Instructions / Assembly

COVER CENTER PLUG
COVER BOLTS
COVER NUTS (8" AND LARGER)
COVER PLUG
COVER
COVER BEARING (STEM GUIDE)
UPPER SPRING DISC (4" AND LARGER) * †
SPRING †
LOWER SPRING DISC (4" AND LARGER) * †
STEM NUT
STEM WASHER
DIAPHRAGM WASHER
(DIAPHRAGM DISC)
DIAPHRAGM*
UPPER STEM O-RING
*
DISC RETAINER
(PLUNGER)
LOWER STEM O-RING*
DISC (SEAL RING)*
DISC GUIDE
(SEAL RING RETAINER)
STEM
SEAT SCREWS (8" AND LARGER) ‡
SEAT ‡
COVER STUDS (8" AND LARGER)
SEAT O-RING ‡
BODY
BODY PLUGS
STEM ASSEMBLY †
* RUBBER REPAIR KIT ITEMS
† COMPLETE REPAIR KIT ITEMS
‡ SEAT REPAIR KIT
TABLE 5. VALVE TORQUE SETTINGS
8. To remove the seat, on valves 6” and smaller the seat is
threaded into the body and will require a seat removal tool. Care
should be taken when removing the seat to avoid damaging. On
8” and larger valves, the seat is held in place with at head hex
screws. For larger valves a seat puller may be required to remove
the seat from the body. A seat tool may be made by grinding
three notches for the spokes in the end of a pipe. Turn with a pipe
wrench.
INSPECTION OF COMPONENTS
Cleaning of components is required for proper inspection. Lime
deposits are common in systems that use water. To remove
deposits, ne grit wet/dry sandpaper (400 grit or higher) can be
used. If deposits cannot be removed, off the shelf lime deposit
remover can be used. Prepare a solution following the lime
deposit remover instructions and soak components (excluding
rubber components) until lime deposits are removed.
CAUTION: When handling chemicals (acids) be sure to use
proper safety equipment (gloves and eye protection) and prac-
tices. After soaking components, be sure to thoroughly rinse
all components before handling and re-assembling valve.
Once all valve components have been cleaned, inspect each
component looking for damage, abnormal wear & corrosion,
and replace all components that look questionable. Replace all
rubber components including the diaphragm, o-rings and disc
each time the vale is serviced or inspected (rubber components
are standard in ZW200 repair kits.
REASSEMBLY
1. First reinstall seat into body. Be sure to use lube around
seat o-ring before tightening. Tighten seat according to torque
values in Table 5 using seat tool.
2. Next place valve stem in a vise clamping on the hex portion
of the stem. Then assemble the diaphragm assembly as
shown in Figure. When assembling be sure that the diaphragm
is centered on the raised step of the disc retainer. It is also
recommended to apply lube to stem threads and o-rings before
tightening. Then tighten the stem nut according to Table 5 for
torque values.
3. Lower diaphragm assembly carefully into the seat bushing
Be careful not to damage the seat or stem while installing as-
sembly. Rotate the assembly as needed until the bolt holes on
the diaphragm line up with the body bolt holes.
4. Place lower spring disc on the diaphragm disc and place
spring on top of the assembly. Then install cover, aligning
the bolt holes and insuring that the cover is not pinching the
diaphragm between the bolt holes. Position cover so plug holes
are in original position.
5. Install cover bolts and tighten in a star pattern to the torque
values in Table 5.
6. Before installing center cover plug manually check that
assembly has full operating travel before installing the pilot
assembly (refer to “Diaphragm Movement” in the diagnosis
checks section).
7. Once full operation range of the main valve is veried, begin
reinstalling pilot system.
8. After installing pilot system double check that all plugs, bolts,
and ttings are sealed and tight before applying pressure.
9. Slowly open upstream isolation valve to pressurize the system
and check for any leaks.
10. Stop leaks as needed and proceed to “Start-Up” and “Di-
agnosis Check” sections for returning valve to proper system
operations.
4
ZURN WILKINS
1747 Commerce Way, Paso Robles, CA 93446 Phone:[phone] Fax:[phone]
www.zurn.com
®
VALVE
SIZE
(in)
COVER
(ft-lbs)
DIAPHRAGM
ASSEMBLY
(ft-lbs)
THREADED
SEAT
(ft-lbs)
SEAT
BOLTS
(ft-lbs)
1-1/4" 3.5 7.5 11 N/A
1-1/2" 3.5 7.5 11 N/A
2" 15 20-25 30 N/A
2-1/2" 25 25-35 60 N/A
3" 25 35-45 70 N/A
4" 55 40-50 85 N/A
6" 110 50-60 95 N/A
8" 120 60-70 N/A 7.4
10" 184 70-75 N/A 7.4
12" 200 110-115 N/A 7.4
14" 275 170-175 N/A 7.4
16" 360 230-240 N/A 7.4