Cashco PGR-1 - Manual (Page 7)

IOM-PGR-1 7
1. Shut down system in accordance Section VI.
2. Disconnect the external sensing line, from the
pilot valve sensing port.
3. Loosen all fi tings and remove tubing that con-
nect the inlet fi lter to the stablizer, the cover
dome to the metering valve and the outlet of
the metering valve to the outlet of the body.
4. Loosen and remove the two nuts (24) that
secure the mounting bracket (3) and pilot to
the cover dome (2).
5. Remove pilot assembly from main valve.
6. Place the pilot valve body (31) in a vise with
the spring chamber (32) upwards.
7. Loosen adjusting screw nut (48) one revolu-
tion CCW. Relax range spring (34) forces
by rotating adjusting screw (47) CCW until
removed from spring chamber (32).
8. Loosen the diaphragm fl ange bolts (49) and
nuts (51) uniformly and remove bolting.
9. Place match marks on body (31) spring cham-
ber (32) fl anges. Remove spring chamber.
10. Remove spring button (35), range spring (34)
and pressure plate (36).
11. Remove diaphragm (43).Examine diaphragm
to determine whether failed; determine if op-
er at ing conditions are exceeding pressure,
pressure drop or temperature limits. If just
replacing the diaphragm, proceed to Step H.9
and skip the following instructions.
12. Grasp pusher post (42) and lift up to remove.
Place socket wrench over retainer (40) and
rotate CCW to remove from body.
13. Remove seal gasket (45), piston seal (44) and
a second seal gasket (45) from bore inside
the body.
14. To remove the stem (38), remove the body
from the vise and slowly turn upside down.
Stem will slide out of the body, Do Not let the
stem fall and hit the fl oor.
15. Place body (31) in a vise with the body cap
(33) upwards. Rotate cap bolts (5) CCW to
remove bracket and body cap. Remove cap
seal (46).
16. Remove return spring (41), ball holder (39),
and ball (52).
17. Place socket wrench over seat (37) and rotate
CCW to remove from body.
18. Remove body (1) from vise. Clean all re us able
metal parts according to owner's pro ce dures
H. Pilot Valve Reassembly:
1. Place body (31) in a vise fl ange face down.
2. Apply "Gasoila" or equivalent, thread sealant
to the threads of the seat (37). Engage the
seat threads into the body and apply 20 - 25
ft-lbs. torque. Place the ball (52), ball holder
(39) and return spring (41) onto seat.
3. Place the o-ring (46) into the groove in the
body cap (33) and place onto the body.
Position the bracket on the body cap and re-
install cap bolts (50). Make sure the return
spring (41) fi ts inside the bore of the body
cap. Tighten nuts evenly in a star crossing
pattern. Apply 15 - 18 ft-lbs. torque to tighten
the cap bolts.
4. Remove body from the vise. Reinstall body
again in vise with the bolt fl ange facing up.
5. Insert the stem (38) into the center hole of
the body and the seat (37), square end fi rst.
6. Place one seal gasket (45), one piston seal
(44) and one seal gasket (45) into the center
bore on top of the stem ((38). See Detail "A".
Ensure to align the seal and gaskets so they
are centered inside the threaded bore hole.
7. Engage the retainer (40) threads into the
center bore hole to hold the piston seal and
gaskets in place and apply 75 in-lbs. torque.
to tighten.
8. Insert pusher post (42) into retainer (40).
9. Place diaphragm (43) on bolt fl ange, centered
between bolt holes. Center the pressure
plate (36) on top of the diaphragm.
10. Place range spring (34) in center of the pres-
sure plate (36) cup. Apply Mobile XHP 222
grease or equivalent into recessed area of
the spring button (35) and place on top of the
range spring. (Also lubricate the threads of
the adjusting screw lightly).