Residual air pressure at rotochamber. Check air system to insure zero pressure - at rotochamber.

Rotochamber retraction obstructed. Inspect rotochamber to insure full re-

- traction.

Master cylinder power piston not re- Inspect cylinder bore and power piston tracting. OD tor burrs, chips, or other obsrruction

-- -- and correct.

Master cylil~der floating piston not Inspect cylinder bore and floating piston retracting 011 for burrs. chips, or other obstruction

---. -- and correct.

Return sprimg hetween master cylinder Seat spring in p o v c on end of each pistot~s out. or engagement. - I broken or liattmcd brake retracting Cotnpa~e spring arch with new spring and spring. replace flattened or brokcn springs

with complete s e t of twelve. ___________

sert blunt tool into small hole in face of piston and push inward. If definite movement cannot be obtained, replace with new part.

- TROUBLE -

Brakes will not apply.

I ~acuuUm,trapp;d in reservoir. (lnsure vent air passage

nsuffic~ent oil reserve. l ~ e e p reservoir filled with hydraulic oil as

AIR OVER HYDRAULIC ACTU ATNG SYSTEM (Continued)

piston nor closing.

piston It air passes, replace with new

POSSIBLE. CAUSE

Brakes not bled of a i r allowing master cylinder to hottom.

Rcscrvoir locatcd bclow m a ~ r c r cylindcr restricting oil flow,. -.

Feed-line from reservoir restricted or- too small.

Master cylinder power piston not re ; tractingto seat. closing off inler.

Master cylinder.power piston stuck in cylinder bore.

-

pan.

power piston Replace packing with new B.F.Goodrich. replacement part.

----- Check lines and fittings to insure sealing.

Air pessure a t rotochamber should be not less than 80 psi with brakes applied. Correct air system as required to ob-. tain 80 psi min.

Mastcr cylinder Replace all master cylinder packings. leaking at mount-

CORRECTION

Bleed system andbrakes in accordance with: paragraph. 4 4., -

Relocate reservoir ,hove. mastcr cylinder to ~ l low. gravity feed.

Insure free flow using 5/16 min. ID l i n e without restriction.

Adjust rotochambec push rod attachment as a t l i n e d in Manual 6.

Free piston by removingobstruction. If cylinder wall or piston OD is excessive- ly damaged, replacewith new pan.

ing bracket joint.

Brake leaking. Expander tube nozzle packing not sealing.

If surfacc does not appear satisfactory for sealing, replace connector with new part.

Expander tube leaking. If tube shows definite leak, replace with a new tube.

STRAIGHT HYDRAULIC ACTUATING S YSTFM

I I s e n blunt tool into small hole in face of I

TROUBLE

Brakes dragging or running hot.

Residual hydraulic pressuretrapped in brake system.

In-lineadjuster not working.

Inspect control valve to insure c m p l e t e release. -

Remove floating piston assembly and in-

POSSIBLE CAUSE - Air trapped in hydraulic actuating

system.

-

CORRECTION-'

Bleed system and brakes in accordance with paragraph 4 5.

piston and push inward. If definite move- memt cannot be obtained, rebuild in accordance with Mhnual 20, replacing all defective parts.

Revised: 1 November 1963

STRAIGHT HYDRAULIC ACTUATING SYSTE.M (Continued\ .. . \ ~-~~~

TROUBLE I,

POSSIBLE CAUSE CORRECTION 1 :Brakes dragging or

running hot (Conrinued)

7

I 4.4.5 Do not apply brakes. Open bleeder valve to vent air from brakes. Do not close bleeder valve until flow of Fluid has stopped completely, then close bleeder valve.

Brakes will not apply.

Brake leaking.

-. -.

I! 4.4.6 Reocat 4.4.4-and 4.4.5 until no air can be detected in complete cycle.

Broken o r nattened brake retracting springs.

Improperoil in system causingvapor- izatiorr in brakes.

4.4.7 Actuate brakcs repeatedly until brake shoes contact brake drum. Test by holding hrakes against engine power.

-- - Compare spring arch with new springand

replace flattened or broken springs with complete s e t of twelve.

Purge system, replace all rubber parts, and refill with hydraulic oil a s specified in paragraph 4.2.

-- 4.4. MASTER CYLINDER BRAKE SYSTEM BLEEDING PROCEDUREI 4.4.1 Fill reservoir with the hydraulic oil to be- used in the brake. Check reservoir frequently

throughout bleeding procedure, and keep i t full.

4.4.2 Hold brake pedal down, open bleeder valve to vent air from master cylinder, close bleeder ualve and release brake pedal..

4.4.3 Allow 30 secot~ds for Inaster cylinder to replenish: Rcpeat 4.4.2. Repeat this cycle until fluid ilows from bleeder valve. ,

4.4.4 With bleeder valve closed, apply and release brake. Wait 30 seconds and apply and.

I release brake again. Continue cycle waiting.30 seconds between each application, until brake shoes c,ontact drum.

Control valve not letringoil pressure enter brakes.

In-line adjuster not working:

* Supply line leaking;

-- Expander tube nozzle packing not

sealing.

---- Expander tube leaking;

4.4.8 Aftcr operating vcliiclc a half day or work shift , open hlccdcr valvc wi th brakcs released, to vcnt air which may have workcd to top or systcm during vchicle operation. CIosc 1)lccdcr valvc

: after- flow of fluid has stoppcd crmpletely.

Insure proper oil pressure in brake supply line.

Remove the- floating piston assembly and insert blunt tool into small hole in face of piston and push inward. If definite movement cannot be obtained, rebuild in accortiance with Manual 20, replacing all defective pans.

Check lines and fittings to insure sealing.

Replace-packings and inspect connector block nozzle- hole for surface damage. If surface rlws not appear satisfactory for sealing, replace t h e c ~ n e c t o r with a new part.

--.+---

If tube shows definite leak, replacr with a new. tube:

4.5 STRAIGHT HYDRAULIC BRAKE SYSTE,M BLEEDING I'ROCKDURE:

4.5.1 With engine idling, open each bleedcr valve and depress hrakc pedal until oil flows free of air.

Rarvised: 1 Mny 1967 5

Note

Use bleeder hose to keep oil off braking surfaces. Bleed each valve separately.

4.5.2 Closc hlecder valves after complete ventingof air from brakc lines is assured.

Note Ai~proximately one-half gallon of fluid should h e flushed from each bleed- e r valve.

4 5 3 . Apply brakes, holding pedal down. for at least 10 seconds. Repeat t h i s cycle three times: allowing 30 seconds: between. applications.

4.54. Release b a k e s and open all four bleeder valves. located on t h e brake side of each o f ' t he sutomatic adjusters. Bleed. fluid. from brake until flow stops then c lose bleeder valves.

I 4.5.5 Repeat paragraphs 4.5.3 and 4 S.4 until no air can be detected escaping from the fluid. Remember to allow a[I fluid to escape from the bleeder before closing the bleeder valve.

4.5.6 Repeat the entire bleeding procedure- i f the brakes show any evidence of dragging or overheating during the first few hours of operation after bleeding.

5 OVERHAUL

5.1 DISASSEMBLY:

3 5.1.1 Hold thebrakeeithervertically a- horizontally so that both frames are exposed.

5 . 1 2 Place a. screwdriver against the.hook of t h e retracting spring and, with a sharp blow, disengage he spring. from t h e frame. Drive the springs through the brake and out of the assembly. On brakes of seven-in. width, this method may damage the- lining blocks. I f it is desired to salvage the l i n i n ~ blocks of seven-in. wide. brakes, use a curved plate (an old or extra brake shoe will serve) and - .a C.clarnp to support t h e lining as shown in Figure 2.

--*,_ _ -----____--.- - .-

'. __I_

SPRING ED OR

- c C - . - - - - - - -- - -. - -. .,

Figure- 2.

5.1.3 After all retracting springs have been removed, l i f t the block andrsh+ assemblies from 7 . . . their poslt~on. . : b.

8- , .

Note 'I.

Brakes, may be relined without further disassembly. Relining should be done in full sets o t 1 2 linings only, and each block should b e installed with a new retracting spring and shield. If old springs. a re re-used. they ,nay break because of fatigue. Before re l in in~ brakes, remove all dirt from between. t h e expander tube and the side frames s o thae the tube w i n h a v e space to flatten out again. See, paragrpph. 5 5.6 for shield instarlation and re1 ining procedure.

5.1.4 Removenuts,. bolts, and washes or bushings i f used. Bushings may be removed by driv- ing with adr i f t pin: Disassemble the frameassemblies from thetorque plate. ,5t . . *' 51.5. Slip t h e &pander tube. and. inlet connection from the torque p l a t e

5.1.6 Remove theinlet connection fran the nozzle of theexpander tube.

5.2 INSPECTION: , I ' ..

5.Z1 Inspect t he expander rube for signs ol leakage, excessive by brittleness, OII i w s e fabric or rubber around. the base of the nozzle- that might permit fluid. Discard. expander & b e nozzle packings.

, 4. 5.2.2 fnspect the brake block and shoe assemblies for damage and separatroni,of lining from shoe

',,A f 52.3. T h e friction. or braking, surface of the lining may develop ridges. and.@oves. The leading

edge, that which is. in t h e direction. of rotation, tends to wear slightly uneven' i ther of these condi: \ tions is normal. .&' 5.2;A. Inspect Lame assembly for unusual wear or distortion on the torque bars, cracks a t t h e

welds of t he torque- bars, and for cracks or elongation of the frame bolt holes. F:ames used with bush-. irlgs should have no elongation. bf the bolt holes. Frames of 26 in. dia. b rakes~hou ld not havemore than 1/16 in. elongation of the bolt holes. All other brake frames should. not b e used when the elong- aiion of the bolt holes exceeds 1/32 in. Frame bolt hole elongation is an indication that frame bolts have not remained. tight during operation. Check frame bolt torque carefully during brake reassembly.

5.2.5 Check fa broken or distorted retracting springs.

5.2.6 Inspect t h e inlet connection block bore where packings seal for scratches and groovea. 1,eplace i f bore is scratchedor grooved.

- 5.3 REPAIR:

5.3.1 If any linings have come loose- from the shoe, rer ivet them.

5.3.2 Replace frame assembly if cracked, broken, or distorted. In an emergency, end drill and \I the crack; weid with AWS7016 rod. Replace repaired frames a t

5.4 REPLACEMENT: * ,. ,c:,

54.1 Replace- expander tube i f cracked, charred, or i f the nozzle has bii$&;liaking. Expander o ~ b e s are expendable pans and they will not last the life of the vehicle. Life iG function of t he service conditions a g w i t h a tire. Through experience with each vehicle, operatois can determine the useful service life of the expander tubes. To avoid excessive down time, it is, s&ggested that the tubes tie replaced on a schedule established by service experience. - - . . , - . - . . - . ... . . --. . . - .

% CAUTION 9

Do not use lubricants of any kind between the ineide dinmeter of the expander tube and ita mating aurface. I

Ilcvised: 24 Oclobcr 19'72 7

Manual C 1

5.4.2 Replace brake lining if won1 beyond the usable thicknesvaaspecified in paragraph 4.1.2, if torque bar forms ridges UII t h e Cace o i the Iini~lg that may muse the block and'shoeasscmblies to hang up, o r if excessive cracking,or-chipping is cvident. New. linings areavailable i l l brake relining kits (seeapplicable parts breakdown).. Do. not intwmix new and usrd linings..

Note l r two o r m o r r brakcs i t r r r ; ~ c t ~ ~ a ~ r J L! tmr I I I ~ A I ~ cyli~ldrr, r q u d lii~ing t l ~ i c k w ~ ~ ~ I W I -

bu maintained lo assure bdanced ~ l l l l i l I g clearaucein 811 brake?. Unequal lining thickness-will result in a dragging brakcund possible failureol thc expander tubes. irom.overheating.

5.4;3 Replace the frnmrs if inspect io~~ in ac:cordunce with puragraph 5.2.4 requires replacement..

5.4-4 Replnce rctmcting springs if they are-broken or distorted o r when new linings arc installed to ~(cplace worn out l i~~ings . Reprdca all twelve springs to insure uniform retraction. New sprin are available in lbrake relining kits (see appIicabIe parts breakdown). ff

5.4.5 Replace the packing in theexpander tube nozzle.

5.4.6 Repluceexpander tubeshields if cracked or broken or if lining is being renewed in accordance with i r a ~ q r a p h 5 5.6. New shields we available in brake relining kits. (See applicable parts catalog). Shields are included w d attached on expander tube assemblies identified by 397- series part numbers.

5.5 REASSEMBLY:

5.5.1 Lnstsll two new packingson the expander tube nozzle, lubricnting them with vaaeline beforeinstalla- tion t o avoid damaging the packing.

5.5.2. Lubricate inlet connection nozzle bore only and insert the nozzleof the expander tube.

CAUTION The-inlet connec t io~~ must be in the 12 o'clock position with inlet port facingvehicle when installed. Do not use lubricants of any kind on the inside diameter of the expander tube or outside diameter or torque plate as an aid to installation. Torque plate must be clean and dry.

5.5.3 Slip the expander tube and the inlet con~bct ion ovcr the torque plate.

5 . 5 . 4 Slide thc frames over the expander tube and torque plate, making sure that the inlet connection lines ..ip with the frame cubout and all freme bolt boles line up. If m i ~ l i g n n ~ e ~ i t occurs, the frame is on backward and should be turned amund.

5.5.5 Instdl the frume bolts and wusl~ers o r busl~inga where used. Ury torque self-locking place bolts in accurduncc with the chart below. If through bolts and nuts are used, the nuts should be torqued to the t o q u e values listed in the chart, and the threads lubricated with engine oil.

~ ~ ~ O U E (l.B F T ) / NUT TORQUE (L~FT) elf Locking With Or (Threads Lubricated

Rcviscd: 24 Octobcr 1972

IN. / Without washe r With Fngine Oil) 1

Manual GI

5.5.6 Assemble block and shoe aeacmbliee, springs. .tnd expandertube shields (on 3,4, end 5 inch wide brakes o r s l y diamrtrr) ua followu:

5.5.6.1 Rrcc:n~wt all 01' i h r oxpaiider tube shidds which i r e l o o w o r can ba trasily mmovcd without t l i s ~ ~ ~ r t i i ~ ~ t l ~ ~ ~ s l ~ i ~ ~ l t l ~ .

Note

Aceto11o~or~h1.E.K. .wlvc!nt iipplicd aL thr bond liucwill aid in theremoval of Lhc sllialds. Use ;I n~iiiinui~n oC wlvcnt a i d rcntove residue from the rxpalidortube ; ~ k r tlwsl~iald ia rvnmvril.

55.62 (lean rcmoved shirlds with h1.E.K. o r acetoue.

CAUTION

Do n o t use petroleum base solvents

Raviscd: 24 Octabcr 1972 ,/ 8 A

. ...~ ... . . ...~ ~ . . . . .~ .. . . -.

5.5 6.3 Place one shoe in position on t h e espander tube and mark the location of the end of the s l~oc. u s i n g a pencil o r s~mt lar marking tool, on the tube. Note the position of the mark in relation 1 thc hrnke torque bar and mark the location of the remaining eleven shields on theexpander tube.

5.5.6.4 Coat the iirside (orconcave) surfaceof the shields with adhesive. Allow the adhesive 11, dry i n .~rrord:mcewith thema~iufocturer's instructions (usually r i v e min~~tcs) .

5.5.65 Coat a 1E. inch wide arcx with :tdhcsive at cac11 of the twelve loc:~tion marks on ihc cs- , .

p : ~ ~ ~ J e r - tube, to within: 8. inch oi rube edgcs. l l~e ccmcnr is to be centered on the mnrk hetwecn the pmkc irzmes. Allow. adhesive. to dry in. accordance w i t h t h e manufacturer's instructions (usually two- to f i v e minutes).

Note IJse a good neoprene base- adhesive compound as instructed. T h e following: brands have been tested and approved by B.F.Goodrich.

1 5.5.6.6 Using a shoc, center a shield between the sides of the brake frames and install shield on the adhesive coated spot on the expander tube.

8

5.5.6.7 Align shield s o that one half protrudes from under the- end of t h e shoe. Press the shield f i r m l y i n place to the expander tube, and remove the block and shoe assembly used to align the shicld.

- COMPOUND NO. --- - - COMPANY --

I 3001. Min~~esota Mininl: and hlanufacturing Co., St Pml , Minnesora (;.isgacinch 4404' o r 325NP Porter Manufacturing andSupply Co., Los Angcles, California 77-138 General Adhesives and Chemical Co., Nashville, ~ e n n ~ s s c e 5112471 or 7F2770

7 Caterpillar Tractor Co., Peoria, Illinois

5.5.6.8 Install the next shicld in accordancewith the procedure of paragraphs 5.5.6.6 and 5.5.6.7, end assemble a block and shoe on the shield s o that one half of the shield protrudes from under the en& oi the shoc.

5.5.6.9 Insert retracting spring inserting tool (Part No. 114-38) through the frame assembly spring ind do^. Insert a retracting spring through the opposite window s o that the tool blade is between the spring and the lining material of the block and shoe assembly. Drive the spring into place with a mallet. then pull spring inserting tool out..

5.5.6.10 Install the remaining expander tube shields, block and shoe assemblies and springs using the procedure of paragraphs 5.5.6.6 through 5.5.6.9.

Note When new expander tubes wi th shields attached (Part No. 397-) are furnished, install block and shoe assemblies and springs in accordance with paragraph 5.5 6.9 and 5.5.6.10 only, making sure that the ends of the shoes rest on the expander tube shields.

5.5.6.11 On seven inch wide brakes of all diameters, install retracting springs in accordance ~ ~ i t h Figure 2. Install expander tube shields and block and shoe assemblies in accordancewith the procedure of the preceding paragraphs.

5.6 WARRANTY CIAIMS:

5.6.1 Material returned to B.F Goodrich for warranty claims must be accompanied by the following iniurmation.

5.6.1.1 Vehicle model number.

5.6.1.2 Type of vehicle.

Revised: 18 D e c c m h r 1967 9

5.6.1.3' Name and locnrion of the firm operating t h e vrhiclc

5.6.1.4 Name of t h e mnnufncturers dcnlcr or distributor.

5.6.1.5 Number of hours tilot thercturncd component hm bcrn in service.

Note Wxranty claims will not be considcrcd tutlcus accompnnicd by the above information.

6, SPARES.

6.1 SPARES RECOMMENDED FOR AVERAGE CONSTRUCTION SERVICE FOR 10 BRAKE AS- SEMBLIES ON YEARLY OVERHAUL BASIS:

ITEM I QUANTITY

SPRING, Retracting.. ................ BLOCK AND SHOE ASSEMBLY ..... SHIELD ........................... BOLT, Frame ..................... WASHE.R (when used). ................ BUSIIINC (wlien used). ...... :. ..... NUT (when: used) ................... FRAME ASSEMBLY ................ EXPANDER TIJBE ASSEMBLY.. .... INLET CONNECTION.. ............

......................... PACKING TORQUE. PLATE. .................

.Them part. nre nvolfablr(arhcrs~oppl1csble). In brnks rsllnlilng kit.. Each kh Lnclvdcs 12 block and .horas..mblle. , .hl.Id.T and rsrractlng srelnc..

7 PARTS STORAGE

7.1 Expander tubcs must be stored and shipped in a c i rcu la or oval condition. Do not kink or distort tubes by nestingor jamming into a small carton.

7.2 Shelf life of expander tubes is limited to cight years from thc curc datc which appear* on rhc inside diameter of the tube Expander tube nozzles must be capped and t h e tube boxed to prevent exposure to sources of light and circulating air Storage tempcratures should be at normal roan t e m p erature or lower.

CAUTION The shelf life of expander tubes is greatly reduced when stored at temp- crntures in excess of 100°F for long periods of time.

. 10 Revised: 1 May 1167

. -__.... _ . . . . . . . . . . . . -

B.F.COODRICH AEROSPACE k DEFENSE PRODUCTS A DlVlSlON O F THE B.F.GMDRICH COMPANY

WHEEL AND BRAKF PLANT TROY. OHIO

ILLITSTRATED PARTS CATALM; B.F.GOODRICK EXPANDER TUBE BRAKE

PART NIIMB ER 2- 794-3

This parts catalog illustrates and describes t h e pans and assemblies available formaintcnance, re@ and overhaul of B.F Gwdrich brake, Part Number 2-794-3

This catalog is designed to be used with B.F .Gdr ich Manual I, "Operation, Maintenance and Overhaul of Expander Tube Brakes for Industrial Equipment".

1 SPARES

1.1 SPARES RECOMMENDED FOR AVERAGE CONSTRUCTION SERVICE FOR 10 BRAKE ASSEMBLIES ON MARLY OVERHAUL BASIS:

ITEM QUANTITY

............... SPRING, Retracting.. ..... B L K K AND SHOE ASSEMBLY..

SHIELn.. .......................... BOLT, Frame.. ...................... WASHER (when used). ...............

.............. BUSHING (when. used). ................... NUT (when, used).

FRAME ASSEMBLY. ................ EXPANDER TUBE ASSEMBLY. ...... INLET CONNECTION.. . . . . . . . . . . . . . . PACKING. .........................

2. PARTS STORAGE:

2.1 Expander tubes must be stored and shipped in a circular or oval condition. Do not kink or ,distort tubes by nesting or jamming into a small carton. Shelf life of expander tubes is limited to eight years from the cure date which appears on the inside diameter of the tube. Expander tube nozzles m u s t b e capped and the tube boxed to prevent exposure to sources oi light and circulating air. Storage temperatures should be at normal rwm temperature or lower.

CAUTION- The shelf life of expander tubes is greatly reduced when stored at temp

0 eratures in excess of 100 F for long periods of time.

Revised: 5 December- 1969

,7- k d e x No.

Brake Assembly - 26 x 5 ET Spring - Leaf, Retracting Lining & Shoe Assembly Shield - Expander Tube Bol t - Se l f Locking, 0.625-11 UNC Thd. Washer, F l a r Frame & Torque Bar Assembly Expander Tube & Shield Assembly Expander Tube Assembly I n l e t Connection Packing - Preformed Torque P la te

.-.

1 %omposed of t e s 3 and 7. -

P a r t No.

The following k i t s are avai lable for service:

Description 1 2 3 4 5 6 T

Quant i ty Per Assy

12 12 12 28 28 2 1 1 1 2 1

Revised: 5 December 1969

Par t No.

328-31-1 328-20-1 328-21-1 328-22-1

Description

Par ts K i t - Brake Relining, Std D r u m Size Par ts K i t - Brake Relining, 0.125 Oversize D r u m Par t s K i t - Brake Relining, 0.250 Oversize D r u m Par t s K i t - Brake Relining, 0.375 Oversize Drum - - -

INTERCHANGEABILLTY: This brake replaces the following B.F.Goodrich brake assemblies. Users of the l i s t e d replaced brakes should order replacement pa r t s from t h i s catalog. Par t s a r e 100% interchangeable.

2-794 2-794-1 2-794-2

8. STANDARD AND OVERSIZEPARTS KITS

8.1 Thechaart below lists standard and oversize brakcrelining parts kits bv brakesize, available for overhaul.

Note

Where more than oneset of parts kits arc shown for a specific brakesize, refer to applicable brake parts catalog forthe specific standard parts kits used with that pcuticular brake.

ITS 0.375

328.19 -- -- --

328-25 -- --

328.13 328.97 -- 3286-1 328-74

v

- 328-28

328-22-1 328-69

328-3-1

BRAKE STANDARD PARTS KITS

328-30 32880 328-81

SIZE PART: 0.250

328-18

AEROSPACE & DEFENSE PRODUCTS A Division of The B.F.Goodrlch Company

Wheel and Brake Plant Troy, Ohio

MANUAL 6

INSTALLATION, OPERATION, M:IINTENANCE, AND OVERHAUL O F B.F.GOODRICI1 MASTER CYLINDER ASSY..

FOR 1NDUSTRIAL EQUIPMENT

Used.omB.F.Goodricb Expander Tube Brake Assemblies

ISSUED: I Novcmbcr 1957 REVISED: 30 April 1971

NOTE: Tbis edition replaces a l l prevrous issues .

.- Manual 6 .

TABLE OF CONTENTS

Section Page

1 DESCRIPTION^ ....................................................................... I :

Z OPEFWTION. ............ ., ............................................. .. .......... 2

3 INSTALLATION! ................................................................... 2

4 MAINTENANCE .................................................................... 4 . 4.1 Inspection ........................................................ .. ........... 4 . 4.2 Repair ...................................... ..................................... 4. 4.3 Replacement ................................................................ 4 . 4 . 4 Dragging Brakes ............................................................ 4 . 4 . 5 Trouble Shooting .............................................................. 5 4.6 Cold Weather Maintenance: ...................................................... 6 .

5 OVERHAUL ..................................................................... 7 . 5 . 1 Disassembly .............. : ..................................................... I

5.2 Cleaning ................ :. .................................................. 7 5.3 Inspection ................................................................. T 5.4 Replacement ................................................................... 7' 5.5 Hydraulic Oil ................................................................. 7 5 6 Reassembly ................................................................ 8

................................................................. 6 SPECIAL TOOLS 9

7' SPARES: ............................................................................ 9

8: PARTS CATALOG ................................................................ 10

LIST OF ILLUSTRATIONS Figure

1 Air and Hydraulic Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 Exploded View. 3.000 ID Master Cylinder Assembly ................................. 10 3 ExplodedView.. 3.750 ID Master Cylinder t\ssembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ' 4 Actuator Assembly -Installation Positions OIjnlet Port ............................. 14 .

i i Revised: 15 Scprember 1964

. . . . . ...... ................ .........

MANUAL 6 INSTALLATION, OPERATION, MAINTENANCE, AND OVERHAUL O F B.F.GOODRICH MASTER CYLINDER

ASSY FOR INDUSTRIAL EQlJlPMENT

Revised: 30 April 1971

Note referencing proper use of 26-90 bushings with No. 36 Roto-chambers added a f te r paragraph 3.2.1 on page 2.

Replace existing. pages o f manual with- latest revised pages attached.

10 v- ---4 - Figunr I . Air and Hydraulic Actuator Assembly

1.1 The master- cylindcr assembly may bc shippcd separately or asscmblcd to an air actuatcd Rotochambcr. As a separate u n i t thc master cylinder assembly is identified as B.F.Guodrich Part go. 87-. Whcn assembled to a Rotochamber t h e combination is identified as B.F.Goodrich Part No. ??I-. See Figurc 1 for typical assembly of Rotochamber and master cylinder.

Note

The mnstcr cylinder alone, or assembled ro a Kotochmhcr m.iy hc purchased from D.F.Gwdrich Aerospace and Dcfcnsc Products, rroy l'lnnt. Troy, Ohio. 'The Rotochambcr is manufactured hy Bcndix-Westinghousc, Ialyria, Ohio, and may bc purchased, by itself, dircctly from them.

1.2 The master cylilider assembly consists basically of a housing (19), a mounting bracket (7), an actuation piston (14), and an automatic adjusting piston assembly (10). The unit is available complctcly assembled.

1.3 This master cylinder assembly has a Four-in, strokc capacity :~nd its fluid inlct is at the pressure facc of the piston whcn thc piston is i n the i:omplctcly rctractrrl position. In thc cap end of thc l~otrsing, ttic diametcr or the bore increases for a distance of about thrcc-in. [ram tllc cap end. This incrcased bore.contains the floating automatic adjuster piston (10). An cnd cap (8) closes t l~c housing.

1.4. The Rotochambcr conveys external force into the actuation piston (14) through a 114 i n . maximum dinmctcr rod. Jam nuts ( 5 ) attach the actuating rod to thc actuating piston. The nuts arc loca[cd on thc rod hctwecn washcr (4) which is ahead of the nuts, and washcr (6) and rctaining ring (j) behind thc nuts. The retaining ring ( 3 ) is located in the actuating piston (14). Thc piston has two packings

, ( 1 5 . liAi along its cylindrical surface a d a bdl rheck n l r e (17. 181 in thc pressure ( r r c hu~omrtir

Revised: 15 September 1964 1

3 adjusment is. made by a scnsing piston backed by a sensing piston spring. moving. in ahousingto open. and i losc a porn through. which fluid passes into and through the: adjuster piston (10). A ligbt s p r i n ~ ( I?) scparatcs: the actuating and adjuster pistons.

T OPERATION

2.1 From t h e reservoir tank, actuation fluid. enters the thrcadcd inlet hole located ahout mid- way of the piston housing (19). When the actuation piston (14) is fully retracted, fluid fills the piston housing between i t and the adjuster piston (la). When t h e actuation piston moves. forward, thc adjuster piston also moves forward the length of its available travel, about half the strokeof the.actuation piston. Continued pressure on. t h e actuation piston causes the sensing piston to opeti the port, allowing fluid. to pass through the automatic adjuster into t h e brake a s long as the piston is under pressure. The fluid leaves the piston housing thcough the port i n t h e cap to be cunveyed to the brake assembly.

2.2 When the. pressure is removed from t h e actuation piston, brake pressure decreases until al l that remains is the back pressure- caused by the brake. block retracting springs. ,411 linings are still in contact with t h e drum. Then the sensing piston closes and both actuation piston and adjuster piston rctract in t h e piston housi~tg The adjuster piston rctracts the. entire length of its available travel and the actuatiot~ piston retracts to its starting position. Fluid can pass through the ball-check valvc ( 1 7 . 18) into the front of t h e piston as i t retracts, thereby preventing a vacuum lock in front of the actuation piston-

3 INSTALLATION i

CAUTION. Use mineral base oil (see paragraph 5 5 ) only.

3.1 The master cylinder is shipped from the factory complctcly asscmhled. Removr the 50.171 Instruction Plate wired to the master cylinder and attach i t to the filler neck of [he reservoir to be used with the master cy kinder.

N o t r lnsuuctions for installing a 221- Air and tlydraulic Actuator 4ssembly are covered i n paragraph 3 . 3 .

3.2 To assemble the master cylinder to thc air Kotochamber proccrd as follows:

3.2.1 Remove mounting bracket (7) from master cylinder and a t t x h to air cylinder \lsinr: io6:k washcrs undcr the nuts and tightening securely.

Note,

\Vhen attaching mtutntin; imckrt to n No. 36 K o t o s l ~ a ~ ~ ~ b w , t w o buultinp (20) mual be installed ancl itsc~l.. T y l ~ e KO. 50 Roto*hamber d c ~ s u c r l requirt: Imahings.

3.2.2 Rcmove retaining ring ( 3 ) , washer (6), and jam nuw (5) from the rear of the piston

3.2.3 With air cylinder ~ u s h rod retracted. position jam nuts (5) so that the ilistancc from the face of the mounting bracket (7) to closest face of washer (6) is 9/16 in.; then lock jam nuts (5) topether.. See Figure 4.

2 Reviwd: 30 April 1971

adjustment is made by s sensing piston backed by a sensina piston spring moving in ahousing to operr and closc- a. port through which fluid passes into and through the adjustcr piston (10). A light spring:

. (I?) scparatcs t h e actuating andadjuster pistons.

2.1 From the reservoir tank, actuation fluid. enters the thrcadcd inlet hole located a b u t mid- way of the piston housing (19), When the actuarion piston (11) is f u l l v retracted. fluid fills t h e piston housing between it and theadjuster piston (10). When t h e actuation piston moves forward, the adjuster piston also moves forward the length of its available travel, about hall the stroke of t h e actuation piston. Continued pressure on the actuation piston causes the sensing piston to open the por5 allowing. fluid to, pass through the automatic adjuster into t h e brake as long as the piston is under prcssure. The fluid icaves t h e piston housing through the port i n the cap to be conveyed to the brake assembly.

2.2 When t h e pressure is removed from the- actuation piston, brake pressure decreasc:~ until ail that remains is the: hack pressure caused. by the. brake block retracting springs. 411 linings are still

in contact with t h e drum. Then the sensing piston closes and both actuation piston and adjusrer piston retract in the pisron housin:. The adjuster piston retracts the entile length of its available travel and the actuation piston retracts. to its starting position. Fluid can pass through the- ball-check valve (17. 18) into die front of the piston as it retracts, thereby preventing a vacuum. lock i n front ot the actuatiocr piston.

3. INSTALLATION,

CAU.TION. Use mineral base oil ( see paragraph 5.5) only.

3.1 The master. cylinder. is shipped from the factory con~plctely assembled. Removr t h e 50-171 Instruction. Plate wired. to the master cylinder and attach i t to t h e filler neck of the reservoir to be uscd. with the master cylinder

Note; instructions for installing a 221- Air and Hydraulic .Actuator ,issembly are covered i n paragraph 3 . 3 .

3.2 To assemble themaster cylinder to the air Kotochamber proceed as follows:

3.2.1 Rcmove mounting bracket (7) from master cylinder and attach to air cylinder using lock washers under the n u t s and tightening securely.

Note

I When attaching rnwnt in ; Imckrt to n No. 36 Kotoch;trr~l~cr, two bu8hings (20) 1nus1 be instnlled and IIXI 11. Tvlw No. 50 Roto-ehmnber d<ws 1 1 0 1 rcquin: btr~hin~a.

3.2.2 Rcmove retainini: ring (3), washer (b ) , and jam nuts ( 5 ) from thc rear of the piston

3.2.3 With air cylinder push rod retracted, position ism n u t s ( 5 ) so that the distan, c from the face of the mounting bracket ( 7 ) to closest face of washer ( 6 ) is 9/16 in.; then lock jam nuts [ -F) together. See Figure 4

2 Rcviscd: 30 Apnl 1971

3:2.4 Apply pressurc to air cylinder to extend push rod-

Nota

Check to s e e that the washer(4) is correctly seated in thc piston.

32.5 Insert air cylinder push rod into t h e cnd. ol piston (I$), seating the jam nuts nqainst the wadicr (4.).

32.6 Lock the retaining ring ( 3 ) in its groove in t h e piston

3.2.T Release the air from the air cylinder.

Note-

The springs in thc air cylinder should pull mounting brachct and master cylinder firmly together. Forward packing ( I S ) should he viaible through thes ide port in thc piston housing (19).

3.2.8 Align the threaded holes in the mounting bracket with the holes in the master cylinder so that thc oil inlet is a t tht: top when the unit is installed.

3.2.9 Install luck washers (2) and. bolts (1) a d tighten evenly and firmly to 130 to I40 Ib It.

Note

The entire unit, conbisting of the air cylinder, mounting brackrt, and mastcr cylindcr, is ready to attach to the vehicle through holes i n the mounting hracket.

3.3 To mount the master cylinder and. Rotochamber asscmbly prmccd as follows:

3.3.1 Install the master cylinder and Rotochamber assembly in a horizontal position, w i t h t h ~ inlct a t the top of thc barrel.

Note

Engineering approval is required i f the assembly is to bc mounted difler- cnLly.

3.3.2 Aftcr mounting the assembly, conncct the air line to the air cylindcr, the brake linc to the cap (8), and the reservoir line to the cylinder inlet.

Be sure thc inlet. fitting docs not protrude through the piston housing wail into the piston lhousing(19) because this would rause Jamage to the power piston packings (15).

3.3.3 Bleed [he brakrsvstem in accordance w i t h rhe lr>iloui 11:- :!r,ta *tlrsl.:

3.3.3.1 Checking: Bcfore trying to bleed the cquipmcnt, chcr k ~ I I C follwinK:

3.3.3.2 Reservoir Line Size: Recommended size is 5/16 in. m i i t i m ~ i m ID

3.3.3.3 Reservoir Sizc: i\ vented reservoir oi at least 2 qt. capacity is required for rnch lnahtrr cylinder used. The reservoir should be equipped with an r:llrlct sti'ainer and an inlet filter scrcen.

3.3.3.4 A l l reservoir lines should drain to the masrer c!iindcr

3.3.3.5 Bleedcr valves should be installed at t11c highest point i n the l i n r between the masrer cylinder and brake, a s near the brake as possible.

3.3.3.6 Use additional bleeder valves a t the master cylinder outle! i f supply lines lo hrakrs F X -

cccd 1 it.

3.3.3.7' l% bleed fill t h e reservoir with oil as. noted in paragraph 5 . 5 and. proceed as lollmvs:

Note

Keep reservoir full throughout the bleeding proc:edt~rr. Fach t imc t l~c bleeder is opened, permit complete drainage from t h e blccder until all flow stops.

3.3.3:8 Hold brake pedal down and open bleeder valvc to vent air from master cylindcr. When

fluid >tops draining; close bleeder valve and release brake pedal.

3.3.3.9 Wait two minutes for master cylinder to replenish and repeat t h e procedurc in thc above paragraph.

3.3.3.10 Actuate brake pedal with the bleeder valvc closed, hold pressure for 10 secnnds, and release. Wait two minutes and rep6at cycle.

3.3.3.11 Repeat paragraph 3 3 3 8 to clear air lrom the brakc 5idc of thc a~itomatic adjuster in thc master cylinder, and from the expander tube Repeat until no air can hc detected escaping from the blccdcr valve. Wait two minutes between each brake relcase and the next applicarion.

3.3.3.12: Repear paragraph 3 . 3 . 3 8 enough times to asburc that thc brake shoes arc c ontacting the drum. Tcsr by holding brakes against engine power. I f hrakcs do nut hold, refer to paragraph 4 . 5 .

3.3.3.13: After operating the vehicle for approximately an hour, opcn the bleeder w i t h brakes released, to the escape of remaining air which may work to the top of the system during operation.

4. MAINTENANCE

- 4.1 INSPECTION: Whon the vehicle is available for insl~c<tion, axaminc master cylindcr r np

(8) cnd and fluid connections for leakage and the master cylinder mounting bracket (7) for tiphtness

4.2 REPAIR: Tightrn loose cap bolts (1) to 130 to 140 lb it. to assure proper support. (.orrect any Icak a t the fluid connections by tightening the fittings.

4.3 REPLACEMENE I f thcre is a leak i n the cap that cannot be stopped by t i q h t r n i n l : the cap on the piston housing (19), remove- the cap and replace the packing (9). I f there is a lcak at the fittings that cannot be stoppcd by tightening, replace the fitting.

4.4 DRAGGING BRAKES: .Air in the hydraulic system may cause the brakc to drafi I f this condition is suspected, w i t h brake released, opcn blccdcr scrcw and drain all air and fluid t h ~ u w i l l ctme out. Thcn tighten bleeder screw, check the reservoir lcvcl, and refill i f necessary. Apply t h e brakcs three times allowing a t least 30 seconds between applications. Repeat the proccdurc u n t i l rcmoval of all air from brake is assured.

4.5 TROUBLE SHOOTING:

m k c s will not apply.

-

AIR OVER HYDRAULIC ACTUAT POSSIBLE CAUSE

ir trapped in hydraulic actuating system. - esidual a i r pressure ac Rotochamber.

.--- otochamberretraction obstructed.

TROUBLE

Brakes d r a ~ f i i n g or running hot-

- n

,astercylinder actuation piston not re- tractin g.

lastercylinder floating piston not retracting.

Leturn spring between master cylinder pistons out of engagement. -

lroken o r flattened brake retracting spring.

mproper oil in system causing v a p r - ization in brake.

daster cylinder adjuster not working.

3rakes not bled 01 air allowing master cylinder to bottom.

Rcstxvoir located below master cylindcr restricting oil flow.

Feed-line from reservoir restricted or too small.

Master cylindcr actuation piston nor retracting to seat, closing off inlet.. -

Master cylinder actuation piston stuck ir cylinder bore.

Vacuum trapped in reservoir.

insufficient oil reserve.

- Check valve in mastcr cylinder actuation

piston not closinp.

Reviscd: 15 September 1964

iG SYSTEM CORRECTION

lleed systcm and brake in accordancc with paragraph 3.3.3.

:heck air system to insure zero pressure- a t rotochamber.

rlspcct Rotochamber to insure full retraction.

nspect cylinder bore. and actuation piston OD for burrs, chips, o r other obstruction and correct.

nspect cylindcr boreand. floating piston OD for burrs, chips, or other obstruction and correct.

ieat spring in groove on end of each ys7is. I o m p r c spring arch with new spr inc and-

rcplacc flnrtcncd or- broken springs with complcre se t of twelvc.

Purge systcm, replace all ~ b b e r parts and rciill with hydraulic oil as specified in paragraph 5.5.

Remove i l o a t i n ~ piston assembly a1111 in-' . . se r t blunt tool into small holc i n favc ni piston and push inward. I f rhcre is no definitc movement, replacc with a new part. -- -- I

Blecd systcm and brakes in accordancc with paragraph 3.3.3.

Relocate rcscrvoir abovc to allow gravity iced.

Insure irec flow using 5/16 min. ID linc without rcstiiction. -

.Idjust Rotochamber push rod attachment a s outlinod in paragraph 3 . 2 . 3 .

Free up piston rcmovinfi obstruc tion. I f cylinder unll or piston OD is rxcessivc- ly damared, rcplacc with ncw 11Nt. --

insure vcnt air passagc in rcscrvoir.

Keep rcscrvoir fillcd with hylraulic oil a s specified i n paragraph 5 . 5 .

lnsurc frcc motion of ball check and re- nlove all foreign particles.

- 'TROUBLE

;rakes will not

apply" (Cbn tinued)

..

, ., , , ., ,,! ~:

.....

Aastcr cylinder Icaking at mount- inr : brackct joint.

Brake Icaking.

AIR OVER HYDRAULIC ,ACTUATINC'S\rSTEM (Continued)

Supply line leaking. Chcckl incs and fittinas to i n h ~ ~ r e h c a l & - -- Air pressure inadequate. Air prcssurc at Rotocharrber shrrultl he

not less than 80 psi with brakes op- t plied. Correct air system a s required

Packing not sealing. Kcplacc all master cylinder packings.

POSSIBLE CAUSE

Aaster cylinder adjuster not working.

?acking.on master cylinder actuation piston.not sealing.

I

Expander tubenozzle packing not Rcploce p a k i r ~ p s and inspect Lonncctor sealing. block nozzlc hole for surfacc damage.

I f surfncc docs not appear satisfactory for seaiiiiy, rcplaceconncctor with new part.

Expander tube leaking. ll tubr shows definite Icak,

CORREC'I'ION

Remove floatinr pis tm assembly and blow with mouth into small lhole i n iacc of piston I f air passes, rcplacc with new part.

Replace packing replocemcrlt part.

/ with a ncw tube. -

I

4.6 COLD. WEATHER MAINTENANCE: When the 711-8 asscnlbly i s used a t temperaturcs hctwecn -40' to -6S°F, the following maintenance procedure i s requircd:

4.6.1 Drain all compnents , including the oil rcscrvuir. nlaster cylinder, hydraulir, l ines , and. brakes, o i oil. Allow time lor retracting springs in thc brakes to rt%tracr arid cxhairst a11 thc d l frrm t h e brakes.

4 .6 .2 Rebuild the 221-8 assembly using the cold weather mmlification k i t (Part No. 198-25). This kit includes the following cold weather parts; diaphragm for ihc Typc 36 Rotochambcr.rcplacvmcnt O-rings for items 9, 11, 15, and ISA, a n d a replacement piston asscmbly (10). The IS!\ 0 - r i n ~ i s identi-

' fied by a molded. white dash, this is in addition to the moldud orange dash founti on each of thc O-rings included in this kit.. T h e floating piston assembly (Part No. 116-110) is impression stamped Cold IVeathar:

4.63 After 221-8 assembly i s rebuilt, fill with MIL-1%-5606 hydraulic fluid and completely bleed the brake system.

CAUTION Do not use cold weather parts or maintenanct procedure when equipment is to beoperated in normal temperatures above JZ°F

4.6.4. Re-identify the converted assemblies by changing the part numbers from $7-'J7 t t , $7-99, and thc :.?I-8 to 221-13. Stamp the new part numbers on thc piston housing (19) a s a permancnt record.

46.5 The 87-100 and 221-10 assemblies are equipped with components suitable for cold weather operation to -6S°F.

G Revised: 15 Scpremho 1964

5 OVERHAUL

Nota When the master cylinder requires overhaul, modify i t to t h e latest dash numberdesign in accordance with t h e Parts Breakdown.

5.1 DISASSEMBLY:

5.1.1 Unscrew outlet end cap (8) and removeend cap packing (9).

Nota Recareful nor to let t h e adjuster piston (10) fall out as you remove cap.

5.1.2 I f adjuster piston does not come out when you remove. thc cap, tap end of piston w i t h a plastic mallct to loosen it so that thc- spring (12) can push it out thc open cnd..

5.1.3. Removespring (17) and take bolts (1) from brackct end of pisron housing (19).

5.1.4 Apply air to air chamber to extend. rod. Then, rcmovc lock ring (13) from piston housing-

( 1 9).

5.1.5 Rcmove actuation piston (14).

5.1.6 Rcmove lock ring (16), washer (IbA), conical spring(Ii) , and ball (18) from ballwheck end of piston. I

5.1.7 Rcmove packings (I I . I S ) from all grooves.

5 2 CLEANING Clean all parts.

Note. Ih not immerse adjusterpiston (10) i n cleaning fluid

5.3 INSPECTION:

5 . 1 Inspect adjuster piston (10) by inserting a smooth, h l u n t :uol into the small lholc i l l the iacc of the piston and pushing inward. I t diere is no dcfinitc n~ovcmcnt, replace w i t h ncw part. I f dcfinitc movcmenr occurs, blow with mouth into the small hole. I t air passes through ihc assembly replacc w i t h a new part.

5.3.2 Inspect piston housing (19) bore for surface condition. I t unsatisfactory for packinl: scal. replacc wi th a new part

5.3.3 Inspect ball-check scar surface in piston (14) [or lodged foreign particles aud rcmove i f found..

5.4 REPLACEMENT: If replacement oi parts is ncccsssry, uhe only those parts listed for thc latest dash number assemblies. Replace all packings.

Note. 1\11 packings (I SA) used at the low prcssurc cnd ill thc a6 tuntion piston (1.1) are identified with a white slash on the OD of thc packinr.

5.5 HYDRAULIC OIL: Check level of oil in reservoir, daily.

Rcvised: IS September 1964 -

5.5.1 Only mineral oils meeting the following specifications should be used in expander tuhc brakes andmaster cylinders covered in this manual.

CAUTION. Do. nor u s e any other types of oil o r fluid. 4uoid the use of aulon~ofirw

brake lluid. as. it: is especially destructive to the brake s y s t e m components.,

5.5.2 PHYSICAL PROPERTIES:

Saybolt Universal Viscosity a t 210°F Saybolt Universal Viscosity a t 100% Viscosity Index (Dean and Davis) Pour point (ASTM) Color (ASTM) Neuualization Number (ASTM) Copper Strip T e s t (Corrosion) 3 ibs.

a t 212OF Emulsion T e s t at 1 3 0 9 , Distilled Water. Time for Complete Separation

Rust Test (ASTM) Distilled Water Oxidation Tes t (ASTM) Time to Neutralization Number 2.0

Foam Tes t (ASTM) Scquence 1, 2, 3ML foam after 10 minutes standing

Flash Point A n i l i n e Point Additives

43 seconds, minimum 145 to 155 seconds 90 minimum -25OF minimum No. 2 or lighter 0.10 or less

30 minutes, maximum No rust

1500 hrs, minimum

3 7 0 9 minimum 200'~ or more

Additives harm/ul to Buna N and neoprene rubber cornpotmds turll nor be used

5.5.3 For military vehicles, oil in accordance with MIL-L-2104 has been npprovcd for thc: 87-97 master cylinder and the 2-907 brake. MIL-11-5606 hydraulic fluid may he used, with engineering approval. at ambient tempcraturcs below thc operating range of MIL-L-2104.

5.6 REASSEMBLY: Reassemble in reverse order of disashembly, replacing all packings. Before installing, remove identifying paint slashes from packings (15A) using a cloth saturated with mineral oil (MIL-H-5606). Dry torque cap (8) to 50 lb ft minimum.

Note Inler fitting must not extend through thc piston housing wall.

5.6.1 Adjust rotochamber rod attachment to piston (14) in accordance with paragraph 3.2.3.

6, SPECIAL TOOLS

6.1 W a l d e s T r u a r c p l i e r s No. 1 wi th 45" r i p s , u s e d to rcmove ba l l c h e c k retain in^: r i n p ( l 6 ) .

6.f Waldes. % a r c p l i e r s No. i wi th 4P t i p s , u s e d t o r e m o v e p i s ron r e t a i n i n g r i n e ( I i).

6.5 Waldes T ~ a r c p l i e r s No. 3 w i t h 4S0 t i p s . u s e d to r e m o v e a t t a c h i n g p a r t s f rom p i s ~ o n .

r SPARES

( S P A R E S RECOMMENDED F O R A V E R A G E C O N S T R O C T I O N K R V I C E : F O R 1 0 MASTER C Y L I N D E R ASSEMBLIES O N Y E A R L Y OV1;Rllhlll . BASIS)

I N D E X N O . I ITEM .. 1 QUANTITY- 1 / BOLT .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .I 10 7 -. 3 4- 5 6 T 8 .. 9.

1 0 '11

12 1 3 1 4

' I S '15A

16 I6A 1 7 1 8 1 9

LOCKWASHER . .. . . . . . ., . . . . . . . . . . . . . . . . . . . . . . . . . RING. R e t a i n i n g ( W a l d e s K o h i n o o r ) . . . . . . . . . . . . . . .. . WASHER.. . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . N U T , J a m ... ..... ... ... ... .....,. . .... .. . . .. ... .,

'WASHER, F l a t .. . .. .... . . .. . . . . .. . . . . . . . . . . . . . . B R A C K E T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . .. . CAP: . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G A S K E T , C a p . . .. . . . . . . .,... .. . . . . . . . . . . .. . . P I S T O N ASSE.MBLY . . .. .. . . ..... .. . . .. .. . . . . . . . . . PACKING, O- r ing . .. . . . . . .. . . . . .. . . . . . . . . . . . . . . . S P R I N G . H e l i c a l c o m p r e s s i o n . . . .. . . . . . . . . . . . . .. . . RING, R e t a i n i n g (Waldes-Kohinoor), . . . . . . . . . . . , . . P I S T O N , M a s t e r c y l i n d e r . . . - . . . . . . . . . . ., ,, . . . . . , . , .

P A C K I N G , O-r ing, .,. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . I'I\CICING, O-r ing .. . . . ., . . , . . . .. . . . . . . . . . . . . . . RING, R e t a i n i n g (Waldes-Kohinoor). . . . . , , . . . . . . . . ,

WASIIER.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . ,

S P R I N G , C o n i c a l . .. . .. . . . . . . .. .. . . , . . . . . . . . . . . B A L L - C H E C K . .. . . . . . . . . . . . . . . . . . . . . . . , . . . . . . HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

'Included in p a n s k i t s l i s t e d in p a r s cnrdog. Older k i t s far pocking s tock.

12 Revised: IS September 1964

Revised: l5 Seprember 1964

8 PApTS CATALOG

8.1 .41( pans listed for each master cylinder arc !firerchangeable rvt!h, and replace previously l isted parts when necessary, a s die earlier parts are po longer . . available. Service both the basic part numbel and

;hc -1 master cylinder wtth the particular parts listed for that s i ze of master cylinder.

8.2 The 68-309 packing (used on the 3.000 ID master cylinder) and the 68-308 packing (used on the 3.750 ID master cylinder) listed a s item (!:A) in the parts breakdown are marked with a white paint streak on the OD to distinguish them from item (! 5 ) packings.

8.3 The 328- Part Kits cons t s t of one each (91, ( I t ) , ( ] j j and (15Aj packings.

8.4 The 50-171 instruction plate shipped attached to the master cylinder i s to be removed a ~ d attached

wi& no. IS gage s tee l wire to :lie f i l ler neck of [lie reservoir to be used with the master cylinder.

8.5 The flat washer ( 4 ) takes the place of the two-piece waslier preytously used. The two-piece

washcr may be used by nesting the curved surfaces logether and mserttng the washer wlth the small hole to. ward the jam nuts ( 5 ) .

. . ,

~ Q ., i .:

, .

! j

@ @ 0 ~j~~~~ 2. Exploded v i e w , 3.OW ID Master Cy!inder A f s e m b 1 ~

Part ?lame Vo. -

1 BOLT, \I.4CHlSE 2 \\.ASHER, LOCK 3 RING. RET.41NING 4 WASHER. FLAT 5 NCT. jAhf 6 WASHER. FI..$T 7 UR.4CKETI I\IOUNTING 8 C.$P 9 PACKIXG. PREFORMED

I 0 PISTON ASSY. 3.250 D1:\. I I P.ACKING. PREFORhlED 2 SPRING. IIELICAL CO,I!PRESSIOI' 13 RING. RETAINIYG 1 4 PISTON I5 PACKING. PREFORMED 15A PACKING, PREFORAIED 16 RING, RET.4INING 16A NASIIER, FLt\T 17 SPRING, CONICAL 18 BALL. 0.500 DI.4 19 PIS'KN 110US1NG 20 BUSIIIxG - WIRE. STEEL - IYSTIIL'CTIO~ ?I.ATE

I 'CO I~ Weather Operation

lo. 18 Gage \Sire 50-17: 328-1

43498 80-37' 8 5-289 80-250 63-223 8 0 2 6 5 1 4 8 4 0 32-260 68-293 116-34-2 68-296 40-224 85-257 74-292 68-295 68-309 85-259 80-305 qo-?ol-[ j30-10 260-34 26-90

io. 18 Gage Wire so-171 328-7

-

- cable \laster Ck 87-97-1 & -2

43-498 80-322 85-289 80-250 63-223 80-265 14% I68 32-363 68-293 116-34-2 68-296 40-224 85-257 74-292 68-295 68-309 85-259 80-305 40-201-1 130-10 260-392 26-90

328-7

~ d e r Assembly 87-99-1 k - 2 1

7 , 87-103 -

43-498 80-322 85-289 80-250 63-202 80-25 148-60 32-326 68-293 116-34-2 68-296 40-221 85-257 74-292 68-295 68-309 85-259 80-305 40-201-1 130-10 260-222

$0. 18 Gage Wire 50-171 328-7

Note: A l l parr numbers are B.F.Goodrich numbers except where otherwise indicated.

Nwnmal Norntal Normal Cold Wcathcr Cold Wcather Cold Weather Normal Normal Normal Normal Normal

rcmator Assy. No. Rotochamber No.

Bendix-Westinghouse Rorochamber part number;

astcr Cvlinder No. Inlet 1,ocation

( S e e Figure 4)

Rcviscd: 3 M u c h 1971 17

. .~ . . . ~ . ~ . - ~ . ..,. ..

NORMALLY- CLOSED. VALVE

' . EXHAUST W%W PRESSURE

Top view~indicatesllow thru 3.vsyi valvewilh m i l de"energized.

NOTE: For normal. valve open- tion, over4de must b e i n "oul!' posilion:

DIMENSIONS.(in inches)

. . - - . . - 1%"' VALVE

A -7 . . . :-2

OPEN VALVE

TOP VIEW:

PARTS LIST-FOR PILOT PARTS SEE PAGES E-13. 15

1 PART NUMBER. , - ..... ;., ........... KEY 1%. VALVE . I . _._ . . - .. - . -. - ..

1' Tap KOU-111 -.-. --

1%' Tap. KOU.113

. - . - . . - - . 1K" Tap KOU-116 . -- . ...

2 1 K313.029

SERVICE KITS include all parts. normally required lor in.sewice maintenance: Normally-closed Valve-

Kit K352.059 Normally-open Valve-

K i l K352.060

WHEN OROERING PARTS-Show mmplele model number of valve and pilot to assure recetpl o l mr- rect replacement p a r k

"RECOMMENDED SPARE PARTS

--

-

- c -4 Bellows-Valvair- olvlStON . AKRON. onlo 4 4 3 0 9 - -- . -

PART NAME - - - -- - .. .... . KEY . .. ...... - - -- PART NAME . - -

M y (NormallyClosed)

-

..-.. ... . . . . . - 3

4

5 6 7 8 9

10

Body (Normally.Opm)

------ _ ._ - HI3742 - - - - . -- H145.21 . -

IOA 11 --- -- 12 -

.- - .- - - Seal -- - , . . - - . -. - Seal , - . . -. - - - -

-- K103.061 ..... - - K183.058

- . . -. .- - - - . - - Adapter

O.Ring -. --

Upper Piston

K493.016 Stem -

- . . . . . . . . . . Bottom Cap - (N.o.)

K313.028 .- H145-21 ~1{:7 - - - - . H063.38

13 I4

- Lower Piston - . . -- . . ,--

Seal - . ., - - - -- - - . - ..- Washer -- ., . . -- Slop . _ Nut .

. Casket

KOIZ-W3 H137-49

-_- KG32046 . _ Bottom Cap . (N C.)

K473.016 -- - - . - - - . ., -. P

Spring

SERVICE PARTS CATALOG HEAOOUARTERS 6 MAIN PUNT, ELYRIA, OHIO W035 9 D 1

DV-Z AUTOMATIC RESERVOIR DRAIN VALVE -

la . Pc.80. Quan. O s r c r i o t l o n

S q r S c h r d u l , I ADAPTER L F I L T E R ASSY. I 7 d R 7 f i R I r l l ire

7 2 0 3 4 1 4 4 C A P SCREW 8 2 3 7 6 4 1 4 LOCK W A S H E R 9 2 4 6 2 6 6 1 I N L E T & EXHAUST VALVE

10 2 4 6 2 6 2 I B O O I

. .... - - Z 2 4 6 2 6 7 1 ADAPTER 3 2 4 6 2 6 9 1 F lLTER RETAINER 4 2 4 6 2 6 4 1 SEALING R I N G . 3 . 2 5 ' 0 . 0 5 2 4 6 2 6 3 1 VALVE GUIOE

March. 1968

DV-2 AUTOMATIC RESERVOIR

DRAIN VALVE PC. l o . - 2 8 1 9 2 3 1 2 8 1 9 2 5 1 . . . .

I -

2 8 1 9 2 4 . . 12330571 2 8 1 9 2 6

6 2 4 6 2 6 1 1 C O V E R

PORT A I PORT R Adapter &

F i l t e r Assy. P i p e P luo

Adapter h F i l t e r Assv.

P i p e P l u a

C a Heavy Vehicle! cs, ,.: SystemsGmup <. " SERVICE PARTS, CATALOG

HEADQUARTERS & WAIX.PUYT. ELIRIA: OHIO UW35 ? - \

RD-L WSH VALVE

3 2 4 1 8 2 8 1 Boor 4 2 3 8 6 8 7 1 S P R I N G S E A T 5 2 3 5 7 2 9 I S P R I N G 6 2 3 4 8 4 0 1 C A P N U T 7 2 3 8 6 8 6 1 I N L E T V A L V E

8 2 3 4 3 0 5 1 GROMMET 9 / 3 2 . 0.D 9 2 3 4 3 3 3 1 N U I

LIB' P.T.

SUPPLY

BUITOH B U I I O t l 2a1810 IIil81b

RD-2 PUSH'

V A L V E PC. Ha. 2 7 7 0 0 0 - 2 7 8 9 6 3 2 8 1 1 0 9 .

-- REMOTE CONTROL DRAIN VALVE

Button

Pc.No. 2 4 1 8 3 0 2 4 3 8 1 6 - 245516 . .

0'4-1 REMOTE C O N T R O L D R A I N V A L V E

r PC.NO. 2 7 7 1 2 0 1

... 4 2 4 1 R 5 1 1 S P R I N G 5 2 4 1 8 5 2 1 PLUNGER 6 2 4 1 1 5 3 1 C A P N U T 7 2 4 2 3 9 3 1 GRDUUET , 6 2 5 ' O . D 8 2 4 0 5 4 3 1 GROMMET. I / 2 0 . 0 . 9 2 4 0 5 4 2 1 GROMUET 3/0. O O . ,

1 0 2 4 1 R 5 6 I HOSE C L A M P 1 1 2 3 0 4 0 2 1 E . S . N I . NUI

P.T. CORrROL

Heavy Vehicle Bend IX - West~nghouse 3 Systems ~ m u p Instruction & Service matfa

A DV-2 AUTOMATIC RESERVOIR

~ D V - 2 WITH HEATER & THERMOSTAT--

DESCRIPT ION The IN-? A u t o m z t i c R c s c r v o i r D r a i n Valve e j e c t s m o i s t u r e and c o n t a m i n a n t s From t h e r e s e r v o i r i n n h i c h i t i s c o n n c c t c d . I t o p c r a t c s ~ u c o m a t i c a l l y and r e q u i r e s

no manual a s s i s t n n c e o r c o n t r o l l i n e s Fsom o t h e r s o u r c e s . The a u t o m a t i c r e s e r v o i r d r a i n v a l v e h a s a d i e c s s t aluminum hody and c o v e r and i s n o r m a l l y

mounted e i t h e r i n t h e h o t r o m o f t h e r e s e r v o i r u s i t l g t h e t o p p o r t o f t h e d r a i n v a l v e o r i n t h e end o f an end d r a i n r e s e r v o i r u s i n g t h e s i d e p o r t of t h e v a l v c .

The DV-2 is a l s o a v a i l a b l e w i t h 3 h e a t e r and t h e r m o s t a t c a s t i n t o t h e c o v e r For v c h i c l c s o p e r a t e d i n subfreezing t c m p e r a r u r c s . I h c I k a t r d DV-2 i s s u p p l i e d i n c i c l i e r a 12 V o r 2 i V o l t model and i n b o t t o m o r e n d d r n i n c o n f i g u r a t i o n . A I / & " male p i p e a d a p t c r i s s u p p l i e d w i t h a11 W-2 d r a i n v z l v e s , end d r a i n and hoc tom d r z i n , h o t h ~ s t a n d a r d and h c a t e d . T h i s a d a p t e r s h o u l d b c i n s t n l l c d d i r c c c l y i n t o t h e r e s e r v o i r . Thc u s e o f a d d i t i o n a l f i t t i n g s o t h e r t h a n t h e a d a p r c r p r o v i d e d i : i n o t r e c o m c n d c d . -

~~ . ...~.

D V - 2 A U T O M A T I C R E S E R V O I R D R A I N V A L V E

--%-= ' %& I F 1 v e h i c l e cquipped wich 1 DV-2 Automztic Drain V d v c ( s ) i s ope ra ted i n s u b - f r e e z i n g -- cempcraturcs, . i t i s recommended t h a t an a l c o h o l e v a p o r a t o r be i n s r ~ l l e d and p r o p e r l y mnincained r e g a r d l e s s o f t h e f a c t t h a t a hea ted r e s e r v o i r d r a i n valvc is i n s t a l l e d . The xicoho1 c v n p o r a r o r p r o v i d e s complete- system Freeze-up p r o t e c t i o n .

P R E V E N T 1 V E M A I N T E N A N C E Fvcry 1800 o p e r a t i n g . hours o r 10,000 m i l e s o r eve ry 6. months t h e au tomat i c d r a i n v a l v e should b e r.emoved, d isassembled, c l eaned , and. l u b r i c a t e d , P a r t s showing s i g n s o f wear o r d e t e r i o r a t i o n should. b e replaced. S p e c i a l a t t e n e i o n s h o u l d . b e g iven t o t h e f i l t e r - w h e n t h e maintenance check i s made. The F i l t e r must b c clean- and should. b e c l e a n e d o r r ep laced i f c logged o r damaged. Under no c o n d i t i o n s s h o u l d v a l v e b e i n s t a l l e d wichout a. f i l t e r i n s t a l l e d i n t h e adapter..

SERV I C E C H E C K S -,

O P E R A T I N G T E S T Wich system charged, make s c v e r d f o o t va lvc a p p l i c a t i o n s and n o t e each t i m e -?

an a p p t i c a c i o n is made, an exhaus t o f a i r o c c u r s a t t h e exhaust p o r c O F t h e d r a i n valve. I f no a i r comes o u t , push t h e w i r c stem. I f no a i r comes o u t , t h e f i l t e r i s plugg- t d snd valve- should b e removed and cleaned.

JTE: Because t h c au tomat i c r e s e r v o i r d r a i n va lve f u n c t i o n s a s r e s e r v o i r p r e s s u r e i s reduced, -- - e x c e s s i v e l eakage i n t h e system cou ld cause c o n s t a n t exhaus t ing of t h e valvc.

L E A K A G E T E S T ' Wich system charged and p r e s s u r e s t a b i l i z e d i n system, t h e r e should be no - l e a k s a t t h e d r a i n v a l v e exhaust . A c o n s t a n t s l i g h t exhaus t o f a i r a t t h e

d r s i n valve exhaust c o u l d b e caused by e x c e s s i v e leakage- i n t h e a i r b rakc systcm. I f t h e W-2 Automatic- Drain Va lvc does n o t func t ion a s d e s c r i b e d o r i f l c a k a g e i s

excess ive , i t i s recommended, t h a t i t b e r e t u r n e d t o the- n e a r e s t Bcndix-Westinghouse. author- - i r cd d i s t r i b u t o r f o r a f a c t o r y remanufactured valve. 1 f t h i s i s n o t p o s s i b l e , t h e v a l v e

c:te lrc r epn i rcd us ing g e n u i n e Bendix-Wescinghousc p a r t s , i n which c a s e t h e f o l l o w i n g should prove h e l p f u l .

I N ~ ~ T A L L I N G AND REMOV l N G

I N S T A L L I N G Block and ho ld v e h i c l e by means o t h e r than a i r brakes. Draln a i r svscem.

To p r e v e n t e a r l y p lugg ing o f t h e F i l c c r , thoroughly f l u s h and c l e a n r e s e r v o i r b e f o r e i n s t a l l i n g d r a i n valve. A e r a t e any tank thoroughly i f any s o l v e n t s have been used i n t h e c lean- i n g process .

I M P O R T A N T - When i n s t a l l i n g a W-2 d r a i n valve equipped wich a h e a t e r and thc rmos ta t ,

f i r s t de termine i f t h e v e h i c l e electrical system i s 1 2 V o r 24 Vol t , and c h a t t h e He3ter lThcrmosta t U n i t i s O F t h e same vo l t age . The #14 gauge l e a d wi re on t h e va lvc should bc connected t o t h e "bn" p o s i t i o n o f t h e eng ine c o n t r o l o r i g n i t i o n switch. Use an 8 amp f u s e f o r one valve , a 11 amp Fuse f o r two va lves , and a 20 amp f u s e f o r t h r e e valves . ALl e l e c t r i c a l connec- -.,

t i o n s must be- waterproof.

R E M O V I N G Block and ho ld v e h i c l e by means o t h e r than a i r brakes. -- Drain a i r system. Disconnect h e a t e r wirc i f va lve i s s o equipped. Removc automat ic r e s e r v o i r d r a i n valve.

DI:IASSEMBLY Remove 4 cap screws and lock washers. - Remove cover and s e z l i n g r ing.

NOTE: Thc h e a t e r and the rmos ta t o f t h e W-2 ' s so equipped a r e not se rv icczb le . - - I f t h e heater . o r thc rmos ta t has f a i l e d , t h e e n t i r e covcr must be replaced. Cc not remove t h e the rmos tz t cove r p lace . I t i s moi s tu re s e a l e d and re-

/ moval cou ld r e s u l t i n e a r l y the rmos ta t f a i l u r c .

Rcmovc va lve guide . Rcmove i n l e t and exhaust valvc. Removc a d a p t e r and f i l t e r assembly. Remove f i l t e r retainer. Remove f i l t e r .

i - 5 2 ~- .. .- ~ ~.

3 D V - 2 AUTOMATIC R E S E R V O I R D R A I N V A L V E

CLEAN1 -- NG AND I N S P E C T I O N C I e a n ~ n g s o l v c n t may be used on meta l pares. Rubber D a r t s shou ld be wioed c l ean . , . I n s p e c t a l l p a r t s For wear o r deterioration. , ,

Clean a n d i n s p e c t F i l t c r and r e p l z c c i f clogged.

I t i s i m p o r t a n t t h a t F i l t e r b c i n good cond i t ion . Do n o t p u t - valve back i n t o s e r v i c e w i t h o u t a c l c a n f i l t e r .

Replace a l l p a r t s no t c o n s i d e r e d s e r v i c e a b l e d u r i n g t h e s e in- s p e c t i o n s . Bendix-Westinghouse F i e l d Maintetiancc K i t 2821.34 c o n t a i n s a l l p a r t s necessa ry For s e r v i c i n g a l l models O F t h e W-2.

ASSEMBLY Before assembl ing t h e va lve , apply a l i g h t f i l m of g r e a s e on i n l e t v a l v c s c a t . DO h'9T APPLY OIL. T3 THE INLET AND EXHAUST VALVE. P l a c c s e l l i n g r i n g i n groove o f cover. P!ace va lvc gu ide o v e r i n l e t and cxhaus t valvc. P l a c e v a l v e gu ide and i n l e t and e x h a u s t assembly i n t o cover (wire w i l l p r o j e c t through exhaus t p o r t ) . P l a c e body on c o v e r and i n s t a l l cap screws and lockwashers. I n s t a l l F i l t e r and a d a p t e r and screw i n F i l t e r r e t a i n e r . I n s t a l l a d a p t e r and F i l t e r assembly i n body and t i g h t e n . I n s t a l l d r a i n va lve i n r e s e r v o i r a n d reconnect h e a t e r wi re i F d r a i n v a l v e i s s o equipped.

Covers on t h e s t a n d a r d and h e a t e d d r a i n va lvcs can be in terchanged. -

T E S T I N G R E B U I L T A U T O M A T I C R E S E R V O I R D R A I N V A L V E

Perform "Operat ing and Leakagc Checks" a s o u t l i n e d i n t h i s seccion.

FIGURE 1 1 FIGURE 2

4 DV-2 AUTOMATIC RESERVOIR D R A I N V A L V E

FIGURE: 3: FIGURE 4

! )PERATION, R e f c r r i n g t o F i g u r e # I , wi th no a i r p r e s s u r c i n chc sysccm, t h e i n l c c and exhaus t va lves a r e c losed. Upon cha rg ing chc system, a s l i g h c p r e s s u r e opens

chc i n l c t va lvc ( F i g u r c 112) which pe rmi t s a i r and contaminants co c o l l c c t in rhc sump. Thc i n l e c valve rcmains open when p ressu rc - i s ascending i n t h c sysccm u n t i l maximum (govcmor cut -our) p r e s s u r c i s reachcd. The s p r i n g a c t i o n of chc valve gu ide i n chc sump c a v i t y ; l o s e s t h c i n l c t va lve . Re- i n l e t va lve and che cxhaust v a l v e a r e now c losed (Figure # 3 ) .

M e n r e s e r v o i r p r e s s u r e d rops s l i g h c l y (approximarely ? ~ s i ) , a i r p r e s s u r e in rhe sump cav icy opens chc exhaus t va lve (F igure $4) and a l lows mois tu re and contaminants ;o be e j e c t e d From t h e sump cav icy u n r i l p r e s s u r e i n t h e sump c a v i r y drops sufficiently co ( r lose t h e exhaust valve.

The l e n g t h of t ime che exhausc valvc rcmains open and t h e amount of moi s tu re and contaminants e j e c c e d depends upon che sump p r c s s u r e and t h e r e s e r v o i r p r e s s u r e drop ? h a r o c c u r s each t ime a i r . is used From che syscem.

Manual d r a i n i n g can be accomplished a s fo l lows: Using a coo l , move t h e wire i n che cxhaus t p o r t upward, holding i t i n

u n t i l d r a i n i n g is complctcd.

Thc chcrmoscat on the hentcd model W-2 au tomzt i c d r n i n va lvc w i l l a c c i v a c c t h e hear ing elcment when chc vz lvc body rcnchcs a ccmcracure o f ~ S O F and will d e a c t i v a t e chc hcacing e lement when t h e va lvc body i s u-armed t o B ~ F .

G C W C I A I O i l l C I S . AND' F ' l M T - E l Y P I A . OHIO. BRANCHES - BERKELEY, CALIF., OKLAHOMA CITY, OKLA. b SALISBURY.

SAFETY V ALVES

-BODY

P I P E THREAD

No.. Pc.No. Quan. O s s c r l p t l o n :

1 2 1 3 2 0 3 1 STEEL 8 A L L

2 2 0 1 6 1 1 1 A D J U S T I N G NUT

3 2 4 0 5 1 7 1 RELEASE P I N

4 2 0 1 6 1 2 1 LOCK NUT

LA. & SALISBURY, W.C. 1

QUICK RELEASE VALVES

no. Pc.So. Quan- O e s c r l p t l o n

1 2 3 7 9 2 5 1 O I A P W R I G U

2 2 8 1 7 5 6 1 COVER ASSEMBLY 3 2 4 2 8 3 7 1 S E A L I N G R l H G 2 2 4 6 " 0 0 d 2 1 1 0 2 8 I COVER

P- i I I I I I I hperscdcr Q R. Value, 227637. I

BODY SPRING )/a' p 1. OIAPHRAGW FOLLOWER

AW No. Pc.Ho. Vuan. O a s c r l p t l o n

I 2 4 O O I l 1 O I I P H R A G U

2 2 4 2 8 3 7 1 S E A L I N G RlNG 2 2 4 6 ' 0 0

3 2 4 0 0 1 2 4 I / ~ . ~ ~ N A C H I N E S C R E W

H e a v y Vehicle Systems Gmup

SERVICE PARTS CATALOG HEADVUARTERS b HAIYPUNT. E l . Y R l A , OHIO Uu035

THROTTLE CYLINDER

no.

I 2 3 4 5 6 7

8 9

10 I t I 2

- - .. T A K E - U P S P R I N G 15 231152 O I L S E A L . 33/64" 0 0 . 16 231150 P I S T O N ROO 17 230111 GROMMET 3 / 8 " 0 . 0 . I 8 232999 O I L S E A L . 1 " 0 . 0 . 19 203147 P I S T O N CUP F O L L O I E R 20 231160 F A S T # O L E P I S T O N 21 231149

CYLIHDER ASSEHBLY C I L I N O E R

B U S H I H G

THROTTLE CYLINDER

PC. no.

D s s s r i p t l o n Ma. Pc.80. Quan. O s s c r i p t l o n

S E T SCREW 13 214314 1 GROMMET I 1/4" 0 - D .

P U S H T U B E A S S E M B L Y 14 231159 1 G R O M M E T 1 19 /32" 0 . 0 .

I C Y L I N D E R C A P

I L O C I NUT

I P I P E P L U G . 1/4' I P I P E P L U G 118. I NUT

I P I S T O N C U P

I P I S T O N

F a s t I d l e S p r i n g P C . NO.

Push Tube A d a p t e r PC. YO.

G r a d u a t i n g Spr ing PC. no.

Heavy Vehicle Sys tems Group

SERVICE PARTS CATALOG HEAOQUARTERS b H A l l P U N T , ELIRIA, OHIO U9035

THROTTLE VALVE PC.N 0. 221946

7his i h r o r l l e Va lue i r obsolete * a l l is l i r l c d ]or Service Ports m l y - Gpcr. redrd by 7hra l t l e Va lve 224931 r h m a 6 1 o I a n 12-A-%.

T H R O W L E VALVE P C . l 0 . 221996

( ~ r ~ d w t l n g flange 16 to 65 p o d s per rqvnre i n c h )

l o . PC. l o . Qua". Oascrlptlon l o . Pc.Xo. g u m . O a * c r l o t l o n

1 213735 1 C O V E R HUT I 3 231234 1 P L U N G E R 2 214458 S H I M 0 1 0 " 14 214334 1 S T O P RING

15 214321 1 C D Y E R P L A T E 3 221155 I P I S T O H A S S E M B L Y 16 214311 I BODY

4 233117 1 S P R I N G 17 201319 1 L O C K W A S H E R

5 222151 1 S T E M 8 P I S T O N 1 5 S E U B L Y I 8 231678 1 S T O P SCREW

6 214320 1 S P R I N G S E A T 19 214314 I GROMMET

7 214379 ' IHiU 0 1 0 " 20 212268 I GROMMET

8 203021 1 HUT 21 230115 1 E X H A U S T V I L Y E P L U N G E R SPRING 9 203842 1 C O T T E R P I N 22 220770 1 #"LET V A L V E A S S E M B L Y

23 213734 1 CROWYET 10 203233 2 C A P SCREW

11 203145 2 N U T

12 202982 2 L O C K WASHER ' A S k q u ~ r d

. . . -

. - REGULA,TU'RS. FOR WA-TER- AND AIR

: ..., SPECIALLY DESIGNED FOR- DOMESTIC SERVICE

APPLICATION: TYPE E SERIES 3. The Type- E Series 3 pressure. regulator- reducer a high pressure. in a domestic: water supply line to a lower pressure and. maintains i t at the desired lower pressure. level automatically. Eliminates pipe noiseand rapid wearing of f i x t u rq faucets; and va lm. Campletelyautornatic, easily installed, featuring large inbuilt rnonel strainer with separate clean.out plug that is simpleto remove and clean.

For use where supply line- inlet pressure- does not exceed 300 psi. Standard factory outlet setting 45 psi unlen; specjlied otherwise. See. Spring Chart and specifications on page 3.,

These regul&ors are. desigwted Type E Series 3 due. to the complete redesign and up.dating of the f o r m U\SH.ACME T g p ~ E Series w k h has been a high quality staodard of the lndtntry for over 30 years. The- new- Type- E Series 3 regulators incorporate: all of the. time-proom. features of l h t former design; plus new and improved pnforrnance. charaderistiy much higher capacity (see. page 4). a s d l as other impmvemmts that p r d e Ion@ service life; durabiliiy and mainteeam free oplmfion.

C 0 N.S.TRUCTIOP1- High& qdty bmma body, aluminm. s* chamber. s t a i n lm st&^ body seat, umpmmon SSA ddbr, BunaN, diaphragm wi th nylon insert; built-in straimr; cadmiam plated cartmn. st& spriail, b m s assembly and adjmting. screws ad I d nuk

Yoketype- dedgn rnem t h a the reguMor. dmm against the inlet pressure; providing quieter opcratimr undn- wide and varjmg tlm- und i t i om For nor- capaci i iaformlim see page 4

TYPE E& SERIES llCtTH 1EHltttt.f G H f C X VALVE The Type-€ S m k 3 is-a ls-maikblewi ih m inbuilt back.pn check valvewhich operata indtpmdtnHy of Mc regnbta. Thr.Type EB Series 3 produces and regulates M)n- prmure in- the regular mnnn, bot if prmure on the. omtld or downstream side of the regul&ar increases to a paint bi$w Hun the inlet or upstream prrrmre, the inbuilt back-paa ch& uiH opm and permit flow back into t h t id& side of the regalator. Such a situation can be caused by thermal expansion in a watu he*.

I( A. W. CASt4VALYE M*. COW. ; - ) DECATU?, I L L I N O I S 6 2 5 2 5

- *

.AfW awitabla with- tdloa; diaduagm tmparalura protector linsr a, special order only at erlra charge:

TtE L.E -,3: IWl3NW:

% - =103Mt / ,'I0364 hi10637 e l0638 SPECIFIMTIOW DATA:

I '

1040 2070 71.100 101 150

SIZES-Sf', 1'; I%*, 1%'; 2' 5- $l12aSm $10320 $10639 #lo640 1040 20.70 71.100 101.150

CONNECnOWtandad E S m a . 3 furnished uitb-Wed &. For union. inlet specify Type EU Se+s 3 and. state. whdhef 1- #l0558' $10558 #I0644 #I0645

1040 2070 71100 101.150 sweat coppec. or lhreaded. union end- dnked. Also available wilh inbuilt. bwlt-pur: c M - vale Ask fa T g p £0 Seria 3 1%-

$10559' #I0559 #I0646 ,YIOMZ.

or EB-U -3. 1 0 4 2070 71.100 I01 150.

INITIAL PRESSME--Up to.3W) psi. 1%' $10641' $10641 $10642 g 10643

1 0 4 2070 711W 101 150 OUTLET PRESSURE-Aditntabk range 20.70 pri: ztandard Fddmy

settin5 45 pk 0 t h outlet-settings from 10. u p t o 150 psi 2- #l06aJs #106&3 #lo684 $10685 10.40 20.70 71100 101 150

are. also available; p~ sprint ranges at right: S E R V I C E 4 d a hat w a t s (t6 200" F) o r air: 'Valvsa for low. pressure sening available on special wder only a t small

CAPACIW-Set page 4. extra ant : A - special spring and accompanying piston xpring are re. quired.

: H O W TO ORDER' I

X Y P E E SERZES 3' REPAIR KITS -- I tior c o n v e n i m in or-: a handy p p x i a g e d rq&r k i l is available fur all T p c E Serin 3 p i p e s i r n The kit contains the parts that an. mnnally subjected to ertemivv rser in~ . Set i h 3 - !:ration at r ight The hit alva indudn a set of installation instruc- 1:ions. To ordu, rpKify E Serin 3 kit, give p i p size and date. $:educed p r m m scHing. S p k for 45 psi setting standardly {urnished. Whm ordwing; also please state- Mhn Lit is for liew Type E Series 3 regulator or old Typs E.

A. W. CASH VALVE MfG COW. W A U S Y AT YO-

REPAIR KIT

PRCXRGE- IH€LUDLS: Diaphragm Composition Seat Disc Composition Seat S c r n Strainer Scrnn Bottom Plug Gasket Cleanout Casket Body Seat Pressure Spring

DECATUR, I L L I N O I S 6 2 5 2 5 r a w n o m ~ 1 r l o z ~ - a 5 - 1 4

N O . /593- 0- &//cG 're )

. I "1

-3 M O O E L L PAGE-

. A@aS LET 20-8 20-11 20-30 DATE ISSUED 9/14/66 -

BECAUSE OF DEUBLIN'S BALANCED SEAL DESIGN, NO EXTERIOR BRACING SHOULD BE USED TO PREVENT THE HOUSING FROM ROTATING. TO COMPENSATE FOR ANY ECCENTRICITIES OCCURRING FROM INSTALLATION, IT IS IMPERATIVE THAT A FLEXIBLE CONNECT!ON BE USED. DO NOT PlPE SOLID. USE A 45-DEGREE ELBOW AND PIPE UNION ON THE RISER, MAKING CERTAIN THERE IS A SLIGHTCURVEIN THE HOSE. DO NOT INSTALL HOSETAUT.

TO AVOID WRENCH TORQUE DAMAGE TO THE BEARINGS DURING INSTALLATION, THE FOLLOWING PROCEDURE IS RECOMMENDED:

1. GRASP THE REAR OFTHE HOUSING IN A BENCH VISE AND INSTALL FLEXIBLE HOSE.

2, INSTALL ROTATING UNION INTO MACHINE SHAFT.

3. CONNECT FLEXIBLE HOSE TO SUPPLY LINE. USE A 45- ELBOW AND PlPE UNION ON THE RISER. BE SURE HOSE IS NOT INSTALLED TAUT.

LUBRICATION

ONLY THE BALL BEARINGS REQUIRE LUBRICATION. ANY GOOD BALL BEARING GREASE CAN BE USED, BUT CARE SHOULD BE TAKEN NOT TO OVER-LUBRICATE. MINIMUM LUBRICATION -APPROXIMATELY EVERY 60 DAYS - IS NEEDED FOR WATER OR OTHER LOW TEMPERATURE INSTALLATIONS. ON STEAM INSTALLATIONS THE BALL BEARINGS SHOULD BE LUBRICATED WITH HIGH-TEMPER- ATURE GREASE AS NEEDED. USE GREASE SPARINGLY. THE MICRO-LAPPED SEALING FACES ARE LUBRICATED BY THE WATER, STEAM OR OTHER MEDIA PASSING THROUGH THE UNION. FOR THIS REASON, ANY MECHANICAL SEAL TYPE UNION SHOULD NOT BE RUN DRY FOR EXTENDED PERIODS OF TIME.

Bullolio No. 8.9-68

IMSTRUCT1IONS FOR 1NSTALLlNG A N D LUBRICATIING DEUIBL1N U N l O N S

DEUBLIN CO. - --

N O R T H B R O O K , ILL --- -

MODELTS100 SERIES UP and UPTransducers

VOLTAGE / PRESSURE

*Smallest, lightest, most compact un l t

*+Resistant to vibrations.

* Factory Mutual approved (TC, TD, T F Serles)"

*'Multi-range selection.

*fTemperature compensated.

*# External zero adlustment.

The Fairchild VP Models T5100 and T5120 are the smallest, lightest current to pressure transducers on the: market. They are designed to accept a Miili.. ampere dc signal in the range of 1-5 ma; 4-20 ma; and 10-50 ma and conveit this signal to a proportional 3-15 PSlG pneumatic output. The linearity of the current to pressure relationship is less than l/2 of 1% over the output span. The Models T5100 and T5120 may be mounted in any position required. Also, these units exhibit excellent stability when subjected to shocks and vibrations and may be used for direct valve mounting without jeopardizing their performance. Both Models can be changed from Direct Acting to Reverse Acting in the field with only a simple Zero adjustment.

The-T5120 differs from the T5100 only in that the T5120 has an integral Volume Booster for appiica- tions requiring high capacity output volume.

FORTOTALCONTROL WHEN THE PRESSURE'S ON.

The Model T5109 is similar to the Model T5100 except it is.an V P device- which converts 1-9 volts dc to a 3-15 PSI output. The T5129 isalso an E/P transducer but like the. T5120 has a much higher output flow. capacity.

The Fairchild. Model T-51210 IIP transducer with- infinitely adjustable gain relay has created a milliamp to pressure capability that is unsurpassed in versa- tility of performarice by any other instrument. The T-51210 is. designed to take a low level milliamp electrical signal in the. range- of 4-20 or 10-50 ma's and convert it to a 3-15 PSI output; then subtract a negative bias, multiply, or divide the results, then add a positive bias to obtain the final output or pressure required.

FACTORY MUTUAL APPROVAL. The- Fairchild TC series transducers are ap-. proved by Factory Mutual for groups C and D intrinsically safeapplications when installed with- Taylor barrier Models #124S931 or #124S932. The, Fairchild T F series. transducers are approved by Factory Mutual for Groups 8, C, and D intrinsically safe applications when used with the Foxboro Spec 200 system Models 2AO-V21 -FGB. 2AO-V31- FGB, 2AO-VAI-FGB, and 2AT-SBU-FGB., The Fairchild TD series transducers are dust ignition proof as approved by Factory Mutual for Class II, Division I, Groups E, F; and G are also intrinsically safe for either Groups 8. C, and D, or Groups C and D locations depending on the unit model number and whether it is used with Taylor barriers or the Foxboro Spec 200 system. The Fairchild TC. TD, and TF series transducers meet requirements of ISA- RP12-2 - "Intrinsically Safe and Non- incendive Electrical Instruments."

OPERATION. The Fairchild Models T5100 and T5120 are force balance systems. (Refer to Fig: 1 .) In a direct acting unit. an increase in the dc milliampere signal to the coil will increase the magnetic field strength around the coil. This increase in flux density, or field strength of the coil, opposes the permanent magnetic field of the magnet; thereby creating a thrust on the coil in a downward direction. The downward movement of the coil moves the beam or flapper closer to the nozzle and restricts the flow of air: The restriction of the flow of air through the nozzle causes a build-up in the output pressure. The change in output pressure is directly proportional to the change in dc current to the coil..

The same condition exists in a reverse acting unit except that with an increase in the dc milliampere signal, the coil will be attracted toward the permanent magnet and will lift the flapper away from the nozzle. With this increase in nozzle clearance, there is a corresponding increase in flow through the nozzle; thereby creating a lower output pressure. Here; output pressure is inversely proportional to the input d c milliampere signal. The principle of operation of the- T5109 and T5129 units is essentially identical to that 7 I of the T5100 and T5120 IIP transducers.

The. Fairchild Model T-5121D has been created by joining the T-5120 IIP Transducer and the Fairchild Model 210 Adjustable Ratio Relay with dual bias together as one unit. With this combination, a 4-20 ma input signal to the IIP will produce a 3-15 PSIG signal output to the Model 21D Ratio Relay. The

Figure 1

OPTIONAL MOUNllNG BRACKET DIMENSIONS

FOR TOTAL CONTROL WHEN THE PRESSURE'S ON.

0ARREl-r EQtJlPMENT CO.

- -. SEATTLE, WA 98105

INSTALLATION, OPERATING & MAINTENANCE INSTRUCTIONS FOR

/

3 MODELS T-5 100, T-5120, T-5109, T-5129 MODELS TC-5100, TC-5120, TC-5109, TC-5129 MODELS TD-5100, TD-5 120, TI)-51 09, TD-5129

TC &: TD units are INTRINSICALLY SAFE only when connected irr accordance with Drawing Number EA-11597.

GENERAL INSTALLATION INSTRUCTIONS The Fnirchilrl T-5100 series operates ns a force balance system..

1 he incorpartion of a torsion bar in these hansducers insures bcttcr b;il;mcc, stability and repeatability by eliminating any friction which may be caused by moving parts.

The T-5100 series may he wall or panel mounted o r mounted directly to a valve with thc bracket which is available as an option.

ELECTRICAL CONNECTIONS Elcctricnl cunncction is m:& through 'h" NPSM conduit con-

nection on onc cnd of the tmnsducer case. Unscrew the cnp from 1110 COYCT and remove the shunt wires and tag connected ncross the tcrminnls hcfore wiring unit; For dircct acting arrangement. connect positive wire to the positive terminal and negative wire t r ~ the ncgative terminal ns shown on the P C . Bonrd. For reverse at:ting armngcment, connect negative wire to positive terminal !nd positivc wire to negative terminal as shown on the P.C. Bonrd.

($CC Figwcs I11 nnd 1V) If a range selector switch is incorporated irl the circtritry. (T-5100 and T-5120 series) be sure to turn the rqncc switch tr t the correct point for the input siwnl that is being wcd lrrforc applying ctment. FAILURE T O DO SO ,MAY BURN 0117 COIF.. ....

NOTE: n<;chcck switch position prior to connecting power supply.

PNElJMATlC CONNECTIONS C1c:tn ;ill lincs to rrninvc dirt nnd scale hcfore instnllntion is

n,;ldr. \Vlwn instnllinc pipe o r ttthe fitting into the unit, it is ~pqrfrr;tl,lc to w e tcRon tape ns a sealant; bult if pipe compound is twc : r l . ~ r c o t C:IW must he titkcn to prcvcnt thc intrnduction of any. 4 1111. cnmprmnrl into t h e tr:tnsduccr. It is prefcrnble to s t x t with tl~ird thrc:~d h ; ~ k anrl work nwny from end of linc to nvoxd posst- hility i r f g c t t i n ~ compnwd into transducer. Install transdttcer in the air linc Unit is fittcd with a YI" NPT port for inlet and outlet vonncctions. Inlct and oc~tlct connections are labeled and fittings sl~,ndd hc tirhtcned sec~~rc ly . NOTE: Instrument air should be iucd Howcvcr. if instnmcnt air is not avnilable, use n filter air set rcc111;1tor (Fairchild hlotlcl fi5) to remove dirt nnd entrained liri~lid in t h e air line ;ahcad of the tmnsducer.

I f an air line lubricntor is used, it MUST be located downstream hoyontl the tnnsducer in order to avoid introduction of oil which wxll intcrfcre with the tmnsducer's performance,

ZERO SETTING. Tlir tr:mstl~~cr-r is c:tlilrrntd and tvstrtl a t the fnctnr to mcct

I : I i : i t i 1 in the cnttthg. Shottld fich adinst- m n t s In r< rptirul, us<; 11w M h w i n g prc~c~cl~trc. Apply a cflnstmt 51 PSIC sl~>l>ly p rcss~~rc TO check thc output prcsstm mngc. a mxarrc c:iw shoold be mounted in the outlet linc. \Wtcn cnli- Imt ins tlw unit. mnkc ccrtain that all tubing connections are hul~blc-tight. Zcro adimstments should be made with the unit in 111s: snmc jposition ns it will h e installed. However, zcro adiust- rnsnts may be required if the installation position is cbnnged from above.

(a) Direct Action On dircct nction units, set t h e input to the minimum value of the rnnse heinr uscd. If the output is bclow 3 PSI, turn the zero nrliwsr screw clockwise until 3 PSI is obtained. If the output is ahove 3 PSI, hlrn zero adjust screw counterclockwise until 3 PSI is obtained.

6) Rcversc Action On rcvcrsc nction units, set the input to the minimum value of the range being used. If the output is below 15 PSI. turn the zero ndiust screw clockwise until 15 PSI is obtnined. If the

output is nbove 1 5 PSI, turn the zero adirwt screw countcr- clockwise until 15 PSI is obtained- NOTE: When reversing the action of the tmnsduccr, the electrical input leads must be reversed and the zero ndiust screw turned clockwise until an output pressure of 15 PSI is obtained with minimum input. turn in^ the zcro arliost screw clockwise increases the outpok pressure, and titrnins the zero adillst scrcw co~mtcrclockwise reduces thc output prcssure. (nr\f. Fiwrcs 111 & IV )

SPAN ADJUSTMENT- Set input sijrmal to high point in tlic range. If ~ . i g c :clloes not in-

dicate correct output (15 PSI for direct acting 3-15 PSI mnge. 3 PSI for rcvcrsc acting 15-3 range). the tmnsduccr spnn can he ntlittstcd per the following paragraph:

Rimec of m i t can be checked by setting the inpttt d.c, signal to tlle low point of the range and noting that thc output pressure is. as set ahove Adiusl input siwnl to high point of range and note output pressure. Spnn should be 12 I'SIC. If reqnired, span 2nd- iwtmcnt can be made hy removing the cap from the cover and turning span adir~stmcnt potcntiomctur on P.C. Roarrl A slicht turn will usonlly prodttcc thc dcsirerl chnngc in spnn To increase span, turn potcntiomcter clockwise- to decrmsc sp;m turn po- tcntinmcter countrrclockwisr Clwrk snnn ns duscrihctl nhovc, and if ncccssnry, cnnlinw nrlitrstmcnt until correct span is obtnincd. lie-zrm nr ncccsmry Rcplncc c ; ~ p in cover

OPERATION In n dircct acting unit, an incrcnsc in the input signal to tho

coil will incrmse the mawetic flcld strcnmh arntnnd thc coil This increase of fins density, or the field of the coil. opposes the permanent mnwctic fidd in the mawetic circuit: thcrchy creating R thrust on the coil in a downward direction. The downwarrl movement of the. coil mnvcs the flnppcr closer to tlic nozzlc and restricts t l ~ e flow of air. This restriction of the flow of air through the nozzlu awrcs tltc ootput prcssurc to incrcose. The chnnse in output prcssure is directly proportional to the change in the input to the mil.

The same condition exists in ;I reverse acting unit, except that with an increase in the input siplnl. the coil will be moved toward the permnncnt magnet and will lift the flapper away from the n o d e . \Vith this incrcasc in nozzle clcnmnce. there is a m n e - sponding incrcasc in florv d>rougll the nozzlc: thereby crcnfinp: a lorvcr o u t ~ t ~ t prcssure, Thc outpl t presstrrc ir invcrscly prormr- . ~ . lionnl to thc inptrt sikmal, 'Thr principle of opcrntion is i~lcntical for hoth the T-5100 nnd

T-5108 serics.

TROUBLE SHOOTING Pneumatic: 1. Chcck supply pressure-should be a constant 20 PSIG. 2.. Make certain that tubing connections are tight. 3. Clteck zero adjust and span as previoidy outlined. 4. Clicck to see if wire screen vent In cover is obstructed. 5 I f dirt or flt~id has entered intcmal pncumntic section, it may

clac the fixcd unficc nemovr ortIice xsumhly 2nd rcmove d in or U u d by hlowtng i n air stre3m into arsemhly

F.lechicnl: 1. Xlcasure d c simnl to h.ansducer. Is i t the orooer n n e e ? . . 2. Check to see chat input signal leads are connected to proper

terminals. 3. Make certain there are no loose wires nt terminal or solder

connections

6ARREl-T EQUIPMENT CO., Foamy Rrprcwn~mw

(206) 522-8325 INDUSTRIAL PRODUCTS OlVlSlON

1501 Fatrchlld o w e . WmstonSalcm. N c 27105 2500 N. E. 49th ST. i e ~ 1 1 9 7 6 7 6010 Tciei 806429 SEATTLE, WA 98105 -- -. --

V I C . I VIRINO SCHWATIC B(1MD.

WDZLS T-51W 6 T-JllO

mn. R - I ~ ~ J R 3-15 PSIG. 10 PSI0

1-15 PSIG. 10 PSIC.

1 - 9 V Z CuTFlr CWmJT INPm l Z O P TUUM 110. I 1 1 T U T S Z T UP. TIC. 1V TLST SZT UF

( - - OH. P.E.. ) a O U S T-31W 6 T-3110 WDLLS T-5109 d 1-3119

.. ?IO. I 1 VlRIHO SCHPJUTIC BMRD

WOLLS T-5109 6 T-5129 N.L 11UGPNG ARK FOR DIRECT K'IIffi OPlRATIOH

MAJOR DESIGN FEATURE5 .- Stability at all ratios. .. Venturi aspiration to compensate for down-

stream pressure losses. .. Large relief valve. %.>

.; Balance supply valve. .. i:j

.. High frequency response. ,. ;.. .. Optional input & output biasing.

OPERATION: The Model 21 adjustable ratio relay provides

an output pressure with a high volume of flow whichsis a reproduction of the signal pressure. The ratio of output pressure to signal presslire is infinitely adjustable. The adjustability range permits signal amplification of as high as thirty times or signal reduction as great as 30:l. By rotating the ratio adjustment knob, an infinite number of ratios can be obtained within the limitation of the relay.

The signal pressure ac t ing on the signal chamber diaphragm transmits a force through a lever to the control diaphragm and thus sets output pressure. The lever fulcrum is adjustable. Output pressure is a function of signal pressure times the ratio of lever arm lengths on either side of the fulcrum.

h'endall >lode1 21 adjustable ratio relay is a itce relay with the superior operating

, . tcrlsttcs of the Kendall line of pressure regu , and relays. Its operating features include a.

i strength, deep convulation balance diaphragm ch tinlances supply seat forces. The output side-

8 incorppratcs a floating seal ring: which isolates wmtrol chamber and increases. the- stability by

!~cing tl.,e cffcct o€ high flows.

c : The Model 21 can besup lied with a tapped. i' . lust port for safe venting. o t o m or explosive .s Tbe :itandard unit is supplied with an adjust- knob. The unit is available with a slotted screw istment and a tamper proof cap. A gage can be ,.idcd 'The Model 21D is also available. with ii input and output adjustable bias. Maximum ~t bias is 3 psi. Maximum output bias is 9 psi.

hnsic mathematical expression for the bias. in rclny is:

P,, f Ps - K t ) R + Kz

= I h t i c ~ of %ttinS = Inp~tt Bins ( - ) Only = Output Bias (5) Only cn ordering, the suffixes listed below should be x l to the bastc catalog.number to indicate the ired feature. qxd Exhaust-E Gage -C -cr ProoF Cap - T Bias -D

1

SPEC "! t.tT!3N5: Flow ............................... .40 SCFM

Exhaust capacity (Downstream pressure 5 PSI: above-

................... set Pressure) .5H SCFM

Sensitivity ........................ Si" Water

Effect of supply pressure variation - Less than 0.1. for 100 PSI change.

Max. supply pressure: ............... .250 PSIG

Max. signal or output pressure. ....... .I50 PSIG-

Ratio, range.. ................. .30:1 thru 1:30 (first number indicates. signal pressure, second number indicates output pressure)

Mounting .................... .Panel o r Line

Material Body & Housing. ................ .Aluminurn Diaphragms ............... Buna-N & Dacron Lever &. Fulcrum. ............ Hardened Steel Tiim. ................ .Stainless Steel, Brass,

Cadmium Plated Steel and Neoprene.

. . . - . .

.7 . .

8 ,

.?.

.. 2 . . ..,: .. - . - . . . . . . . . A . A ? :; . . . . . . , , .g. )

.KETT EQUIPMENT CO. F a c q ~ R v / n r i i t ,

(2( 522-8325 FAIFCCWILD HILLER 2500 hl. E. 49th ST. I N D L l S T R l A L P R O D U C T S O l V l S l O N

1501 Fairchild Drive. Smith Reynolds Airport EATT;E, WA 98105 winston-~a~em. N. C. 27105

Tel. 919-7676010 TWX 510-931-3584 - -- - Telex 80.6429 *... 59" . lZ , .P, I . I . . ...

INSTRUCTIONS FOR THE INSTALLATION, OPERATION AND MAINTENANCE OF

7 MODEL 21 ADJUSTABLE RATIO RELAY . .

INSTALLATION

f l m n 31il lines to remove- dirt.and scale- before- installation i s tapped %" NPT connection. A11 connections should be 111:1de Apply minimum amount of pipe compound. to male securely tightened. Avoid. undersized fittings that will limit tl~rc:~ds o S air line only. Start with third thread. back and. flow through the booster. :vork a w y from end. of line to avoid possibility o f getting, mnpouwJ into air lines. Install booster: the unit should be: The use of a l i t e r to remove dirt and entrained liquid in the

mounted; in the horizontal position for best operation. ~h~ air line. ahead of the- regulator is recommended. for best

i-:" or 3/5" N f l inlet and outlet connections are: labelled: perf0IInance. If an air, line lubricator is used, it should be look foq arrows denoting direction of flow through the located downstream beyond the relay in order to avoid booster on t h e underside of the unit. The signal line is interference with performance.

OPERATION

The Model 31 adjustable ratio relay provides an output pressure with 3 high volume of flow which is a reporduction o i the signal prcssure multiplied by t h e ratio. The ratio of mtpl ' r pressure to signal pressure is infinitely adjustable. The I + i l i ty range permits signal amplification of as high as thirty .mes or signal reduction as great as 30: 1. By rotating ;lie ratio adjustment knob, an infinite number of ratios can I ohtained within the limitation of the relay. The signal iprvssurc acting on the signal chamber diaphragm transmits a l i w e through :I lever to the control diaphragm and thus sets <>titput presstire. The lever Sulcrum is adjustable. Output ;prcssi~re is 3 lunction of signal pressure times the ratio of lever :~rrri lengths on either side of the fulcrum.

BIAS AIIJUSTMENT. Set ratio at 1:l as indicated on the mdicator. Back out both bias adjusting screw (%3) (at cither end ol' the unit) apply supply pressure to the relay. Turn clmkwise bias screw on the output end, until the desired bias is reached (do not excehd 9 psi)., Note the

output pressure of the unit. Apply 10 psi signal to the signal port. Note the output should only increase by 10 psi. (If not, adjust the ratio until the output reads I 0 psi. increase.) Now, adjust (clockwise) input bias adjusting screw until the output is decreased by the exact amount of imput bias desired. The unit is now set for the correct input and output bias. Adjust the ratio to any desired setting.

GENERAL MAINTENANCE INSTRUCTIONS

The booster is easily disassembled for the occasional cleaning or removal of foreign matter. Before tllis is done, however, shut down valve upstream of the relay to prevent escape of air when the- relay is disassembled. There is no need to remove the instrument from the line: merely removing the two No. 10-32 screws on the bottom of the unit and taking out the inner valve assembly is all that is required. Wash inner valve assembly with solvent exercising care to avoid damaging diaphragms and valve facings. Replaceassembly.

BARRET EQUIPMENT CO. Fmmy Rlprtwn~ariw

FAIRCHILD HILLER' I N D U S T R I A L P R o o u c r s D I V I S I O N

(206) 522-8325

1501 Fairchild Drive e Winston.'Salem. N. C. 27105 2500 N. E. 49th ST.

Tel. 919-767..6010 TWX 510-931-3584 SEATTLE, WA 98105 Telex 80-6429

Exwnded M e b l Rotqctlvs Houslne:

\ Washer (Tap and Bottom) ' /

Ralnforcsd Syncllnd Inser t Centering Tube Asrcmbly

I R.movr Unscrew COUPLING TOP COVER from csntsr1ng.tube

4

1. c1.m. SYNCLINAL INSERT

R.mov. EXPANDED M R A L

PROTECTIVE HOUSING

'St 'd - HYDRAULIC OILS - COOLANTS - LUBRICANTS 5 -PHOSPHATE ESTER BASE F IRE RESISTANT FLUIDS N -AQUEOUS BASE (WATER GLYCOL) F I R E RESISTANT FLUIDS W - W A T E R

TO REASSEMBLE- SIhWLY REVERSE PROCEDURE

r P A R T NUMBERS FOR STANDARD MESH -CHANGE SUFFIX TO CORRESPOND FOR OTHER MESH SIZES @J 1 ~ 6 3 MARVEL ENO. co I P A R T NUMBER FOR "W" FILTERS IS P3O7

j

7227 N. H o m l l n Av.. . Chirago, 111. 60645 . AREA CODE 312 . 267-5200

125 lb. s Screw-in Bonnet * Integral Seat Renewable Discs

125 PSI Saturated Steam 200 PSI Non-Shock Cold Water, Oil, or Gas

Federal Specification: WW-V-5ld Class & ~ y p e I

I NlBCO INC., ELKHART, INDIANA

T-211-8 F S P S. l o F S.P.S.

MATERIAL LIST

PLRT SPECIFICLTIOHS - I. Handwheel Nut Bronze ASTM 8-16 -- 2. ldenl~l ical~on Plate Alumtnum

3. Handwheel Aluminum ASTM 8.85- ntt... r 376 .-- ""U, "..L"

4. Stem Silicnn Bronze ASTM 8.371-62 Alloy A (Rod) or ASTM 8.198 Alloy 138 -

5. Packing Gland Bronze ASTM 8-62 - - 6. Packing Nut Bronze ASTM B.6? - 7. Pack~ng Teflon lmpregnaled Asbestos -- 8. Bonnel Bronze ASTM B 62 9. Disc Holder Nut Bronze ASTM B 97 Alloy A

'10. Disc ~ o l d e / . Bronze ASTM 8-62 -- 11. Seat Disc. Water, Oil or Gas (Buns-N) (W)

Sleam [Teflon) N) , . , 'Ila. Seat Disc Bronze ASTM B 62 (8)

'12. 01rc Nut Bronze ASTM 8.62 13. Bodv Bronze ASTM 8 4 2

DIMENSIONS -WEIGHTS - QUANTITIES

T-211 threaded

S-211 solder

i3FCM ITE., vitreous enameled rheostats (potentiometers)

dimensions: MODEL.S H, I. G. K. L '

'A" 20 THO roR MTG S C R t V I S I lSUPrLlI0 vlITll

3 MODEL N ONLY1

Rundel-IDEC has simplified the normally difficult speci- ,cation of cam arrangements by making. two new contri- utions lo the industry.

1) Establishment of numbers. to Identify all usable 2- ;osition and 3-position contact arrangements. SeeTable 1.

2) De\plopment of an exclusive universal cam for the 252-a single cam that will provide- any contact arrange- nent sim,ply by selection and placement of contact blocks. ;ee Table 3.

Thc d j l single rod unit is the most versatile of all se- x t o r switches. Its many features include:

Choice of Activation

a) 6 colors of knobs b) 3 ciolors of levers - c) key operated

'3) coin operated

m u d return (maintained) units can be, quickly field 2 changed from 2- to 3-position in arr averagwtime of 15 seconds. (Consult nearest sales office)

1 All possible contact developments for 2- and 3-position switches can be made by specifying proper contact block:$ from Table 1. (Can mounron either side)

:. 2-pos,ltion spring return units available with spring action from left to right or right to left. 3-position avail- a 'eft to center or right to center. For spripg return bob, :!ides to center, specify SS2 operator;

The 552 is a twin-rod unit used primarily for 3-position spring rcturn from both sides to center. For this applica- :ion the F-4 cam is preferred. (See Table 2.)

The Gniversal Cam is preferred for 3-position manual return ai?piications because only one contact block is re- wired for each contact arrangement. (See Table 3.)

also olfers 6 special cams, similar to other dacturers. Contact nearest sales office for information.

SS2 units are available with 4 colors of knobs or 3 ::dlor- 71 levers which snap on permanently. Key-operated SS2'; , e also available.,

TABLE 1

CONTACT ARRANGEMENTICONTACT BLOCK SELECTION

Contact Contact arranqement block . number t Y P*

t Threw Position t ). fi I # 1 X O O A .. - - I *2 0 X 0 A & i3 Contact B lock* I *3 O O X E in ser~es . -

~4 X X 0 A - E M - : *5 0 X X B - L B , ! *r6 X 0 X A & B Blocks in parallel .- ' Two Position t #

X 0 B 0 X A - X - O ( o v e r 5 - L B 0 - X lapping) A - EM

TABLE 2 SSZSPRING RETURN CONTACTDEVELOPMENT ARRANGEMENTS F4CAM

E F T ,\ yGHr 1 P S OXX r t 4 x x o

P l X O O * 3 0 0 X ypy7 TABLE 3,

SSZ MAINTAINED CONTACT DEVELOPMENT ARRANGEMENTS UNIVERSAL CAM

RIGHT

A

r* 2 ox0 * 1 xoo B A

TOP I

- - I21 CON. T A C T

3LOCKS - List Rice --

53.00 See Page 26 to order

(1) OPERATORS:

TYPICAL EXAMPLES O F COMPLETED UNITS

HANDLES shipped permanently.

Cawlog No. - --

I

-- I I I

--

-- f

.- oat. o n - 2 2 3 3

- 2 2 3 3

- 2 2 3 3

- 2

2

3

3

)exr ip t iou

SELECTOR SWITCH KNOB OPERATED

Rmurn L\Rion - Manual Spring Manual Spring

Manual Spring Manual Spring

Manual Spring Manual Spring

Catslog No. Color

7

led ireen llack 'ellow ,due )range

- led ireen llack

:hrorns

- :hrornt

Catsloe No.

SE TOR SWITCH LE\ OPERATED

S3.W See Page 26 ro order

- S3.W See Page 26 ro order

SELECTOR SWITCH N O T REQUIRED - 0 I N OPERATED

SELECTOR SWITCH KEY OPERATED

NOT REQUIRED

I Manual

Spring

Manual

Spring

$3.00 See Page 26 t o Order

, l i Srxsll ls SDrlng Ac i lon I s lndicmod b y use of Comloq No. O K o v Ramoval Salscrlon O n Kay ooarocad Salocror shown In Tablo 1 Sw%tchw lndlcofa key rarnovabie podr lon (See Table 2

Po. 161 lmmadlstdv after op~raror number. 0 % KSS1-KRL-2MR-2A18.

Table 1 . .

, ' ..- ... .._I_,__^L.. . _ Catalog No.

Spring Return 2 Position 1 3 Position

Right to Lett Lef t t o Right Left to Center Right t o Center

,,-<.-- v--.....,,-- ..... ..- -...... ..:- , r , . .

SR..RL SR-LR ---

---- ---- SR-LC SR43C

Rundel-IDEC transformers are rated a t 1 V A All transformers arecurnrn limiting. preventing d a m e t r a n .Hudrn.m ar- : ' ': ' : ;. loadingi or shorting. 7. . ........ . ..TW

. . . . I;--

,,'<'' :'.,"', . ,, ;:.,- . ' .. , . X T A L N

NO.

T1 T 2 T4.

p??= t!. :.: &lh_r)ii

'RIMARY f0 LTAGE

120 240 480.

DESCRIPTION

1 VA TRANSFORMER

... : i ;-

Lamps used with RundeblDEC control units have-miniature bayonet bases to insure positive contact brtvran lcmpmd I ., et. even under extreme conditions of humidity, temperature, shock and vibration. Amperage and lamp l i f echow m tfm. : ' , .

table below apply when operating at design AC. voltage. DC voltage. can reduce life as much as 50%.. Over v d t a g s drmiartty. t reduces life. Decreasing voltage substantially increases life: i.e; LG lamps (rated a t 7.5Vl used with T-Series transformer should have l i f e in excess of 18,000 hours. .---- - Y F - T

< , .. . . :"..::, &-

RUNDEL IOEC. CATALOG NO.

. . . . . 2.>-.<&c&

AMPS

. . . . . .; i;-. ..-l

MFG. CAT. NO.

DESIGN VOLTAGE

VALUES A T DESIGN VOLTAGE

WATTS AVG. LIFE IN HOURS

- r G3%

TTA

50W MOO m o S O W

25.000 I (D Requires exre;nsl resirtor,

F7-* .... I -..l....-.v*?. -.*-.1.-.- . . . . . . . . . . . . . . . , ,. ., , ., . .

3 , .I.. L . . ... . .

-~ G3% 8 loti 8 .o,/ ME

T3% Use only with round ligMed vnin and Lexan Lenses. LlZO I m p not

Ma, f~ used with any Rundel.,lDEC Use only with round lighted units recommended under madmama . . at Pilot lqht or Illuminated Operator. and Lexan lenses. vibration and shock.

EDITION NO. 1 DATED 9-20-74 .-

CATALOG PAGE NO: f 42 0 -

SPECIFICATIO

19289 1 R I N G , s t o p r e t a i n i n g 19287 1 SEAL, s t o p 19288 1 STOP, l u b r i c a t o r 19294 1 SPRING, p i s t o n a c t u a t o r 10517 1 PLUG, p i p e

19298 1. HOUSING ASSEMBLY, lubricate 19492 1 PISTON ASSEMBLY, l u b r i c a t q r 1 9 2 8 7 L SEAL, p i s t o n

TEST PROCEDURE

-1. BEFORE INSTALLING SPRING (19294) STROKE PISTON (19492) I N HOUSING (19298) SEVERAL TIMES, TO INSURE FREE MOVEMENT.

2. AFTER LUBRICATOR I S FULLY ASSEMBLED, PRESSURIZE FUEL CHAMBER WITH FILTERED AIR TO 23-25 PSTG AND SUBMERGE ASSEMBLY I N TEST FLUID (REPRASENE). NO AIR LEAKS SHALL APPEAR

CATALOG PAGE NO^ I 4: 1 0 - f MODEL 19000'

I

BLARING. dovbl. row

1. HORSEPMiER 1 8 P 110 P.S.I.

I. LUBRIUTIONs- DIESEL OIL 0 8 L I M T LME O I L - ONCE WEEKLY

6. POSITION m O R mOUP AND DRIVE CROUP Pa XL-712 o r S.8.1

GASKET; and cap covsn. t;wr lng PLATE, name LOCKYASIIER, name p loca . . SCREW. numr p l a t e

..a m b l y . b. Una I" dl.. a i r ho.-.od gv l ck op.nln8 v.lvh. c. Uae c l u n air ar .hop pressure (puimtra 100 p s l ) d. Apply c1s.n s i r pm..ure CD .tarter lnlsr lor

luxlmm of 10 mcond. t o decermlns p r o p e r Emcclonins of r h s laotor..nd t h e Bsndlx Orlv..

C&SUET. p l a t e PLUG. havs lnq .. HOUSIM: ASSY.. rocor

CASE. scar

S H U T d r l v r LOWASHER. dr . hag. bo l l

THENVIAL. TRANSFER PRODUCTS,, LTD .. e

L509 Rapids D r i v e

Racine, Y i s c o n s i n 53404

I INSTALLATION' AND SERVICE RECOE.IP.fENDATTONS -- , . . . .

I n s t a l l a t i o n :

Ths s a t i s f a c t o r y u s e o f t h i s h e a t exchange equipment is dependen t upon c e r t a i n p r e c a u t i o n s which must b e t a k e n a t t h e t i m e of t h e i n s t a l l a t i o n .

Connect and c i r c u l a t e t h e h o t f l u i d i n t h e s h e l l s i d e ( o v e r s m a l l t u b e s ) and t h e c o o l i n g w a t e r i n t h e t u b e s i d e ( i n s i d e s m a l l t u b e s ) .

If an a u t o m a t i c w a t e r r e g u l a t i n g v a l v e is u s e d , p l a c e it on t h e i n l e t end of t h e c o o l e r and keep t h e t u b e s f l ooded w i t h wa te r when t h e v a l v e is c l o s e d . The t e m p e r a t u r e probe is p laced i n t h e h y d r a u l i c r e s e r v o i r t o s e n s e a sys tem temper- a t u r e rise. W r i t e t h e f a c t o r y f o r w a t e r r e g u l a t i n g v a l v e recommendations . There a r e n o r m a l l y no r e s t r i c t i o n s a s t o how t h i s c o o l e r may b e mounted .. The. o n l y l i m i t a t i o n r e g a c d i n g t h e mounting. o f t h i s . equipment is, t h e p o s s i b i l i t y of h a v i n g t o d r a i n e i t h e r t h e water. o r t h e o i X chambers. af ter t h e coole r . h a s been i n s t a l l e d . The bottom- d r a i n p lugs shou ld t h e n b e l o c a t e d t o accomplish t h e d r a i n i n g of t h e s e f l u i d s . D r a i n s on al l . . ou r , models e x c e p t t h e 400 s e r i e s .

It is p o s s i b l e t o p r o t e c t your c o o l e r from h i g h f l o w and p r e s s u r e s u r g e s o f h o t f l u i d b y i n s t a l l i n g a f a s t - a c t i n g r e l i e f v a l v e i n t h e i n l e t l i n e t o t h e c o o l e r .

It is recommended t h a t w a t e r s t r a i n e r s b e i n s t a l l e d ahead o f t h i s c o o l e r when t h e s o u r c e of c o o l i n g w a t e r is from o t h e r t h a n a mun ic ipa l w a t e r s u p p l y . D i r t and d e b r i s c a n p l u g t h e water p a s s a g e s v e r y q u i c k l y , r e n d e r i n g t h e c o o l e r i n e f f e c - t i v e . Write t h e f a c t o r y f o r wate r s t r a i n e r recommendations.

Se rv i ce : --.- Each h e a t exchanger h a s been c l eaned a t t h e f a c t o r y and shou ld n o t r e q u i r e f u r t h e r t r e a t m e n t . It may be w e l l t o i n s p e c t t h e u n i t t o be s u r e t h a t d i r t o r f o r e i g n m a t t e r has n o t e n t e r e d t h e u n i t du r - i n g sh ipment , The h e a t exchanger shou ld be mounted r i g i d l y i n p l a c e w i t h p i p e c o n n e c t i o n s t i g h t . C A U T I O N : If s e a l a n t t a p e is usnd on p ipe t h r e a d s , t h e d e g r e e of r e s i s t a n c e between mat ing p a r t s is l e s s and t h e r e is a g r e a t e r chance f o r c r a c k i n g t h e h e a t exchanger c a s t i n g s . Do n o t o v e r - t i g h t e n . When s t o r i n g t h e u n i t

o r any l e n g t h OF t i m e , be s u r e t o !ceep t h e o i l and wa te r p o r t s s e a l e d .

INSTALLATION AND S E R V I C E RECOI@4ENDATIONS - - Fage Two. ,

i

Performance. i n f o r m a t i o n shou ld b e noted and r e c o r d e d on newly i n s t a l l e d u n i t s s o t h a t any r e d u c t i o n i n e f f e c t i v e n e s s c a n b e d e t e c t e d . Any l o s s i n e f f i c i e n c y can normal ly accumula t ion of o i l s l u d g e o r w a t e r s c a l e .

Replace g a s k e t s when removing e n d c a s t i n g s .

be t r a c e d t o an:

C o r r o s i v e c o o l i n g w a t e r , such a s s a l t o r b r a c k i s h w a t e r , c an have an a d v e r s e effect on t h e metal used i n t h e c o n s t r u c t i o n of :he exchanger . Zinc anodes i n t r o d u c e d i n t o t h e e n t e r i n g w a t e ~ t r eam w i l l reduce- t h i s r a t e of c o r r o s i o n .

It may b e n e c e s s a r y t o d r a i n t h e wate r chambers o f t h e exchange r t o p r o t e c t it from damage b y f r e e z i n g t e m p e r a t u r e s . Dra ins a r e provided i n most s t a n d a r d models f o r removing t h i s w a t e r .

The o i l chamber- o f t h e exchanger may become: f i l l e d w i t h s l u d g e accumulat ion and requi re - c lean ing- . It is. recommended t h a t the.

>', u n i t be- f l o o d e d w i t h a commercial, s o l v e n t , s u c h as . T r i c h l o r o - e t h y l e n e , and lef t . t o soak. f o r one-haJf hour . Backf lowing wi.th t h e s o l v e n t o r - r e g u l a r o i l w i l l remove most of ' t h e s l u d g e . Repeated s o a k i n g and b a c k f l o w i n g may be. r e q u i r e d , depending on. t h e d e g r e e of s l u d g e bu i ldup .

TRICO MULTIPLE OILERS

(Read b e f o r e i n s t a l l i n g - - -Keep f o r f u t u r e r e f e r e n c e )

To reduce damage i n t r a n s i t , t h e r e s e r v o i r s and mas te r t ubes a r e packed s e p a r a t e l y . s i m p l y screw r e s e r v o i r on to mas ter t ube ( reasonably t i g h t ) and o i l e r is ready f o r use.

The MANUAL type has a t o g g l e l e v e r a t t h e t o p of r e s e r v o i r . To s t a r t f e e d , r a i s e t h e l e v e r . To s t o p f e e d , f l i p l e v e r t o t h e s i d e .

The SOLENOID t y p e has an e l e c t r i c s o l e n o i d va lve mounted d i r e c t l y under t h e r e s e r v o i r which, when energ ized , s t a r t s t h e f eed and s t o p s feed when c u r r e n t i s s h u t o f f . I t can be connected t o any l i g h t i n g c i r c u i t and opera ted by a s e p a r a t e swi tch . I t can a l s o be connected d i r e c t l y a c r o s s t h e s t a r t i n g swi tch of t h e motor t o s t a r t and s t o p t h e f eed au tomat i ca l ly when t h e motor is s t a r t e d and stopped. Always make s u r e t h a t t h e proper v o l t a g e i s a p p l i e d t o avoid damage t o t h e c o i l . Th i s type is a l s o provided wi th a push bu t ton loca ted a t t h e t o p o f t h e r e s e r v o i r which when depressed opens t h e so l eno id va lve wi thou t energ iz ing . This f e a t u r e permi ts the o p e r a t o r t o make needle va lve ad jus tments w h i l e machine is i d l e . I t ' s an e x c l u s i v e TRICO s a f e t y f e a t u r e .

S ince t h e s e o i l e r s f e e d by g r a v i t y , they must be i n s t a l l e d above t h e h i g h e s t p o i n t t o be l u b r i c a t e d , F i l l r e s e r v o i r and s t a r t t h e feed. On new i n s t a l l a t i o n s open a l l need le va lves a t r i f l e t o permi t t rapped a i r t o escape from t h e mas te r tube . If a i r bubbles a p p e a r a t some d r i p o u t l e t s , they w i l l d i s appea r a s soon a s a l l a i r has escaped.

P l a s t i c r e s e r v o i r s can be used where temperatures do n o t exceed 1600 F. For h ighe r temperatures , o i l e r s wi th g l a s s r e s e r v o i r s a r e recommended.

TO c l e a n r e s e r v o i r s when necessary , remove l a r g e n u t a t t o p of r e s e r v o i r t o t ake i t a p a r t . The master t ube can be f lu shed o r blown o u t by removing end d r a i n plugs. Soap and water , g a s o l i n e o r carbon t e t r a - c h l o r i d e can be used f o r c l e a n i n g g l a s s o r p l a s t i c p a r t s . - + = once. Never use a l coho l , l a c q u e r t h i n n e r s , e t c . , a s they may d e s t r o y - p l a s t i c p a r t s o r t h e s e a l i n g gaske t s .

Repair p a r t s a r e a v a i l a b l e . When o rde r ing any of them g i v e a complete d e s c r i p t i o n and mention t h a t t h e p a r t i s f o r T R I C O MULTIPLE OILERS.

NOTE -- Metal o r nylon p l a s t i c t ub ing can be a t t ached t o t h e compression f i t t i n g s fu rn i shed with t h e O i l e r and extended t o p a r t s t o be l u b r i c a t e d . Where excess ive v i b r a t i o n e x i s t s o r where i t is necessary t o l u b r i c a t e e c c e n t r i c o r pitman bear ings , i n s t a l l a s h o r t p i ece of Neoprene rubber tub ing between t h e metal o r p l a s t i c tub ing and t h e bea r ing .

i ' i i l C O FUSE MFG. CO. MILWAUKEE, WISCONSIN 5 3 2 1 2 U . S . A .

F o r au tomat ica l l y app ly tng a cor rec t f i l m o f o i l to Chatns. (.ears. S l ides o r i r regular suriaces. e t c TR ICO C h a ~ n O ~ l e r s y r ra t l y ; reduce l i n k wear. stretch. rus t and corros ion. f r tc t ion, puwer: losses. accidents and l i r e hazards. They el iminate- r t n n e c c ~ s a r y repairs and rec lacements, shutdowns, l os t productton, wasre o f o t l and expensbve hand o i l i n g methods. T R l C O C h a ~ n O i l e r s and O i l A p p l ~ c a t c r s aredesigned for i ns ta l l a t i on a t any convenient

locat ton. 011 i s re leased by g rav i ty from the reservoir e i ther man., u a l l y or e lectracal ly . T h e amount o f o i l requ / red i s metered by ' p rec is ion needle va l ves w h ~ c h requ i re no further a t ten t ion af ter i n i t i a l set t ing.

N o t j u s t ordinary b r i s t l e brushes. 00 not overhang cha in - rro "s ide" dripping. Do no r spread o r become distor ted. Need n o t b e rotated constant ly to compensate for wear. Can be shaped to any angle-or contour. Wi thstand cha in temperatures up to 275" F. Wear r es i s t an t - las t up to 10 t imes longer than b r i s t l e brushes.

The manual ly con t ro l led types have a lever shot-of f loca ted a t the top o f the reservoi r . T h e e lec t r i ca l l y con t ro l led rypes are equipped w i t h an e lec t r tc s o l e n o ~ d va l ve mounted d i rec t l y beneath the o i l reservoi r T l ie solenotd vn lve can be con. nec ted d i rec t l y across the l i n e o f the motor s tar ter for automat ic operat ion or i t can b e operated b y a separate sw i t ch or t imer for in termtr tent use. T h e so leno id US* ELOOW I.,

I*b,,<.,l.. ..,,,<a,

va l ves are deslgned forconstanr duty, and are ava i l ab le ~ n p r a c r i c a l l y any vol tages .h.in.. .id... . a x H. 35

and cyc les . a lso D C.. and are approved by the l i n d e r w r i ~ e r s ' Laborator ies. Inc

T R l C O Cha in O i l e r s are b u i l t to g ive long. troilblc.,free sc rv lce . The f i nes t m a t e r ~ a l s and work rnansh~p are ~ n c o r - parated throughour Ye ta l parts o f a l l heavy dury models arc. s o l l d brass and a l l jo in ts are s i l ve r brazed t o ptoduce

a compact and substant ia l leak-proof assembly - an exclusive TR lCO !earure. A l l needle va lve feed ndjustmonts are made from the f ront where they car. be eas l l y reached 2nd have f r i c t ton ~ d l u s t ~ n c n t s ro guard agnlnst l o o s t m ~ n g from vzbrarion The reservoi rs and s ign t i ~ t t t n g s are o i c rys ta l c lear P y r e x elass or shatterproof L u c t t e cylinders

so that o i l supply 1s v i s ~ b l e at a l l t w e s A l l app l i ca to rs are f u r n ~ s h e d w i t h leak-proof adapters so that vc t t t ca l adiustrnents can be made e a s ~ l y and c u i c k l y Substant ia l centrai mount:n:: s tud and nu t 10 pernirt r o ta t l ng the a s - sembly l a any desi red posi t ron i s provided

TRlCO FUSE MFG.. CO. MILWAUKEE. WIS., U.S.A. 53212 .,:? -- - ~~.

IMPORTANT' Oilers. *rich pl;~.tvc rcsorvoirs can b c used: w h e r e tcmpernturas. do not ercccd 160' F Far higher tamparaturss. oilers. w i r h glass, rarcrvoirs a r e rccommendcd.

For easy relsction- and. convenience- when ordering.

a l l types. are furnished. complete with reservoir. mounting: studs. o i l applicacws- and adiustable: adapters.

f- -4 ". TYPES - CA and CAE

.+ese small compact models ara: intended for l ight duty applications. Avai lable only with shatterproof reservoirs. and 1-1/4" o i l applicators which can be trimmed to any width to avoid overlap and "r ide" dripping.

TYPE C k ha. laver shutoff and lock-r ing feed adjustment a t top of reservoir: TYPE CAE has. an electr ic solanold shut-of f valvc; A needle valve- lead ad- iustmsnt is. lncorpuared i n the sight fitt ing.

Ilourn.n. C1,

T Y P ~ cap. A, 0' c D stud M. .- CA. 4 0 1 ! . . i 1 . - 1-7/11.' 4 . 1 W 1..5/86- 0 5501 CA 8 01. 6 . / O . 7 I F 4 d / I 1/2-70 SSOI

CAE 4 ; 1 ., LJ.1'' l l 3,lb' 8 1 1 6 1 5 l l V 1/4- lb IS05

C A E 8 01. 8 . I / C 11.1116' I 1.516 3 - 5506

If - Specify voltages and cycles.

TYPES - CB and CBE Heavy Duty Models

Pyrex glass or rhatterproof Lucita-reservoirs 1-1 i 4 " and 1'' O i l Applicators

TYPE CB has. lsvar rhu t -o l l and lock-ring, Iced zdiurcment n l top of reservoir

TYPE CBE has, an electr ic solenoid shu t -a l l valve. A needla- valve. faed ad- juscrnsnc is incorpcrated i n thesight fitt ing. - * ..". -. C1, Hn

. .. . . . $ 0 . I" , . , 8 , 1' J h I5lh 5571

C(LC I Pt 2" 11 ,1116- d i/r I I " 114 - 16 $5>S 55IV , al: 1- ,..1/is- 8 , ,,<" 4 . ,,I J , 5530 5514 2. 111 G!t ? I 8 . 8 , I $ 7 1 - I $511 5511

I G l I , 3 ' . 5.5IB' I,.- t & 5515 r - --- I I - Specify voltage and cycles

TYPES - CC and C C E Heavy Duty Models

Pyrar g l m r or zharrerpraof Luc81e rcscrvoirs Dual 2" Oi l Applicators

TYPE' C C has lever shut-df with needle valve feed tdiustmsnt i n each sight j f itt ing.

TYPE CCE has an electric solenaid shut-of f valvs. A nssdls valve feed adjustment i s incorporarcd in each right fitting,

*o"nlln. C1, Hq

I ? ( I' ilil/'d' i L l / W > I / ? - 111' -16 if47 55Il cc I 0 , 4 ' 4 . 3 7 5 4 I / I 7,r. - l b $Ill I515

1 iil at 4 0 5 I 5 1/?' I,< - l a 55.6 55.1

t Gt. 4 7 7 SIC 5 5 6 1 1 4 ' - 16 5547

10 0. 1.' I 1 l l r f 8 I O U ? - 8 5550 5558 I P, I.. 1 5 , - 8 i l l 6 I . ,,I" I,, - 8 6 $551 I551

CCE I 0 # I i l b 8 7 I I E 4 4,- 114' - 86 IIII IS55 2 , i/l Q, 4. 86 I / C 8 l t l b I III 1 - 8 55% IS57

I GI. a ' 1 . 6 ' 1 1 1 1 6 ' 5 1/* - l b IIIP

If - Specify voltagc and cycles

T H E SINGLE L INE SYSTEM

(Wlth va lve rype manlfaids) Pyrex glass or shatterproof Lucbte reservotrs

Consists of a. heavy duty c e n t n l i y mounted o i l dispenser and single, dual a mul t ip le a i l applicators. fw remote mounting in l imited or hazardous.quanerz. T h e va lve type.manifolds are connected to t h e dispenrer by means of 1 /4" O.D. p last ic ar copper- tubing. Each out le t i s equipped w i th a needle v a l v e feed adjustment incorporated i n thes igh t f i t t ing. The.various manifolds can be c w n c c t a d in series-so that only one.dispenser i s needed f o r a s m n y a s 12 outlets.

T Y P E D. Dispensers. h a v e a lever shut-off a t top.

T Y P E DE Dispensers h a v e an elect r ic solenoid shut-off va lve d i rect ly beneath t h s dispenser.

DISPENSERS

0: 1 (11, L 7 l W 1..41/16" 4 . i / * 1/1"-16 116.. SSdS 1 .1 , IOt . tT. 7 1 1 5566 Sib7

I G I 17- I. C 4 , C b " s i / s >,r"-ca 1569-

I 0 0 ~ 7 . V l I b " 1.111 1" A 1510 $57, 1 P( 6 - l.,nl' 3. r 1 A s i n 1573

OEi 10% P. , l l l l b " 1 1 1 1 - f I - I I l l . S i l l I . S / I Q , I I . . I I / ~ ~ . 1 . 5 . r I 1516 $171

I C, . . 1 - 1 . , ,I* , . , 5 , 6 - , / V - , 6 - 5579

I f s iect r is -Specfry voltaga and cycias dsslrsd

V A L V E T Y P E MANIFOLDS AND 011. APPLICATORS

Compists.with o i l applicators, adiurtabls adapter, and compression f i t t ings for 1 /4" 0 D. tubing.

Plast ic sights w i l l be furnished un las rg lasa right, s r a specified.

T H E MULT IPLE LINE. SYSTEM (Wirh shank typemanifoids)

Pyrex glass a. rhattarproof L.ucite re.srvoirs

Consists of a heavy duty central ly mounted mult iple outlet dispenser and s i n g l e w. multiple- shank type o i l applicators for remote mounting in l imited spaces. Each a i l appi icatw is connected to its. own out ic t a t the dispenser by means of i l 4 " p last ic or copper tubing. Feed adjurtmants are made.st the dispenser. thus eliminating t h e danger of reaching inro hazardous places. When only one lead outict or o i l appl icator w i t h manual control i s desired, type,"ACL" gravity fssd oiler is recommended.

TYPE E dispensers have a lever shut-off at top.

TYPE EE dispensers have an electr ic soianoid shut-off vaiva d i rect ly bemath, the dispenser:

DISPENSERS Ma""<,", C., Y*

T Y P E C-. I II C 0 Stud GI... Lucat..

10 0. P l l l l b " 1 7 / B . 1111&. I(' 1/4"-16 4000 400,

P o g c 14

F o r e f f i c i en t se

OIL APPLICATORS FOR TRICO CHAIN OILERS Far cham temperatures up to 275' F TRlCO 011 Applicators should nor b e confused with. ordinary bristle. : b rusher a s they are entirely dlfferenr in l r l n c l p l e o f d e r l g n applicatton, and performance. They da nor averhang: the. cham. rht reforeno rtde dripp6r.g They do not spread and become distorted They need nor be roraied c o n s t a n l l ~ lor even wear. .?nd last up to 10 rtmes longer. They can be mm-shaped to apply f i lm of 0 3 1 EX;IC:~Y whcreneeded.

I % " - WIDE CAT. NO. 6033

Thousands. o f a p p l ~ c a r o r s now i n serv ice under many varbous cond l r lons have- proven t he serv ice. they render ou ts tand in f . Users report exce l l en t - resu l ts and complete sa t i s f ac t i on Jus t two stan-. dard s l zes are- av r t t lab le wh i ch f i t the complete r a n g e o f T R l C Q Cha in O i le rs . W ~ r h t h e s e two s izes. any w id th o f cha in or sur face from %'# t o 12.. (wider on specia l order) can be lobr lcated, e l im i - na t ing the. need to order spec ia l w id th appl icators or brushes a t any time..

2" WIDE- CAT. NO. 6036

~

ACCESSORIES FOR QUICK I N S T A L L A T I 0 1 :OMPRESSION IITTINGS - i!E PIPE INREAD - TUEINC 114 0.

STRAIGHT ELBOW UNION CONNECTOR CONNECTOR -

N O 41 NO. 42 d~ 45

(ID El ,I% -. 46

' & - 47 /y-' -',

:OMPRESSION COMPRESSION dV SLEEVE

m 48 NUT TUBING CLIPS

GENUINE N Y L O N PLASTIC TUBIN( VERY f l E X I 8 L C - WITHSTAN05 TECRllrlC A8 l lSE A N 0 UP TO 200' fAHR 11: 0 o 25 50 A N 0 100 FOOT COILS - N O 3 1

TRlCO FUSE M F G CO M I L W A U K E E . WIS., U.S A. 53212 ,' - --

.- - r.&*@ Use with 5-micron cleanable filter element for w)+* applications where removal o f aN liquid and dirt particles

is vital. Use with 3-micron absorbent filter element when o i l must b e removed.

ss.r

3-5 Tab 6,-

HOW IT WORKS

Fixed baffle (A) causes air to whirl dirt and liquid particles outward against bowl sides. The particles drop past the baffle (6) into the storage area. Partially cleaned air passes through the filter element (C) where particles larger than 3 or 5 microns are removed, depending on filter element used. Contaminants drain from bottom of bowl (Dl.

CONTENTS d?h

Slnndard Industrial Olrollly R"(~"lstor 10

Slnndard lndustrfsl O ~ ~ l l t y Lubrlcalor 14

F "

Mechanical Drain Optlonal

Puncture-proof cellular rubber float lriggers pilot valve which. in turn. opens the drain passage Operates wlth air pressure from 20 lo 175 psig Opens only when water in the bowl rises enough to move the float Screened valve seat guards against dirt reaching the valve and holding it open

Flexible rain\ Oot~onal

Manually operated drain In botlom o f transparent polycarbonate plastlc bowl Just push rubber L I P 10 s16e to dram the bowl Ideal for use in areas where a pelcock would be hard lo reach or !urn Use $1 wllh or wtthout a flexcble dram tube attached

Pressure-Controlled Automatic Petcock

Opt~onal Opens automallcally when pressure drops to 1 psig after the ltnc is turncd of f Closcs automatically when pressure reaches about 2 5 pslg after ltne 1s turned on

W M A P IT DOES FOR YOU

Rigid filter element-3-micron o r 5-micron- purifies and dries the air, protects your equipment. Although abrasive particles larger than 5 microns can damage equipment, the possibility of damage. from smaller particles is highly unlikely Being non-metallic. the element is never affected by electrolysis as is often the case with filters t~sing dissimilar metal elements..

V,-x~ seldom have to replace the element. It cleans- - - i l y The element in % " through 1" pipe size unt.- nas a molded-on gasket at each end, so i t can be used with either end up. There's no chance of forgeMng the gasket as with some other makes.

* The thin-walled element exposes a large areato the air system. Dirt particles tend to stay on the surface instead of becoming embedded. The clcmcnt in some other makes cakes readily. When

+is h.ippens, theirs literally become.5-micron filters A ours but with severely restricted airflow. Our A,. v s baffles remove muchof the-airborne d i r t

before i t reaches theelement. Since the element primarily traps finer particles, it usually stays clean longer, cleans easier and causes almost no dressure loss.

Small slits in the top baffle increase airspeed enougn to whirl the air against bowl sides even when Ihe pressure is relatively low. The large diame1:er of the baffle permits high flow without c ,wive pressure drop.

FL.4 on % " through 1" pipe size units quickdisconnects with one hand. Safety lock inst~res bowl i!; refastened properly

SPECIFICATIONS

Standard units have a transparent polycarbonate plastic bowl-for use where pressure does not exceed 250 psig andlor 150" F CAUTION: Never install 3 unit with plastic bowl in a system in which synthatic fire-resistant or phosphate ester lubricants are used or where any materials or fumes in the compressed or ambient air will harm the plastic bowl IFor use at temperatures up to ZOO0 F andlor

wig, order with plain metal bowl or with metal 11 with water-level gauge Units come in x " ugh 3" pipe sizes.

.At 100 psi% 5 11sI press~m dIlleren1181 To order any of the above litters wilh an optional bowl or draln. change the piece number as lollaws: . TO order wtth metal bowl change the ssoond dlgil alter !he

dnsh Itom zero to 1 To order %" lhrough 1 " umls only wbth metal bowl and stghl gaugs.change the socond dlglt alter the dash lrom zero to 2. I TO order wlth bowl auord lshmoed separate) tor standard I plastic bowl, changi the second d u l l alter the dash lrom zero 10 3 . To order 5-mtcron unlt wlth pressure-controlled automGtlc p s t ~ o ~ k change the lhlrd dlglt alter the dash lrom zero to 2 I TO Otder 3-mtcron unlt wlth pressure-controlled aulomatlc petcock change tho thlrd dlgit attor !he dash Itom 1 to 3 To order 5-mlcron unll wtlh mochanlcal dram chnnge the lhtrd drgii alter the dash lrom rera to 4 To order 3-macron unll wllh mechanical dram change the thkd digat alter the dash lram 1 to 5 To order piastlc bowled 5-mtcron unlt wllh llexlble dram change ihe lhlrd dtglt alter the dash lrom zero to 6 To Order olostic bowled 3-micron unll wtth llsx6bte draln change !he thlrd drg~t alter the dash lrom 1 to 7 --

G ,.: ! f!T +; ... .. . ?..* .;: ,..: ::>::., , : cb; ... . .

, , , . ,

Removes odors, oil vapors, all bacteria and

1 almost 100% of dirt and. aerosols.

Use with oil-lubricated compressor for any application calling for oil-free pure air-sl~ch as breathing apparatus or food or beverageprocessing.

We. strongly recommend installing one of our Standard Industrial Qualiiy filters, described on pages 2 and 3, in the line between. the Microfineair filter and thecompressor; If you use a dryer, install it in the line just after the filter. If .you use an oil absorber, install it after the dryer or just after the filter if you do not use a dryer. Do not use a valve that will allow more than 50 psi pressure differential through the filter element.

Air enters inside the filter element and Gasses through a core liner -. ich removes large particles of

..- t t4ext comes a labyrinth of wrosilicate glass fibers having 0.5 micron average diameter. This. microfilter section traps all 03- micron or larger particles and converts all aerosols to droplets A porous plastic covers the outside of the cylindrical part of the filter element Droplets removed from the sir collect on the inside of this cc and fall into the bowl

l n t : filter element is not affected by high humidity It will not rot or deteriorate with age, does not support bacteria growth or allow bacteria ta pass.

WHAT IT DOES FOR YOU

It"s SO efficient that when you use it with an oil- lubricated compressor it gives you the same oil-free. a i ryoud get using a costly non-lubricated compressor.

Removes most dirt, water, oil and odors. so you don't have to install and maintain separate devices to get pure air.

Contaminants collect on the inside of the porous plastic cover and flow down into the bowl. Since the filter element cannot saturate, there is no way it can teed contaminants back into the airstream like an absorbtion-type element does when it becomes saturated.

Standard units have a transparent polycarbonate plastic bowl-for use where pressure does not exceed 250 psig and/or 150° F CAUTION: Never install a unit with plastic bowl in a system in which synthetic fire-resistant or phosphate ester lubricants are used or where any materials or fumes in the compressed or ambient air will harm the plastic bowl. % " through 1" pipe size units are die-cast zinc alloy, The 1!4" size is sandcast aluminum..

HOW, TO ORDER ks-I r 1 1 Aoomz. Dimnnrion

To order w l h bowl guard (shipped scparatel, change the second digit alter the. dash from m o lo 3

All unlls ercepl Piece No. PF7505..10002 have an autamak drain A puocture- Proof cellular rubber float triggers a pilot valve which, in turn; opens the drain passage. Operales with air pressure from 20 to 175 psig. Opens only when water in the bowl rises enough l o move the Iloal.

Piece No. PF7505-10002 drains through a manually overated petcock. Designed for pressures up l o 250 psig

AIRFLOW WITH I PSI lNlTlAL PRESSURE DROP

Efficient, autamatics, economical Use it in t h e a i r line just ahead o f intermittently operated equipment Every t ime the a i r flows for about two seconds or more the f i l ter drain opens a n d ejects any water m t he sump. When used ~n a n application hav ing cont inuous airflow, y o u merely have to s top the airf low about every two hours so the filter can drain automatically.

An easily cleaned permanent-type filter element [A] traps all 5-micron r larger particles. After being forced through the element's tiny holes. 3 air expands as i t reaches the main chamber (8) and moisture drops i t W.Den air is notflowing, the piston (D) is down and the lower chamber

(C ) is open to the atmosphere, as illustrated. As soon as airflow resumes it lowers the pressure in the chamber (El above the piston. The higher pressure beneath the piston forces it up until the air can flow past the O-ring (Fl to the outlet port.

When the piston rises, the valve stem attached to it also rises and pulls the lower O-ring (GI into place. so it seals the discharge port below the lower chamber (C). At the same time, the V-packing (H) which has sealed the passage between chambers (8) and (C) rises enough to allow flow in' he lower chamber. A baffle O-ring (Jl seals the opening between thi amber housings..

As sson as the airflow stops, air bleeds through the hole (11, equalizing pressure above and below the piston The spring then pushes the piston down, again opening the drain at the bottom of chamber (C) If no water is present in the chamber, only 0006 cu ft. of air ejects.

WHAT ilT DOES FOR YOU Moisture collected in the upper sump ejects as a mist from the lower

si.lmD. so you need no drain line. Sealing is positive Even i f a leak de- velops downstream, the bleeder hole in the piston bypasses enough air to keep the piston from rising when it should be down

You pay no more for this automatic drain filter than you would for many li2ving a manual drain. . ):ig~cl jelt element cleans easily A molded-on gasket at each end does

-1;:iiiy with the possibility of losing a gasket. You can install the element 'with e~ther end up * r lss properly even when the element has to trap heavy rust and s c h ~ 411 YOU have to do is clean the element more often

HOW- TO ORDER r I I I appro^. i7imenrionr /

SPECIFICATIONS Die-casl zinc bowl-lor usn a l pressures from 10 lhrough 250 psig and'or 200" F Buna-N plston O-ring Neoprene baflle 0-rlng Polyurethane valve stem O4ng Sirvena No 407085 stem V-packing

PRESSURE-CONTROLLED AUTOMATIC PETCOCK

Insc,;t in place of any manual drain petcock on any pnewnatic equipment. Opens automatically when pressure drops to 1 psig after line is turned off: Closes automatically when pressure reaches about 2.5 psig

?r line is turned on Can be opened or closed man- t ,I. Maximum pressure 250 psig. 2%'' high. Order Piece No.. P7128.

HEAVY-DUlY AUTOMATIC SUMP DRAIN

Drains 150 gph at 100 psig. Handles up to 50% oil sludcje mixed with water A 30 x 30 mesh prevents scale and rust from reaching the mechanism actuated by a puncture-proof cellular rubber float. As water rises, the float triggers a valve that admits screened air tc a large diaphragm This, in turn, opens wide a large soft-seated valve and allows air to blow contaminants out of the bowl When the float drops, it cause the pilot valve to snap closed. 10 to 250 psig pressure range One-quart plastic bowl quickdiscon- neck for easy cleaning. X " NPT female outlet drain. !'; NPT inlet connection in top of die-cast zinc head.

' high CAUTION: Never install in a system in

/' ich synthetic fire-resistant or phosphate ester lu-

bricants are used or where any materials or fumes in the compressed or ambient air will harm the plastic t ' Order Piece No. P7654. For matchlng bowl guard, order Piece No. P7525.

MANUAL OR- AUTOMATIC SUMP DRAIN

Manual unit drains through a petcock Automatic unit has a puncture-proof cellular rubber float that opens the drain when the liquid rises in the sump The 3- ounce plastic bowl quick-disconnects for easy clean.- ing. Diecast zinc head has :/," NPT female connection Maximum pressure 250 psig at 1500 F. 43," high. CALJTION: Never install in a system in which synthetic fire-resistant or phosphate ester lubricants are used or where any materials or fumes in the compressed or ambient air will harm the plastic bowl. For Manual Drain. order Plece No. P7648'. For Auto- matic Drain, order Piece- No. P7647. For matching. bowl guard.tor either drain, order Piece No. P7541.

PNEUMATIC TIME DRAIN

Timing device controls length of drain period Has two independently controlled drain valves-if one

I fails, the other will hold. Can be cycled by an air compressor unloader, an air governor or any intermittent source. A blast of intermittent air from the unloader. governor or other source opens the valves. allowing the tank to drain The valves stay open until internal pressures equalize. The unit is ready for recycling when actuating pressure drops to zero. Die-cast zinc body 30 to 50 psig operating range. % " NPT male in- iet connection.XW NPT female discharge outlet and % " signal connection. 5X" high. Order Plece No. P7652.

Use where excessive pressure variation would be harmful, where a conventional regulator cannot provide the necessary degree o f control or where a l o w s~ lhoue t te unit i s desirable. The speed with which the settings can be changed also makes it possible to use the unit as a 3-way valve o r a speed control valve.

HOW IT WORKS entering through the inlet port (A) is blocked by the main

\,..re seat (6) and the pilot valve seat (C). The dial knob (D) sets the pressure desired. I t opens the pilot valve seat (C) so air can flow into thecontrol chamber (El. The pressure pushes Ihe lower piston (F) down, causing the relief valve seat (G) altached to the piston to push down the main valve stem. This opens the main valve seat (6) and lets air flow through the line Meanwhile, the pressure in the control chamber (El also pushes the upper piston (H) against the spring (J) above it. his, in turn, closes the pilotvalve seat (C) as soon as the esired line pressure is reached. The secondary pressure in he lower chamber (K) is balanced against the pressure in the-

control chamber (El. If the pressure in the line and in the lower chamber (K) goes over the dial setting, it forces the lower piston (Fl up, closing the main valve seat (6) and opening the relief valve seat (G). Excess pressure vents to the atmosphere through the relief outlet beneath the dial knob. The relief orifice is approximately equivalent to a :$" diameter ortfice

If the pressure in the line and in the lower chamber (K) 2s below the dial setting, the pressure in the control cham-

ber (El forces the lower piston (F) down, opening the main valve until the pressure downstream reaches the dial setting.

HOW TO ORDER The aoove unds aic supplied withoul gauge To order regulator wdh d~tfcrenl pressure nngo and/or w l h standard pressure gauge. change the plecc number as l0tt"ws: . For 3 10 160 psi und wtth gauge, change the second

digtt alter the dash lrom I to 2 . For 2 10 40 p51 unit wtlhoul gauge, change the sccond dlglt atler the dash lrom I to 3

. For 2 to 40 Psi u n ~ t with eauge. change the second digit alter the dash lrom I lo 4

"To order lhe PR7560 uods wlth mounting brachel. change the third dlgit alter the dash lrom 0 lo I To order any o l the regulators with a tamperprool hit change the fourth digil alter the dash lrom 0 to 1

WHAT' IT' DOES FOR YOU' The dial indicates system pressure when the air is on, so i t serves as a pressure gauge and saves you the costof a separate gauge. When you set the dial to, a specific pressure, the system pressure will be accurate to the same degree it would be with a conven-. tional gauge.

An adjustable stop lets you preset and lock the dial so i t cannot be moved to pressure settings higher or lower than those you select The built-in relief valve saves you the cost of a separate valve

KNOBTURNED TO S i O P KNOB

The ease. speed and accuracy of the dial movement coupled with the almost immediate response of the mechanism inside let you use the unit in place of an air valve and air regulator, The instant- acting built-in relief valve enables you to use the unit as a 3-way valve to actuate a spring-return cylinder, as illustrated.

Flow.characteristics with 100 psig supply pressure.

100

80

MI

'0

20

0 0 20 do 60 80 100 120 I40 140 180 200

SCFM

100

80

00

no

20

0 0 SO 100 130 200 250 300 350 400 500 600

SCFM

100

80

00

40

19

'0 100 200 300 100 100 400 700 SCFM

- - '3r use where pressure does not exceed 300 psig and/or ZOO0 F. B . ~ ~ ~ , a ~ e ~ ~ ~ ~ conditions, the pressure relief valve opens at about

" , 3 PSI^ over lhe maximum pressure indicated by the dial setting Die-cast zinc body Polycarbonate plastic dial. Delrin plastic lock kt Belleville spring. Buna-N valve seats and O-rings Main v;Wo seat is self-cleaning.

Use where relat ively constant working pressure must be maintained o r where regulation is needed to p reven t waste or otherwise reduce a i r cost.

UT WORKS.

When an increase in pressure is callel 3 for dou 'earn. air moves freely from the inlet port (A] to the outlet port - I nl The adiusting screw (C) forces the spring (Dl against

o diaphragm disc (El and, in turn, against the valve. ;m (F). When the spring's force is greater than the.

pressure beneath the diaphragm, it pushes hard enough against the valve (GI to open the valve and allow air to flow through the line.

When the pressure downstream builds up in the chamber beneath the diaphragm enough to overcome the upper spring's force, that pressure plus the force of the lovier spring (HI causes the diaphragm and the valve stem to rise. This closes the valve opening between the

,' and outlet ports.

In "nits with built-in relief, if pressure beneath the diaphragm goes over the desired psi, the diaphragm disc (E) will rise and lift the disc seal from around the valve stem (F) Excess pressure will bleed through the opening into the regulator bonnet and on to the atmosphere.

In units without built-in relief, the diaphragm disc seal around the valve stem is permanently attached to the stem In the event of excessive pressure buildup, it must be vented downstream from the regulator outlet.

WHAT IT DOES FOR YOU . Large diaphragm accurately regulates pressure so your equipment gets the proper amount.

Extra-large main valve opening ailows air to flow at a high rate. avoiding excessive pressure drops. . Finger-tightened cleanout plug lets you quickly and easily remove the air screen for cleaning.

SPECIFICATIONS Maximum inlet pressure 300 psig. Maximum operating temperature 2000 F Units with built-in relief vent excess pressure to the atmosphere at about 6 Psi9 over regulator setting Die-cast zinc body Neoprene diaphragm Buna-N valve seats.

fi\

HOW TO ORDER

N m v e umtr are supplied wothout gauge. l h w undr do not have an a v screen.

\'Ih8r snit is not adjurlable: has no gauge.porl (WalshHealy Act)

3, order regulator wfth different oressure range andlor with standard w?ssure gauge. change the piece number as follows:

For 3 to 125 psi unit with gauge; change the second digit after the dash from 1 to 2. For 2 to 60 psl range on PR7563 unit w~thout gauge, change the second d~git after the dash from 1 to 3 For 2 to 60 psi range on PR7563 unit with 060 psi gauge, change the second digit after the dash from 1 to 4. For 10 to 250 Psi unit without gauge in any model except Series PA7565 or PR7566. change the second digit after the dash from 1 to 5., -7r 10 to 250 Psi unit with 0-300 psi gauge on Series PR7563 or PR7564.

Tge the second digit after the dash from 1 lo 6.

To order PR7563 and PR7564 Series units with mounting bracket, panel mounting or plastic knob instead of T-type adjusting handle. change the Diece number as follows:

,,,,,. For unit with mounting bracket, change third digit after the dash from 0 to 1 .

For unit with panel mounting, change the thlrd digit after the dash from 0 to 2

0. For unit with plastic knob, change lhe lhird digit after the dash from 0 to 3, For unit with plastic knob and panel mounting, change the lhird digit after the dash from 0 to 4

*-For unit with plastic knob and mounting bracket. change the third digit after the dash from 0 to 5

To Order with tamper-proof kit or without built-in relief, change the piece --. ::'trnber as follows:

For unit with tamper-proof kit. change IRE- the fourth digit after the dash from 0 to 1

KIT CAP 9 For PR7563 and PR7564 Series units

with non-relieving diaohragm. change the fourth digit after the dash lrom 0 lo 2 For PR7563 and PR7564 Series m i l s with tamper-proof kit and non-relieving

SCREW diaphragm. change the fourth digit after the dash from 0 to 3

Flow characteristics with 100 psig supply pressure

: 20 c.

g o SCFM

t

20 + 3 0 0

0 70 80 90 IW SCFM

a too - D

80 a: 3 m 60 Y1 Y

bf 40 C "2 4 20 C 3 0

'0 60 120 I80 240 300 360 420 480 540 600 SCFM

Handwheel adjusting screw

Wrench adjusting screw,

Tee handle adjusting screw

Use- it w i t h a compressor having a w i d e range o f pressure change. between cut-in a n d cut-out, in any applicatiorr where a relat ively constant supply pressure is called for or in any application where air is being wasted through higher-than-needed pressures.

HOW IT WORKS,

At zero setting, the inlet port (A) is sealed from the outlet- port (El by the hollow-stem spring+pposed valve(C). The outlet line is open to the atmosphere B through the valve stem. A

Tightening the adjusting screw (0) forces the dia-. phragrn disc (El against the valve stem, blocking the outlet port from the atmosphere. As the screw is tightened. further; it unseats the valve. and allows air to flow from the inlet port to the outlet port. At the same time, air enters the chamber (F) beneath the diaphragm and applies pressure to the. underside of the diaphragm:

When the pressure- under the diaphragm matches the spring's downward pressure on the diaphragm. the valve remains open the distance necessary to maintain the outlet pressure for which the adjusting screw has been set If a decrease in downstream pressure allows the diaphragm to drop, the force of the spring above it pushes the valve open and allows more air to pass through the unit until the proper downstream pressure is restored.

If the downstream pressure increases beyond the pressure setting, the pressure causes the diaphragm to rise. This, in turn, raises the section of the diaphragm disc blocking the exhaust passage in the valve stem and allows the excess pressure to vent to the atmosphere.,

WHAT ST DOES FOR YOU Y o u get constant output with outlet pressure variations virtually eliminated even though inlet pressure fluctuates. .- Balanced valve initiates flow when downstream pressuredrops as little as 1 psi, . Nylon-reinforced diaphragm does away with seepage characteristic of the conventional cotton-reinforced. kind..

if service is needed, you need only remove the bonnet to get to the part to be serviced You seldom have to disturb line connections

SPECIFICATIONS Maximum inlet pressure 250 psi. Temper- ature range - 20° F to +I 60" F: Die-cast zinc body Anodized aluminum or plated internal parts. Hycar (Buna-N)-nylon-reinforced diaphragm. Hycar valve seat.

HOW TO ORDER

I Piece Number 1

\ 'WOE CONNECTION (DELIVERY) H.27 DRYSEAL

NPTF'(2 PLACES) BOTH HOLES PLUGGED WHEN SUPPLIED LESS GAGE.

Wrench adjusting

screw

Tee handle. adjusting

screw.

Wrcnch Trc Handle Handrhrel Pips Pmsurc lppror imalc Dimensions (Inchsr) Adiusled. Adiuslcd. Adiuslcd. Sizs Range '

with Gauge" l i l h Gauge.'. nilh Gauge... (Inches) [Psi) A 6 C- D E F C H J K L

P556721 P55675-1 P55678.1 % 0.50 fi I 4% 2% 3% 4H R l D 2 4 . 3% 1 % ~ l'h --- P55673.1 P55676.1 P55679..1 % Dl50 % 1% i'Hr 4 1 % ~ . 2ffr 3% 4H X1024' 3% 1% 1%

.-.

.Equally r e x e d on I 250" dia boil ciicle-3'' maximum thread engagemenl

.-To order wlhoul gasge. o m i t I lrom the Piece No dellred

tEsually rpaccd on 1 375' dia boll circle-'As" maiimum lhread engagemenl

: 5 , '''1% " ,! 4

Use- itwhere- lubricated air must be delivered through simple o r comolex alumbinw to sinsle or multialeoutlets or where it is

I 5s desirable' to fill the lubric>tor withoot turning off the air o r 1 where. excess pressure must sometimes b e vented back through the lubricator without picking up oil. Use it in a rapid-cycling or

I steady-flow system. Use itwhere-a relatively small amount of I ,? oil must be. added to a large volume of air- or where a relatively ! :! 3%. large- amount of oil must be added to a small volume of air;

IT WORKS A portion of the air entering through the Inlet port (A) flows through a small tube leading to the pressurizing valve (0). This, irl turn, applies pressure to the oil in the ,torage bowl (C ) . Meanwhile, mqst of the air flows hrough the hole in the. center of the airflow regulator

(D) and into the mist-generating section (E). The slight pressure differential between the mist section (HI and the oil bowl (C) causes oil to flow through the syphon tube from the bowl to thedrip tube (F). A screw-adjusted needle-valved orifice (GI in the syphon tube regulates the amount of oil mist per cubic foot of air The oil-to-air ratio is adjusted while the correct amount of air is flow-. ins through the unit.. Once set; the adjustment normally .ever needs to be reset unless a change is desired..

If increased airflow is called for downstream, the airflow regulator adjusts the rate, as illustrated, Increased airflow in the mist-generating section causes the pressure lo drop slightly at that point, proportionately increasing Ihc amount of oil drawn from the oil bowl and into the alrstream

The design of the mist-generating section breaks up the oil into fine particles which normally remain in suspen-

- sion for at least 20 feet. Once the inside of the line is oil ated, it is not unusual for lubricated air to travel as as 300 feet downstream, regardless of the line's path

or changes in direction.

WHAT IT DOES FOR YOU 0. Bowl can be filled completely with the air on The bowl

quickdisconnects for cleaning. It can be removed with the air on if you vent it first through the petcock drain. It cannot be removed if the pressure inside is about 2 psig or more nor will it hold pressure unless it is properly latched in place

Every drop of oil you see in the see-through dome covering the drip tube gets into the a~rstream You see the oil, so you can adiust the 011-to-air ratio quickly and easily There s no guesswork about it

The airflow regulator does away with the manually adjusted air vane used in other makes Oil and air remain in proper balance, according to the needle-valve set- 7 mg, even when more air is called for downstream

"Al 100 psig. 5 psi pressure differential.,

To order with force-fill adapter, change the thlrd digit after the dash from zero lo 1 - order with meddler-proof cap. change the third digit after the dash

n zero to 2

To order with force-fill adapter and meddler-proof cap, change the third digit after the dash from zero to 3.

To order with bowl guard (shipped separate) for plastic bowl. change the lhird digit after the dash from'zero to 4

To order with force-fill adapter and with bowl guard for plastic bowl. change the lhlrd digit after the dash from zero to 5.

To order with meddler-proof cap and with bowl guard for plastic bowl. change the lhird digit after the dash lrom zero to 6

To order with force-fill adapter. meddler-proof cap and bowl guard for plastic bowl. change the thlrd digit after the dash from zero to 7

TO order l-quarl bowl units with float operated oil valve, change the fourth digit after the dash from zero lo 1

To order metal bowi units with oil level gauge; change the fourth digit atler the dash from zero to 2 . To order lquar t metal bowl units with float operated oil valve and with _ 011 level gauge. change the fourth digit after the dash from zero to 3.

-,

SPECIFICATIONS Unils with polycarbonate plastic bowl are for use at pressures up to 250 psig at 150° F CAUTION: Never install unit wilh a plastic bowl in a system in which synthetic iire-resistant or phosphate ester lubricants are used or where any materials or fumes in the compressed or ambient air will harm the plastic bowl For use at temperatures up to 200° Fat 250 psig, order with a metal bowl Die-cast zinc alloy body Flexible parts ate of Buna-N or polyurethane

OIL-TO-AIR RATIO WITH 100 PSIG SUPPLY All3 12

I t

10 Y

9 a Z 8 = 7 e Y 8 a B = % :: 3

2

1

0 10 20 30 40 SO 80 70 80 80 100

SCFM

One drop per minute of oil per 20 cubic feet of air is considered ideal by many pneumatic tool makers

MINIATURE AIR FILTER Brass body Special baffle and cleanable element capable o f removing parlicles as small as 5 microns as well as all entrained moisture. Polycarbonate plastic bowl removes without tools. CAUTION: Mever install in a system in which syn-

?tic fire-resistant or phosohate ester xicants are used or where any mate-

rials or fumes in the compressed or am- btent air will harm the plastic bowl Not available with metal bowl Flow rated 100 psig with 5 psi pressure differential

Order Piece No P R 6 2 9 for N" NPTplpe size. 18 scfm airflow (Manual Drain). Order Piece No PF7630 for X" NPTplpe. size, 23 scfm airflow, (Manual Drain).

rder Piece No. PF7631 for r NPTplpe; ze, 18 scfm airflow (Automatic Draln). rder Piece No. PF7632forX" NPT pipe.

slze, 23 scfm airflow. (Automatic Drain).

MINIATURE LUBRICATOR A I-orass m a y Self.aoiustlng atr oypass ?Utomatlcally holds constant 011-to-alr ref10 Set oy the 0 8 1 adlustlnq screw Fill Dy turning off air and removing iransparent oolycarbonate plastic bowl CAUTION: Never install in a system in which syn- thotic fire-resistant or phosphate ester

-. ihhr icant~ are used Or here any mate- ,I!> or furnos in ihe comorossed or am- - ,ii l i t nlr will 1h;lrm the plastic bowl Not

;~Catlnbie wl lh metal bowl Use where --%.sure does not exceed 250 PSI andlor Oo F Flow rated 100 pstg wllh 5 i st

pressure dlfferenttal 1 oz bowl Order Piece No PG7633 lor V NPTpipe size. 32 scfm airflow Order Piece No. PG7634 for X" NPT pipe

MINlATlJRE AIR REGULATOR Dle-cast zinc body Balanced valve for accurate regulation Large valve and diaphragm area provide good airflow wilh little or no secondary pressure fiuctua- tion. Molded Buna-N seals. Rubber dia- ohraom. Built-in relisf Maximum inlet . - Dressure 400 psig Maximum temperature 180° F. Order Piece. No. PR7567-21001 for 5- 125 psi unit, 'X" N P T plpe size, wi lhoul gauge. Order Plece No. PR7567-21002 for 5- 125 psi unit. N" NPT pipe size, wi lhoul gauge. To order wlth gauge anolor olllerent oressure rango Or wttn any o i tne aot on9 I stea below cnsnqo tho moco numoer as lottows TO order wilh gauge, change the sacond

digit altar tho dash lrom t to 2. To order 2 to 50 psi unit without gauge.

change the second digit alter the dash lrom 1 to 3 ,

Toorder 2 to 50 psi unit with gouge. chnngs the saoond dlgit after the dash lrom 1 to 4

Toardor un t ~ 8 t h mountmq bracket change the lhlrd 0,gd otter tho aasn from zero to 1

TO Order unit with panel mounting nut. change the third digit after thedash lrom zero to 2

To order unit with high'limit adlusting nut. change tho fhlrd digit alfer the dash lrom zero to 6 ,

To oroor unlt ~ 8 t h mnel moLntmg and hlgn mlt ad,usting n ~ l s change the lhtrd dlglr

alter me darn lrom zero to 7

TO order unit with mounting bracket and hign limit adiusting nut. change the thtrd digil alter the dash from rero to 8 ,

TO order unit with tamper-oraol kit, change the lourlh diwt alter the dash irom zero 10 1

To order untf wlth non-relcevbog dkaphrogm change the laurth diglt alter the dash lram zero to 2

To order vnjt wjth tamoer-pro01 kjt and non- r s l i ewn~ draohril(jm change lho fourth dlgd alter the dash lram zero to 3

COMBINATIONS To order %" pipe size 0 i o 200 psi Integral filler-regulator unit. without gauge, spec- i ly Plece No. PS7568-11002.

To order unit with gauge and/or diflerent pressure range or with any 01 the aotions listed below. change the piece number ss ioII0ws: Toorder unlt with gauge change the second

digit alter the dash from 1 to 2 TO Order 2 to 50 psi unit without gauge.

chnnge the sacond dlgit aller the dash from t to 3

Toorder 2 to50 psi unit with gauge. change the sacond digit alter the dash lrom 1 lo 4

Toarder unit with mounting bracket. change the lhtrd digit alter the dash lrom zero to 1

TO order unit with Dane1 mounting nut. change lhs third digit after the dosh from zeroto 2, (Mount in vertlcal position only I

Toordet unit with regulator iocknut. change the lourlh dtgif alter the dash lrom zero to 1

TO Ordor unit with non-reiieving regulator. change the fourth digit after lhe dash lrom zero to 2

TO order unit with regutator tocknUl and non-reliovlng regulator.change the laurth dlgit after the dash irom zero to 3

TO order unit with aulomstlc drain change the lourth dlgit after the dash lrom rero to 4

TO Order unit with automatic drain and regulator locknut. change the lourth digit a l lw tho dash from rero to 5

TO order unit with automatic drain and non- relievmg regulator. change the lourth dtg- it after the dash irom zero l o 6

Toorder unit with automatic drain. regulator locknut and non-relieving regulator. change the fourth dlgit after the dosh from zero to 7

-- size. 53 sclm .?irftow. . - ~ ~

WHBEC3 cessories

IN-LINE FILTER Designed for use at the inlet of a governor or hose line oiler: Also usable with other pneumatic devices. Aluminum. 30-micron replace- able element. Can be used with airflow from either end. % " NPT ports. male on.one.end, female on the other. 2%" high. 1" hex. Order Piece No. P7658:

RELIEF VALVE-Air or Oil Line Protects line from excessive pressure. Provides semi-precise: pressure control for a recirculating system. Can be used to valve-oft flow. At 10 psig excess pressure. the 0-50 psig unit will flow 2.8 scfm and the 0-100 Gsigunit will flow 2 scfm. Die-cast zinc body with two gauge ports. Molded Buna-N seals. Rubber diaphragm. Maximum operating temperaturp 180° F To order.%" NPT pipe size; specify Piece No. P7660 for 0-100 psig unit or specify Piece- No. P7661 for 0-50 psig unit.To order %" NPT pipe size, specify Piece No. P7662 lor 0-100 psig unit or specify Piece No. P7663 lor 0-50 psig unit.

HOSE LINE OILER Installs in the line just ahead of the connection to a portable air tool Holds X ounce of oil-normally enough to lubricate the average small production-line tool for an &hour shift. Aluminum. Can be filled with the air on. Tamper-proof.. 2%'' long. 1:$" hex. :<" pipe size unit has female inlet and outlet ports. X u size has female inlet, male outlet. Maximum pressure 250 psig Order Plece No. P7664 for % " pipe size. Order Piece No. P7665 for YI" pipe size.

Piece No. PS7265 combination device HOW. TO ORDERt shown consists of a Piece No. PF7502- 10002 filter described on oaaes.2 and Consists o l Dimensions 3, a Piece No ~~7563-5100i regu la tor dr ibed on pages 10 and 11 and a Pi&..; No PG7602-23002 lubricator descr~bed on pages 14 and 15

CAUTION: Never use plastic bowled filters Or lubricators in a system in which synthetic lire-resistant or phosphate ester lubricants are used or where any materials or fumes in the compressed or ambient air will harm the plastic bowl

STANDARD PISTON-DRAINED FILTER

Piece No PS7283 combination device shown consists of a Piece No.PF7111-2 filter described on page 5, a Piece No. PF7564-11005 regulator described on panes 10 and 11 and a Piece No. PG7603-23005 lubricator described on P- 3s 14 and 15,

ChuTION: Never use plastic bowled lubri- CalOrS in which synthetic lire-resistant or phosphate ester lubricants are used or where any materials or fumes in the compressed or ambient air will harm the Dlastic bowl

HOW TO ORDERt

"A1 100 pslg. 5 psi pressure dllfcrcntlal across lubricalor "A1 100 Psle. 9 Psi P ~ S S U I C d#lferenl#al across filler of which 4 psi is used lo raise piston

<We can also SUDDIY cornbinalion devlces made u p of any filter-regulalor-lubricator filter-regulator or filter-lubricator unlls in this catalog. To order specify combination aevtce consisting of the piece numbers deslred. Other combinalions are available For details contact one of our representalwes or our main ol f ice in Lexington. Kentucky

acked by rldwide service organization

-, trtta le I10

5 Dunwoody Park Atlanta. Georgia 30341 (4041 458-9305 Boston 1838 Massachusetts Avenue Lexington Massachusetts :6 171 862-3325 Chicago 4738 North Harlem Avenue Ch~caqo Illinois 60656 13 1 2 ) E67-9240 Cir Tali 7 6 , arretl Road 'Ilcsc dhesler. Ohio 45069 ' c t l i 777 .1 ' 9 ,

uoveiana 5 i00 West 154th Street Cleveland Ohio 44142 (2161 267-1948

Dallas Room 131 2331 Gus Thomasson Road Dallas. Texas 75228 (2141 328-3464

SALES OFFICES

Delroil Su11e 108 17251 W 12 M ~ l e Road Southfleld. Mlchlgan 48075 (313) 557-9639 Greensboro, North Carolina 3604 Brandywine Orive Greensboro. North Carolina 27410 (9191 288-2336 Houston 2400 West Loop South Suite 308 IMC Building Houston. Texas 77027 (7131 626-1622

Indlan_apolis - ' C . . . I . .- r n.:,.,

Lexington 1953 Mercer Road Lexington. Kentucky 40505 (6061 254-8031

An Arnerican.Standard Company

WABCO Fluid Power products

are available off-the-shelf from

more than 100 stocking distrib-

utors in principal cities These

same distributors also offer

qualified, dependable parts and

service. You're never far from a

supply and service source.

Los Angeles 11906 W~lshlre Boulevard Su~te 11 West Los Angeles. Caldornla 90025

7 (213) 477-6550 and 477-6559 Milwaukee 6490 South Crane Orive Oak Creek. Wisconsin 53154 (414) 762-5820 New York 654 Rahway Avenue IJnion. New Jersey 07083 (2011 687-6565 Sf. Louis 120 Progress Parkway St. Louis. Missouri 63043 17341 R7R-3134 < o n t-TilnCIS,:"

P 0 Box 5576 Concord. California (4151 825-6390

V Anghouse Air Brake Company - Fluid Power Division 1953 Mercer Road. Lexington. Kentucky 40505

Printed in U S A Rev Januaw. I S 7 2

W E S T I N G H O U S E AIR BRAKE C O M P A N Y FLU10 POWER DIVISION . LEXINGTON, KENTUCKY

CHECK VALVE

SERVICE INFORMATION and -40' F t o +160U F temperature (+200U F temperature intermittent exposure).

ADJUSTMENTS No adjus tments a r e neces sa ry in t h e s e c h e c k

va lves or the c h e c k and choke valves.

MAINTENANCE

T h e schedu led inspec t ion perlods wi l l b e determined by frequency of u s e and the working en- vironment of the valve. T h e pipe connect ions

Check Valves a r e used in a l ine t o permit free f low in one direct ion only. When it is des i red t o have a control led back flow a t a spec i f i c rate, a check and choke v a l v e i s used.

INSTALLATION Check Valves may b e instal led. anywhere i n -

\ any posi t ion w h e r e flow cont ro l i s desired. T h e f r e e f low direct ion i s ind ica ted on the body.

T h e opera t ing l imi ts a r e 250 p s i air p ressure

need not b e disturbed. A c c e s s t o a l l internal parts i s through t h e body after removing the c a p nut 1.

Remove a l l of the parts a s shown by the ex-. ploded view. Wash the metal parts with a non- f lammable so lvent and a l l rubber parts with s o a p and water. Examine e a c h part careful ly and re- p lace them if it is apparent, that they w i l l not pro-- v i d e trouble free s e r v i c e unti l the next s chedu led maintenance period.

L u b r i c a t e the metal t o metal su r f ace s with No. 107 Lubr ip la te and. the packing r ings wi th No, 55 Pneumatic. Grease (Dow Corning) or their equivalents .

OPERATION

CHECK VALVE

Fluid Circuit Symbol u FREE FLOW

CHECK AND CHOKE VALVE

u FREE FLOW RESTRICTED FLOW

Fluid Circuit Symbol

EXPLODED VlEW

PARTS LIST

IDENTITY - :hoks- Sirs. - -

.025"

.031" ,047" .064" -- "025" .031" .047" .I)64" - .025" .031" ,047" .OM" -. - - .025" .03l" .047" .OM" - .025" .031" .047" .064" - .025" .031" ,047" .064" -

.Recommended spare parts to be retained in stock at all times.

Rel. No.

i >* 3* 4' 5

PIPE TAP 'A'-\ BOTH ENOS

OUTLINE VlEW

Descr~pt~on p-

NUT, Cap RING, "0" SPRING VALVE BODY

DIMENSIONS

IZ 8,

D I E

P ~ r c e Number

Printed in U.S.A. P R Apri l , 1969

1 - P54991 P49708-220 P54948

P55004-1

1

P53015 P49i08-116 P53013

P53024 P49i08-114 P53022

P53029 P49708-112 P53027

i P54991 P49708-220 P54948

P53029 P49708-112 P53027

P55004 P55001 (See IDENTITY Schedule)

P55001-1 1 P55002 1 P55003

\ - 'AECO FLUID POWER DlVISlON .,A Divlslon of American-Standard, inc 1953 Mercer Road * Lexington, Kentl~cky 40505 .,(606) 254-8031

QUICK RELEASE VALVE

SERVICE INFORMATION

T h e Quick R e l e a s e V a l v e s p e e d s t h e e x h a u s t i n g of your axr c y l i n d e r s , c l u t c h e s , or o t h e r pneumat ic d e v i c e s . A i r p r e s s u r e i s vented c l o s e t o t h e opera ted d e v i c e i n s t e a d - nf hack through the control valve:

STALLATION .

T h e Quick R e l e a s e V a l v e should b e i n s t a l l e d a s c l o s e a s p o s s i b l e to the. d e v i c e to b e vented. If t h e con t ro l s t a t i o n is c o n s i d e r a b l e d i s t a n c e from the. r e c e i v i n g d e v i c e , i n s t a l l another Quick R e l e a s e . V a l v e near the con t ro l v a l v e to vent t h e volume of a i r in t h e line.

F i v e port s i z e s a r e a v a i l a b l e with a number of mounting w s for piping c o n v e n i e n c e . Bui l t of l igh tweigh t

n l , einum, the 1/4 and 3 / 8 - i n c h s i z e s c a n b e suppor ted by piping a l o n e , but mounting b r a c k e t s a r e a v a i l a b l e for i n s t a l l a t i o n s with vibrat ion or long p i p e runs. Longer s c r e w s a r e no t required. T h e 1 / 2 , 3/4, and 1 - i n c h v a l v e s h a v e a mounting bracke t a s an in tegra l part o f the cover .

T h e IN and OUT ports a r e u s u a l l y on t h e s a m e c e n t e r l ine , but the cover of any of the Quick R e l e a s e V a l v e s c a n b e rotated in 6 0 d e g r e e s t e p s to accommodate piping. The cover is often rotated 180 d e g r e e s to e l imina te an e lhow f i t t ing in the piping s y s t e m . T h i s a s s e m b l y p l a c e s the IN port a t a 9 0 degree a n g l e to t h e O U T port.

O P E R A TlON

imum operat ing pressure i s 200 p s i for the 1 / 4 and - i n c h Quick R e l e a s e V a l v e s and 150 p s i for t h e 1/2. , and 1 - i n c h va lves . Tempera ture range is -40 F t o

160 F with intermit tent e x p o s u r e up to 200 F. T Quick d e l e a s e Valve h a s 3 por t s a s shown in t h e a s s e m b l y view. Air p r e s s u r e e n t e r i n g t h e IN port f o r c e s t h e diaphragm to s e a l the EXHAUST port and open a

d i rec t p a s s a g e between the IN and O U T (Cyl inder ) port. When a i r p r e s s u r e a t t h e IN port i s reduced , and t h e p r e s s u r e i s s l igh t ly g r e a t e r a t t h e O U T port, t h e diaphragm is forced a g a i n s t t h e IN port. With t h e IN port s e a l e d off, a d i rec t p a s s a g e i s opened between t h e OUT por t a n d EXHAUST port, a l lowing t h e opera ted d e v i c e t o ven t quickly.

ASSEMBLY VIEW'

ADJUSTMENT

T h e Ouick R e l e a s e V a l v e d o e s not require ad jus tment .

MAINTENANCE

By removing only t h e s c r e w s (1) and w a s h e r s (2), t h e cover c a n b e removed for e a s y replacement o f t h e d ia - phragm (6) without d i s tu rb ing p ip ing connec t ions .

When comple te d i s a s s e m b l y i s required, c l e a n a l l meta l par t s with a nonflammable s o l v e n t and w a s h a l l rubber par t s with s o a p and water. R i n s e thoroughly and blow dry with a l o w - p r e s s u r e a i r je t . R e p l a c e t h e diaphragm (6) and g a s k e t (5) i f damaged o r worn. R e a s s e m b l e the v a l v e , u s i n g t h e e x p l o d e d and a s s e m b l y v i e w s a s reference. No lubricat ion i s n e c e s s a r y , and n o s p e c i a l t o o l s a r e required.

IDENTITY SCHEDULE

PIECE PORT NUMBER SIZE P52935.2 I/d"

'P52935-21 1 '4"

DESCRIPTION Lass Mwnring Brackst L/Mtq. Bkt.. Cove, Rotated 180'

P52935-22 l/A" P52935- 3 3/8"

'P52735-31 3/8" P52935-32 3/8" P52935-4 1 /2"

With Mounting Bmckat Lass Mounting Bracket L/Mts Bkl., Cover Rotated 180° With Mounting Bracket With Intsgrol Mounting Brackst

P52935-6 3 '4" P52P35-8 1"

With Integral Mounting Breckcl With Inregrd Mounting Brmkct

' D i m m ~ i o n s not shown

WAeCo FLUID POWER DIVISION AMERICAN-STANDARD, INC. 1953 Mercer Road Lexington, Kentucky 40505 (6W) 254-8031

PNEUMATIC D I R E C T I O N A L V A L V E

S E R V I C E INFORMATION

NEW, DESIGN FEATURES

Design improvements in the. Super Spool Valve mean . Manual override standard on solenoid operated models. faster response, increased reliability, simplified mainte- - a x e , and more.flexibility. Option of normally open or normally closed function

in o n e valve, depending on piping, with external pilot . New free-floating piston-cylinder arrangement for 3-way models. solenoid and air pilot operators allows u s e of va lve with exhaust restricters and mufflers, a n d u s e of . Exhaust restricters for speed control of cylinders (all valve a s 5-way. s i z e s available from WABCO).

. Extra-large surface area on new piston for f a s t e r Stacked manifolds - off-the-shelf aluminum blocks - response a t lower pressure. for space saving and elimination of piping ( see

Catalog A4-78.00). ' Simplified, one-piece, a i r pilot car t r idge in solenoid

operators extends trouble-free operation. E a s e s For more detailed information on design changes, s e e mamtenance when necessary. Page 6 of this catalog.

SERVICING THE VALVE

Understanding the "Piece Number Code" on Pages 2 & 3 is "a must" in determining service requirements and

a i r parts for your valve. The piece number stenciled the nameplate of each valve body and/or subplate

identifies the model, s i ze , function, etc.

~ r t i cu la r ly important i s determining whether a valve to be serviced i s of the current or obsolete design. All parts l i s t s and exploded views shown in th is ca ta log a re

of the current design. If the model designation shows the valve t o be of the obsolete design, see Page 6 before servicing.

A complete Super Spool Valve will include a valve portion and spool (Pages 8 - 9), a subplate portion (Page 10) when applicable, an operator kit (Pages 11 - 15) on either or both ends, and an end cover or detent kit (Page 16) when a s ingle operator i s used.

- 84-78.00

PIECE NUMBER CODE

D I V I ~ I O N LETTER

I PORT SIZE

2 - 1/4" 3 -3/8" 4 - 1/2"

I I

"A!' END "0" END OPERATOR OPERATOR

VARIATIONS L - Alnnually Operated -End Guides - +-Externa l Pi lot P o r t -- Piston "A" End 5 - External Pi lot Po r t s -- Piston "A" &. "B" Ends G - In te rna l Pi lot P o r t -- Piston "A" End 7 - Inter,nal Pi lot P o r t s -- Piston "A" &. "B" Ends

I

VALVE FUNCTION \-SPOOL 6 - 3/4" 2 - 3-way 0 - Standard 8 - 1" 3 -&way, Open Exhnust. 1 -With Centcr Springs 9 - 1-1/4" 4 - 4-way. Tapped Exhaust

AODEL CENTER FUNCTION L). T -Tapped Body V d v e 1 - Closed Ccntcr L - Standard Subplate Valve Body only 2 -Closed Center. Normally Open- M - Standard Subplate only 3 --Closed Center. NormaUy Closed) only X - JIC Subplate Valve Body only 4 - 11~Iet Open Center Y - JICSubplate only 5. -Exhaust Open Center

STANDARD OPERATOR COMBINATIONS -0100 Lever , no spring. --End Cover 'Single Solenoid, with re turn spr ing --End Cover -011-1 Lcver, no spring--2-Position Detent -3100 l l 5 V AC. 60C -- (30V DC) -0115 Levcr , no spr ing -- 3-Position Dctent -3100 220V AC, GOC -- (64V DC) -0200 Levcr , with re turn spr ing --End Cover -3 iOU 41OV AC, GOC -.. (140V DC) -0300 Levcr , wilh ccntcr springs --End Cove r -2500 llOV AC, 50C -0400 Button, no spr ing --.End Cover -2900 22OV AC, SOC -0414 Button, no spr ing --2-Position Detent -4000 12V DC

5 Button, no spr ing -- 3-Position Detent -4300 24V DC - I Button, with return spring -- End Cover 4 0 1 1 230V DC -0700 Ball Cam, with re turn spr ing -- End Cover -1000 Peda!, with return spring -- End Cover *Double Solenoid, with o r without center springs -1100 Treadle, no spr ing --End Cover -3030 l l 5V AC. GOC -- (:iOV DC) -1200-, Trc:ldle, with center springs --End Cover -3333 2 2 0 ~ AC, GOC -- (WV DC) -1Gll1 Doublc Air Pilot, with o r without centcr spr ings -36-G 4iOV AC, GOC -- (14OV DC) -1700 Single Air Pilot, with return spring -- End Cover -2124 llOV AC. 50C -1'319 Doublc Diaphragm, without center spr ings -2W" 220V AC, 50C -2000 Single Diaphragm, with return spr ing -- End Cover -3030 12V DC -2121 Double Diaphragm, with center spr ings -4242 24V DC -2200 Roller Cam, with return spring -- End Cover -4444 2::OV DC

*Monuul ovcmido i s stundurd on a l l salanoid aporetorn.

EXAMPLE PT22105-4242

The model designation and the f i r s t two digits of the piece number identify a tapped body valve with 1/4-inch ports and

.- ' -way function. A double solenoid operator with a 24V DC coil is indicated by the piece number sufiix. The suffix

nc does not nlways show whether a valve i s two-position o r thrce-position (with o r without center springs); however. t.n a slandnrri spool i s specified by the 4th digit of th4 piece number of a double solenoid operated valve, the valve

c in hnvc only two positions of operation.

Sir the valve has no normal (de-energized) position (the valve can be ei thcr normally open o r normally closed depending 3 on like position of the spool) and, although there i s no center position. a "cioscd cc111cr" designation i s chosen for the 3rd digit because al l ports a r e closed on 3-way valves a s the spool passes through tile ccnter position..

The 5th digit indicatcs xn external pilot with pistons on both ends for the double solenoid operator

CHANGES IN PIECE NUMBER' CODE

Redesign of the Super S m l Valve ( see Page 6) has. made s o m e changes necessary in the piece number coding system. ~ l t h o u g h most design improvements relate to solenoid and a i r pilot operated models. new "Model Designations" have been assigned to all valves. These designations a r e the "key" to identifying thecur ren tva lves and obsolete valves. A detailed explanation of coding changes follows:

DIVISION LETTER -- Unchanged

MODEL -Both obsolete and current designations are shown.

OBSOLETE A B K. E F G H

CURRENT T Tapped Body Valve - Standard Subplate Valve. Complete L Standard Subplate Valve Body only M Standard Subplate only - JIC Suhplate Valve. Complete X JIC Subplate Valve Body only Y JIC Subplate only

1ST DIGIT (Por t Size) --Unchanged

2ND DIGIT (Valve Function) --Unchanged. except that 2-way valves (designated "1") a r e no longer offered; however the 2-way function can be obtained by plugging Por t 1 (NC) o r Port 3 (NO) of 3-way models.

3RD DIGIT (Center Function) --In both the ohsolete and current designs, single operator valves wlth an internal. pilot have n 3rd digit designation of "2" to indicate normally open o r "3" for normally closed. In the ohsolete design. a single operator valve with external pilot and no piston could be normally open o r normally closed. depending. on piping, and had a "I!' designation; however; the same valve with a piston could only be normally closed, with. a 3rd digit "3" being the designation. After redesign. any single operator valve with external pilot i s e i ther normally open o r normally closed. depending on piping, and the "1" designation i s always used.

4TH DIGIT (Spool) -Unchanged

5TH DIGIT (Variations) --In the obsolete design, some single and double solenoid operated models were offered without plstons and given a "1" o r "2" o r "3" designation. Some a i r pilot operated models also had a "1" designation. These models have been functionally replaced hy valves with piston6 and their designation deleted f rom the piece number code; however, the "1" has been retained to identify manually operated valves. A functional relationship of the obsolete and current valve, based on the 5th digit designation. can be made a s follows:

On all external pilot solenoid o r aIr pilot operated valves of the oheolete design which have "1" ae a 5th digit of the piece number:

Change "1" to "4" on single operator models. Change "1" to "5" on double operator models.

On all internal pilot solenoid operated valves of the obsolete design which have "2" o r "3" a s a 5th dlgit:

Change "2" to "6" on single operator models. Change "3" to "7" on double operator models.

SUFFIX (Operators) -- Tho piece number suffix coding has been expanded to incorporate coil voltage of the solenoid operators into the complete piece number of the valve. At the same time, the manual override has been made standard on a l l solenoid operated valves. The former code a s shown here does not incorporate coil voltages and i s given to help identify obsolete valves with solenoid operators.

.. -5050 Double Soienoid, with o r without center springs --with manual override -5100 Single Solenoid, with rchlrn spring -- with manual override -8080 Double Solenoid, with o r without center springs --without manual override -8100 Single Solenoid, with return spring -- without manual override

SERVICE IN F O R M A T I O N

'Y7 ALL AT'0N Uefore installing t h e Super Spool Valve , all, air l ines i n t h e system should b e blown clean- to remove any moisture or loose material. T o further ensure long; trouble-free service, an ef f ic ient manual-drain f i l t e r should b e installed in the a i r l i ne on t h e supply s i d e o f thevalve; . Although t h e va lve i s lubricated a t the factory, an a i r line lubricator i s a l s o recommended for high-cyclic applications. S e e Catalog A6-115.01 f o r complete- a i r l i n e conditioner units.

Install the, v a l v e in any convenient position- but, if. installed with t h e spool axis. vert ical , a spring-returned. model provides more posi t ive operation. T h e preferred mounting for al l models. i s horizontal. In th is position the solenoid a i r pilot exhaust h o l e in the a i r pilot sec. tion of the operator i s on t h e bottom. to allow for f r e e drai- -ye.

The rd lve i s offered in s i x port s i z e s , both tapped body and subplate mounted models. Por t s i z e s are 1/4, 3/8, I /?, 3/4, 1, and 1-1/4 inches NPTF. Port numbers or designations are marked on t h e bottom of the valve body or the subplate. All 4-way, tapped body, 3-port va lves have an open exhaust , exhausting out the ends of the valve through the end cover o r operator housing.

lenoid and a i r pilot opera ted models h a v e a n external. t port in t h e operator tha t : i s tapped 1/4-18 inch F. Th i s port i s plugged on solenoid operatois when:

the valve i s internally piloted; Diaphragm operators h a v e a 1/8-27-inch N P T F external pilot port.

Spring-returned 3 w a y valves, except for internal pilot solenoid operated models, may be connected for ei ther normally open o r normally closed operation.

For ~ o r m a l l y open operation, pipe supply to Por t 1. For -mally c losed, pipe to Por t 3.

Prior to connecting power supply, be su re that the coi ls m t c h the power supply. Voltage characterist ics for solenoid operators are indicated by the suff ix of the piece number on the nameplate of the valve ( s e e the "Piece Number Code" on Page 2). Voltage of a solenoid coil is indicated on the coil nameplate and.further ~den t i f i ed by the color of the coil wrapping ( s e e "Sole- noid Coils" on Page 12).

When mounting a combination of valves with different operators in a stacked. manifold, excess ive wiring can 4); b e eliminated, and a neater assembly will result from proper placement of manifold. blocks. Manual and air pilot operated valves should b e placed a t t h e top of the s tacked manifold, next to the top cap; Single solenoid operated valves should follow, with double. solenoid. operated valves being l a s t in order of placement before adding t h e power entry block.

For ou t l ine dimensions or further mounting information on any Super Spool Valve, see Catalog A4-78.00.

OPERATION

Maximum operating pressure of the Super Spool Valve i s 150 psi, with a temperature range of -20 F to 160 F. Air pilot pressure i s 150 psi maximum, with a minimum of 15 ps i without springs and 3 0 ps i with springs (40 psi minimum on 1/4 & 3/8-inch valves under poor lubrication conditions). Diaphragm operator air pilot pressure i s 5 psi minimum; 60 ps i maximum.

Voltage characterist ics for solenoid operators are indicated by t h e suffix of t h e p i e c e number on the name- p l a t e of t h e valve ( s e e t h e " P i e c e Number Code" on Page 2). Voltage tolerance is: DC co i l s - plus o r minus - 10%; 60 c y c l e AC-p lus lo%, minus. 15%; 5 0 cycle AC-- plus o r minus 20%. T h e voltage of a solenoid. coil i s indicated, on t h e coil nameplate and further identified by the color of the coil cover, and a l s o indicated directly on t h e bobbin i tself ( s e e "Solenoid Coils" on Page. 12).

'3

Single Solsnoid, Subplots Mountad Mods1 Stacked manifolds ( s e e P a g e 7) are a l so available for mounting of subplate-type Super Spool Valves. T o operate a Super Spool Valve a manual, mechanical,

pneumatic, or electrical force i s required. This force Super Spool Stacked Manifolds are designed in two bas ic positions the valve's spool in ei ther two or three sepa- s i zcs , each accommodating two s i z e s of manifold blocks rate positions. Internal passages in the valve are far valve mounting. Either 1/4-inch manifold blocks or opened and c losed, permitting directional control of air

inch manifold blocks, or a combination of both, can flow in and out the valve's main ports. Diagrams of ssembled only with the 1/4 & 3/8-inch power entry these valve functions are shown in Catalog A4-78.00.

block and top cap. Inlet and exhaust ports for th is manifp'd are tapped 3/4-14 inch. Manually operated valves have a lever, pedal, t readle,

or button operator. The cam operator i s mechanically In the same manner, 1/2 & 3/4-inch manifold blocks mate operated. Remotely operated valves have air pilot.

3 only with the 1/2 & 3/4-inch power entry block and top diaphragm, and solenoid operators. Solenoid operators cap. Inlet and exhaust ports are 1- 11-1/2 inch. require electrical control of the air pilot pressure.

.~. d -- .. . -

.. --.-- - .- . . .~ . . . ~ . . . ~

SERVICE INFORMATION;

nually or mechan~cal ly operated valves usually re- quzre only a s ingle operator, normally assembled on t h e "A" end of the valve. Remotely operated valves usually have a s ingle operator, a l so on t h e "A" end, or an operator on both ends of t h e valve.

Valves with s ingle operators must h a v e an end cover kit or de tent kit on t h e "B" end o l theva lve . End cover kits may or may not h a v e a return spring. A return spr ing is contained in the end cover kit for a l l va lves that require self-returning operators, except for t h e lever operator, which contains i t s owrr return spring. T h e pedal operator a l s o contains a return spring, a s well as . the spring in the end cover kit. Two-position and three- position detent k i t s are available- with valves. that must be manually operated in both directions.

Any Super Spool Valve can be provided. to obtain ei ther w o or three positions of operation, except for pedal

1 cam operated models. Peda l and cam operators . .ue only two posit ions, and require a return spring returning the operator to thenormal position.

T h r e e - p o s ~ t ~ o n valves offer a choice of center functions, determined by the spool used ( see Page 9) a s well a s the operator or operators. T h e s e functions a re c losed center (all ports blocked), inlet open center (supply port open to both delivery ~ o r t s ) , and exhaust open center -~ (dellvery ports open to the exhaust port).

& Vhile a manual or mechanical operator moves t h e valve. spool by direct connection, a remote operator uses air pilot pressure acting on a piston or, in t h e c a s e . o f the diaphragm operator, a rubber diaphragm.

The air pilot signal is controlled on solenoid operators by energizing the solenoid coil to open and c l o s e a 3-way valve in the operator. When electrical power i s not present, the valve may be operated by depressing

s manual override button located on the end of t h e . ..erator. Although the solenoid coil may be energized for extended periods of time, it i s better practice for the coil to be de-energized for the extended period. and energized for t h e shorter period.

ADJUSTMENTS

No adjustments are required on the Super Spool Valve.

MAINTENANCE

Before servicing the Super Spool Valve, first determine whether the valve i s of the current or obsolete design ( see the "Piece Number Code" on Pages 2 & 3). If the model designation in the piece number shows the valve - to be of the obsolete design, s e e Page 6 for service formation and repair parts.

. -

T:ippcd body valves may be serviced by shutt ing off and nting the main air supply, but removal of the valve

irom its mounting i s recommended. On subpiate mounted models, the complete valve portion can be removed from

t h e subplate for servicing without disconnecting piping; however, air pressure must b e shu t off and vented.

If a solenoid operated va lve fa i l s to operate; depressing t h e manual override button on t h e end of the operator should. quickly indicate whether t h e trouble i s electrical o r mechanical. If required, t h e solenoid coil can b e eas i ly replaced by removing only t h e cover from t h e operator. Care should be exercised. in reassembly of t h e solenoid cover t o prevent cutting t h e c o i l leads. S e e "Solenoid Coils" on P a g e 12 for coi l voltages and p iece numbers.

Super Spool Valves are lubricated a t the factory for long, trouble-free service. An efficient a i r line lubri- ca to r will further extend t h e service. l i f e of the valve. When no additional lubrication i s provided, the valve. should b e disassembled every one million cycles for lubrication, cleaning, and inspection. Clean all metal parts with a nonflammable solvent, and wash all rubber parts with soap and water. Rinse thoroughly and blow dry with a low-pressure air jet. When applicable, check t h e internal pilot ports in the valve body t o make su re the passages are open.

Replace any parts that a r e damaged or worn, giving particular attention to the s e a l rings (13) in the valve portion. Repair parts for valve portions (Page a), solenoid operators (PBge l l ) , and air pilot operators ( P a g e 12) a r e ava i l ab le in convenient repair kit form a s shown under the appropriate parts l ists .

Reassemble t h e valve, using the exploded views and cutaway view a s reference. No spec ia l tools are re-. quired. When reassembling the valve portion, one new spacer (14) should be ins ta l led in the s t ack of space r s and seal ing rings (13) to make the necessary compression in the post sockets and as su re a tight s e a l s tack. P lace the new spacer in the center of the valve body, with sea l ing rings and space r s added on each s ide a s assembly of the s tack proceeds. Lubricate each s e a l with Shell Alvania EP-RO Grease. T i l t the sea l ing rings a s they are inserted into the valve body t o avoid cutting or damage from sliding over port openings.

Spring-centered models of the remote operated Super Spool Valve will have center spring assembl ies recessed into both ends of the spool. The center springs are caged in these assembl ies and s e t at the factory because the dimension i s cri t ical for the centering function. For dimensions, see "Spools" on Page 9.

Lubricate a l l metal-to-metal su r faces with Number 107 Lubripiate and a l l rubber parts with Shell Alvania EP-RO Grease.

Although other o i l s 9 work equally a s well, the following oi ls are recommended when air line lubrication is used: Mobil DTE Medium, Chevron OC Turbine 11, Texaco Regal R & OB, Gulf Harmony C, Shell Tel lus .33, Pure Oil Puropale RX Antiwear & Phi l l ips Condor 1006.

OBSOLETE DESIGN lctcrmine whether a valve i s of the current o r obsolete deaign, s e e the "Piece Number Code" on Pages 2 & 3.

T h ~ s section of the catalog applies only to the obsolete deaign of the Super Spool Vake. and only to the extenLthat the obsolete design differs from the current design. P a r t s o r assemblies not covered in this section a r e interchangeable between both designs.

Most design improvements.relate only to solenoid o r a i r pilot operated valves. aifecting-both operator kits andvalve portions: on these models. Qutlinedimenaions a r e affected only to the extent that tho a i rp i lo t opera tor and the end cover used with a single a i r pilot. single solenoid, o r single diaphragm opera tor a r e each 1/8 inch longer in the current design.

OBSOLETE V A L V E PORTIONS In thc current d e s ~ g n , a new free-floating pistan assembly f o r solenoid and a i r pilot operated models allows use of the valve wlth oxhnuat rcs t r ic ters and mufners, and use of the valve a s 5-way. The piston i s sealed off from the exhaust port, and ~ i r pressure between the piston and the end of the valve spool i e vented through a bole in one side of the valve body -- approx~mately 3/16 inch f rom the end.

In the obsolete design, the piston was not sealed off, and a i r vented directly into the exhaust. A vent in the valve body was not required.

Be se of the different designs of the piston assembly, and because of thedifferent venting conditions in the valve body. the . .ton assembly and valve body of one design valve a r e oot interchangeable with those of the other design. Valve portions for manually o r mechanically operated valves. where piston assemblies a re not required, a re not affected by design chnnges and all parts a r e interchangeable.

:An illustration of the obsolete piston assembly and piece numbers of component parts a r e shown f o r convenience in servicing an obsolete valve.

PIECE NUMBERS

Piston A s s a m b l y

CYLINRER P57783 P57790 P57799 RING

Thc quantities of sea ls and spacers (Ref. Nos. 13 & 14 --Page 8) used in a valve portion a re also affe-ted by redesign of thc piston assembly. Since the length of an obsolete piaton assembly i s greater than the current deaign. one leas sea l and spacer i s uscd fo r each piston assembly installed in the obsolete design.

E. of the following repai r kits contains one obsolete piston assembly, six seals, and one spacer, and will meet most service requirements for an obsolete valve portion.

1/4" & 3/8" Valves -- PC. NO. P58298 1/2" & 3/4" Valves -- PC. No. P58301 1" &. 1-1/4" Valves -- PC. No. P58303

OBSOLETE AIR P ILOT OPERATOR KITS Since the new piston assembly eliminates the need for the cushion washer and retainer used in the obsolete design. the a i r pilot operator kit has been completely redesigned and no parts a r e interchangeable between the current and obsolete design. The obsolete assembly i s shown and service parts listed fo r your convenience.

Woshor Ratoinsr (required on ly when end

/ p i d a i s usad)

Cover (for svbplota mounted valves)

c u J h t a n wo.har COY" (f-(. t m ~ ~ e d

9

DESCRIPTION

WASHER. Cush~on

RETIVNER. Washer

P E C E NUMBERS 1/4" & 1/8"

P57785 P49708-0030 P57862

1/1" & 3/4"

P57697 P49708-0032 P57862-0001

1" & 1-1/4"'

P57773 P49708-0036 P57862-0002

OBSOLETE DESIGN OBSOLETE SOLENOID OPERATOR KITS

ihe new improved solenoid operator kit contains a simplified, one-piece, a i r pilot cartridge: Thie cartr idge Is not inter- 7 changeable with the combined; separate components in the obsolete kit ...

Since the ncw piston assembly eliminates the need f o r the cushion washer and retainer used in the obsolete design, and to accommodatethe new a i r pilot cartridge. the solenoid body has been redesigned and i s not interchangeable. Aleo. the currentopera tor body requires longer screws to attach it to the body of the valve.

Manuol overr ide i s now standard on all current solenoid operated valves, and the manual override details a r e permanently assembled in the opera tor cover. Obsolete valves were furnished e i ther with o r without manual override. Should replnce- rnent of an obsolete cover f o r a solenoid operator be necessary, o r d e r a current cover (Ref. No. 3 --. Page 11).

l l lus t ra t~ons and piece numbers f o r all normal service parts f o r an obsolete solenoid operator kit a r e shown below. T h e foilow~ng repai r klts contam those parts noted (*) ---plus Ref. Nos. 4. 5. 11. 12 & 19 on Page 11 -- and will meet most service requirements..

. , , . . 1/4" & 3/8" Valves -- Pc: No. P58116

1/2" &. 3/4" Valves --PC. No. P58120 1" &. 1-1/4" Valves -- PC. No. P58295

- REF.

,M N* 0

A B * C * D E F * G* H* J K* L* -

DESCRIPTION

SCREW WASHER, Cushion RETAINER. Washer

POLE RING. 13/16" OD "0" RING. 11/32" OD "0" WASHER SEAT. Supply Valve RING, 13/16'' OD "0'' VALVE. Supply SPRING. Supply Valve WASHER RING. 7/16" OD "0" RING. 5/16" OD "0"

- PIECE NUMBERS

P57785 P57697 P57773 P57862,

COMMON PARTS LN ALI: SIZES P57633 P49783-0017 P49783-0009 P49904-0033 P57618 P49783-0017 P5173 PSI613 P49904-0034 P49783-0011

- P49783-0008

S T A C K E D M A N I F O L D S (See Catalog A4-78.00 for Ordering Information)

REPAIR PARTS

1 MANIFOLD BLOCK SEAL TOP CAP SEAL

(3 req'd aoeh block) / (3 tsq'd) POWER ENTRY BLOCK SEAL

(solanoid type only)

PIECE NUMBER 1/4" & 3/8" ( 1/2" & 3/4"

1A RLNC. 1-1/4" OD "0" 1B RING, 1-5/8" OD "Ow 2 RING, 2" OD "0"

P49708-0214 - P49708-0224

- P49708-0210 P49708-0294

3-WAY T A P P E D EXHALJST &WAY O P E N EXHALIST

VALVE: PORTIONS EXPLODED VIEW

4-WAY T A P P E D E X H A U S T S U B P L A T E M O U N T E D MODELS

Not required for 3-Way Tappad Exhoust or 4-Woy Open Exhousr Models.

I

End

For Solenoid or Air P i lot Operator

For End PARTS LIST

BODY. Valve SCREW, Cover Plate PLATE, Cover PLATE, Cover

4A SEAL, Body 4B SEAL. Body

Cover

GASKET PIN

7

GUIDE, End PISTON RING. Plston "0" CYLRiDER. Spncer RING. Cylinder "0" SPOOL RING, Spncer Seallng SPACER

' Included in reooir k i t s far solenoid and air

PIECE 1 1/4" & 3/8"

l r d e r by deso: P49648 P57643 PSI663 P5182 P5183 P58109 P49705-0003 P57621 P58525 P49427-0021 P58500 P49708-0024 - P5168-0003 P57632

REF.

?Ii ot opcrotor k i t s .

DESCRIPTION

tion and complete v P49648 P57704 P57714 P5184 P5185 P58110 P49705-0003 P57706 P58518 P49427-0025 P58499 P49708-0028 - P5175-0003 P57707

"A!' End.

For Solenoid or Air P i lot Opsrotor

JRT SIZE 1" & 1-1/4"

,e piece number: (not rcquired) (not required) (not required) (not required) (nor required) P 5 8 l l l P49705-0003 P57750 P58536 P49427-0029 P58501 P49708-0030 - P5177-0003 P57751

For Manual

tSix spacer sealing rings and one spacer uv P58884. 1/2" & 3/4" valves - P58880, 1'

able in Repair K i t s P58875, I / J " & J/8" velvoe - 1-1/4" vnlves .

S P O O L S (Rcfr 12)

, pcen te red models of the double solenoid and double- Center spr ings on manually operated valves a r e contained -$ tr pilot operated valves have. center springs assembled within t h e operator portion of the valve; on the ends of t h e spool. Piece numbers of spools with center springs include t h e s e spring assemblies. They Note: For a l l subplate mounted models, u s e 4-way, mav b e ordered s e ~ a r a t e l v . if desired. tapped exhaust spools.

k e n t e r Sprlng Assembly (2 required) 1/4" & 3/8" Valves --PC. No. P58529 1/2" & 3/4" Valves -- PC. No. P58539 1" & 1-1/4" Valves -- PC. No. P58532

3- WAY TAPPED EXHAUST

4-WAY OPEN EXHALJST (Closed Center)

4-WAY OPEN EXHAUST (Inlet Open Center)

4-WAY OPEN EXHAUST (Exhoust Open Center)

Y PC. No. P58529 -- 1.315" PC. No. P58539 -- 1.750" PC. No. P58532 -- 2.315"

W R T SPOOL S W a L S U E (With Center Springs)

1/4" & 3/8" P57630-0001 P59321 1/2" & 3/4" P51670-0001 P59311 1" & 1-1/4" P57144-0001 P59763

1/4" & 3/8" P57624-0001 P59328 , 1/2" & 3/4" P57671-0001 P59318 1" & 1-1/4" P57141-0001 P59383

4 - WAY TAPPED EXHAUST (Closed Ccnter)

1/4" & 3/8" P57625-0001 P59329 1/2" & 3/4" P57613-0001 P59319 1" % 1-1/4" P51143-0001 P59381

4 - WAY TAPPED EXHAUST (Inlet Open Center)

1/4" & 3/8" P58088-0001 P59330 1/2" & 3/4" P58090 P59380 1" & 1-1/4" P58092 P59382

4 - WAY TAPPED EXHAUST (Exhaust Open Center)

9

SUBPLA.TE PORTIONS.

EXPLODED VIEW, or Doubla.Solsnoid J lC Subplate.. For Stondoid Subplarss. or

Singla. Solsnoid

., , For JIC Subplmes.

PARTS LIST

DESCRIPTION

NO -Pipe lo OUT 2 , EXH. 2 (OUT I plugged, EXH. I choked). NC- Pipe to OUT 1, EXH. I (OUT 2 pluggcd. EXH. 2 choked).

PIECE NU1 1/4" & 3/8"

SUBPLATE SCREW, Valve Mounting WASHER PLUG, (1/4" - 1/2" - 1" ) PLUG. (3/8" - 3/4" - 1-1/4") PLIJG, Choke (1/4" - 1/2" - 1" ) PLUG. Choke (3/8" - 3/4" - 1-1/4") COVER. Subplate End SCREW, Pan Head COVER. J u n c t ~ o n Box GASKET. Junctlon Box Cover SCREW BOX, Junctlon PLUG. E l e c t r ~ c GASKET, Junction Box RING, 7/16" OD "0" TUBE. Lend SCREW CHAIN. Saicty

d on 3-way subplale only:

E R BY SUBPLATE 1/2" & 3/4" --

(Order by descrl P49635-0003 (not r equ~red ) P49909-0013 P49909-0014 P49868-0006 P49868-0007 P57608 P49637 P57651 P57664 P49635-0001 P57650 P57675 P57652 P49708-0011 P57G44 P49987-0011 P49636-0001

on and complete val P49635-0004 (not required) P49909-0015 P49909-0016 P49868-0008 P49868-0009 P57698 P49637 P57703 P57717 P49635-0001 P57693 P57675 P57116 P49708-0011 P57644-0001 P49987-0011 P49636-0001

3T SIZE - 1" & 1-1/4"

piece number) P49701-0003 P49866-0010 P49909-0017 P49909-0011 P49868-0010 P49868-0011 (not required) P49637 P57765 P57766 (not required) (not required) P57675 (not required) (not required) (not required) P49987-0011 P49636-0001

rpiece numbers sham apply only when one junction box and one plug are used. When two junction boxes are uscd, a suffix i s added lo lhe piece number: -0001 for the "A" end junction box and -0002 lor lhc "8" end junction box. The plug piece number remains lhe same lor the ''A" end, and -0001 i s added lor lhc "8" end.

10

.. *-.- - ....-..-A,-.--..... . -- ..

/" , ,,+ 7 f i SOLENOID OPERATOR KITS.

/I6 (Less Coil - P ~ g c 12) .. <. EXPLODED VIEW

QTY -

V- PARTS L I S T

DESCRIPTION

KIT; Solenoid Operator

No Spr ing or- With Center Springs (use with an identical solenoid opera tor kit)

With Return Spring (use with appropriate e n d c o v e r kit, with r e tu rn spring)

Tapped Body, Tapped Exhaust Valves (Les s Ref. 21-24) Externa l Pi lot (Les s Ref. 20) Internal Pl lot

Subplate Mounted Valves

SCREW WASHER COVER (for tapped body vnlves) COVER ( ior subplate mounted vnlves) GASKET SCREW BODY GASKET RING, "0" Retaining

SPRING. Exhaust Valve SEAT, Exhaust Valve PLUNGER COIL, Solenoid SHELL BUSHING, Shell RING, "0" RING. "0" SCREW PLATE ASSEMBLY, Cartr idge RING. "0" PLUG. Pipe PLUG. Conduit SCREW

1/4" & 3/8" -

P58821 P58823 P58820

P49639 (not requlred] P57612-0005 P57612-0006 P57649 P49639-0007 P574184001 P5112 P49108-0006

LECE NUMBE 1/2" & 3/4"

P49639-0004 (not required) P57702-0005 P57702-0006 PSI699 P49639-0008 P57419-0001 P5114 P49108-0008

COMMON PARTS IN ALL SIZES

P57660 P57645 P57647

(order separately - Page 12) P57614-0002 P57863 P49708-0212 P49783-0015 P49609-0013 P54825-0002 P59788 P49708-0017 P49685-0002 P49431 P49987-0011

CHAIN. Safety P49636-0001 'Ava i l ab le in Repair K i t s P58873, 1/4" & 3/8" valves - P58885. 1/2" 6r 3/4" va lves - P58878, 1" dr 1-1/4" valves. Eech kit includes R e f . Nos. 8 , 9 & 11 o f valve portions (Page 8) .

SOLENOID COILS

QTY.

i 1 1

* Available 1 ki t includa.

-. COVER C O M R

White

SOLENOID RATING

115 Vol t --GO Cycle AC

DC

AIR PILOT OPERATOR KITS EXPLODED VIEW

1 230 Volt 1 P57620-0006 1 P57679-0006

KIT; A i r Pi lot Ope ra to r

PIECE NUhlBER

220 Vol t -- 60 Cycle ,440 Volt -60 Cycle

12 Volt 24 Volt

PARTS LIST

Tapped Body Valves

P57620-0001 P57620-0002 P57679-0002 P57620-0003 P57679-0003 P57620-0004 P57679-0004 Yellow P57620-0005 P57679-0005 Green

P51620-0007 P51620-0009 AC

Tapped Body. Tapped Exhnust Valves , No Spring o r With Center Springs (use with a n

identical a i r pilot operator kit) With Return Spring (use with appropriate end

cover kit, with re turn spring) Suhplate Mounted Valves

No Spring o r With Center Springs (use with an identical a i r pilot operator kit)

With Return Spring (use with appropriate end cover kit, with re turn spring)

JIC Subplate Mounted Valve -- Plug-in Coi l

P57679-0001

110 Volt -- 50 Cycle 220 Volt -- 50 Cycle

- PLECE NUMBER

1/4" & 3/8" 1 1/2" & 3/4" 1 1" & 1-1/4

SCREW WASHER COVER (for tapped body valves) COVER (for subolate mounted valvea)

P49639-0001 (not required) P58493-0001 P58493-0002

P49639-0003 (not required) P58491-0001 P58491-0002

GASKET

P49856-004 P49866-0011 P58492-000 P58492-000:

P5112 1 P5174 1 P5178 lepair K i t s P60693, 1/4" & 3/aL' valves - P60692. 1/2" 6. 3 /4" valvsa - P60691. I" & 1-1/4" valvas. Eoch 'e l . Nos. 8 , 9 6. 11 d valve ponlona (Pegs 8).

12

PARTS. LIST

DESCRIPTION - KIT; Lever Operator

No Spring. (usewith end cover kit, no spring. o r with either detent kit)

With Return Spring.(use with end cover kit, no spring) With Center Springs (use with end cover kit, no Spring)

. KIT; Pedal Operator --With Return Spring (Use with

appropriate end cover kit, with return spring)

KIT. Treadle Operator

REF. 1 - 11 PIECE PLIlS 1/4" &.3/8"

No Spring (use with end cover kit, no spring) With. Center Springs (use with end:cover kit,

no spring) I SCREW COVER

1 SCREW 1 PIN (for lever operator kits) 1 PIN (for pedal and treadle operator kits)

GA 1 SCREW (for 4-way, open exhaust valves) GB 1 SCREW (for all. valves except 4-way, open exhauet)

ADAPTER SCREW

LEVER

SPRING. Return SPRING. Center

? -; 13 i I i? I

P51805

P51805-0001 P57805-0002

P51808-0003

P51809 P57809-000

P49604-001 P51641 P57684 P49151-000 P49817-002 P49817-002 P49604-009 P49604-002 P49004-00: P51G40 (not requlr P49604-001 P57642 P57654 P57662 PSI686 P51689 P51G88 P57655 P57634 P57635 P51683

- -

BUTTON: OPERATOR KlTS

"9 EXPLODED VIEW PARTS. LIST

KIT. Button Opera tor / ~ 5 7 8 2 0 1 REF.

No Spring ( u s e with end c o v e r kit. no spring, or- with either-detent kit)

With Return Spring (use with end cover kit, with re turn spring)

SCREW COVER STUD (for a l l valves except

4-way, open exhaust) STUD (for 4-way, open

exhaust valves) ADAPTER BUTTON SHAFT

QTY.

CAM OPERATOR KITS

PIECE NUMBER

-.

B A L L CAM

PARTS LIST

DESCRIPTION

I I I

DESCRIPTION

KIT, Bal l Cam Operator --With Return Spring (use with appropriate end cover kit, with re turn spring)

'KIT. Roller Cam Opera to r -- With Return Spring (use with appropriate end cover kft, with return spring)

1/4" & 3/8" 1 1/2" k 3/4"

- LNCLUDES

7

REF. NOS.

1. ZA. 3. 4. 5A

SCREW COVER COVER SCREW WASHER FOLLOWER, Cam FOLLOWER, Cam PIN. Roll ROLLER .Cam roller con be easi ly rotated 90 dcgrces from view shown.

14

ROLLER CAM

- PIECE NUMBER

1/4" & 3/8" 1 1/2" & 3/4' I

D I A P H R A G M O P E R A T O R K I T S EXPLODED VIEW

- QTY.

-.

4 4 1 1 1 1 1 1 1 1 1 1 4 1 3 3 3 1 -

P A R T S LIST DESCRIPTION

KLT. Diaphragm Operator -- Tapped Body, Tapped Exhaust Valves

No Spring --Less Ref. 10 & 11 (use with a n identical diaphragm operator kit)

With Return Spring --Less Ref. 10 & 11 (use with appropriate end cover kit, with r e m r n spring)

With Center- Springs (use with an identical diaphragm operator kit)

SCREW WASHER COVER DIAPHRAGNI -

SCREW WASHER FOLLOWER, Diaphragm ADAPTER EXTENSION, Stem SEAT. Spring SPRING, Center STOP, Follower SCnEW n m Y NUT SCREW WASHER PLATE. Valve MounUnc

15

P49639-0003 P40G30-0003 P57725 P57725-0001 P40001-0023 P49901-0023 P40635-0004 P40835-0024 (not required) P4086i;-0009 P57753 L P57759

P57814-0001

P49604-0006 P49804-0012 P51727 P5176 P49604-0095 P49804-0042 P57728 P57678 P57130 P57752

P57828-0001

P40604-0015 P49804-0014 P57727 P5176 P49604-0100 (not required P57728 P57719 P57730-0001 P57731

- QTY. -

4- 4 1 1 1 1 1 1 --

END C O V E R KITS'

No Spring (for lever, button, o r treadle operated valvee)

With Return Spring. (for. button, cam. o r pedal operated valves-- subplate.rnounted.or tapped body. tapped exhaust)

With ReNm-Spring (for button. oam o r pedal operated valves--tapped body, open exhaust)

With Return Spring (for solenold,or~ a i r pllot operated valves--subplate mounted o r tapped. body. tapped exhaust)

With.ReturnSprlng.(for diaphragm operakd valvee-tapped M y . tapped exhaust)

3C PARTS LIST

SCREW WASHER COVER COVER COVER PISTON RING, Piston "0" SPRING. Return

DESCRLPTION - KZT.End Cover

1/4" & 3/8" -

P57801

P57801-0001

P57802

P58831-0001

P58831-0002

P49639-0001. (not required) P57681-0002 P57637-0001 P58493 P58525 Pj9708-0212 P58571

WCLUDES - REF. NOS. -

DETENT KITS' PARTS LIST

P49639-0003 (not required) P57722-0002 P57723-0002 P58491 P58518 P49708-0123 P61526

EXPLODED VIEW PIECE

DESCRIPTION 1/4" & 3/8"

I 1 KIT, Detent (use with lever o r button operator kit, no spring)

I I 2 Position P57810 3 Positlon P57811

P40G39-0001

way, open exhaust)

vdves only) ADAPTER P57G78

1 P57G80 - intad in U.S.A.

WESTINGHOUSE AIR BRAKE. COMPANY FLUID POWER DIVISION. .- LEXINGTON; KENTUCKY

MULTtPOSlTlON~ AIR' CY LINOER' CAST' ALLJMINUM

F0UR:POSITION: -ALL AIR'

SERVICE I&4FORMATION *

i n providing a. mounting for t h e cylinder, an. a d j u s t a b l e l ink must b e included between. t h e piston rod and the- lever t o which t h e rod i s . connected. The. cy l inder stroke. should b e checked in one. of i t s in te rmedia te posi t ions. when a l igned with the l e v e r t o be. operated. Supply a i r a s indicated. in the. "Rod Pos i t ion-Por ts Supplied" table. ( s e e "Operation"),. and. check for exac t register. In t h i s position; the c l e v i s pin should b e free. from load. . T h i s . procedure will allow a n y inaccurac ies i n leverage ratio or manufacturing to le rance to b e absorbed a t t h e ex t remes of t h e s t roke where exac t registrat ion i s of least importance. Also, any inaccurac ies wil l b e d i v i d e d between t h e ex t r eme positions. When. alignment i s . done. a t o n e of t h e ex t reme pos i t i ons , inaccurac ies a r e al l in t h e s a m e direction.

OPERATION r

The four-posi t ion cylind,er i s a positioning. d e v i c e controlled by a four-positiom cont ro l v a l v e s u c h a s t h e 2-HA-3 PILOTAIR @ VALVE: T h e cy l i nde r h a s a , w i d e range of applicat ions, be ing particularly su i ted l o r shift- ing transmissions. an& posi t ioning hydraulic va lves . It i s corrosion-resistant and. cons t ruc ted of. lightweight, d ie -cas t , anodized aluminum heads , pistons. and body.

1 imum s t roke of t h e piston rod i s 3 /4 inch between each of the four posi t ions, making. a total piston rod travel of 2-1/4 inches. Externa l envelope d imens ions of the cy l inder d o not change , but shorter s t rokes a r e availab!e,.in increments of 1/16 inch for e a c h position. The ?oGp!&e p i e c e number- and t h e p i e c e number of the p is ton s t o p (8A) for cylinders:' with equal -s t roke increments wil l have. an. ident ica l f ou rd ig i t suffix. The- f i rs t d ig i t i s always: zero; the l a s t three d ig i t s show the s t roke i n thousandths of an inch; Complete: p i ece numbers wil l b e ass igned for c y l i n d e r s w i t h unequal- s troke increments a s required.

INSTALLATION 8 ADJUSTMENT

Because cy l inders a r e ins ta l led a t the. end of an a i r ystem, they a r e vulnerable to dir t and moisture carr ied hrough t h e a i r l ines . Therefore , before ins ta l l ing the our-position cylinder, a l l a i r l ines in the sy s t em should

be blown c lean . It i s recommended that the cy l inder be. mounted with t h e por t s fac ing down. Gravity c a n then z i s t i n preventing foreign material from accumulat ing in the cy l inder by removing i t through the control va lve exhaust .

Maximum operat ing pressure. of t h e four-position c y l i n d e r i s 150 psi. a t a temperature r a n g e of - 4 0 F t o 180 F: T h e cy l inde r a s s u m e s a n y one of i t s four posi t ions. when a i r p r e s s u r e from t h e control v a l v e i s suppl ied in a c c o r d a n c e with t h e tab le below.

ASSEMBLY VIEW

The forces developed by the cy l inder a r e functions of exposed piston a r ea s and amount of a i r p r e s su re applied, and a r e tabulated in the f o l l o w ~ n g table according to rod position.

1~0s. 1 (Extended) t o Pos . 2 1 171 / 3 &4 1

N E T FORCE WITH 100 PSI AIR PRESSURE

I POS. 2 i o POS. 1 Pos . 2 to P o s . 3

*PORTS

Pos. 3 to P o s - Pos . 3 t o Pos. 2 1~0s. 4 (Retracted) t o Pos . 3 1 210 2"" -.

L -- POUNDS SUPPL.IE,D

MAINTENANCE

FLUID POWER DIVISION 1953 MERCER ROAD, LEXINGTON, KENTUCKY 40505 American-Standard POWER and CONTROLS GROUP

TYPE "A" CYLINDER

SERVICE INFORMATION

T h e WABCO "A" Cylinder i s a precision-manufactured pneumatic or hydraulic cylinder designed fo r high performance and reliable service under the most seve re operating conditions. Design simplicity provide? a mini-

- mum number of parts with resultant reduction of maintenance requirements. T h e "A" Cylinder i s available i n 4 s tandard mountings and 8 bore s i z e s from 1-1/2 through 10 inches.

INSTALLATION

Before mounting t h e cylinder, be. s u r e that all supply l ines are f r e e of foreign matter. An accumulation of foreign matter can c a u s e corrosion, l e s s efficient cylinder operation and shorter cylinder life.

t 1s very Important that the cylinder thrust be kept a s c lose a s possible t o the centerl ine of the piston rod and f ree of misalignment or s ide thrust. Off-center thrusts or s ~ d e loads increase bearing wear and c a n result in bindlng in the cylinder or linkage.

Never allow the cylinder head or c a p t o s top t h e piston at the end of i ts stroke:. Either provide external s tops t o prevent the piston from "bottoming" or use a cylinder with built-in cushioning. Cushioned cylinders s top the piston just before it reaches the end of i t s stroke. Ex- ternal s tops may b e required t o supplement the cylinder cushioning under certain conditions of load. For outline dimensions and other mounting considerations, s e e Catalog A3-41.01.

-. OPERATION

T h e standard "A" Cylinder has an operating temperature -ange of -40 F to 160 F (200 F intermittently). Maximum ~ p e r a t i n g pressure of the cylinder i s 200 psi pneumatic and 500 psi hydraulic.

ADJUSTMENT

A noncushioned cylinder- requires. no further adjustment a f t e r i t h a s been installed. and properly aligned. A cushioned. cylinder, after instal lat ion and alignment, must b e adjusted t o obtain t h e degree: of cushioning: desired. A n adjustment i s provided by a screw-type needle valve in ei ther or both ends of t h e cylinder: T h i s va lve (7) controls t h e r a t e a t which trapped air or fluid i s allowed t o vent from the end of t h e cylinder- when t h e piston i s near t h e end of i t s stroke. Turn the valve- clockwise t o inc rease the amount of cushion and counter- c lockwise to decrease the amount of cushion. Tb obtain the most effective cushioning, final adjustment must. b e made- while the cylinder i s operating under normal con- dit ions and a t normal operating pressure.

MAINTENANCE

Periodically disassemble t h e cylinder for cleaning and. inspection: Clean a l l metal parts with a nonflammable, so lvent and wash a l l rubber parts. with soap and water. R i n s e thoroughly and blow dry with a low-pressure air j.et.. Replace t h o s e parts which aredamaged o r worn.

Most parts: t ha t normally wear in t h e "A" Cylinder a r e furnished in a convenient repair kit ( see "Service Kits"). Particular attention- should be- given to the. Pis ton Rod Guide. (12) s ince cylinder l eakage can result from a worn guide: A rough or scored guide may damage^ the piston rod, and subsequently, the rcd packing.

In reassembling the cylinder, u se the exploded and assembly views a s reference. Be careful not t o cut or damage the rcd packing and s e a l s . U s e shim stock or other similar material to cover threads, sharp edges and corners that could cut t h e packing and s e a l s a s they a re being assembled.

As the assembly proceeds, lubricate a l l rcd packing and s e a l s with Sun Oil Company Number 1897 antirust grease or equivalent. Lubricate a l l o-rings with Wow Corning Number 55 Pneumatic Grease. After reassembly i s complete, tes t for correct operation and any evidence of leakage.

1-1/2" AND 2-1/4" NON - CUSHIONED ( Alsc raspages T a n d 8 )

PARTS. LIST

DEBCRIPT1ON REQ'D

WABHEA, Loak CLAMP, Loaklng NUT, Hex CAP "0"

@UP, P8aking #ETAIN$Ii, "V" Ring NUT, Errna POLrnWER, Piston lrorr RiNB, D/iW 0, D‘ OUP, Pletm PlllTOt4 ROD, Pletbn TUBE, Cyflhder - 1 . - - - .-

BORE '2-1/4" 3/4" Rad

* The a%" cylinder wds drl&ally / w i s h e d with a 3" diameter rod, which wee later chahged to a,%" dieiiietet fdd, t l f de f s lor complete 2%'' cylindeta should a ~ e c i i p /he desl& with s" rod,

f 70 ordef pisfon fods attd tubes, s.gedi)i bore, stroke stid model oi cylinder, Also bpecily whether body i s td he b m i s or steel.

$ Recdriiended sj)8f~ perld td be refeltied iil sidck f 3 e e l'SE#VICE 81TS")

1- l/Z" A N D 2-I/$" CUSHIONED ( Also. see pages. 7" and. 8')

I I I

PARTS: LIST'

DESCRIPTION

1 Z 3 4 5.

2 6 7'

t- 8 9

10 t 11 t 12 t 13

14 15 16

$ 17 18

t 19 t 20

2 1 22 23

NO. REQ'D

' One requi red lor cushioning a t one end. Two requi red lor cushioning a t both ends.

t To o rde rp i s t on rods a n d tubes, spec i t y bore, s t r oke a n d model 01 cylinder. A l so spec i fy whether body is t o b e b r a s s or s t e e l .

X Recomended s p a r e pa r t s to be r e t a ined in s t ock (See "SERVICE KITS")

SCREW WASHER. Lock CLAMP. Locking NUT, Hex CAP. "0" - NNG SCREW. Cushioning Adjusting "0" -RING HEAD RING. Internal Retaining "0" -RING GUIDE. Piston Rod CUP, Packing RING, "V" Reta iner NUT. Esna FOLLOWER. Small Piston CUP, Cushion Packing FOLLOWER. Piston "0"-RING CUP, Piston Packing PISTON ROD, Piston TUBE. Cylinder

CYLINDER BORE 1-1/2"

4 4 4 4. 1 2 2 2 1 L 1. 1 1 1 1 2. . 2 2 2 1 1 1

2-1/4"

P49835-0029 P49866-0007 P58304 P49916-0004 P50567 P4970d-0218 P50517 P49708-0006 P50581 P498d2-0040 P49708-0112 850691 851083 850690 P49923-0012. P50584-0001 P5023 P50583 P49708-0110 P5194-0001 850683

t t

P49835-0029 P49866-0007 P58304 P499lG-0004 P50880 P4970M-032d P50511 ~48708-000'6 P50d81 P49882-0043 P49708-0016 P50057-0001 P49959.-0016 P50056-0002 P49923-0012 P50584 P5041 P50879 P49708-0110 529879 850936

! 1

3" TCL 10'" CUSHIONED AND NON - CUSHIONED:

( A1 so, s e a pages T and 8 )

PARTS LIST

NO. REF. I DESCRIFTTON

1 2 3 4 5

1 6 7

1 8 9

10 I l l t 12 113

14 15 16

117 18

I 1 9 I ZU

3 -

SCREW WASHER. Lock CLAMP, Locklng NUT. liex CAP

"0" -RING scnnv. Cuahloalog AdJusuog "0" - n m i HEAD RING, Internal R e u l o l o g "0" -RING GUIDE. P l e m Rod CUP. Packing RING, "V" Rctalaer NUT. Esm FOLLOWER. Smnll Pleton CUP. Cuehlan Pncklng FOLLOWER. Plsron 4 * ~ p * - RING CUP. Plelan Pncklng PISTON ROD. Plston TUBE. Cylinder

-- NO.

IEQ'D -- 4 4 4 4 1 2 2 2 1 1 1 1 1 1 1 2

2 2 2 1 1 1 -

' None required lor "on-cushioned cylinders. One roquired for cushioning a f one end. Two required for cushioning at both ends.

t To order piston rods snd Lubes, spec i f y bare, stroke and m d e l of cylinder. Also s p e c i f y whether body Is Lo be brass or s f e e l .

1 Recornended spare perfs to b e retained in s f o c k ( S e e "SERVICE KITS") t

P49856-0043 P49866-0010 P50059 Not i q u l r e d P50052 P49108-0443 P50237 P49708-0012 P50055 P49882-0051 P49708-0329 P50057 P50080 P50056 P49923-0010 P50048 P5000 P50046 P49708-0222 539535 P50047

t t -.--

--- - -. -. .. . . . .~. . .

ROD END: KIT

I

1 P49913-0010 P.19913-0011 P.19913-0016 P49913-0015 PW. Rod End I P49Mlb0020 P191)lB-OO2U P501211 P50.126 PSOOOS END. Hod I P+3536- P4953G-0001 PSM26 PSOIZG PG1215 PO1213 P500d9 NUT. Jam 1 P19803-.0018 P98903-0021 P.19903-0023 P.10903-0023 P50091

FOOT MOUNTING KIT

IBOOEd CTOO'BBRGtd

6ZZOSd

tEIlSd

,,OI 3 U 0 8 K 3 a N n h 3 -

IDO05d C101-9BR6td

6ZZOSd

PFITSd

, a

CTGOSR ZI00-99R6td 1000-ZCR6bd

ISI lSd

,,B

619099 6000-5986bd 1100-W66td

m71Sd

.d

ICOTSR ZTOO-DBRCtd LCOO-ZC9GI.d

DCTISd

,IS

PI6059 TIOO"lBR6td C100-ZCRSVd

SI715d

..t

1000-IBOOSd 6000-9186Dd lIO(rW66td

6CIISd

FW ,.b/C ,,c/I-z

t6915R LOOb9986td OZO(r9586Pd

QCITSd

d / r - T

C Z 7 ---

1 t t.

au.13 'LNIIOW aJ01.II3HSVM

M3113S

aab3II 'ON

7

IC '2 'I P"1) wsldurr~ 'ilx

HOUdlK3S3a 'mr

TRUNIONMOUNTING KIT

5

METALLIC ROD WIPER

ROD GUIDE ASSEMBLY

PISTON ROD GUIDE' "0" RlNG

RETAINING RING / Remove retaining ring, piston rod guide "0" ring and rod guide. Insert the correct Rod Guide Assembly and reinstall the retaining ring.

.-

-

METALLIC ROD WIPER

llOD GUIDE ASSEMBLY CP.

GUIDE. Piston Rod

I WPER. Met. Rod

CYLINDER DIAMETER

1-1/2"

P51415-0007

P51415-0006 P49838-0003

8" & 10"

P51415-0000

P51475-0008 P49838-0004

2-1/4"

P51475-0001

P51475 P49838

3" & 4"

P51175-0003

P51415-0002 P49838-0001

5" & 6"

P51415-0005

P51415-0004 P49838-0002

HYDRAULIC ROD PACKING

ROD GLJIDE

IT--- I !

ASSEMBLY

R o o G U I D E ' /kZNG P I S T O N ROD GlJlDE "0" RING

Remove retaining ring, piston rod guide 'TI" ring, rod guide , packing cup a n d "V" ring retainer. Inser t t h e cor rec t Rod G u i d e Assembly and re ins ta l l t h e r e t a i n i n g ring.

SERVICE KITS. 'I

''YDRAIILIC ROD PACKING I--- ROD GUIDE ASSEMBLY CP.

GUIDE, Piston Rod "V"-RING, Pka. S e t "0" -RING

CYIJNDER' DIAMETER

SERVICE KIT P K C E NUMBER

P54224 P54225 P54226 P54227 P54228 ~ 5 4 2 2 9 P54230 P54231

I --

- -- CYIJNDER DIAMETER

.

P52871-0012

P52399-0012 P49700-0012 P49708-0112

KITS INCLUDE

1-1/2"

DESCRIPTION - "0" -RING, Tube Seal "O" - RING, Cushion "Ow -RING. Rod Guide GUIDE, Piston Rod CIJP. Rod Packing CUP, Cushion Packing "0" -RlNG, Piston Follower CUP, Piston Packing

P52871-0016

P52399-0016 P49700-0016 P49708-0116

QUANTITY

2 2 . 1. 1. 1 2 2 2

2-1/4"

The above serv ice ki ts contain a.U the expected wearing pa r t s o r those that should be replaced a t servicing intervals for both the cushioned acd non-cushioned "A" Type Cylinders.

P52871-0020

P52399-0020 P49700-0020 P49708-0214

83-11.01 Printad in U.S.A. R e v . Jon.. 1973

. -- - . . . - ~ ~ .~

3" & 4"

P52871-0024

P52399-0024 P49700-0024 P49708-0218

59, & 67,'

P52871-0031

P52399-0031 P49700-0031 P49708-0329 -

8" & 10"

WESTINGHOUSE A I R BRAKE C O M P A N Y ~ FLUID POWER DIVISION. LEXINGTON, KENTUCKY

MULTIPOSITION AIR ' CYLINDER. ,

CAST ALUMINUM,

THREE-POSITION: -SPRING-CENTERED

SERVICE INFORMATION-

.., three-position cyl inder is. a dev ice

trolled by a four-way, three-position, exhaust-center, control v a l v e such a s t h e "A" o r "D" PILOTAIR. O VALVE. T h e cylinder h a s a w i d e r a n g e o f applications, being particularly sui ted for shift ing transmissions. and. positioning hydraulic- valves.. I t i s corrosion-resistant- and constructed of lightweight; die-cast, anodized. aluminum heads , pistons and body.

Cylinder P i e c e Numbers P57378-0000 a n d PS9211. use a spring that can se rve only a s a centering spring; how- r -, with the spring used in Piece- Number P58822-0000,

cylinder can a l s o be used for low-sensitivity infinite positioning by se lec t ing the proper graduating pressure. control valve ( s e e Catalog A4-65.00. CONTROLAIR@ VALVE; Catalog A4-72.03, FLEXAIR @ VALVE). T o se l ec t the required pressure- range of t h e control valve s e e the graph shown under "Available Forces" on Page 4.

Maximum s t roke of t h e piston rod i s one inch on each s ide of the- center position, making a total piston rod travel of two inches. External envelope dimensions of the cylinder d o not change, but shorter s t rokes a re ma i l ab le in increments of 1/16 inch for each position. The complete piece number of the cylinder and the piece number of the piston s t o p (13A) will have an identical Lour-digit suff ix . The first digit denotes the s t roke in inches: the las t three digits show the stroke in thou-

-. sandths of an inch.

STALLATION & ADJUSTMENT

R-cause cylinders are instal led a t the end of an a i r item, they are vulnerable to dirt and moisture carried

through the air lines. Therefore, before instal l ing the three-position cylinder, a l l air l ines in the system

should b e blown clean. I t i s recommended that t h e cylinder bemounted w ~ t h the ports fac ing down. Gravity can t h e a a s s l s t in preventing foreign material from- accumulating in. t h e cylinder by removing i t through t h e control valve exhaust.

In providing- a mounting for. the: cylinder; an adjustable link must b e included between the- piston rod and the. lever to which. t h e r o d i s connected. The cylinder stroke should. b e checked in its: center position when aligned with the- l e v e r to beoperated. Check for exact register, making s u r e the- clevis pin i s free- from load in t h e center. position.

lhis procedure will allow any inaccuracies in l eve rage ratio o r manufacturing tolerance to b e absorbed a t the extremes of t h e stroke where e x a c t registration i s of l eas t importance. Also, any inaccuracies will be divided between t h e extreme positions. When a i i g m e n t i s done a t o n e of t h e extreme posit ions, inaccuracies a r e a l l irr the samedirection.

OPERATION.

Maximum operating pressureof the three-position cylinder is: 150 ps i a t a temperature range of -40 F to 180 F. T h e cylinder i s h e l d in i t s cen te r position by a coil spring caged. on t h e p is ton rod. When a i r pressure i s supplied. to t h e Cap-End Port, t h e piston rod moves to i t s ex-. tended position.. When p ressu re i s supplied to the Head- End Port, t h e piston rod moves to i t s retracted position.

ASSEMBLY VIEW

Periodically disassemble the cylinder for cleaning, inspection and lubrication. Clean all metal parts with a nonflammable solvent, and wash all rubber parts with soap and water. Rinse thoroughly and blow dry with a low-pressure air jet. Replace those parts which are damaged or worn.

Reassemble the cylinder, using the exploded and assembly views a s reference. No specia l tools are required. T o avoid cutt ing or nicking the piston "0" ring, carefully insert the piston rod assembly into the cylinder bore with the piston tilted a t a sl ight angle. As the assembly proceeds, lubricate a l l "0" rings with Dow Corning Number 5 5 Pneumatic Grease.

83 - 49.16

EXPLODED VIEW

2 -- - -

PARTS LIST (In Order of Oiwwm&ly)

REF'. QTY; DESCRIPTION PC.. NO.

CYLINDER, Three-Positlon P57378-0000 CYLINDER, Three-Positlon P58822-0000

t CYLINDER, Three-Position (1.062' Stroke) P59211

NUT,. 7/16"-20 Jam SCREW, 1/4"-20 x. 7/8" Hex: -Head. C a p WASHER, 1/4" Lock HEAD, Bushed. WIPER. 3/4" OD Rod RING, 11/16" OD Sen1 SEAL, 2-3/8" OD NUT; 1/4"-28 Lock PISTON RING; 1.-3/4" OD "0" RING. 3/8" OD "0" WASHER. 3/4" OD Plston STOP. Piston (except fo r PC. No. P59211) STOP, Piston ( l o r PC. No. P59211 only) SHIM (for PC. No. P58822-0000 only) SPRING. Centering (except for PC. No. P58822-0000) SPRING, Centering (for PC. No. P58822-0000 only) CAGE, Sprlng, ROD, Plston BODY

*Recommended s p a r e pa r t s t o b e re ta ined i n s t o c k a t all times. T h e s e pa r t s a r e ava i l ab l e in k i t form-by ordering Repa r r Kit PC. No. P59819.

t C y l i n i e r with f ixed stroke. l onge r than s t anda rd - s t roke l eng th c o d e i n p i ece number suf f ix d o e s n o t apply.

438'

1 10 NEUTRAL POSITION

OUTLINE DIMENSIONS

3

5.5 SJ.

m a f w r i a l ~ .

part. material ASTM spec.

body composition bronze 0 62 bonnet comporition bronze, 8-62 stem cost cu-m-si. alloy 0.198 AL 875-

wrt. cu-zn-si alloy B 371 AL697

wedge %"- la ' comporition bronze*. B 62: wedge 2%" a.3" valve. bronze. 8 61

stuRing nut composition bronze 0 6 2

$and brass rod 8 16

,oocking lubricatsd osbaslor. commercial gasket 2%"-3"' composition osbeslos commercial handwheel %"-I % " alum.; duct. o r mall. iron commercial hnndwheel 1 %"-3" duct. o r mall. i r m commercial wiieel nut steel, cod. pl. commercial idonli~calion plote ~Iuminum commercio/

Figure 5 split wedge and flgure551olid wsdgsgateva lvo have- screwed bonnets, rising rtcms, ond.xrewed ends. Wedges are-tapered and properly guided in thebody; Sluffing boxer h o w glonds filled:wilh, a high grodaof pocking; Valves aredesigned to permit repacking under presure whrn fully opened. Sirer2%".ond 3"'hovescrewed-over bonnet conrtruction. Core must betoken with solder joint volver (Fig. 55s)) l o use o older suitable for thcscrvice temperature. Volver hove non-heoting hondwheelr snd carry convenient identificotion plates for reordering. Rccommended for rsrvicer on >fenm up. to 400F and "on-hod. water, oil, or gas. Fed. Spec. WW-V-54C.Typer I1 (Figs.558 55SJ, %'-2") and Ill (Fig. 5, 1"-2") Class A.

a d i m e n s i o n s

sizo % % Y >/4 1 1% 1% 2 2Yz1

9 1% 1'536 2% 2% 2'56 3% 3% 33% 4%

a 155SJ) I"& iT9h 2% 2"hr 3%6 3% 4% dl%b

b 4I'h 41x4 5 h 6% 7% 8% 10 11% 15

c 2 2% 2% 2% 3 3% 3% 4 4%

sizo % 1 Yz ?4 1 1% 1% 2 2% I 3

a 11%~ 1 1 % 2% 2 % 2!%a 3% 3% 33% 4% 474s

I"& iT9h 2% 2"hr 3%6 3% 4% dl%b 5%.

41'/i/ia 41% 5 h 6% 7% 8% 10 11% 15 17%

c 2 2% 2% 2% 3 3% 3% 4 4% 5%

wt. (55) 83 1. 13 2.1 3.5 5.1 6.8 12.9 18.6

wl. (S5SJl 30 .90 1.3 1.9 218 4.4 6.2 12.0 18.3

wt. 5 . . . , . . . . . . . 2.1 3 5 5.1 6.8 12.9 (18.6 P

125 psi. wsp. 400F

2W psi. wog. IMF

Fig.5 q u a r t e r v iew. split wedgs sizes 1'4"

Fig. 55 full-view solid wedgs. sizes %"-3"

Fig. 55SJ solid wedge, ' solder ioint

sixes %"4*

X WESTINGHOUSE A I R BRAKE C O M P A N Y

7 FLUlO POWER DIVISION LEXINGTON, KENTUCKY

- -.

ITHIS PUBLICATION S U P E R S E D E S 8940.21, W A R . IDSO! a3 -49.21 Printad in U.S.A. - -. . -. c D - L I . . L - l Q ~ Z _ . . _ ~

. . . . ~ .. ~ ,. : ~... ~~ . .. .

FLUID: POWER DIVISION

The WABCO Minimaster is. the biggest value available in a small-bore, cylinder. Ail. components: have been carefully designed and manufactured to assure dependable, long-lasting performance. And the: success of these efforts has been thoroughly proven: through. extensive laboratory testing and rugged, on-the-job. field. performance.

Incorporating- a unique: streamlined design; the WABCO Minimaster cylinder offers three. separate-

mountings.. integral to the: standard unit; And. . . . . . . . an: aqdi- tional selection. qf. mountings is available: in: kit, form .,,.

The cylinder comes in standard bore sizes. . of. . ?+" agdi 1 %!?

This. small-bore cylinder has nearly a century; oE: fluid: power. experience: behind it,. and. carries the. full. WAW0:g"arantee. C g p a q e the quality features of thk Minimaster- and. you, will see why it's the, biggest value available: in: small-bore cylinder;

STAN BAR ID, B WCATB Q N S PRESSURE RATING PORT§

200 psi pneumatic; 500 psi. hydraulic : !&NPTF (dryseal) tap. is standard. TEMPERATURE RANGE. i . I?IS,XQN RQDS:

-40°F t o 160°F: St.ain1es.s- steel f o r m e m u m strength . . and. cor- . . . . rosion resistance;

%"andl%" CUSZEIONIN(; - I

STROKES. Standqd with polyurethane. bumpers., i Available from s tock in 1" increments. to 4". 2 CYLIWER TUBE

RQD END THREADS, Hard-anodized extruded aluminum . . . . . fo r light Standard male thread- weight, high strength agd maximum . . corrosion

WREXCH FLATS. resistance.. Standard a t no extracost. nni.OU\rrINGS;

Thre~mountings are integral to the basic cyl- i n d e r d e ~ i g n . Three 0th;; mount ings a r e av4lable in &it form.

i i g u r e s : 5 /' 5 5

e r cret.wl,evd;. tho~tw~~et: 1s; psi: w ~ w 400F . . , ., ,. . . , . . , . . . . . .. . . . .. . . . , . . . . .

wriri'mg: stemi 2~.:.p&~0wogi IMP

pert materiol kS?M!:rpeg;,., . ,,-..

body composition- bronze 8? 62, bonnet stem.

wedge %":Zr wedge2%*'&3" stufing nut glond pocking gosl:ct 2%":3N' hondwhecl %-:I % " Lnndwheel 1 %.*.3" wheel nut idontificotion.~late.

' compositiort bronzb costcwm-si olloy wrt. cuun-sibolloy. composition bronze v o l v t bronze,, composition bronze.- brass.rod: lubricoted:osbestor. compoailion o~bu to r ; olum.; duct: or molLiron dwt. or mall. irow steal, cad. pl.. aluminum:

P. 6 2 8.1 981aL,..87zz, 8:371 A4.69: 8: 62 B161i: 8.62 8.16. cornmercial~ commwcial; commwciol, commercipl, cornmercio(i. co,mmerciol!:

Figura-5 split wsdgs.ond.flgure55solid wedge.gotavqlves,hovs rcrowed bonnets, rising:dems,ond. screwed ends. W.edge%orstap.crcldi: and properly guided in'thebody; Stuffing: boxer heveglond~filla,&.willr- o high groda-of packing..Volver oredesignsd:to.permit repockingi.underi; pressure when fully opened. Sizes Z%"'ond,3" hovescrewdro.veri: bonnet. construction: Core must. b e token-withsolder iointvolWz:.(Fig., 55SJ) to use o. solder suilobls for.ths serv ice~temperature i ,~q I~e~.hqv~ non-heating hondwhoels. and: corry convenienbidentifi'~otio~'pJqtes!:f~~~ reordering. Recommended forservicas on rteqm.up.t0;400Fond;non~sh9&. water, oil, o r gor; Fed.. Sbac;. WW-V-54CTyper.ll (Figs. SSi'&55$J+ %'-2") and.lll (Fig. 5,. 1"'-2") Class. A-

solid wedge! sixel; %53:'

solder ioint sixor %".,3" -

'b' WALWORTH COMPANY: Volvar for i d d r y . . . evorfwhare

sag subsidiary - salvex manual11.pdf · have been combined with the torque converter and...

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