Marotta Valve Tech Pub

S6434-AF-MMO-010
0910-LP-048-7000
[SGML Version See Change Record ]

TECHNICAL MANUAL
OPERATION AND MAINTENANCE
INSTRUCTIONS
WITH PARTS LIST
PNEUMATIC PRESSURE
REGULATING MANIFOLD
DISTRIBUTION STATEMENT B: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT

AGENCIES ONLY: THIS PUBLICATION IS REQUIRED FOR OFFICIAL USE OR ADMINISTRATIVE OR OPERATIONAL PURPOSES: (DATE OF PUBLICATION). OTHER REQUEST
FOR THIS DOCUMENT MUST BE REFERRED TO THE NAVAL SEA SYSTEMS COMMAND (SEA-09T)
WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS
RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C., SEC. 2751, ET
SEQ.) OR EXECUTIVE ORDER 12470. VIOLATION OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAL PENALTIES.
DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION OF THIS DOCUMENT.
THIS MANUAL SUPERSEDES NAVSEA 0983-LP-013-0010, DATED 20 NOVEMBER 1975
AND ALL CHANGES THERETO.
PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND
1 OCT 1981
15 JUN 1991
Change B
TITLE-1 / (TITLE-2 Blank)@@FIpgtype@@TITLE@@!FIpgtype@@
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CHANGE B
TITLE-2
Change B
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S6434-AF-MMO-010
RECORD OF REVISIONS
CHANGE
DESCRIPTION
DATE
APPROVED
BY
CHANGE A
TECHNICAL MANUAL CHANGED TO

REFLECT ADDITION OF PNEUMATIC PRESSURE REGULATING MANIFOLD, MODEL RM
21FA-1, PART NUMBERS 281166-0002 AND
281166-0003.
TO REPLACE AIR DRY CORPORATION
MANIFOLDS WITH NEWLY-DESIGNED
MAROTTA MANIFOLDS AND UPGRADE
EXISTING MAROTTA MANIFOLDS TO NEW
DESIGN SPECIFICATIONS.
8 AUG. 1990
W. GLOSS
6 JUN. 1991
S. NGUYEN
CHANGE B
NOTE
THIS TECHNICAL MANUAL (TM) HAS BEEN DEVELOPED FROM AN INTELLIGENT ELECTRONIC
SOURCE KNOWN AS STANDARD GENERALIZED MARKUP LANGUAGE (SGML). THERE IS NO
LOEP. ALL CHANGES, IF APPLICABLE, ARE INCLUDED. THE PAGINATION IN THIS TM WILL NOT
MATCH THE PAGINATION OF THE ORIGINAL PAPER TM; HOWEVER, THE CONTENT IS
EXACTLY THE SAME. ANY CHANGES RECEIVED AFTER RECEIPT OF THIS TM WILL ONLY FIT
IN THIS PAGINATED VERSION.
Change B
RECORD OF REVISIONS-1 / (RECORD OF REVISIONS-2 Blank)
RECORD OF REVISIONS-2
Change B
S6434-AF-MMO-010
FOREWORD
Ships, training activities, supply points, depots, Naval Shipyards and Supervisors of Shipbuilding are
requested to arrange for the maximum practical use and evaluation of NAVSEA technical manuals. All errors,
omissions, discrepancies, and suggestions for improvement to NAVSEA technical manuals shall be reported to
the Commanding Officer, Naval Ship Weapons Systems Engineering Station (Code 5H00), Port Hueneme, CA
93043-5007 on NAVSEA Technical Manual Deficiency/Evaluation Report, NAVSEA Form 9086/10. To facilitate
such reporting, a copy of NAVSEA Form 9086/10 is included at the end of each bound part of each technical
manual. All feedback comments shall be thoroughly investigated and originators will be advised of action resulting therefrom. Extra copies of NAVSEA Form 9086/10 may be requisitioned from the Naval Publications and
Forms Center (NPFC), Philadelphia, PA 19120-5099 (S/N 0116-LF-090-8651).
MACHALT 551-48019 (ECP-346) replaced Air Dry Corporation manifolds with newly-designed Marotta
manifolds and upgraded the existing Marotta manifolds to new design specifications.
This technical manual is applicable to pneumatic pressure regulating manifold Model RM21FA-1, Part
Number 281166-0004. Disregard all references to Part Number 281166-0001.
Change B
FOREWORD-1 / (FOREWORD-2 Blank)
FOREWORD-2
Change B
S6434-AF-MMO-010
TABLE OF CONTENTS
Chapter/Paragraph
Page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1.1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1.2
General Data . . . . . . . . . . . . . . . . . .
1.2.1 Part Number 281166-0004 . . . . . .
1.2.2 Part Number 281166-0002 . . . . . .
1.2.3 Part Number 281166-0003 . . . . . .
1.2.3.1. Operating Pressure Setting
1.2.3.2. Operating Pressure Setting
.
.
.
.
.
.
1-1
1-1
1-1
1-2
1-2
1-2
1.3
Special Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
OPERATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
REMOVAL & DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5.1
Removal of the Entire Manifold from the System . . . . . . . . . . . . . . . . . . . .
5-1
5.2
Removal and Disassembly of the Filter Element (2 ; and ).
. . . . . . . . . . . . . .
5-2
5.3
Removal and Disassembly of a Pressure Reducing Valve (See ; and Item 4, ). . . . .
5-2
5.4
Removal and Disassembly of the Pressure Relief Valve Assembly
. . . . . . . . . .
5-3
5.5
Removal and Disassembly of the Inlet Handvalve
. . . . . . . . . . . . . . . . . . .
5-4
5.6
Removal and Disassembly of the By-Pass Handvalve
. . . . . . . . . . . . . . . . .
5-5
5.7
Removal and Disassembly Needle Valves (Gage bleed, gage shut-off (2, and ). . . .
5-5
5.8
Removal and Disassembly of Needle Valves: Filter/Reducer Bleed (1, and ) . . . . .
5-6
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6.1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6.2
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7.1
Cleaning Methods for Metallic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
. . . . .
. . . . .
. . . . .
. . . . .
(Low)
(High)
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Change B
S6434-AF-MMO-010
TABLE OF CONTENTS - Continued
Chapter/Paragraph
7.2
Cleaning Method for Non-Metallic Parts and Coated Parts . . . . . . . . . . . . . . .
7-2
7.3
Cleaning Method for Synthetic Rubber Parts (o-rings) . . . . . . . . . . . . . . . . .
7-3
7.4
Quality Assurance (Cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
ASSEMBLY AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9.1
Assembly and Installation of the Inlet Handvalve . . . . . . . . . . . . . . . . . . . .
9-1
9.2
Assembly and Installation of the By-Pass Valve . . . . . . . . . . . . . . . . . . . . .
9-2
9.3
Assembly & Installation of the Filter Element . . . . . . . . . . . . . . . . . . . . . .
9-4
9.4
Assembly and Installation of the Pressure Reducing Valve . . . . . . . . . . . . . . .
9-4
9.5
Assembly and Installation of the Pressure Relief Valve . . . . . . . . . . . . . . . . .
9-6
9.6
Assembly and Installation of Needle Valves . . . . . . . . . . . . . . . . . . . . . . .
9-7
9.7
Final Assembly and Installation of the Manifold into the System . . . . . . . . . . .
9-8
10
ADJUSTMENTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1
10.1
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1
10.2
Reducer Valve
10-1
11
ii
Page
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1
11.1
Pressure Regulating Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1
11.2
Reducer Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2
11.3
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3
11.4
By-Pass Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3
11.5
Reducer and Filter Bleed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-4
11.6
Gage Shut-Off and Gage Bleed Valve
. . . . . . . . . . . . . . . . . . . . . . . . . .
11-4
11.7
Filter Element
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-4
11.8
Inlet Handvalve - (7, ; and ) and Outlet Handvalve (8, ; and ) . . . . . . . . . . . . .
11-5
Change B
TROUBLESHOOTING
S6434-AF-MMO-010
TABLE OF CONTENTS - Continued
Chapter/Paragraph
12
Page
TESTING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1
12.1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1
13
STORAGE AND PREPARATION FOR RESHIPMENT . . . . . . . . . . . . . .
13-1
13.1
Storage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1
13.2
Preparation for Reshipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1
14
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-1
Change B
iii
S6434-AF-MMO-010
LIST OF TABLES
Table
Title
Page
General Data, Part Number 281166-0004
. . . . . . . . . . . . . . . . . . . . . . . .
1-1
. . . . . . . . . . . . . . . . . . . . . . . .
1-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
Operating Pressure Setting (High)
Pressure Regulating Manifold Troubleshooting
. . . . . . . . . . . . . . . . . . . . .
11-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1
Parts List for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-1
Parts List for and
14-2
Testing
iv
Change B
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S6434-AF-MMO-010
LIST OF ILLUSTRATIONS
Figure
Title
Page
PRESSURE REGULATING MANIFOLD (REF. 281166-0001) SHEET 1 OF 3 . . .
14-5
1A
PRESSURE REGULATING MANIFOLD (REF. 281166-0002) (SHEET 1 OF 3) . .
14-11
1B
PRESSURE REGULATING MANIFOLD (REF. 281166-0003) (SHEET 1 OF 3) . .
14-17
FILTER (REF233032) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-25
2A
FILTER ASSEMBLY (P/N 236285-0002) . . . . . . . . . . . . . . . . . . . . . . . .
14-27
PRESSURE REDUCER (REF 280038)
14-31
3
3A
. . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE REDUCING VALVE ASSEMBLY (P/N 283371-0002)
. . . . . . . . .
14-33
RELIEF VALVE (REF280039) SHEET 1 OF 2 . . . . . . . . . . . . . . . . . . . . .
14-37
4A
PRESSURE RELIEF VALVE ASSEMBLY(P/N 2800397-0003) . . . . . . . . . . . .
14-41
BYPASS HANDVALVE (REF 280566) . . . . . . . . . . . . . . . . . . . . . . . . .
14-45
INLET HANDVALVE (REF 233188)
. . . . . . . . . . . . . . . . . . . . . . . . . .
14-49
OUTLET HANDVALVE (REF. 233695) . . . . . . . . . . . . . . . . . . . . . . . . .
14-51
NEEDLEVALVE (REF. 233029) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-55
OPERATIONAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-57
10
ORING PICK (T10723)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-58
11
SEAT PULLER (T10722) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-58
12
TEST FIXTURE (T11293)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-59
13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-60
14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-61
15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-62
16
TEST FIXTURE (TF-1813) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-63
Change B
v / (vi Blank)
vi
Change B
S6434-AF-MMO-010
CHAPTER 1
GENERAL INFORMATION
This manual provides maintenance and overhaul instructions for a Pressure Regulating Manifold, Part Number 281166-000; Model Number RM21FA-1, as manufactured by Marotta Scientific Controls, Inc., Montville,
New Jersey.
MACHALT 551-48019 (ECP-346) replaced Air Dry Corporation manifolds with newly-designed Marotta
manifolds and upgraded the existing Marotta manifolds to new design specifications.
This technical manual is applicable to pneumatic pressure regulating manifold Model RM21FA-1, Part Number 281166-0004. Disregard all references to Part Number 281166-0001.
1.1
Description
The RM21FA-1 pressure regulating manifold consists of a pressure reducer and a downstream relief. Handvalves provide alternate flow paths, enabling the system to be operated without interruption, should servicing of
the filter or pressure reducer be required. A gauge port connection with independent shut-off and bleed valves is
provided to permit monitoring.
1.2
General Data
1.2.1 Part Number 281166-0004

Operation
Pressure Regulating Manifold
Operating Pressures:
1. Inlet = 900-3000 psi Range
2. Reducer = 20-250 psi Range (Set to Lockup at 175 psi)
3. Relief = 150-255 psi Range (Max Accumulation 245 psi, set to crack at approx. 225 psi with Min.
Reseat at 190 psi).
Proof Pressure
4500 psi at inlet
Burst Pressure
9000 psi at inlet
Service
Air or Nitrogen
Operating Temperature (Ambient)
+20F to +140F
Weight
83 Pounds without fittings
1.2.2 Part Number 281166-0002

Operation
Operating Pressures:
1. Inlet = 1000-3000 psi Range
2. Reducer = 20-250 psi Range (Set to Lockup at 175 psi)
3. Relief = 150-255 psi Range (Max. Accumulation 240 psi, set to crack at approx. 200 psi with Min.
Reseat at 185 psi).
Proof Pressure
4500 psi at inlet
Change B
1-1
S6434-AF-MMO-010
General Data, Part Number 281166-0002 - Continued
Service
Weight
Air or Nitrogen
+20F to +140F
1.2.3 Part Number 281166-0003

NOTE
The equipment pressure settings concerning configuration 281166-0003 are as
follows:
1.2.3.1. Operating Pressure Setting (Low)
1. Inlet = 1000-3000 psig Range
2. Reducer = 175 psi (Lockup pressure)
3. Relief = 150 psi (max. accumulation 300 psig) 195 psi (cracking pressure) 185 psi (reseat pressure)
1.2.3.2. Operating Pressure Setting (High)
1. Inlet = 1000-3000 psig Range
2. Reducer = 225 psi (Lockup pressure)
3. Relief = 255 psi (max. accumulation 300 psig) 240 psi (cracking pressure) 232 psi (reseat pressure)
Operating Pressure Setting (High)
1.3
Proof Pressure
4500 psi at inlet
Service
Weight
Air or Nitrogen
+20F to +140F
Special Equipment
The following special tools and fixtures are recommended for the maintenance and overhaul of the unit:
Part No. Figure No
Description
Function
Reference Paragraph
T10723 (Fig. 10)
O-ring Pick
O-ring Removal
T10722 (Fig. 11)

1/4 20 UNC Bolt
Seat Puller
-
Seat Removal
Reducer Disassembly
and Assembly
5.2D; 5.3J; 5.4F; 5.5A;

5.3A; 5.6G; 5.6J
5.3H; 5.4B 5.6H
2, 3, 6.4
Hex-socket wrenches,
Assorted sizes
Test Fixture
General Assembly and

Disassembly
Testing and Adjust. of
relief valve
1/4 inch dia. rod
T11298 Fig. 15
1-2
Change B
5.3D
6.5
S6434-AF-MMO-010
Part No. Figure No
Description
Function
T11294 Fig. 14
Test Fixture
T11392 Fig. 13
Test Fixture
T10238 Fig. 16
Test Fixture
T11293 Fig. 12
Test Fixture
Testing and Adjust.

reducer valve
Testing and Adjust.
inlet handvalve
Testing and Adjust.
outlet handvalve
Testing and Adjust.
bypass handvalve
Reference Paragraph
of
6.4
of
6.1
of
6.1
of
6.2
Change B
1-3 / (1-4 Blank)
1-4
Change B
S6434-AF-MMO-010
CHAPTER 2
INSTALLATION
No adjustments are necessary for installation. Connections for operation are as follows:
A. Mounting:
Six threaded mounting holes, 5/8-11UNC-2B x 1.12 min. thread are provided.
B. Fittings:
Part Number: 281166-0001
Inlet - 1/4 IPS per Buships 810-1385884, Linear Adj.
Outlet - 3/8 IPS per MIL-F-1183, Linear Adj.
Vent - 3/8 IPS per MIL-F-1183
Gauge - Threaded port per MS16142-4 (1/4 TS)
Part Number: 281166-0002 and 281166-0003
Inlet - 3/8 IPS per Buships 803-1385943 Linear Adj.
Outlet - 1/2 IPS per Buships 803-1385943 Linear Ajd.
Vent - 1/2 IPS per Buships 803-1385943
Gauge - Threaded port per NS16142-4 (1/4 TS)
NOTE
Manifold is supplied with gauge port plugged with a fitting comprised of components: MS21902-4C MS21921-4J and MS 21922-4C.
Change B
2-1 / (2-2 Blank)
2-2
Change B
S6434-AF-MMO-010
CHAPTER 3
OPERATION
NOTE
Refer to the Operational Schematic (Figure 9) as an aid to the following functional description of the operation of the pressure regulating manifold.
Note that the RM21FA-1 manifold incorporates two identical flow paths. Both flow paths have inlet and outlet handvalves, a filter and a pressure reducing valve. The two flow paths are connected to the common inlet and
outlet ports, gauge port and pressure relief valve.
Fully close the inlet and outlet handvalve for one flow path or side. With the bypass handvalve fully closed
and the inlet and outlet handvalves fully open, inlet line fluid enters the manifold and is directed to the open inlet
handvalve and the closed manual bypass valve. Fluid flowing at inlet pressure through the inlet handvalve is filtered and reduced to the preset outlet pressure by a spring referenced reducer assembly. The reduced line fluid
then passes through the outlet handvalve and out of the manifold at a reduced pressure.
The outlet system is connected to a spring referenced pressure relief valve, which senses any pressure
changes, and vents all excess pressure above the preset pressure level. A gauge connection is connected to the
outlet system through a shut-off valve and permits a check of the downstream pressure conditions at all times.
Normally only one flow path is in use, the alternate flow path is used when maintenance or the filter or reducer
is required, and uninterrupted service must be maintained. This may be accomplished as follows:
A. Slowly open the alternate inlet and outlet handvalves until the outlet pressure just starts to exceed the preset
valve. If a gauge is used at the gauge port to check the downstream pressure, wait for it to stabilize before
proceeding. The relief valve may temporarily vent until the pressure has stabilized. Fully close the inlet and
outlet handvalves in the side or flow path to be serviced. Slowly open the filter/reducer bleed valve to vent
the trapped pressure.
B. Both of the flow paths may be isolated simultaneously by slowly opening the bypass valve until the outlet
pressure just starts to exceed the preset valve. If a gauge is used at the gauge port to check downstream pressure, wait for it to stabilize before proceeding. The valve may temporarily vent until the pressure has stabilized. Close all the inlet and outlet handvalves for both paths and adjust the bypass valve until the outlet pressure equals the preset outlet pressure level. Slowly open the filter/reducer bleed valve to rent the trapped
pressure. The filter and reducer have been isolated from the system.
WARNING
Make certain the trapped pressure has been vented through the bleed valve
before attempting any disassembly.
The manual bypass valve may also be used to check the cracking pressure of the relief valve. This may be
accomplished as follows:
With inlet pressure applied, and the outlet handvalve either opened or closed, slowly crack the bypass handvalve. Note the pressure at which leakage is first observed from the relief vent. This is the cracking pressure.
C. The outlet side of the bypass valve may be vented through the gauge bleed when the gauge shut-off is open.
Change B
3-1
S6434-AF-MMO-010
NOTE
This will vent any pressure downstream of the manifolds.
D. To monitor outlet pressure, proceed as follows:
Close the gauge shut-off and install desired gauge into the gauge port. (See Paragraph 12.1C for gauge
information).
For operation, open the gauge shutoff.
For removal, shut the gauge shut-off and vent pressure through the gauge bleed.
3-2
Change B
S6434-AF-MMO-010
CHAPTER 4
MAINTENANCE
At time of overhaul, the manifold should be disassembled and inspected. All o-rings and damaged parts
should be replaced and all parts should be cleaned and properly lubricated before assembly. Refer to paragraph
6.0, Inspection and Repair; paragraph 7.0 Cleaning and paragraph 8.0 Lubrication for proper maintenance
procedures. The filter element may require periodic replacements due to contamination by the line fluid. The
contamination will be indicated by the differential pressure indicator button popping out. Before replacing the
element, verify the indication by resetting the indicator button and observing whether or not it pops out again. To
replace the filter element, proceed as per paragraph 3.0 (A).
4.1
Suggested Maintenance Schedule
Maintenance is largely corrective and is performed when required by: Troubleshooting (Paragraph 11.0); by
visual inspection; as a result of the leakage and functional tests (Paragraph 12.0) or as part of an overhaul.
(A) Overhaul every (2) years or when o-ring cure dates have expired.
(B) Monthly visual inspection for visible signs of leakage using a bubble fluid.
(C) Servicing of filter element as indicated by indicator button popping up.
NOTE
Functional and leakage tests (Paragraph 12.0) are to be performed after any
major reassembly of the valve, or as an aid to Troubleshooting (Paragraph
11.0).
WARNING
Follow all caution and warning notes before attempting any maintenance on
the equipment. Otherwise personal injury and/or equipment damage may
result.
Change B
4-1 / (4-2 Blank)
4-2
Change B
S6434-AF-MMO-010
CHAPTER 5
REMOVAL & DISASSEMBLY
The following disassembly procedures are divided into paragraphs describing all the phases of complete disassembly. Each paragraph describes a complete and particular phase of the disassembly that is independent of
any other phase unless otherwise stated. To disassemble any component of the manifold, it is necessary to refer
to the paragraph describing the disassembly of that particular component only. DO NOT PERFORM UNNECESSARY DISASSEMBLY. The assembly drawings (Figures 1 - Figure 8) and other figures as indicated, are to
be used in conjunction with the following procedure for the disassembly of the manifold. During disassembly,
cut only the lockwire required and assort all disassembled parts.
WARNING
Make certain that all the pressure is bled from in and around the component to be disassembled as described in each paragraph before attempting
any disassembly. See Paragraph 3.0, A.
NOTE
Item numbers and other callouts regarding Figure 1, Figure 2, Figure 3, or Figure
4 also apply to Figure 1A, Figure 1B, Figure 2A, Figure 3A and Figure 4A.
5.1
Removal of the Entire Manifold from the System
WARNING
Remove all line pressure and open all handvalves, needle valves and bleed
valves before removing the manifold from the system.
NOTE
Cut lockwire before assembly.
A. Unscrew the fitting nuts (91 and 92, Figure 1 from the inlet and outlet and vent fittings, and slide nuts over
the tailpieces (93 and 94, Figure 1).
B. Unscrew the (6) mounting screws, and carefully remove the manifold from the mounting brackets.
C. Unscrew the eight socket head cap screws (68, Figure 1) from the adapters (19, Figure 1) and remove with
assembled components.
D. Remove o-ring (62, Figure 1) and retainer (21, Figure 1) and from the inlet and outlet fittings (12, 13, Figure
1).
E. Unscrew inlet and outlet fittings (12, 13, Figure 1 out of adapters (19, Figure 1).
Change B
5-1
S6434-AF-MMO-010
F. Unscrew the vent fitting (14, Figure 1) from the body (9, Figure 1) and remove o-ring (63, Figure 1) from the
vent fitting.
G. Do not remove the fitting nuts (91, 92, Figure 1) or tailpieces (93, 94, Figure 1 from the system piping unless
it is necessary.
H. Remove the instruction plates (16 or 17, Figure 1) from its location only if it is damaged or the lettering is
obliterated.
I. Remove O-rings (64, 65, Figure 1) and rings (20, Figure 1) from the inlet, outlet, and vent tailpieces (93, 94,
Figure 1).
J. Unscrew nut (84, Figure 1) from union (83, Figure 1). Unscrew union (83, Figure 1) from body (9, Figure
1). Remove o-ring (61, Figure 1).
5.2
Removal and Disassembly of the Filter Element (2 Figure 1; and Figure 2).
A. Isolate the filter and bleed the pressure through the reducer bleed valve (1, Figure 1) as per para. 3.0 A.
B. Unscrew cap screws (67, Figure 1) and remove housing (91, Figure 2) from body (9, Figure 1).
C. Gently pull element (90, Figure 2) from body (9, Figure 1). Remove orifice (15, Figure 1) from body (9,
Figure 1).
D. Remove o-ring (83, 84, Figure 2) from disassembled parts using o-ring pick (Figure 10). Remove ring (82,
Figure 2).
CAUTION
Do not attempt to further disassemble the filter assembly.

5.3
Removal and Disassembly of a Pressure Reducing Valve (See Figure 3; and Item 4, Figure 1).
A. Isolate the pressure reducing valve assembly (see Para. 3.0.A) and bleed the pressure through the filter bleed
valve (1, Figure 1).
B. Cut the lockwire (82, Figure 1) and unscrew the four socket head cap screws (66, Figure 1). Carefully pull
the reducer assembly (4, Figure 1) out of the body and pin assembly (9, Figure 1).
C. Remove the two set screws (81, Figure 3) and back the screw (21, Figure 3) out with a 3/8 Allen wrench.
D. Unscrew the nut (22, Figure 3) by the two-inch flats and carefully remove spring (24, Figure 3), guide (25,
Figure 3), o-ring (69, Figure 3), bearing (92, Figure 3), and two races (91, Figure 3). Unscrew the screw (21,
Figure 3) from the nut (22, Figure 3) with a 3/8 Allen wrench.
NOTE
Do not remove the decal (26, Figure 3), as it is permanently affixed with epoxy
glue.
E. Screw a 1/4 - 20 UNC bolt into the piston (20, Figure 3) and pull the piston out of the body (23, Figure 3).
Unscrew the bolt from the piston.
5-2
Change B
S6434-AF-MMO-010
F. Unscrew the end nut (15, Figure 3) with a 15/16 wrench and remove the spring (14, Figure 3) and the guide
(12, Figure 3).
G. Carefully push the poppet (19, Figure 3) and the internal parts out from the piston end of the body (23, Figure
3) with a blunt brass rod.
H. Carefully remove the seat support (17, Figure 3) and the seat (18, Figure 3) from the body (23, Figure 3)
with the seat support puller (Figure 11).
I. Separate the seat (18, Figure 3) from the seat support (17, Figure 3). Take care not to damage the critical
sealing surface of the seat support.
J. Remove all the o-rings (61, 62, 63, 64, 67, 68, 70, 71, 72, Figure 3) and the three slugs (11 and 13, Figure
3) from the disassembled parts with the o-ring pick (Figure 10).
5.4
Removal and Disassembly of the Pressure Relief Valve Assembly

(See Figure 4; and Item 5, Figure 1).
WARNING
Before attempting any disassembly of the pressure relief valve, close both
outlet handvalves and the bypass valve. Remove the outlet line pressure and
open the gage shut-off gage bleed valve (2, Figure 1) to make certain that the
outlet system is fully vented.
A. Bend up the tab on the washer (17, Figure 4) and unscrew the valve by the 2-3/8 inch hex on the housing
(22, Figure 4).
B. Remove the seat (24, Figure 4) from the body (16, Figure 1) with the seat support puller (Figure 11).
C. Unscrew the set screw (81, Figure 4) and carefully back the cap (23, Figure 4) off the housing (22, Figure 4).
NOTE
Do not remove the decal (20, Figure 4) from the cap as it is permanently affixed
with epoxy glue.
D. Disassemble the race (91, Figure 4), bearing (90, Figure 4), ring (15, Figure 4) and the spring assembly (1,
Figure 4).
NOTE
Do not perform any further disassembly of the spring assembly (1, Figure 4)
after it has been removed from the valve.
E. Remove the piston (16, Figure 4) and poppet (21, Figure 4) from the housing (22, Figure 4) by carefully
pushing on the poppet.
Change B
5-3
S6434-AF-MMO-010
NOTE
Do not disassemble the piston and poppet unless they are damaged. If disassembly is required, carefully remove the Spiral pin (92, Figure 4) with an arbor press
and disassemble the poppet, piston, and spring (11, Figure 4).
F. Remove orings (64, 65 & 66, Figure 4) and the slug (12, Figure 4) from the disassembled parts with the
oring pick (Figure 10).
5.5
Removal and Disassembly of the Inlet Handvalve
(7, Figure 1; and Figure 6) and Outlet Handvalve (8, Figure 1; and Figure 7). Refer to Figure 6 for disassembly of both inlet and outlet handvalves.
WARNING
Before attempting any portion of disassembly, the following precaution must

be taken:
Inlet handvalve: Close both outlet handvalves and the by-pass handvalve. Remove the inlet line pressure
and slowly open the inlet handvalves and filter bleed valves to fully vent the manifold inlet section.
Outlet handvalve: Close both inlet and the by-pass handvalves. Vent the outlet line pressure and slowly
open the outlet handvalves and filter bleed valves to fully vent the manifold outlet section.
A. Unscrew the inlet and outlet handvalves (7, 8, Figure 1), from the body (9, Figure 1) by the large hex on the
valve bonnet (2, Figure 6) and remove oring (13, Figure 6) using the oring pick (Figure 10).
NOTE
The handvalve assembly has a lefthand thread and must be turned in a clockwise
direction to remove.
B. While holding the handle (1, Figure 6), unscrew the nut (15, Figure 6).
Remove the lockwasher (14, Figure 6) and the handle (1, Figure 6) from the valve assembly.
C. Slide the handle (1, Figure 6) back onto the stem (3, Figure 6) and while holding the bonnet (2, Figure 6)
with a wrench, turn the handle (1, Figure 6) in a clockwise direction. This will disengage the seat (6, Figure
6) from its press fit into the bonnet (2, Figure 6) while holding the bonnet (2, Figure 6) with a wrench.
D. While holding the bonnet (2, Figure 6) with a wrench, unscrew the gland nut (7, Figure 6) from the bonnet
(2, Figure 6).
E. Push the stem (3, Figure 6) with its assembled components from the bonnet (2, Figure 6).
CAUTION
When pushing the stem through the bonnet, be careful not to damage the
packing (10, Figure 6) with the threads on the stem.
F. Carefully remove the retainer (8, Figure 6) and the packing (10, Figure 6).
5-4
Change B
S6434-AF-MMO-010
G. Unscrew the stem retainer (9, Figure 6) and disassemble the stem (3, Figure 6) and the guide (4, Figure 6).
H. Remove the o-rings and back-up ring (11 & 12, Figure 6) from the disassembled parts with the o-ring pick
(Figure 10).
5.6
Removal and Disassembly of the By-Pass Handvalve

(6, Figure 1; and Figure 5).
WARNING
Before attempting any portion of disassembly of the by-pass valve, vent the
inlet and outlet line pressures and open the inlet and outlet handvalves to
insure the manifold is fully vented.
A. Unscrew the by-pass valve from the body (9, Figure 1), utilizing the hex on the retainer screw (13, Figure 5).
B. Remove slug (11, Figure 5) from the screw (13, Figure 5).
C. Remove set screw (81, Figure 5) and slug (12, Figure 5) from the retainer screw (13, Figure 5).
E. Screw the screw (14, Figure 5) into the retainer screw (13, Figure 5) until the stem (15, Figure 5) can be
removed by sliding out of the slot in the screw (14, Figure 5).
F. Unscrew the handle (20, Figure 5) from the screw (14, Figure 5) by first loosening the nut (22, Figure 5).
G. Pull cage (17, Figure 5) from body (9, Figure 1) and remove oring (63, Figure 5) utilizing oring pick.
(Figure 10).
H. Remove oring (61, Figure 5) from the stem (15, Figure 5).
I. Utilizing the seat support puller (Figure 11), remove the seat (16, Figure 5), seat support (19, Figure 5) from
the body (9, Figure 1).
J. Remove oring (62, Figure 5) from the seat support (19, Figure 5) utilizing an oring pick (Figure 10).
5.7
Removal and Disassembly Needle Valves (Gage bleed, gage shut-off (2, Figure 1 and Figure 8).
WARNING
Before attempting any portion of disassembly of the gage valves, close all the
inlet, outlet and bypass handvalves.
Remove outlet line pressure and open the outlet handvalve, gage bleed and
gage shut-off needle valves to assure the manifold is fully vented.
A. Snap out retainer ring(s) (81, Figure 1), utilizing retaining ring pliers and remove washer(s) (11, Figure 1).
B. Unscrew the screw(s) (12, Figure 8) and remove oring(s) (61, Figure 8) and slug(s) (11, Figure 8).
Change B
5-5
S6434-AF-MMO-010
5.8
Removal and Disassembly of Needle Valves: Filter/Reducer Bleed (1, Figure 1 and Figure 8)
WARNING
Before attempting disassembly of the filter/reducer bleed valve, isolate the

flow path per paragraph 3.0.A and open the filter reducer bleed valve to vent
the pressures.
A. Snap out the retaining ring (81, Figure 1), using retaining ring pliers and remove washer (11, Figure 1).
B. Unscrew the screw (12, Figure 8), and remove slug (11, Figure 8).
NOTE
The filter/reducer bleed valve (1, Figure 1) does not use an o-ring (61, Figure 8).
5-6
Change B
S6434-AF-MMO-010
CHAPTER 6
INSPECTION AND REPAIR
6.1
Inspection
(A) Check all parts for damage.

(B) Check sliding surfaces for freedom of movement.
(C) Check parts for contamination (dirt, dust, etc.).
(D) Check for scratches, nicks, etc., on sealing surfaces that could cause leakage.
(E) Check for clogged flow paths.
(F) Check for filter contamination.
(G) Check for stripped or broken threads.
6.2
Repair
A. Clean any parts found to be contaminated with dirt, dust, grease, etc., prior to reassembly. Refer to Paragraph
7.0 Cleaning for proper cleaning procedures.
B. Replace with new parts found to be worn or damaged as a result of inspection. Use the following rejection
criteria.
Nicks, scratches, etc., on seating/sealing surfaces that can be seen with the unaided eye or felt with a fingernail shall be cause for replacement.
Any damages such as cracks, breaks, stripped threads, roughness shall be cause for replacement.
Any wear on parts surfaces which can be seen with the unaided eye or felt with a fingernail shall be cause
for replacement.
C. Parts should be lubricated before reassembly. See Paragraph 8.0 Lubrication for proper procedures.
NOTE
O-rings are easily damaged during disassembly. Replace all o-rings removed
during disassembly.
Change B
6-1 / (6-2 Blank)
6-2
Change B
S6434-AF-MMO-010
CHAPTER 7
CLEANING
NOTE
Select one or a combination of the following cleaning methods to achieve visual
cleanness.
7.1
Cleaning Methods for Metallic Parts
A. Detergent Cleaning:
Clean ultrasonically in detergent at 140F (10F) for three minutes.
Rinse thoroughly in tap water.
Dry and wipe clean utilizing lint free cloth.
B. Trichloroethane Cleaning:
WARNING
Hazardous substance. Follow all instructions carefully. Do not use the following procedures in a collective protection HVAC system environment.
Trichloroethane Cleaning Solvent
General Precautions: Handle with reasonable care. Avoid breathing vapors. Store in
a cool place. Keep container tightly closed.
Ventilation: Limit concentration in air to 350 PPM (1974 Data).
Respiratory Protection: Below 350 PPM - None. Respiratory protection required in
the absence of environmental control. For levels up to 2% for 1/2 hour or less, a suitable full-face mask with organic canister should be used. Above 2% and for emergencies, use a self-contained breathing apparatus.
Protective Clothing Suitable leak proof gloves.
Eye Protection
Safety glasses. Eye wash stations and safety showers should be
readily available.
Conditions to Avoid: Open flames, welding arcs or other high temperature sources
which induce thermal decomposition.
Incompatibility: Water - slow hydrolysis produces corrosive acid.
Hazardous Decomposition Products: Hydrogen chloride and very small amounts of
phosgene and chlorine.
Fire Extinguishing Media: Water fog Special Fire Fighting Equipment and Hazards:
Self-contained respiratory equipment. Not considered a flammable liquid under normal
industrial use conditions.
Cleaning Procedure
(1) Clean ultrasonically in trichloroethane for three minutes.
Change B
7-1
S6434-AF-MMO-010
(2) Dry and wipe clean utilizing a lint free cloth.
(3) Rinse thoroughly in tap water. Make sure all surfaces are rinsed.
C. Trichlorotrifluoroethane Cleaning
WARNING
Hazardous substance. Follow all instructions carefully. Do not use the following procedures in a collective HVAC system environment. Trichlorotrifluoroethane Cleaning Solvent
General Precautions: Handle with reasonable care. Avoid breathing vapors. Store in
cool dry place. Keep container tightly closed.
Ventilation: Limit concentration in air to 1000 PPM (Tentative).
Respiratory Protection: Below 1000 PPM - None. Respiratory protection required in
the absence of environmental control. For higher levels and for emergencies, use a selfcontained breathing apparatus.
Protective Clothing Rubber apron and suitable leak proof gloves.
Eye Protection Safety glasses, eye wash stations and safety showers should be readily
available.
Conditions to Avoid: Open flames, welding arcs or other high temperature sources
which induce thermal decomposition.
Incompatibility: Hot reactive metal such as molten aluminum, barium, lithium.
Hazardous Decomposition Products: Halogens, halogen acids and carbonyl halides.
Fire Extinguishing Media: Water spray to knock down vapors and cool container
Special Fire Fighting Equipment and Hazards: Self-contained respiratory equipment. Not considered a flammable liquid under normal use conditions.
Cleaning Procedure
(1) Clean ultrasonically in Trichlorotrifluoroethane for three minutes.
NOTE
For parts too large to clean in ultrasonic cleaner, proceed as follows:
Dry an wipe clean utilizing a lint free cloth.
7.2
Cleaning Method for Non-Metallic Parts and Coated Parts

Detergent Cleaning
(1) Clean ultrasonically in detergent at 70F (10F) for a maximum of two minutes.
(2) Rinse thoroughly in tap water.
7-2
Change B
S6434-AF-MMO-010
NOTE
For parts too large to clean in ultrasonic cleaner, proceed as follows:
Clean in detergent and rinse thoroughly. Dry and wipe clean utilizing a lint free cloth.
7.3
Cleaning Method for Synthetic Rubber Parts (o-rings)

Clean in detergent and rinse thoroughly. Dry and wipe clean utilizing a lint free cloth.
7.4
Quality Assurance (Cleaning)
Parts cleaned per these processes shall be free from particulate contamination as verified by visual inspection
with the unaided eye.
Change B
7-3 / (7-4 Blank)
7-4
Change B
S6434-AF-MMO-010
CHAPTER 8
LUBRICATION
NOTE
If cleaned and lubricated parts are not to be immediately installed or assembled,
the parts should be stored in a clear, sealed plastic bag.
After cleaning, and prior to reassembly, lubricated as follows:
Lubricants
Lubricant:
Manufactured By:
A. Halocarbon Grease 25-5-S or

Krytox 240AC
Halocarbon Products Co.

Hackensack, New Jersey
E.I. DuPont DeNemours & Co.
Organic Chemicals Department
Dyes & Chemical Division
Wilmington, Delaware 19899
Jetlube Co.
Houston, Texas
B. Jetlube #MP50
WARNING
#MP50 is a petroleum based lubricant and dieselization may occur if it is

exposed to high pressure line media. Only utilize MP50 lubricant in areas as
required.
Amount of Lubricant: Apply sparingly.

Items to be lubricated:
A. All o-rings and sliding surfaces. (25-5-S)
B. All races and bearings (Jetlube #MP50)
Change B
8-1 / (8-2 Blank)
8-2
Change B
S6434-AF-MMO-010
CHAPTER 9
ASSEMBLY AND INSTALLATION
The following assembly procedures are divided into paragraphs describing all the phases of complete assembly. Each paragraph describes a complete and particular phase of the assembly that corresponds to a phase of the
disassembly. The assembly drawings (Figure 1 - Figure 8) and other figures, as indicated, are to be used in conjunction with the following procedure for the assembly of the manifold.
NOTE
Item numbers and other callouts regarding Figure 1, Figure 2, Figure 3, and
Figure 4 also apply to Figure 1A, Figure 2A, Figure 3A, and Figure 4A.
9.1
Assembly and Installation of the Inlet Handvalve
(7, Figure 1; and Figure 6) and Outlet Handvalve (8, Figure 1; and Figure 7). Refer to Figure 6 during
assembly of both the inlet and the outlet handvalve.
A. Insert the flanged end of the stem retainer (9, Figure 6) into the guide (4, Figure 6) and screw the stem
retainer (9, Figure 6) down over the stem into the guide (4, Figure 6).
B. Carefully push the stem (3, Figure 6) with the attached parts, threaded end first, into the bonnet (2, Figure
6) until it bottoms.
C. Lubricate the threads on the stem (3, Figure 6) and the packing (10, Figure 6) per Paragraph 8.0 and carefully push the packing over the stem down into the bonnet (2, Figure 6). Make certain the grooved end of
the packing is facing down in the bonnet.
D. Push the retainer (8, Figure 6) small end first, down into the bonnet (2, Figure 6) against the packing (10,
Figure 6).
E. Screw the gland nut (7, Figure 6) onto the stem (3, Figure 6) and engage the external threads on the gland
nut with the threads in the bonnet (2, Figure 6). Continue turning in on the gland nut until the packing (10,
Figure 6) is pushed into the bonnet recess. Tighten the gland nut to approximately 150-inch pounds of torque.
F. Temporarily assemble the handle (1, Figure 6), to the stem (3, Figure 6), and turn the handle in a counterclockwise direction until the stem is raised to the full open position.
G. Push the seat (6, Figure 6), into the bonnet (2, Figure 6) groove, tap lightly with a block of wood or plastic.
H. Assemble the handle (1, Figure 6), to the stem (3, Figure 6). Place the washer (14, Figure 6) on the stem and,
while holding the handle, screw on and tighten the nut (15, Figure 6) with a 9/16 socket wrench.
I.
Position the back-up ring (11, Figure 6) and the o-ring (12, Figure 6) on the bonnet (2, Figure 6).
NOTE
Use test fixture (Figure 13) for inlet handvalve (Figure 6). Use test fixture
(Figure 16) for outlet handvalve (Figure 7).
J. Place the o-ring (13, Figure 6) into the groove in the test fixture (Figure 13 or 16).
K. Screw the valve into the test fixture by the hex on the bonnet (2, Figure 6). Tighten to 45 - 60 foot pounds
of torque.
Change B
9-1
S6434-AF-MMO-010
NOTE
The bonnet thread is left-handed and must be turned counterclockwise to tighten.
L. Set-up the test fixture (Figure 13 or 16), as shown in the following figure. Close the handvalve and slowly
apply 3000 psig to the inlet port. Check for leakage at the outlet port. If leakage persists, refer to paragraph
11.8, open and close the valve several times and recheck for leakage.
Test Fixture Setup, Inlet Handvalve

M. Remove the handvalve from the test fixture (Figure 13 or Figure 16).
N. Remove the o-ring (13, Figure 6) and seat from the test fixture (Figure 13 or Figure 16) and insert all items
into the body (9, Figure 1).
O. Screw the valve into the body (9, Figure 1) by the hex on the bonnet, (21, Figure 6). Tighten to 45 - 60 foot
pounds of torque.
NOTE
The bonnet thread is lefthand and must be turned counter-clockwise to tighten.
9.2
Assembly and Installation of the By-Pass Valve

(6, Figure 1; and Figure 5).
A. Install o-ring (62, Figure 5) onto the support seat (19, Figure 5) and insert into the test fixture (Figure 12).
NOTE
Assemble the support seat (19, Figure 5) with the larger diameter hole positioned
down.
B. Insert the seat (16, Figure 5) into the test fixture (Figure 12) on top of the support seat (19, Figure 5).
9-2
Change B
S6434-AF-MMO-010
NOTE
Assemble the seat (16, Figure 5) so that the side with the larger diameter hole is
seated against the support seat (19, Figure 5).
C. Assemble o-ring (63, Figure 5) onto the cage (17, Figure 5) and assemble o-ring (61, Figure 5) onto the stem
(15, Figure 5).
D. Carefully slide the stem (15, Figure 5) into the cage (17, Figure 5)
E. Assemble components, as completed per Step D above, into the slot of the screw (14, Figure 5).
F. Generously lubricate the internal threads of the retaining screw (13, Figure 5) and the large threads on the
screw (14, Figure 5) per 8.0 and screw the retaining screw onto the screw (14, Figure 5) until it bottoms.
G. Press the slug (12, Figure 5) into the threaded hole in the retaining screw (13, Figure 5). Screw in the set
screw (81, Figure 6) and tighten just enough to keep the screw (14, Figure 5) from turning.
H. Screw the nut (22, Figure 5) onto the screw (14, Figure 5) and thread the handle (20, Figure 5) onto the screw
about half the screw length. Tighten the nut (22, Figure 5) snugly against the handle (20, Figure 5).
NOTE
Final positioning of the handle may be performed after the valve has been
installed in the manifold.
I. Set-up the test fixture (Figure 12) as shown in the following figure. Close the handvalve and slowly apply
3000 psig pressure to the inlet port. Check for internal leakage at the outlet port. If leakage is observed, verify
that the valve is fully closed. If the leakage persists, refer to paragraph 11.4, Troubleshooting. Open and close
the valve several times and recheck for leakage.
Test Fixture Setup, By-Pass Valve

J. Remove the by-pass valve from the test fixture (Figure 12).
K. Remove the seat (16, Figure 5), o-ring (62, Figure 5) and support seat (19, Figure 4) from the test fixture
(Figure 12) and insert orifice (18, Figure 5) into the body (9, Figure 1).
NOTE
Install components in Step L in the proper direction as stated in Step 9.2 A &
Step B
Change B
9-3
S6434-AF-MMO-010
L. Press the slug (11, Figure 5) into the thread in the retaining screw (13, Figure 5) and screw the retaining screw
with the attached parts into the body (9, Figure 1) by the hex. Tighten securely.
9.3
Assembly & Installation of the Filter Element

(Figure 2; and Item 3, Figure 1).
A. Insert orifice (15, Figure 1) into body (9, Figure 1) cavity.

B. Assemble o-rings (83, Figure 2) on element (90, Figure 2). Assemble o-ring (84, Figure 2)
C. Insert element (90, Figure 2) onto body (9, Figure 1). Assemble housing (91, Figure 2) over element and
install four cap screws (67, Figure 1) in body (9, Figure 1).
Tighten and secure cap screws (67, Figure 1) using lockwire (82, Figure 1.)
9.4
Assembly and Installation of the Pressure Reducing Valve

NOTE
A pressure reducing valve may be assembled and installed with the manifold in
service if the reducer has been properly isolated per paragraph 3.0 A.
A. Assemble the seat (18, Figure 3) and the seat o-ring (63, Figure 3) to the seat support (17, Figure 3) and
carefully insert the seat support into the body (23, Figure 3).
B. Insert the retainer o-ring (64, Figure 3) into the groove in the body (23, Figure 3).
C. Insert the poppet o-ring (61, Figure 3) into the groove in the retainer (16, Figure 3) and assemble the other
poppet o-ring (68, Figure 3) to the poppet (19, Figure 3).
D. Slide the retainer (16, Figure 3) over the poppet (19, Figure 3) and carefully position this assembly in the
body (23, Figure 3).
E. Place the spring guide (12, Figure 3) on the end of the poppet (19, Figure 3).
F. Insert the retainer o-ring (62, Figure 3) into the end of the retainer (16, Figure 3).
G. Press the slug (13, Figure 3) into the threads of the end nut and position spring (14, Figure 3) into the end
nut (15, Figure 3). Screw the end nut into the body (23, Figure 3) and tighten to approximately 50 inchpounds of torque.
H. Insert the piston o-ring (67, Figure 3) into the body (23, Figure 3).
I.
Carefully push the piston (20, Figure 3) into the body (23, Figure 3).
J. Lubricate the threads on the screw (21, Figure 3) per Parag. 8.0 and screw the screw into the nut (22, Figure
3) with a 3/8 Allen wrench until it bottoms.
K. Position the valve, as assembled through Step J, in a vertical position so that the piston (20, Figure 3) is on
top.
Place the spring (24, Figure 3) on the piston (20, Figure 3).
9-4
Change B
S6434-AF-MMO-010
L. Generously lubricate the bearing (92, Figure 3) and the two races (91, Figure 3) per Paragraph 8 with the
lubricant (93, Figure 3). Assemble the bearing with a race on each side, to the spring guide (25, Figure 3)
and position the guide on the spring (24, Figure 3).
M. Carefully screw the nut (22, Figure 3) by the two inch flats, into the body (23, Figure 3), positioning the
spring guide (25, Figure 3), and bearing (92, Figure 3) inside the screw (21, Figure 2). Tighten securely.
N. Press one slug (11, Figure 3) into the hole in the nut (22, Figure 3) and screw a set screw (81, Figure 3), but
do not tighten. Press the remaining slug into the hole in the body (23, Figure 3), screw in and tighten the set
screw.
O. Slide the nut o-ring (69, Figure 3) over the nut (22, Figure 3), and position it against the body (23, Figure
3). Secure the decal (26, Figure 3) to the nut (22, Figure 3), if previously removed with the. epoxy glue (94,
Figure 3).
P. Assemble the three body o-rings (70, 71, and 72, Figure 3), to the body (23, Figure 3) and position the valve
in the test fixture (Figure 14). Secure in place with the four socket head cap screws (66, Figure 1).
Q. Setup the test fixture (Figure 14) with the gauges and the downstream handvalve, as shown in the following
figure. Close the handvalves and slowly apply the proper inlet pressure (900-3000 psig) for Part Number
281166-0001; (1000-3000 psig) for Part Numbers 281166-0002 and 281166-0003 to the test fixture. Set the
required outlet pressure (20-200 psig) for Part Number 281166-0001; (150-250 psig) for Part Numbers
281166-0002 and 281166-0003 by adjusting the screw (21, Figure 3) with a 3/8 inch allen wrench. Allow a
short period of time for the system to stabilize and check for leakage at the seat. Seat leakage would be indicated by a gradual and steady increase in the lockup pressure shown on the downstream gauge. If leakage is
detected, refer to Paragraph 11.2 in Troubleshooting.
Test Fixture Setup, Pressure Reducing Valve

R. With the system in the same condition as described in Step Q, verify that the lock-up pressure is as required.
NOTE
The lock-up or no flow pressure is equal to the outlet pressure.
Change B
9-5
S6434-AF-MMO-010
If the lock-up pressure is not as required, readjust (see Para. 10.2), screw (21, Figure 3) and repeat the
lock-up pressure check.
S. Create a downstream flow by opening the downstream handvalve. Slowly close the handvalve and allow the
system to stabilize. Verify that the lock-up pressure is as required.
T. Tighten the set screw (81, Figure 3).
Check for any external leakage. If external leakage is detected, refer to paragraph 11.2 in TROUBLESHOOTING.
Remove the valve from the test fixture (Figure 14) and reinstall it in the body and pin assembly (9, Figure
1).
9.5
Assembly and Installation of the Pressure Relief Valve

A. Position the spring (11, Figure 4) in the piston (16, Figure 4) and slide the poppet (21, Figure 4) into the piston over the spring. Align the hole in the poppet with the slot in the piston and press the Spirol Pin (92, Figure
4) into the hole in the poppet with an arbor press. Make certain that the ends of the pin do not protrude out
of the piston.
B. Assemble the o-ring (65, Figure 4) to the piston (16, Figure 4) and carefully insert the piston with the attached
parts into the housing (22, Figure 4).
Position the spring assembly (1, Figure 4) on the piston (16, Figure 4).
C. Generously lubricate the bearing (90, Figure 4), race (91, Figure 4), and ring (15, Figure 4) per Paragraph 8
with lubricant and position the race, bearing and ring in the cap (23, Figure 4).
D. Carefully screw the cap (23, Figure 4) onto the housing (22, Figure 4), until a slight force is exerted on the
piston (16, Figure 4).
NOTE
Make certain that the ring (15, Figure 4) is properly aligned with the spring
assembly (1, Figure 4).
E. Press the slug (12, Figure 4) into the hole in the cap (23, Figure 4) and screw in the set screw (81, Figure 4),
but do not tighten.
Assemble the o-ring (66, Figure 4) to the cap (23, Figure 4).
F. Secure the decal (20, Figure 4) if previously removed, to the cap (23, Figure 4) with the epoxy glue (93,
Figure 4).
G. Assemble the o-ring (63, Figure 4) to the seat (24, Figure 4) and carefully insert the seat into the test fixture
(Figure 15).
H. Setup the test fixture (Figure 15) with the gauges and the downstream handvalve, as shown in the following
figure. Crack the handvalve and slowly apply the proper outlet pressure (200 psig) for Part Numbers 2811660001 and 281166-0002; (195 psig or 240 psig) for Part Number 281166-0003 (see Paragraph 1.2.3.1 and
Paragraph 1.2.3.2) to the test fixture inlet port. Turn in on the cap (23, Figure 4) until no flow is observed
coming from the handvalve. Close the handvalve and check for leakage at the seat. Seat leakage would be
indicated by a gradual and steady increase in pressure as shown by the downstream gauge. If leakage is
detected refer to Paragraph 11.3 in Troubleshooting.
9-6
Change B
S6434-AF-MMO-010
Test Fixture Setup, Pressure Relief Valve

I. Gradually increase the pressure at the inlet port until the valve cracks and starts venting. Verify that the
cracking pressure is within the specification limits. If the cracking pressure is not as required, readjust the cap
(23, Figure 4), per paragraph 10.1, and recheck the cracking pressure.
NOTE
Valve cracking pressure shall conform to the requirements of MIL-V-24272.
J. After completing Step I, gradually decrease the pressure at the inlet port until the poppet reseats. Verify that
the reseat pressure is as required and recheck the downstream gage for seat leakage.
Check for any external leakage. If external leakage is detected, refer to paragraph 11.3 in TROUBLESHOOTING.
K. Remove the valve from the test fixture (Figure 15) and assemble the washer (17, Figure 4) to the housing
(22, Figure 4). Reinstall the valve in the body and pin assembly (9, Figure 1) and bend down a tab on the
washer (17, Figure 4).
9.6
Assembly and Installation of Needle Valves

(See Figure 8 & item 1 & 2, Figure 1)
A. Press the slug (11, Figure 8) into the threads on the screw (12, Figure 8).
B. Slide the o-ring (61, Figure 8) onto the screw (12, Figure 8), and turn the screw into the body (9, Figure 1).
NOTE
The filter/reducer bleed valve assembly (1, Figure 1), does not include o-ring (61,
Figure 8). Make certain that the needle valves are installed in the proper cavities.
C. Place the washer (11, Figure 1) on top of the screw (12, Figure 8) and snap in the retaining ring (81, Figure
1) with retaining ring pliers.
Change B
9-7
S6434-AF-MMO-010
9.7
Final Assembly and Installation of the Manifold into the System

NOTE
The following procedure is to be performed after all components have been
assembled and installed onto the manifold. (Paragraph 9.1 - Paragraph 9.6).
A. Install o-ring (61, Figure 1) onto the union (83, Figure 1) and screw into the body (9, Figure 1).
B. Insert sleeve (85, Figure 1), into the nut (84, Figure 1) and screw the nut onto the union (83, Figure 1).
C. Install o-ring (62, Figure 1) and retainer (21, Figure 1) onto the inlet and outlet fittings (12, 13, Figure 1).
D. Screw the inlet and outlet fittings as assembled in Step C into the adapter (19, Figure 1).
E. Install inlet and outlet fittings (12, 13, Figure 1) into the body (9, Figure 1) and secure utilizing screws (68,
Figure 1).
F. Install o-ring (63, Figure 1) onto the vent fitting (14, Figure 1) and screw into the body (9, Figure 1).
G. Install rings (20, Figure 1) and o-rings (65, Figure 1) onto the outlet and vent tailpieces (94, Figure 1).
H. Install o-ring (64, Figure 1) onto the inlet tailpiece (93, Figure 1).
I. Carefully align the manifold up to the existing piping and connect by screwing the nuts (91, 92, Figure 1)
onto the fittings (12, 13, 14, Figure 1).
NOTE
The inlet fitting (12, Figure 1) and outlet fitting (13, Figure 1) are linear adjustable by screwing the fittings in or out (as necessary) of the adapter (19, Figure
1).
9-8
Change B
S6434-AF-MMO-010
CHAPTER 10
ADJUSTMENTS
The manifold is preadjusted and should not require any readjustments during operation.
Adjustments are to correct malfunction port for reassembly and are as follows:
NOTE
Item numbers and other callouts regarding Figure 1, Figure 3, and Figure 4 also
apply to Figure 1A, Figure 3A, and Figure 4A.
10.1
Relief Valve
(5, Figure 1; and Figure 4)

Loosen Screw (81, Figure 4).
Turn cap (23, Figure 4) in a clockwise direction to increase the relief cracking pressure or counterclockwise
to decrease the relief cracking pressure.
Retighten screw (81, Figure 4).
10.2
Reducer Valve

A. Loosen screw (81, Figure 3).
B. Turn screw (21, Figure 3) in a clockwise direction to increase outlet pressure or counterclockwise to decrease
the outlet pressure.
C. Retighten screw (81, Figure 3).
Change B
10-1 / (10-2 Blank)
10-2
Change B
S6434-AF-MMO-010
CHAPTER 11
TROUBLESHOOTING
Use discretion in any maintenance disassembly to prevent unnecessary removal, isolate problem area before
attempting any disassembly.
Locate the problem are in the PROBLEM column. The PROBABLE CAUSE column will indicate the
cause of the faulty condition and the CORRECTIVE ACTION column lists the prescribed action to be taken.
(See Chart on following pages)
NOTE
Item numbers and other callouts regarding Figure 1, Figure 2, Figure 3, and
Figure 4 also apply to Figure 1A, Figure 2A, Figure 3A, and Figure 4A.
11.1
(Figure 1)
Pressure Regulating Manifold Troubleshooting

PROBLEM
External Leakage
Internal Leakage
Excessive venting of Relief Valve
Outlet pressure too high.
PROBABLE CAUSE
Loosened fasteners
Damaged o-rings (61, 62, 63, 64, 65,
Fig. 1).
Defective reducer valve (4, Fig. 1).

Defective relief valve (5, Fig. 1).
Defective inlet handvalve (7, Fig. 1).
Defective outlet handvalve (8, Fig. 1).
Defective bypass valve (6, Fig. 1).
Defective needle valve (1, 2, Fig. 1).
Defective filter element (3, Fig. 1).
Outlet handvalve (8, Fig. 1).
Inlet handvalve (7, Fig. 1).
By-Pass Handvalve (6, Fig. 1)
Gage Bleed, Gage Shutoff, Reducer
Bleed (needle valve) (1, 2, Figure 1).
Faulty relief valve or improper setting
(cracking pressure setting too low).
Excessive outlet pressure due to
improper reducer valve setting. (4, Fig.
1).
Defective reducer valve. Internal Leakage Bypass.
CORRECTIVE ACTION
Retighten fasteners as necessary.
Examine o-ring(s) and adjacent sealing
surfaces for nicks, scratches, etc., that
could cause leakage. Replace defective
parts.
See Paragraph 11.2
See Paragraph 11.3
See Paragraph 11.8
See Paragraph 11.8
See Paragraph 11.4
See Paragraph 11.5, 11.6
See Paragraph 11.7
See Paragraph 11.8
See Paragraph 11.8
See Paragraph 11.4
See Paragraph 11.5 & Paragraph 11.6
See Paragraph 11.3
See Paragraph 11.2 (Also see Internal
leakage bypass valve, Parag. 11.4B)
See Paragraph 11.2 See Paragraph
11.4B
Change B
11-1
S6434-AF-MMO-010
Pressure Regulating Manifold Troubleshooting - Continued
PROBLEM
Outlet pressure too low.
PROBABLE CAUSE
Defective reducer valve Filter element
contamination.-
Supply pressure to pressure regulating

manifold too low
Flow path restricted.
11.2
CORRECTIVE ACTION
See Paragraph 11.2 Contamination of
the filter is indicated by the red indicator button in the up position. This can
be verified by pushing the button down
to reset. If the button returns to the up
position, remove and disassemble per
parag. 5.2. Replace the element (3,
Figure 1) and reassemble per parag.
9.3.
Verify that proper pressure is supplied.
Inspect flow path for any foreign matter, (dust, etc.) which may cause blockage & remove.
Reducer Valve

A. Problem:
External Leakage
Probable Cause:
Damaged o-rings (64, 70, 71, 72, Figure 3)
Corrective Action: Examine o-rings and adjacent sealing surface for nicks, scratches, etc., that could cause
leakage. Replace defective parts.
B. Problem:
High outlet pressure
Probable Cause:
Damaged parts or incorrect adjustment
Verification of faulty reducer operation is as follows: (one flow path at a time).

1. Close the bypass valve (6, Figure 1) (and alternate flow path handvalves).
2. Loosen the screw (81, Figure 3) and adjust the screw (21, Figure 3) until the proper outlet pressure is
attained.
3. Isolate the reducer and switch to the by-pass valve (See paragraph 3.0 A ).
4. If correct outlet pressure is not achieved, refer to paragraph 11.4 for bypass corrective procedures.
5. If correct outlet pressure is achieved, proceed to Corrective Action below.
Corrective Action: Remove the faulty unit from the manifold and install it in the test fixtures (Figure 14)
as set-up per paragraph 9.4. Apply inlet pressure and allow the valve to lock-up. Verify that the outlet pressure
is too high and readjust the screw per paragraph 10.2. If the pressure is still too high, proceed with the following examination and replace all damaged parts.
1. Examine all the sliding surfaces of the poppet (19, Figure 3), piston (20, Figure 3) and the attached parts
for dirt, burrs, or misalignment that could cause binding.
2. Examine the seating and sealing surfaces of the poppet, (19, Figure 3), support (17, Figure 3), and the seat
(18, Figure 3), for nicks, scoring, or scratches that could cause leakage.
3. Examine the critical sealing surface of the support (17, Figure 3) for dirt or damage that could cause leakage.
11-2
Change B
S6434-AF-MMO-010
4. Make certain that the sensing hole in the body (23, Figure 3) beneath the piston (20, Figure 3) is not
obstructed,
C. Problem:
Low outlet pressure
Probable Cause:
Incorrect adjustment or supplied pressure
Corrective Action: Verify that the manifold inlet pressure is greater than the required outlet. Readjust
reducer valve setting as per paragraph 10.2 until the proper outlet pressure is achieved.
11.3
Relief Valve

A. Problem:
External leakage
Probable Cause:
Damaged o-rings (63, 67, Figure 4).
Corrective Action: Examine o-ring and adjacent sealing surfaces for nicks, scratches, etc., that could cause
leakage. Replace defective parts.
B. Problem:
High cracking pressure
Probable Cause:
Damaged parts or incorrect adjustment
Verification of faulty relief operation is as follows:

1. Close the bypass valve (6, Figure 1) and the inlet handvalve (7, Figure 1).
2. Open the gage bleed valve (2, Figure 1) as pressure escapes. Verify that the relief valve is not venting. If
venting occurs, proceed as follows:
Corrective Action: Remove the faulty unit from the manifold and install it in the test fixture (Fig. 15) as
set-up per paragraph 9.5. Gradually apply pressure to the test fixture inlet port until the valve cracks. Verify that
the cracking pressure is too high and readjust the relief valve as per paragraph 10.1. If the cracking pressure is
still too high, proceed with the following examination and replace all damaged parts.
Examine the sliding surfaces of the piston (16, Figure 4) for dirt, burrs or misalignment that could cause
binding.
C. Problem:
Low cracking pressure
Probable Cause:
Corrective Action:
achieved.
11.4
Incorrect adjustment
Readjust the relief valve as per paragraph 10.1 until the proper cracking pressure is
By-Pass Valve

A. Problem:
External leakage
Probable Cause:
Damaged o-ring(s) (61, 63, Figure 5)
Corrective Action: Examine o-rings (61, 63, Fig. 5) and adjacent sealing surfaces for nicks, scratches, etc.,
that could cause leakage. Replace defective parts.
B. Problem:
Internal leakage
Change B
11-3
S6434-AF-MMO-010
Probable Cause:
Damaged parts
Corrective Action: Remove the faulty unit from the manifold and install it in the test fixture (Fig. 12) as
set-up per paragraph 9.2. Close the handvalve and gradually apply pressure to the test fixture and check if leakage persists.
1. If leakage persists, proceed with the following examination and replace all damaged parts.
2. Examine the seating surfaces of the o-ring (62, Figure 5), seat (16, Figure 5), stem (15, Figure 5) and support (19, Figure 5) for nicks, scratches, etc. that could cause leakage.
11.5
Reducer and Filter Bleed Valve

Problem:
External leakage
Probable Cause:
Corrective Action:
Damaged parts or valve open

Verify that the valve is closed.
1. Torque the screw (12, Fig. 8) for better seating.

2. Examine the seating area of the screw (12, Fig. 8) for nicks, scratches, etc. that could cause leakage.
3. Examine the seating area of the body (9, Figure 1) for nicks, scratches, etc. that could cause leakage.
11.6
Gage Shut-Off and Gage Bleed Valve
(2, Figure 1 & Figure 8)

A. Problem:
External leakage
Probable Cause:
Damaged parts
Corrective Action: Examine o-ring (6 1, Figure 8) and adjacent sealing surfaces for nicks, scratches, etc.
that could cause leakage.
B. Problem:
Internal leakage
Probable Cause:
Damaged parts or valve open
Corrective Action: Verify that the valve is closed.

1. Torque the screw (12, Figure 8) for better seating.
2. Examine the seating area of the screw (12, Figure 8) for nicks, scratches, etc., that could cause leakage.
3. Examine the seating area of the body (9, Figure 1) for nicks, scratches, etc. that could cause leakage.
11.7
Filter Element

A. Problem:
External leakage
Probable Cause:
Damaged parts
Corrective Action: Examine o-ring (84, Figure 2) and adjacent sealing surfaces for nicks, scratches, etc.
11-4
Change B
S6434-AF-MMO-010
B. Problem:
Filter contamination
Probable Cause:
Clogged filter element
Verify contamination as follows:

Contamination of the filter is indicated by the red indicator button (located on the filter) in the up position.
This can be verified by pushing the button down to reset. If the button returns to the up position, the filter is
clogged.
Corrective Action:
Remove and disassemble per paragraph 5.2
Replace the element (90, Figure 2) and reassemble per paragraph 9.3.
11.8
Inlet Handvalve - (7, Figure 1; and Figure 6) and Outlet Handvalve (8, Figure 1; and Figure 7)
A. Problem:
External leakage
Probable Cause:
Defective parts
that could cause leakage. Replace parts that are damaged. Examine the packing (10, Figure 6) and adjacent sealing surfaces for nicks, scratches, etc. that could cause leakage. Replace any damaged parts.
B. Problem:
Internal leakage
Probable Cause:
Defective parts
Examine the seating areas of the seat (6, Figure 6) and the disc and guide assembly (4, Figure 6).
Change B
11-5 / (11-6 Blank)
11-6
Change B
S6434-AF-MMO-010
CHAPTER 12
TESTING
Testing of the manifold should be performed:
A. When the performance of the manifold is in question.
B. After any reassembly of the manifold which involves readjustment of components.
C. When problems arise such as those described in paragraph 11.0, TROUBLESHOOTING, the following tests
may help to isolate the probable cause.
NOTE
The proof pressure test should be performed only if the structural integrity of the
manifold is in question.
12.1
General Information
A. Standard Testing Conditions:

Test Fluid: Clean air or nitrogen gas unless otherwise indicated for specified tests.
Test Temperature: Room Ambient
Allowable Leakage: Bubble Tite internal and external (except as indicated).
Pressure Rating: 3000 psi max.
B. Descriptive Terms used in Testing
Lock-up Pressure The outlet pressure delivered when the regulators flow rate is equal to or less than the
allowable leakage rate.
Stabilization
changes.
A condition due to temperature variances of the line fluid thus causing slight pressure
C. Utilize gauges with a scale of 1-1/2 times min. to 4 times max. of the required pressure, and accurate to 1/4
of 1% of the full scale.
(See Charts on following pages)
Testing
EXAMINATION &
TEST NO. TESTS
12.2
Proof Test, Perform only

if the structural integrity
of the equipment is in
question.
TEST CONDITIONS
Water, nitrogen, or air at
the pressure of 4500 psig
applied to the manifold
inlet with the outlet
handvalve(s) closed.
PURPOSE OF EXAMINATIONS AND TESTS
ACCEPTANCE CRITERIA
To test strength and sound- No external leakage,

ness of pressure containing permanent distortion or
envelope.
structural failure.
Change B
12-1
S6434-AF-MMO-010
Testing - Continued
EXAMINATION &
TEST NO. TESTS
12.3
Seat Tightness
12.4
External Leakage Test
12.5
Filter operational test.
12.6
Relief Valve reseat test.

(Reducer)
12.7
Relief Valve reseat test

(bypass handvalve)
12-2
Change B
TEST CONDITIONS
Handvalve seating and
unseating with a torque
not to exceed 70 inch/
pounds and a running
torque not to exceed 35
inch/pounds. Check for
leakage at the outlet with
bubble fluid or by immersing the outlet, or a line
from the outlet, under
water. Regulators and
relief valves shall be tested
at lockup pressure.
Air at maximum rated
pressure applied to each
section of manifold. Leakage checked by either
using bubble fluid or by
submerging manifold in
water.
operating conditions.

To verify seat tightness
ACCEPTANCE CRITERIA
No visible leakage over
a 5-minute period. If the
regulators or relief
valves cannot meet this
requirement, they shall
be tested using the
allowable leakage criteria of 15 SCIH (max.)
per inch of seat diameter.
To check for external leak- No visible leakage over

age.
a 5 minute period.
To test operation of differential indicator.

Maximum inlet pressure
To verify relief valve
applied to inlet, regulating capacity, and demonstrate
valve set far enough above ability to reseat at min.
the relief valve accumula- pressure of:
tion pressure or blocked
1) 190 psig for Part No.
open to ensure that the
281166-0001 configuration
regulating valve is open
(Ref. Paragraph 1.2.1).
wide during this test.
2) 185 psig for Part No.
Reduce pressure until the 281166-0002 configuration
relief valve reseats. Max. (Ref. Paragraph 1.2.2).
inlet pressure is 3000 psi. 3A) 185 psig for Part No.
(Ref. Paragraph 1.2.3.1,
cracking pressure 195 psi)
3B) 232 psig for Part No.
(Ref. Paragraph 1.2.3.2,
cracking pressure 240 psi)
Maximum inlet pressure of To test reseat pressure of

3000 psi applied to inlet.
relief valve.
Filter indicator nominal

trip value 50 psid.
1) For Part No. 2811660001 configuration;
minimum reseat 190
psig
2) For Part No. 2811660002 configuration
minimum reseat 185
psig.
3A) For Part No.
281166-0003 configuration; minimum reseat
185 psig (Ref.
Paragraph 1.2.3.1 195
psig cracking pressure).
3B For Part No.
232 psig (Ref.
1) For Part No. 2811660001 configuration;
minimum reseat 190
psig.
S6434-AF-MMO-010
Testing - Continued
EXAMINATION &
TEST NO. TESTS
TEST CONDITIONS
ACCEPTANCE CRITERIA
Manual bypass valve wide

open.
12.8
2) For Part No. 2811660002 configuration

minimum reseat 185
psig.
3A) For Part No.
185 psig (Ref.
3B) For Part No.
232 psig (Ref.
Operating personnel
All isolation valves,
Handvalve pressurization Max. inlet pressure of
rate test.
3000 psi upstream of
including regulator isola- shall be capable of easvalve, zero pressure down- tion and bypass and gage ily limiting the downisolation, shall be tested to stream pressure build-up
stream initially.
demonstrate that they can rate to a value not
Handvavles operated in
accordance with operating be operated in a manner to exceeding 200 psi per
instructions affixed to
limit pressure build-up rate second.
manifold. A volume no
to a safe value.
greater than that corresponding to 30 pipe diameters downstream.
Change B
12-3 / (12-4 Blank)
12-4
Change B
S6434-AF-MMO-010
CHAPTER 13
STORAGE AND PREPARATION FOR RESHIPMENT
13.1
Storage
Items as packaged should be stored in an area that protects all components from the following:
A. Contamination
B. Extreme temperature variations (store at 40 to 120F)
C. Relative humidity (store in area with relative humidity between 20% to 70%).
13.2
Preparation for Reshipment
A. All items with openings leading to internal surfaces shall be covered with protective caps, plugs, or other
applicable closures, and of a material that will not cause corrosive action between the item and the protective
closure.
B. Containers for reshipment shall be of sufficient size and strength to protect the enclosed items and marked
with proper identifying part numbers and nomenclature.
C. Dunnage, cushioning and/or fillers shall be used to minimize shock, dampen vibrations and to protect items
against damage. They shall be of a quality suitable for the purpose of the items being protected and selected
in relation to the weight and size of the item.
D. Holding devices such as bolts, nails, strapping, etc. shall be of adequate strength, size and length to sufficiently contain the item(s).
E. Shipment can be by commercial carrier or whatever method the owner warrants.
Change B
13-1 / (13-2 Blank)
13-2
Change B
S6434-AF-MMO-010
CHAPTER 14
PARTS LIST
The following is a list of parts required to assemble one Model RM21FA-1, Part Number 281166-0004, pressure regulating manifold.
The item numbers in the first column correspond to the item numbers shown on Figure 1. The quantities
shown are for one (1) unit.
Parts List for Figure 1
ITEM NO.
(FIG. 1)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
61
62
63
64
65
66
67
68
81
82
83
84
85
91
92
93
QTY PER
UNIT
2
2
2
2
1
1
2
2
1
3
4
1
1
1
2
1
1
1
2
2
2
1
2
1
1
2
8
8
8
4
AR
1
1
1
1
2
1
MAROTTA PART NO.

233029-1
233029-0004
233032-0006
283371-0002
2800397-0003
280566-5331
233188-0007
233695-0002
234877-0001
180784-1 & 2
120002-48
189790-0130
189791-0213
189945-0013
180339-0009
4001543-0101
4001542-0101
180708-2
189649-0113
4790911-0006
189787-0130
4410571-9040
4410571-1170
4410571-9120
4410571-1140
4410571-0190
4201511-1302
4201611-0301
4201511-2301
4190101-1037
4722102-0404
4781013-0004
4780902-0004
4760313-6004
4781311-0006
4760424-0004
NOMENCLATURE
Needle valve assembly
Needle valve assembly
Filter assembly
Reducer assembly
Relief assembly
By-pass valve
Inlet valve
Outlet valve
Body & pin assembly
Decal
Washer
Fitting - inlet
Fitting - outlet
Fitting - vent
Orifice
Instruction plate
Nameplate
Decal
Adapter
Ring - retainer
Retainer
O-ring - gauge
O-ring - in & out
O-ring - vent
O-ring
O-ring
Socket head cap screw
Ring-retainer
Lockwire
Union
Nut
Sleeve
Nut
Nut
Tailpiece
Change B
14-1
S6434-AF-MMO-010
Parts List for Figure 1 - Continued
ITEM NO.
(FIG. 1)
94
95
QTY PER
UNIT
2
4
MAROTTA PART NO.

4781411-0006
4230000-1001
NOMENCLATURE
Tailpiece
Drive screws
The following is a list of parts required to assemble one Model RM21FA-1 Part numbers 281166-0002 and
281166-0003, Pressure Regulating Manifold.
The item numbers in the first column correspond to the item numbers shown on Figure 1A and Figure 1B.
The quantities shown are for one (1) unit.
Parts List for Figure 1A and Figure 1B
ITEM NO.
(FIG. 1A/FIG.
1B)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
21
61
62
63
64
65
66
67
68
69
81
82
83
84
14-2
Change B
QTY. PER
UNIT
2
2
2
2
1
1
2
2
1
3
4
1
1
1
2
1
1
1
2
2
1
2
1
1
2
8
8
8
3
4
AR
1
1
MAROTTA PART NO.

233029-1
233029-2
236285-0002
283371-0002
2800397-0003
280566-5531
233188-1
233695
234877-0002
192802-0028
120002-48
189790-0230
194697-0013
*
182149-0013
180339-0009
4001543-0101
4001542-0101
180708-2
189649-0113
189787-0130
4410571-9040
4400571-1170
4410571-9120
4400571-2100
4400571-2120
4201511-1302
4201611-0301
4201511-2301
192802-0027
4190101-1037
4722102
4781013-0004
NOMENCLATURE
Needle Valve Assembly
Needle Valve Assembly
Filter Assembly,
Reducer Assembly
Relief Assembly
Bypass Valve
Inlet Valve
Outlet Valve
Body and Pin Assembly
Decal
Washer
Fitting - Inlet
Fitting - Outlet
Fitting - Vent
Orifice
Instruction Plate
Nameplate
Decal
Adapter
Retainer
O-Ring - Gauge
O-Ring - In and Out
O-Ring - Vent
O-Ring
O-Ring
Socket Head Cap Screw
Nameplate
Ring - Retaining
Lockwire
Union
Nut
S6434-AF-MMO-010
Parts List for Figure 1A and Figure 1B - Continued
ITEM NO.
(FIG. 1A/FIG.
1B)
85
86
91
92
93
94
95
*
QTY. PER
UNIT
1
AR
1
2
1
2
4
MAROTTA PART NO.

4780902-0004
4990005
4762413-3006
4762413-3008
4762311-0006
4762311-0008
4230000-1001
NOMENCLATURE
Sleeve
Scotch Held
Nut
Nut
Tailpiece
Tailpiece
Drive Screws
Optional Part No. 182149-0061

CORRECTION PAGE FOR FIGURE 1
MACHALT 551-48109 (ECP-346) REPLACED AIR DRY CORPORATION MANIFOLDS WITH NEWLYDESIGNED MAROTTA MANIFOLDS AND UPGRADED THE EXISTING MAROTTA MANIFOLDS TO
NEW DESIGN SPECIFICATIONS. ACCORDINGLY, THIS MACHALT ADDED THE FOLLOWING PART
NUMBERS TO THE PARTS LIST OF MATERIAL FOR USE WITH THE MODEL RM21FA-1, PART NUMBER 281166-0004, PRESSURE REGULATING MANIFOLD:
ITEM NO.
UNIT QTY
PART NO.
2
3
4
5
6
7
8
61
2
2
2
1
1
2
2
1
233029-0004
233032-0006
2883371-0002
2800398-0003
280566-5331
231188-0007
233695-0002
4410571-9040
62
4410571-9120
63
4410571-9120
64
65
1
2
4410571-1140
4410571-0190
NOMENCLATURE
NEEDLE VALVE ASSEMBLY
FITLER ASSEMBLY
REDUCER ASSEMBLY
RELIEF ASSEMBLY
BY-PASS VALVE
INLET VALVE
OUTLET VALVE
O-RING GAGE, MIL-G-23652,
VITON
O-RING - IN AND OUT, MILG-23652, VITON
O-RING - VENT, MIL-G-23652,
VITON
O-RING, MIL-G-23652, VITON
Change B
14-3 / (14-4 Blank)
14-4
Change B
S6434-AF-MMO-010
Figure 1 PRESSURE REGULATING MANIFOLD (REF. 281166-0001) SHEET 1 OF 3
Change B
14-5 / (14-6 Blank)
14-6
Change B
S6434-AF-MMO-010
Change B
14-7 / (14-8 Blank)
14-8
Change B
S6434-AF-MMO-010
Change B
14-9 / (14-10 Blank)
14-10
Change B
S6434-AF-MMO-010
Figure 1A PRESSURE REGULATING MANIFOLD (REF. 281166-0002) (SHEET 1 OF 3)
Change B
14-11 / (14-12 Blank)
14-12
Change B
S6434-AF-MMO-010
Change B
14-13 / (14-14 Blank)
14-14
Change B
S6434-AF-MMO-010
Change B
14-15 / (14-16 Blank)
14-16
Change B
S6434-AF-MMO-010
Figure 1B PRESSURE REGULATING MANIFOLD (REF. 281166-0003) (SHEET 1 OF 3)
Change B
14-17 / (14-18 Blank)
14-18
Change B
S6434-AF-MMO-010
Change B
14-19 / (14-20 Blank)
14-20
Change B
S6434-AF-MMO-010
Change B
14-21 / (14-22 Blank)
14-22
Change B
S6434-AF-MMO-010
MACHALT 551-48109 (ECP-346) REPLACES THE FOLLOWING ITEMS IN THE PARTS LIST:
ITEM NO.
83
84
UNIT QTY
2
1
PART NO.
4400571-0260
4400571-1280
NOMENCLATURE
Change B
14-23 / (14-24 Blank)
14-24
Change B
S6434-AF-MMO-010
Figure 2 FILTER (REF233032)
Change B
14-25 / (14-26 Blank)
14-26
Change B
S6434-AF-MMO-010
Figure 2A FILTER ASSEMBLY (P/N 236285-0002)
Change B
14-27 / (14-28 Blank)
14-28
Change B
S6434-AF-MMO-010
MACHALT 551-48109 (ECP-346) ADDED THE FOLLOWING ITEMS TO THE BILL OF MATERIAL
FOR USE WITH THE MODEL RM21FA-1, PART NUMBER 281166-0004, PRESSURE REGULATING
MANIFOLD:
ITEM NO.
14
18
19
61
62
63
64
67
68
69
70
71
72
UNIT QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
PART NO.
186776-0057
235324
191782-0030
4400571-0120
4400571-0140
4400571-0150
4400571-1160
4400571-1340
4400571-0050
4400571-1390
4400571-1240
4400571-1270
4400571-1300
NOMENCLATURE
SPRING
SEAT
POPPET
O-RING,
O-RING,
O-RING,
O-RING,
O-RING,
O-RING,
O-RING,
O-RING,
O-RING,
O-RING,
MIL-G-23652,
MIL-G-23652,
MIL-G-23652,
MIL-G-23652,
MIL-G-23652,
MIL-G-23652,
MIL-G-23652,
MIL-G-23652,
MIL-G-23652,
MIL-G-23652,
Change B
VITON
VITON
VITON
VITON
VITON
VITON
VITON
VITON
VITON
VITON
14-29 / (14-30 Blank)
14-30
Change B
S6434-AF-MMO-010
Figure 3 PRESSURE REDUCER (REF 280038)
Change B
14-31 / (14-32 Blank)
14-32
Change B
S6434-AF-MMO-010
Figure 3A PRESSURE REDUCING VALVE ASSEMBLY (P/N 283371-0002)
Change B
14-33 / (14-34 Blank)
14-34
Change B
S6434-AF-MMO-010
MACHALT 551-48109 (ECP-346) ADDED THE FOLLOWING ITEMS TO THE PARTS LIST FOR USE
WITH THE MODEL RM21FA-1, PART NUMBER 281166-0004, PRESSURE REGULATING MANIFOLD:
ITEM NO.
63
65
66
67
UNIT QTY
1
1
1
1
PART NO.
4400571-0160
4400571-0230
4400571-1240
4400571-1300
NOMENCLATURE
O-RING,
O-RING,
O-RING,
O-RING,
MIL-G-23652,
MIL-G-23652,
MIL-G-23652,
MIL-G-23652,
Change B
VITON
VITON
VITON
VITON
14-35 / (14-36 Blank)
14-36
Change B
S6434-AF-MMO-010
Figure 4 RELIEF VALVE (REF280039) SHEET 1 OF 2
Change B
14-37 / (14-38 Blank)
14-38
Change B
S6434-AF-MMO-010
Figure 4 RELIEF VALVE (REF 280039) SHEET 2 OF 2
Change B
14-39 / (14-40 Blank)
14-40
Change B
S6434-AF-MMO-010
Figure 4A PRESSURE RELIEF VALVE ASSEMBLY(P/N 2800397-0003)
Change B
14-41 / (14-42 Blank)
14-42
Change B
S6434-AF-MMO-010
ITEM NO.
61
62
63
UNIT QTY
1
1
1
PART NO.
4400571-0100
4400571-0120
4400571-0160
NOMENCLATURE
Change B
14-43 / (14-44 Blank)
14-44
Change B
S6434-AF-MMO-010
Figure 5 BYPASS HANDVALVE (REF 280566)
Change B
14-45 / (14-46 Blank)
14-46
Change B
S6434-AF-MMO-010
CORRECTION PAGE FOR FIGURE 6.
ITEM NO.
*
12
13*
12**
13**
*
UNIT QTY
1
1
1
1
PART NO.
4405592-2230
4405592-1150
4405592-2220
4405592-1140
NOMENCLATURE
O-RING,
O-RING,
O-RING,
O-RING,
MIL-G-23652, VITON
MIL-G-23652, VITON
MIL-G-23652
MIL-G-23652, VITON
FOR 233188-2, -4, -6, AND -8 OUTLET HANDVALVE.
**
FOR 233188-1, -3, -5, AND -7 INLET HANDVALVE
Change B
14-47 / (14-48 Blank)
14-48
Change B
S6434-AF-MMO-010
Figure 6 INLET HANDVALVE (REF 233188)
Change B
14-49 / (14-50 Blank)
14-50
Change B
S6434-AF-MMO-010
Figure 7 OUTLET HANDVALVE (REF. 233695)
Change B
14-51 / (14-52 Blank)
14-52
Change B
S6434-AF-MMO-010
MACHALT 551-48109 (ECP-346) ADDED THE FOLLOWING ITEM TO THE PARTS LIST FOR USE
ITEM NO.
61
UNIT QTY
1
PART NO.
4400571-0060
NOMENCLATURE
Change B
14-53 / (14-54 Blank)
14-54
Change B
S6434-AF-MMO-010
Figure 8 NEEDLEVALVE (REF. 233029)
Change B
14-55 / (14-56 Blank)
14-56
Change B
S6434-AF-MMO-010
Figure 9 OPERATIONAL SCHEMATIC
Change B
14-57
S6434-AF-MMO-010
Figure 10 ORING PICK (T10723)
Figure 11 SEAT PULLER (T10722)
14-58
Change B
S6434-AF-MMO-010
Figure 12 TEST FIXTURE (T11293)
Change B
14-59
S6434-AF-MMO-010
14-60
Change B
S6434-AF-MMO-010
Change B
14-61
S6434-AF-MMO-010
14-62
Change B
S6434-AF-MMO-010
Figure 16 TEST FIXTURE (TF-1813)
Change B
14-63 / (14-64 Blank)
14-64
Change B

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S6434-AF-MMO-010

[SGML Version See Change Record ]

DISTRIBUTION STATEMENT B: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT

TECHNICAL MANUAL CHANGED TO

RECORD OF REVISIONS-1 / (RECORD OF REVISIONS-2 Blank)

FOREWORD-1 / (FOREWORD-2 Blank)

REMOVAL & DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal of the Entire Manifold from the System . . . . . . . . . . . . . . . . . . . .

Removal and Disassembly of the Filter Element (2 ; and ).

Removal and Disassembly of a Pressure Reducing Valve (See ; and Item 4, ). . . . .

Removal and Disassembly of the Pressure Relief Valve Assembly

Removal and Disassembly of the Inlet Handvalve

Removal and Disassembly of the By-Pass Handvalve

Removal and Disassembly of Needle Valves: Filter/Reducer Bleed (1, and ) . . . . .

INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Methods for Metallic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Method for Non-Metallic Parts and Coated Parts . . . . . . . . . . . . . . .

Cleaning Method for Synthetic Rubber Parts (o-rings) . . . . . . . . . . . . . . . . .

Quality Assurance (Cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLY AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly and Installation of the Inlet Handvalve . . . . . . . . . . . . . . . . . . . .

Assembly and Installation of the By-Pass Valve . . . . . . . . . . . . . . . . . . . . .

Assembly & Installation of the Filter Element . . . . . . . . . . . . . . . . . . . . . .

Assembly and Installation of the Pressure Reducing Valve . . . . . . . . . . . . . . .

Assembly and Installation of the Pressure Relief Valve . . . . . . . . . . . . . . . . .

Assembly and Installation of Needle Valves . . . . . . . . . . . . . . . . . . . . . . .

Final Assembly and Installation of the Manifold into the System . . . . . . . . . . .

Pressure Regulating Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reducer and Filter Bleed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gage Shut-Off and Gage Bleed Valve

Inlet Handvalve - (7, ; and ) and Outlet Handvalve (8, ; and ) . . . . . . . . . . . . .

STORAGE AND PREPARATION FOR RESHIPMENT . . . . . . . . . . . . . .

Preparation for Reshipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Data, Part Number 281166-0004

General Data, Part Number 281166-0002

Operating Pressure Setting (High)

Pressure Regulating Manifold Troubleshooting

Parts List for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts List for and

PRESSURE REGULATING MANIFOLD (REF. 281166-0001) SHEET 1 OF 3 . . .

PRESSURE REGULATING MANIFOLD (REF. 281166-0002) (SHEET 1 OF 3) . .

PRESSURE REGULATING MANIFOLD (REF. 281166-0003) (SHEET 1 OF 3) . .

FILTER ASSEMBLY (P/N 236285-0002) . . . . . . . . . . . . . . . . . . . . . . . .

PRESSURE REDUCER (REF 280038)

PRESSURE REDUCING VALVE ASSEMBLY (P/N 283371-0002)

RELIEF VALVE (REF280039) SHEET 1 OF 2 . . . . . . . . . . . . . . . . . . . . .

PRESSURE RELIEF VALVE ASSEMBLY(P/N 2800397-0003) . . . . . . . . . . . .

BYPASS HANDVALVE (REF 280566) . . . . . . . . . . . . . . . . . . . . . . . . .

INLET HANDVALVE (REF 233188)

OUTLET HANDVALVE (REF. 233695) . . . . . . . . . . . . . . . . . . . . . . . . .

NEEDLEVALVE (REF. 233029) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORING PICK (T10723)

SEAT PULLER (T10722) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TEST FIXTURE (T11293)

TEST FIXTURE (T11392)

TEST FIXTURE (T11294)

TEST FIXTURE (T11298)

TEST FIXTURE (TF-1813) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.1 Part Number 281166-0004

Pressure Regulating Manifold

1.2.2 Part Number 281166-0002

Pressure Regulating Manifold

1.2.3 Part Number 281166-0003