Issued : JUN-2005

Pictorial Maintenance Manual R200

No. : NGC-01

1.1 DISASSEMBLY SEQUENCE

Fig. 1 Valve provided with end caps and plugs to avoid ingress of dust and moisture

Fig. 2 Remove bolts (2) of bonnet (25), take care bonnet under spring tension, see drawing

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No. : NGC-01

Fig. 3 Leave 2 bolts to retain and bonnet @ removal

Fig. 4 Lift bonnet, take care remaining internals may stick temporarily and drop out

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No. : NGC-01

Fig. 5 Put valve internals on soft underground

Fig. 6 Reverse valve assembly

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No. : NGC-01

Fig. 7 Remove valve plug (14) from sleeve (9)

Fig. 8 Remove guide rings (12) and O-ring (11)

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No. : NGC-01

Fig. 9 Remove spring (10)

Fig. 10 Remove sleeve (9) from bonnet (25), use combined rotational and axial cycling moves

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No. : NGC-01

Fig. 11 Remove O-ring (6) from sleeve

Fig. 12 Remove cage (8) from valve, use bolts (23) to split parts

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No. : NGC-01

Fig. 13 Lift cage out of valve

Fig. 14 Put cage including remaining internals on soft underground

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No. : NGC-01

Fig. 15 Remove bolting (18) of seat ring (17)

Fig. 16 To ease removal of bolting use screw driver (with proper bit)

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Pictorial Maintenance Manual R200
No. : NGC-01

Fig. 17 Remove seat ring, use M6-bolt to split the seat ring from the cage (only 2 holes with M6)

Fig. 18 Pull the seat ring from cage using the M6-bolts

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Pictorial Maintenance Manual R200
No. : NGC-01

Fig. 19 Remove O-ring (20) from seat use O-ring tool if necessary

Fig. 20 Remove O-ring (19) from seat use O-ring tool if necessary

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No. : NGC-01

Fig. 21 Remove O-ring (16) from cage

Fig. 22 Remove O-ring (7) from cage

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Pictorial Maintenance Manual R200
No. : NGC-01

1.2 ASSEMBLY SEQUENCE

Fig. 1 Cleaning, use appropriate 3M hand pads, clean all parts thoroughly

Fig. 2 Cleaner, lubricants & sealants

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Pictorial Maintenance Manual R200
No. : NGC-01

Fig. 3 Grease all parts prior use with white grease, dont overdo it (as pictured)

Fig. 4 Start with preparation of cage (9), O-ring (7), grease slightly

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No. : NGC-01

Fig. 5 O-ring (16), grease slightly

Fig. 6 O-ring ( 18), grease slightly

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No. : NGC-01

Fig. 7 Preparation of O-ring (20), grease slightly use Parker Super-O-Lube

Fig. 8 Mounting of O-ring (20), take special care not to twist nor damage the O-ring

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No. : NGC-01

Fig. 9 Position seat ring (17) onto cage (8), mind proper alignment of thread holes

Fig. 10 Push seat ring onto cage

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No. : NGC-01

Fig. 11 Fasten seat ring onto cage with bolts (18) use Loctite 243

Fig. 12 Use screw driver (with proer bit) to ease mounting

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No. : NGC-01

Fig. 13 Tighten bolts (18) cross-wise with wrench

Fig. 14 and/or verify with torque wrench

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No. : NGC-01

Fig. 15 Position cage (8) into vale body (13), mind proper alignment of the thread holes

Fig. 16 You may benefit from using bolts (23) to guide the cage into the seat

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No. : NGC-01

Fig. 17 Push cage into valve body

Fig. 18 Dont forget O-ring (7), grease slightly

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No. : NGC-01

Fig. 19 O-ring (6), grease slightly

Fig. 20 Grease sleeve (9) slightly prior assembly

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No. : NGC-01

Fig. 21 Slide sleeve (9) into cage (8)

Fig. 22 Grease inside of sleeve with Parker Super-O-Lube

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No. : NGC-01

Fig. 23 Seal Plug (24), washer (4) into valve plug (14) use Loctite 577

Fig. 24 Tighten plug, use vice and socket wrench, take care not to damage sealing edge

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No. : NGC-01

Fig. 25 O-ring (11), grease slightly, take care not to twist nor damage the O-ring

Fig. 26 Preparation of guide-ring (12), check for proper length (gap between both ends >1 mm)

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No. : NGC-01

Fig. 27 Remove sharp edges and burrs by polishing with sand paper

Fig. 28 Remove sharp edges if necessary

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No. : NGC-01

Fig. 29 Prefrom guide rings to ease mounting

Fig. 30 Slide valve into sleeve, mount 1st guide ring simultaneously

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No. : NGC-01

Fig. 31 Slide valve into sleeve, mount 2nd guide ring (ends directed to the opposite side)

Fig. 32 Check for smooth travel of valve plug

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No. : NGC-01

Fig. 33 Spring (10)

Fig. 34 Mount bonnet (2) onto valve body (13)

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No. : NGC-01

Fig. 35 Grease bolts (2) with Copper Grease or NeverSeez

Fig. 36 Push bonnet down and fasten 2 bolts (2)

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No. : NGC-01

Fig. 37 Tighten bolts cross-wise with wrench

Fig. 38 and/or verify with torque wrench

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No. : NGC-01

Fig. 39 Finalized R200-assembly

Fig. 40 R200 Repair Package : Sleeve, Plug, Guide Rings, Lubricant and optional Scraper rings

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No. : NGC-01

1.3 Testing Sequence

Fig.1 Test equipment & Set-up

Fig.2 Open needle valve to motorisation chamber prior pressurising

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No. : NGC-01

Fig.3 Pressurise inlet slowly up to max. inlet pressure or operational maximum

Fig.4 Open outlet needle valve

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No. : NGC-01

Fig.5 Check for internal leakage of seat, use appropriate indicator

Fig.6 Throttle supply to motorisation chamber to near closed position

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No. : NGC-01

Fig.7 Disconnect flexible hose and throttle outlet needle valve towards closed position

Fig.8 Slowly open needle valve to discharge motorisation chamber until valve opens

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No. : NGC-01

Fig.9 Close outlet fully and check for external leakage, use appropriate indicator
(foam building liquid or leak detector)

Fig. 10 Fully open supply of motorisation

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No. : NGC-01

Fig.11 Fully close discharge of motorisation

Fig.12 Open outlet to depressurise outlet

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No. : NGC-01

Fig.13 Check if outlet pressure drops to zero while maintaining inlet pressure @ max

Fig.14 Proceed with functional test, throttle supply to motorisation towards near closed position

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No. : NGC-01

Fig.15 Open outlet needle valve a little

Fig.16 Open and close discharge of motorisation to increase or decrease outlet pressure
Check for smooth control

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No. : NGC-01

Fig.17 Finalize testing with leakage check

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