Elwood Parts and Service Manual

PARTS AND SERVICE MANUAL
(EDN 064752 – Rev. A)
PART NUMBER 9794 8070

DECOKING CONTROL VALVE, 6" X 3"
INDEX
SECTION 1: PARTS LISTS (in numerical order by part#, except
for top level assembly which appears first)
SECTION 2: RECOMMENDED SPARE PARTS
SECTION 3: OPERATION & MAINTENANCE INSTRUCTIONS
SECTION 4: DRAWINGS (in numerical order by drawing#)
ELWOOD CORPORATION
FLUID POWER GROUP
195 WEST RYAN ROAD
OAK CREEK, WISCONSIN 53154
TELEPHONE: (414) 764-7500
FAX: (414) 764-4298
www.elwood.com
ELWOOD CORP. - FLUID POWER GROUP
11-14-13 SERVICE MANUAL PARTS LIST
Decoking Control Valve, Basic Unit, 6"x 3"

Elwood Part Number 9794 8070
Refer to Elwood Drawing Number (EDN) 061219
Item Qty EPN EDN Description
1 1 9794 7821 059846 Decoker Basic Asm, 6x3, 2500#-RTJ, SE, HP
2 o 9796 0288 064323 Inspection and Test Plan, Decoker, Pertamina
5 o 9796 0289 Quality Control Dossier
300 1 5641 9058 064204 Nameplate, 6" Decoker Valve, Pertamina
400 1 5641 9059 064205 Nameplate, 3" Decoker Valve, Pertamina
410 1 5641 9060 064206 Nameplate, 6" x 3" Decoker Valve, Pertamina
420 16 313 0412 Screw, Drive, Round Head, #4 x 5/16" Lg Type U,
ANSI B18.6.4,
500 1 9794 8511 064144 Reducer Asm., 1.5 HP, 50 Hz, 380 V,
Reliance/Baldor
600 1 9794 8510 064136 Orifice Pack Assembly
610 0 9784 7830 Seal Kit, Orifice Pack Asm.
700 1 9796 0260 060852 Operation & Maintenance Instruction, Decoker
2010
700 0 9796 0264 061804 Instruction Manual, Reliance Motor
700 0 9796 0253 060560 Instruction Manual, Browing HWN Reducer
Seal Kit, Gearbox Asm, 6 X 3 Decoker Valve
Refer to Elwood Drawing Number (EON) 048647
1 2 3557 0936 049541 Gasket,Cover Plate Cam
2 1 3557 0937 049542 Gasket, Cover Plate Main Gear
3 1 3570 8002 O-Ring, 2 037-V709-90
4 1 723 4500 Seal, Oil, Decoker
5 1 3571 0866 008032 O-Ring, 2-243-V709-90
6 1 724 9962 050147 Shaft Seal, Encoder
Seal Kit, 6" Spindle Asm. Decoker Valve

1 1 3571 0650 048009 O-Ring, 2-155-V709-90
2 1 8400 8800 004 046266 Disc, 6" Stainless
3 2 3570 8701 048010 O-Ring, 2-148-V709-90
Seal Kit, 3" Spindle Asm.,Decoker Valve, SS

1 1 3570 7601 007567 O-Ring, 2 139-V709-90
2 1 8400 5600 003 053037 Disc, 3" By-Pass Valve Decoker (SS)
3 2 3570 5623 007215 O-Ring, 2-130-V709-90
Seal Kit, Main Valve 6", Decoker Assembly, HP
Blwood Part Number 9784 7817
Item Qty EPN EON Description

3 2 725 8475 048006 Seal, Poly-Pak Oil
4 2 3571 3045 048005 a-Ring, 2 263-V709-90
5 2 8610 9961 042817 Ring, Back-Up (8 263 H1750)
7 1 6358 7235 059800 Ring, Wiper, 5 1/8 1.0.
10 2 3571 2702 048004 a-Ring, 2 259-V709 90
11 2 8610 9882 042817 Ring, Back-Up (8 259 H1750)
16 1 725 4380 048007 Seal, Poly-Pak Oil
19 1 3571 4936 041173 a-Ring, 2 454-V709 90
20 1 3571 0538 a-Ring, 2 169-V709 90
29 1 3571 0449 a-Ring, 2 339 V709 90
34 1 9784 7457 Seal Kit, 6" Spindle Asm. Decoker Valve
Seal Kit, 3" By-Pass Valve, Decoker Asm., HP

2 1 725 5460 016054 Seal, Poly-Pak Oil, (2500 2875-375B-P4615A90)
3 3 3571 0866 008032 O-Ring, 2-243-V709-90
4 3 8610 9754 042817 Ring, Back-Up (8 243 H1750)
6 1 6358 7227 049638 Rod Wiper, 2.875 Dia. Rod, Type D
9 2 3571 0361 048011 O-Ring, 2-152-V709-90
10 2 8610 9715 042817 Ring, Back-Up (8 152 H1750)
14 1 725 5591 048012 Seal, Poly-Pak Oil
16 1 3571 3137 O-Ring, 2-443-V709-90
17 1 3571 0886 O-Ring, 2-156-V709-90
18 1 725 2885 048013 Seal, Poly-Pak Oil, (2500 1500-375B-P4615A90)
23 1 3571 0568 O-Ring, 2-240 V709-90
29 1 3570 7547 O-Ring, 2-227-V709-90
35 1 3570 7411 053608 O-Ring, 2-226-V709-90
36 1 8610 8608 042817 Ring, Back-Up (8 226 H1750)
37 1 3535 0065 059806 Gasket, Crush, Decoker Orifice Pak
38 1 9784 7458 Seal Kit, 3" Spindle Asm.,Decoker Valve, SS
Seal Kit, Orifice Pack Asm.

1 1 3570 7411 053608 O-Ring, 2-226-V709-90
2 1 8610 8608 042817 Rin$' Back-Up (8 226 H1750)
3 4 3570 7540 048017 O-Rlng, 2-137-V709-90
4 8 8610 8613 042817 Ring, Back-Up (8 137 H1750)
Tappet Assembly, 6in.
1 1 6727 2502 048999 Tappet, 6 Inch Decoker
2 1 5426 3116 049551 Pin - Roller 6"
3 1 9794 6592 049548 Roller Asm, 3 in. Dia.
4 2 539 9343 049550 Cam Follower 3/4" Dia.
5 2 302 7186 Nut, Jam, Hex, 7/16"-20 UNF2B, American
Standard Finished
6 2 541 4191 Retaining Ring, 5100-100
7 1 292 4070 Screw, Set, Socket Head, Cone Point, 1/4"-20
UNC-3A x 1/2" Lg.
8 1 292 4032 Socket, Set, Screw, 1/4-2PUNC x 5/16 Lg.
Tappet Asm. - 3 in.
1 1 6727 2503 049005 Tappet, 3" Decoker
2 1 5426 3117 049591 Pin - Roller 3", Decoker
3 1 9794 6593 049595 Roller Asm. 2 1/2" Dia.
4 2 539 9344 049594 Cam Follower 5/8 Dia.
5 2 302 5178 Nut, Hex, Amer.Std.Finished, 5/16"-24 UNF2B,'
Cad. Plated Steel
6 2 541 4191 Retaining Ring, 5100-100
7 1 292 4070 Screw, Set, Socket Head, Cone Point, 1/4"-20
UNC-3A x 1/2" Lg.
8 1 292 4032 Socket, Set, Screw, 1/4-20UNC x 5/16 Lg.
Roller Asm, 3 in. Dia.
1 1 2215 0274 051443 Bushing, Roller Asm
2 1 2215 0262 049568 Bushing Roller 3" Dia.
3 4 539 9354 051441 Thrust Washer 1.0 inch dia. X .031 thk.
4 2 539 9353 051442 Thrust Bearing 1.0 inch dia.
5 2 541 4198 057460 Snap Ring 1.75 Dia. Housing, VH-175

Roller Asm. 2 1/2" Dia.
Elwood Part NUmber 9794 6593
1 1 2215 0274 051443 Bushing, Roller Asm
2 1 2215 0263 049569 Bushing Roller, 2.5" Dia.
3 4 539 9354 051441 Thrust Washer 1.0 inch dia. X .031 thk.
4 2 539 9353 051442 Thrust Bearing 1.0 inch dia.
5 2 541 4198 057460 Snap Ring 1.75 Dia. Housing, VH-175
Spindle Assembly, 6" Decoker, Chrome Plated
.
Spindle, 6 in. Decoker, Chrome Plated
1 1 B517 00B6 05905B
2 1 3571 0650 04B009 O-Ring, 2-155-V709-90
3 1 6390 7926 001B59 Ring, Choke, 6" Valve, Decoker.
4 1 B400 BBOO-004 046266 Disc, 6" Stainless
5 2 3570 B701 04BOI0 O-Ring, 2-14B-V709-90
6 1 B500 9243 001B37 Guide, Spindle, 6" Valve, Decoker.
7 1 5164 3720 001B61 Nut, Spindle, 6" Valve, Decoker
10 o 97B4 7457 Seal Kit, 6" Spindle Asm. Decoker Valve
Spindle Assembly, 3" Decoker Valve, Chrome Plated
Blwood Part Number 9794 7458
Refer to Elwood Drawing Number (EON) 057686
.
1 1 8517 0087 059060 Spindle, 3 in. Decoker, Chrome Plated
2 1 3570 7601 007567 O-Ring, 2-139-V709-90
3 1 6389 4816 001846 Ring, Choke, 3" By-Pass Valve, Decoker.
4 1 8400 5600-003 053037 Disc, 3" By-Pass Valve Decoker (SS)
5 2 3570 5623 007215 O-Ring, 2-130-V709 90
6 1 8500 9081 001834 Guide, Spindle, 3" By-Pass Valve, 6 x 3 Decoker.
7 1 5164 1570 001847 Nut, SI?indle, 3" By-Pass Valve, Decoker
10 0 9784 7458 Seal Klt, 3" Spindle Asm.,Decoker Valve, SS
Drain Valve Assembly, Decoker

.
1 1 160 7798 Valve, Ball, 1-1/4" NPT, Brass, Twin-Ear Handle
2 1 155 9450 Nipple, Pipe, 1-1/4" x 4-1/2", Schedule 40,
Galvanized Steel
3 1 155 9449 Plug, Pipe, Square Head, 1-1/4"
Riser Asm, HP., Decoker
1 1 1513 9019 059839 Riser Mach, HP, Decoker
2 1 2215 0257 048668 Bushing, 6" Spindle, Riser, Decoker
3 1 2215 0258 048669 Bushing 3", Spindle, Riser Decoker
4 2 6758 0012 049456 Screw, Tappet Lock, Decoker
5 2 302 7191 Nut, Jam, Hex, 1/2"-20 UNF2B Finished
6 1 2150 2764 060743 Bracket, Limit Switch, HP
7 2 278 2781 Screw, Socket Head Cap, 3/8"-16 NC-3 x 1"
Gearbox Asm., Hp, Decoker
1 1 1513 9020 002 Gearbox Asm., HP
2 1 6871 3516 048610 Shaft, Cam Shaft
3 1 3711 8651 001869 Gear, Spur, Decoker
4 2 539 9352 049617 Thrust Washer 90mm Dia. x .77mm Thk.
5 1 539 9351 049616 Thrust Bearing, 90mm Dia. Shaft
6 1 2250 0132 057386 Cam, 6" Decoker
7 1 4700 6815 048653 Key, 6 in. Cam, Decoker
8 1 541 4188 049164 Snap-Ring, Shaft 3.375, VS 337
9 2 539 9350 049614 Thrust Washer, 3" Dia. x .06 Thk.
10 1 539 9349 049613 Thrust Bearing, 3" Dia. Shaft
11 1 541 4187 049163 Snap-Ring, Shaft 3", VS-300
12 1 4700 6814 048652 Key, 3 in, Cam, Decoker
13 1 2250 0130 052069 Cam, 3 in. Decoker, Spain
14 1 541 4189 049912 Retaining Ring 2.875 Dia. Shaft, VS-287
15 1 4700 6813 048651 Key, Main Gear, Decoker
16 2 292 4580 Screw, Set, Socket Head, Dog Point, 3/8"-16
UNC-3A x 5/8" Lg. ANSI B18.3
17 1 541 4192 050054 Snap Ring, Spiral 3.38 Dia., WS-337
18 1 6871 3523 055975 Shaft, Encoder 12mm
19 1 3571 0866 008032 O-Ring, 2-243-V709-90 •
20 1 2215 0261 050144 Bushing, Encoder
21 1 724 9962 050147 Shaft Seal, Encoder
22 8 306 4467 Washer, Lock, Spring, American Std. Regular,
ANSI B27.1, 5/16"
23 8 277 4531 Screw, Hex Head Cap, 5/16"-18 NC-2 x 1" Lg,
ANSI B18.2.1 Gr.5,
24 1 6871 3515 048603 Shaft Pinion, Decoker
25 1 4700 6816 048654 Key, Pinion Gear, Decoker
26 1 3711 8580 001880 Gear, Drive, Decoker
27 4 539 9348 049611 Thrust Washer, 2" Dia. x .06 Thk.
28 2 539 9347 049610 Thrust Bearing, 2" Dia. Shaft
29 1 541 4193 050288 Snap Ring, Sprial WS 200
30 2 292 4556 Screw, Set, Socket Head, Full Dog Point,
3/8" 16 UNC 3A x 1/2" Lg. ANSI B18.3
31 1 3570 8002 O-Ring, 2-037-V709 90
32 1 2215 0265 050052 Bushing, Drive
33 1 723 4500 Seal, Oil, Decoker
34 1 3557 0937 049542 Gasket, Cover Plate Main Gear
35 1 2749 0365 049536 Cover, Access, Main Gear
36 36 277 4521 Screw, Hex Head Cap, 5/16"-18 NC-2 x 3/4" Lg,
ANSI B18.2.1 Gr.5,
37 2 3557 0936 049541 Gasket,Cover Plate Cam
38 2 2749 0366 049535 Cover, Access, Cam
39 1 3652 0012 Sight Gauge, 1-1/4" NPTF
40 1 9794 7471 Drain Valve Assembly, Decoker
50 o 9784 6594 048647 Seal Kit, Gearbox Asm, 6 X 3 Decoker Valve
Valve Asm., 6" 2500# RTJ, SS, HP, Decoker
Elwood Part NUmber 9794 7817
1 1 8357 4938 059570 Body, Decoker 6", 2500#-RTJ, SS, HP
2 1 6392 0058 059659 Retaining Ring, Lower Bushing, HP
3 2 726 0004 Seal, Cup, Resilon, 5-1/8 ID x 5-7/8 OD x .625
4 2 3571 3045 048005 O-Ring, 2-263-V709-90
5 2 8610 9961 042817 Ring, Back-Up (8 263 H1750)
6 1 2215 0320 059661 Lower Guide Bearing, HP
7 1 6358 7235 05980b Ring, Wiper, 5 1/8 I.D.
8 1 6342 3836 059637 Flange, Bottom, 6"/8", Decoker, HP
9 8 278 5634 Screw, Socket HD Cap, 1 1/2"-3 x 5 11 Lg., ASTM
574 / SA-574
10 2 3571 2702 048004 O-Ring, 2-259-V709 90
11 2 8610 9882 042817 Ring, Back-Up (8 259 H1750)
12 1 8477 3316 059662 Seat, 6"/ 8", Decoker, HP
13 1 9794 7457 057685 Spindle Assembly, 6" Decoker, Chrome Plated
14 1 541 4200 059801 Snap Ring, 6" Housing, VH-600, 302 SS
15 1 2215 0319 059660 Upper Guide Bearing, HP
16 1 726 0001 Seal, Cup, Resilon, 2.0 ID x 2.5 OD x .375
17 1 2343 0011 053943 Cap, Spring, Decoker
18 1 360 1783 053941 Spring, Med Heavy,2.0" x 1.0" x 12" Lg;
19 1 3571 4937 O-Ring, 2-454, 70D Buna-N.
20 1 3571 0539 O-Ring, 2-169, 70D Buna-N
21 1 2749 0423 059820 Cap, Spindle, 6/8 Decoker, HP
22 8 278 5734 Screw, Socket Head Cap, 1-1./2"-6 NC-3 x 9 1/2"
ASTM A574/SA-574
23 2 156 9029 059822 Plug, O-Ring, Hex Head, 7/16-20 UNF Straight
Thread ( #4 SAB )
24 16 7683 4849 004900 Stud, 6 x 3 Decoker
25 16 5149 0851 Nut, Hex, 2"-12UN, ASTM A-194 GR. 2H
26 2 300 1071 Nut, Hex, 1"-8 UNC2B, ASTM A563 Grade A, Heavy
Semi-Finished
27 2 318 0515 Bolt, eye, 1" x 2-1/2" Ig. (under eye), Size 10
28 1 154 0573 Elbow, 90 Degree, Street, 1/4" 125# W.P.
30 16 306 0093 Washer Flat, 2" Grade 8 preferred
34 0 9784 7457 Seal Kit, 6" Spindle Asm. Decoker Valve
35 0 9784 7817 Seal Kit, Main'Valve 6", Decoker Assembly, HP
Valve Asm., 3" Decoker, #300-RF, SS
1 1 8357 4937 059561 Body, 3" Decoker, 300#-RF, SS, HP
2 1 726 0002 Seal, Cup, Resilon, 2-7/8 ID x 3-3/8 OD x .375
3 3 3571 0866 008032 O-Ring, 2-243-V709-90
4 3 8610 9754 042817 Ring, Back-Up (8 243 H1750)
5 1 2215 0321 059752 Lower Guide Bearing, 3", HP
7 1 6342 3837 059655 Flange, Bottom, 3" Decoker Valve, HP
8 8 278 4610 Screw, Socket HD. Cap, 1"-8 NC-3 x 3-3/4" ASTM
A574/SA574
9 2 3571 0361 048011 O-Ring, 2-152-V709-90 _
10 2 8610 9715 042817 Ring, Back-Up (8 152 H1750)
11 1 8477 3295 049451 Seat, 3" Decoker
12 1 9794 7458 057686 Spindle Assembly, 3" Decoker Valve, Chrome
Plated
13 1 2215 0300 054464 Center Guide Bearing, 3"
14 1 726 0003 Seal, Cup, Resilon, 3.0 ID x 3.5 OD x .375
15 1 2215 0301 054465 Upper Guide, Bearing, 3"
16 1 3571 3138 O-Ring, 2-442, 70D Buna-N
17 1 3571 0887 O-Ring, 2-156, 70D Buna-N
18 1 726 0000 Seal, Cup, Resilon, 1.5 I~. x 2 OD x .378
19 1 360 1765 Spring, Compression, 1.25 O.D. x .625 I.D. x
10.0 In. Lg.
20 1 2749 0424 059821 Cap, Spindle 3, Decoker, HP
21 4 156 9029 059822 Plug, O-Ring, Hex Head, 7/16-20 UNF Straight
Thread ( #4 SAE )
22 8 278 4654 Screw, Socket HD. Cap 1"-8 NC-3 x 6" ASTM
A574/SA574
23 1 3571 0568 O-Ring, 2-240 V709-90
24 1 8365 0284 059751 Cap, Orifice Pak, 3" Decoker Valve HP
25 6 278 4594 Screw, Socket Head Cap, 1"-8UNC-2A x 3.0" Lg.,
ANSI B18.3
26 8 7666 0437 049634 Stud, 3/4-10UNC ASTM A-193 Gr B
27 8 306 0049 Washer, Flat, 3/4" USS, Zinc Plated
28 8 300 1052 Nut, 3/4-10UNC ASTM A-194 GR 2H
29 1 3570 7547 O-Ring, 2-227-V709-90
30 1 8365 0283 059636 Cap, Cross Port, 3" Decoker Valve
31 4 278 4084 Screw, Socket, HD. Cap, 3/4"-10UNC-3 x 2-1/2",
ASTM A-574/ SA-574
32 2 300 2071 Nut, Hex, 1"-8 UNC2B, ASTM A194 Grade 2H, Heavy
Semi-Finished
33 2 318 0515 Bolt, eye, 1" x 2-1/2" Ig. (under eye), Size 10
34 1 154 0572 Elbow, 90 Degree, 1/8" Street
52 o 9784 7458 Seal Kit, 3" Spindle Asm.,Decoker Valve, SS
53 o 9784 7818 Seal Kit, 3" By-Pass Valve, Decoker Asm., HP
Decoker Basic Asm, 6x3, 2500#-RTJ, SS, HP
1 1 9794 7822 059853 Lower Unit, Asm, 6" Decoker, HP
2 2 331 0755 Pin, Pull Dowel, 1/2" 1-1/4", w/1/4"-20 Tapped
Hole
3 1 9794 7817 059843 Valve Asm., 6"-2500# RTJ, SS, HP, Decoker
4 1 9794 7818 059844 Valve Asm., 3" Decoker, #300-RF, SS
5 14 278 4329 Screw, Socket Head Cap, 7/8"-9 NC-3 x 2-1/4"
Lg. ANSI B18.3
6 1 3571 0449 O-Ring, 2 339 V709-90
7 4 7666 8895 052276 Stud, 1 1/4" 12 UNF-2A x 17.50 LS.
8 4 300 1241 Nut, Hex, ASTM A-194 GR. 2H, 1 1/4-12 UNF-2B
9 11 306 4464 Washer, Lock, Spring, ANSI B27.1, 1/4", Zinc
Plated
10 11 277 4261 Screw,Hex HD Cap, 1/4"-20UNC-2x 1/2"LG, GR5,
Zinc Plated
11 1 2749 0425 059830 Cover, Riser Front, Decoker, HP
12 1 5426 3119 049662 Pin, 3" Spindle/Valve
13 8 306 0921 049697 Washer, Fender, 3/8" x 1 1/4" OD
14 2 277 4766 Screw, Hex Head Cap, 3/8" 16 NC-2 x 5/8" Lg,
ANSI B18.2.1 Gr.5,
15 1 5426 3123 059850 Pin, Main Valve, Decoker, HP
16 2 266 0045 Screw, Button, Head, Cap, 5/16 18 x 1/2 Lg.
17 1 2749 0426 059900 Cover, Riser Rear, Decoker, HP
18 1 3531 8235 Gasket,Spiral wound(w/Inner Ring)304SS 3"-300#
19 2 3557 0935 Gasket, Ring Joint, R47, Steel Octagonal
20 1 330 6750 051517 Dowel Pin, .5002 x .75 Lg.
21 1 279 6220 Screw, Socket Head Cap Flat, 1/4 20unc 2A x 2.0
Lg.
22 1 302 5011 Nut, Hex, 1/4"-20 UNC2B, Finished ANSI B18.2.2
Lower Unit, Asm, 6" Decoker, HP
1 1 9794 7814 059838 Riser Asm, HP., Decoker
2 1 9794 7815 059833 Gearbox Asm., Hp, Decoker
3 2 331 0755 Pin, Pull Dowel, 1/2" 1-1/4", w/1/4"-20 Tapped
Hole
6 1 9794 6590 049567 Tappet Assembly, 6in.
7 1 9794 659l 049596 Tappet Asm. - 3 in.
8 20 306 0920 049632 Washer, Sealing 3/4"
9 20 278 0109 Screw, Hex HD Cap, 3/4"-16UNF-2B x 2.0 LG.,
GR5, Zinc Plated
10 1 2188 0057 004894 Cap Assembly, Filler, 6 x 3 Decoker
11 6 278 6016 Screw, Socket Head Cap, #10-32 UNF x 5/8"
12 2 7666 8917 061054 Stud, Self Lockin$, 3/8-16 x 1.25 Lg.
13 2 306 4471 Washer, Lock, Spr1ng, Zinc Plated, ANSI B27.1,
3/8"
14 4 302 5021 Nut, Hex, 3/8"-16 UNC-2B, Zinc Plated, ANSI
B18.2.2
Orifice Pack Assembly
1 1 9794 8512 064137 Orifice Assembly, Decoker, First Stage
2 3 9794 8513 064138 Orifice Assembly, Decoker, Middle Stage
3 1 9794 8514 064139 Orifice Assembly, Decoker, Final Stage
5 12 293 4641 Screw, Set, Socket Head, Cup Point, #10-32
UNF-3A x 5/16" Lg.
10 0 9784 7830 Seal Kit, Orifice Pack Asm.
Reducer Asm., 1.5 HP, 50 Hz, 380 V, Reliance/Baldor
1 1 2150 2763 060483 Bracket, Gear Reducer
2 6 278 0109 Screw, Hex HD Cap, 3/4"-16UNF-2B x 2.0 LG.,
GR5, Zinc Plated
3 6 306 0049 Washer, Flat, 3/4" USS, Zinc Plated
Plated
5 1 6103 0910 060492 Gear Reducer, 1.5 HP, 56C, 200:1
6 1 5021 0143 063852 Motor, Electric, 1.5 HP, 1000 RPM, 380 V,
Reliance, Class I, Div II
7 4 278 2781 Screw, Socket Head Cap, 3/8"-16 NC-3 x 1"
8 4 7062 0128 057357 Shim Pack, Decoker
9 6 277 5831 Screw, Hex HD Cap, 5/8-11UNC-2 x 2 1/2 LG.,
GR5, Zinc Plated
10 12 306 0044 Washer. Flat, USS, 5/8", Zinc Plated
Plated
12 6 302 5041 Nut, Hex, 5/8" 11 UNC-2B Zinc Plated
13 1 3806 2912 004884 Guard, Decoking Unit
Plated
15 4 277 4261 Screw, Hex HD Cap, 1/4"-20UNC-2x 1/2 Il LG, GR5,
Zinc Plated •
16 3 029 6120 Key Stock, Square, 1/2" Oversize
17 1 2688 1067 060563 Shaft Coupling, 2 1/8 x 1 3/4
18 1 279 8103 Screw, Socket Head Cap. Flat, 5/16"-18 UNC-2B
L.H Thread x 1" Lg.
Orifice Assembly, Decoker, First Stage
1 1 8511 0575 057504 Sleeve, Orifice Pack, Deocker, First' Stage
2 1 5827 0715 063904 Orifice Disc, Small, 0.633 Area, 1 Hole
3 1 5827 0714 063903 Orifice Disc, Medium, 0.633 Area, 4 Holes
4 1 5827 0716 063905 Orifice Disc, Large, 0.633 Area, 3 Holes
5 1 3570 7540 048017 O-Ring, 2-137-V709-90
6 2 8610 8613 042817 Ring, Back-Up (8 137 H1750)
Orifice Assembly, Decoker, Middle Stage
1 1 8511 0576 057505 Sleeve, Orifice Pack, Decoker, 2nd &. 3rd
3 1 5827 0714 063903 Orifice Disc, Medium, 0.633 Area, 4 Holes
4 1 3570 7540 048017 O-Ring, 2 137-V709 90
5 2 8610 8613 042817 Ring, Back-Up (8 137 H1750)
Orifice Assembly, Decoker, Final Stage
1 1 8511 0584 060446 Sleeve, Orifice Pack, Decoker, Final' Stage
2 1 5827 0714 063903 Orifice Disc, Medium, 0.633 Area,. 4 Holes
3 1 3570 7411 053608 O-Ring, 2-226-V709-90
4 2 8610 8608 042817 Ring, Back-Up (8 226 H1750)
11-15-13 RECOMMENDED SPARE PARTS LIST
Decoking Control Valve, Basic Unit, 6"x 3"
Prices shown below subject to change.
ELWOOD Recom'd List Description
PART Spares Price
NUMBER Qty US$
539 9343 2 55.48 Cam Follower 3/4" Dia.
539 9344 2 66.35 Cam Follower 5/8 Dia.
726 0000 1 76.58 Seal, Cup, Resilon, 1.5 ID. x 2 OD x .378
726 0001 1 78.51 Seal, Cup, Resilon, 2.0 ID x 2.5 OD x .375
726 0002 1 104.65 Seal, Cup, Resilon, 2 7/8 ID x 3-3/8 OD x .375
726 0003 1 91.73 Seal, Cup, Resilon, 3.0 ID x 3.5 OD x .375
726 0004 2 241.21 Seal, Cup, Resilon, 5 1/8 ID x 5-7/8 OD x .625
3535 0065 2 21.40 Gasket, Crush, Decoker Orifice Pak
3535 0065 1 21.40 Gasket, Crush, Decoker Orifice Pak
3570 5623 2 2.85 O-Ring, 2-130-V709 90
3570 7411 1 6.77 O-Ring, 2-226-V709-90
3570 7411 1 .6.77 O-Ring, 2-226-V709-90
3570 7540 3 3.92 O-Ring, 2-137-V709-90
3570 7547 1 6.15 O-Ring, 2-227-V709 90
3570 7601 1 4.08 O-Ring, 2-139-V709 90
3570 8701 2 5.00 O-Ring, 2-148-V709-90
3571 0361 2 6.69 O-Ring, 2-152-V709-90
3571 0449 1 13.26 O-Ring, 2-339 V709-90
3571 0539 1 6.31 O-Ring, 2-169, 70D Buna-N
3571 0568 1 10.86 O-Ring, 2-240 V709 90
3571 0650 1 8.44 O-Ring, 2-155-V709 90
3571 0866 3 14.85 O-Ring, 2-243-V709-90
3571 0887 1 2.92 O-Ring, 2-156, 70D Buna-N
3571 2702 2 14.03 O-Ring, 2-259-V709-90
3571 3045 2 48.29 O-Ring, 2-263-V709-90
3571 3138 1 8.86 O-Ring, 2-442, 70D Buna-N
3571 4937 1 13.33 O-Ring, 2-454, 70D Buna-N
6342 3837 1 625.31 Flange, Bottom, 3" Decoker Valve, HP
6358 7225 1 10.50 Rod Wiper, 3.375 Dia. Rod, Type D
6358 7235 1 45.60 Ring, Wiper,S 1/8 I.D.
6389 4816 1 947.52 Ring, Choke, 3" By-Pass Valve, Decoker.
6390 7926 1 1372~68 Ring, Choke, 6" Valve, Decoker.
8400 5600-003
1 252.00 Disc, 3" By-Pass Valve Decoker ,{SS)
8400 8800-004 1 420.00 Disc, 6" Stainless
8477 3295 1 3391.39 Seat, 3" Decoker
8477 3316 1 5068.00 Seat, 6"/ 8", Decoker, HP ***OBSOLETE***
8610 8608 2 3.46 Ring, Back-Up (8 226 H1750)
8610 8608 1 3.46 Ring, Back-Up (8- 226 H1750)
8610 8613 6 3.39 Ring, Back-Up (8- 137 H1750)
8610 9715 2 5.08 Ring, Back-Up (8- 152 H1750)
8610 9754 3 5.77 Ring, Back-Up (8 243 H1750)
8610 9882 2 ·8.81 Ring, Back-Up (8 259 H1750)
8610 9961 2 12.85 Ring, Back-Up (8- 263 H1750)
9784 6594 1 340.00 Seal Kit, Gearbox Asm, 6 X 3 Decoker Valve
9784 7457 1 260.00 Se<\l Kit, 6" Spindle Asm. Decoker Valve
9784 7458 1 200.00 Seal Kit, 3" Spindle Asm.,Decoker Valve, SS
9784 7817 1 1071.00 Seal Kit, Main Valve 6", Decoker Assembly, HP
9784 7818 1 540.00 Seal Kit, 3" By-Pass Valve, Decoker Asm., HP
9784 7830 1 60.00 Seal Kit, Orifice Pack Asm.
9794 6592 1 691.00 Roller Asm, 3 in. Dia.
9794 6593 1 632.00 Roller Asm. 2 1/2" Dia.
9794 7457 1 13120.00 Spindle Assembly, 6" Decoker, Chrome Plated
9794 7458 1 6880.00 Spindle Assembly, 3" Decoker Valve, Chrome
Plated
9794 8510 1 6880.00 Orifice Pack Assembly
INSPECTION AND TEST PLAN I.T.P. NUMBER EDN 064323 9796 0288 REV. 1 PAGE 1 OF 6
Decoker Control Valve VENDOR NAME Elwood Corporation DATE 7/15/13

Doc. – No. TBD 9794 8070 (EDN 061219)
P.O. NUMBER 4460000785 VALVE TYPE ITEM NO PROJECT NO. SIGN Tony Burch
1
6" x 3" Decoker N.A. 33311 LEGEND :
Pertamina H: HOLD POINT
For Hydraulic Jet W: WITNESSED POINT
O: OBSERVED POINT
R: REVIEW OF DOCUMENT
REQUIRED
DECOKING VALVE
NO. INSPECTION AND TEST REFERENCE DOCU. ACCEPTANCE Vendor Purchaser Third Party RECORDS REMARKS
DESCRIPTION SPEC/DWG./STD CRITERIA (Elwood) (Pertamina)
P (procedure) etc. H/W/R/O H/W/R/O H/W/R/O
A Valve Body -- Main Valve
Mill test certificate

A1 Material Certificate R EN 10204 3.1
TEST METHODS
X-Ray Emission PREFORMED BY
Material Standard SERVICE
X-Ray Fluorescent Spectrometry Test certificate
A2 PMI-Test Specification R PROVIDER AT
Optical Emission Spectrometry Wet EN 10204 3.1
Chemical Analysis ASME / ASTM ELWOOD
FACILITY
ASME SECTION VIII

ASME SECTION VIII DIV 2 DIV 2 Test certificate
A3 UT R EN 10204 3.1
AM-203, 2004 Edition Add 2 AM-203, 2004 Edition
Add 2
1
HOLD means that a hold will apply to the production of the parts within the scope of the test or inspection until the test or inspection is satisfactorily performed. WITNESSED means that a hold will apply to the
production schedule, and the test or inspection will be carried out with the purchaser or his representative in attendance. OBSERVED means that the vendor will be notified of the timing of the inspection or test;
however, the inspection or test will be performed as scheduled, and if the purchaser or his representative is not present, Elwood will precede to the next step. REVIEW OF DOCUMENTS means that the test or
inspection records will be reviewed. The Column where the entry is made indicates by whom the test or inspection will be performed (H) / witnessed (W) / observed (O), or by whom the test or inspection records
will be reviewed (R).

Doc. – No. TBD 9794 8070 (EDN 061219)
A4 Dimension control and visual Production drawings Drawing dimensions H

examination of machined parts
B Gland Flange -- Main

Valve
B1 Material Certificate R EN 10204 3.1
B2 Dimension control and visual Production drawings Drawing dimensions H
C Seat -- Main Valve
C1 Material Certificate R EN 10204 3.1
TEST METHODS PREFORMED BY
X-Ray Emission Material Standard SERVICE
Test certificate
C2 PMI-Test X-Ray Fluorescent Spectrometry Specification R PROVIDER AT
EN 10204 3.1 ELWOOD
Optical Emission Spectrometry Wet ASME / ASTM
Chemical Analysis FACILITY
Dimension control and visual Production drawings Drawing dimensions H
C3 examination of machined parts
D Spindle -- Main Valve

D1 Material Certificate R EN 10204 3.1

X-Ray Emission Material Standard SERVICE
Test certificate
D2 PMI-Test X-Ray Fluorescent Spectrometry Specification R PROVIDER AT
EN 10204 3.1 ELWOOD
Optical Emission Spectrometry Wet ASME / ASTM
Chemical Analysis FACILITY
D3 examination of machined parts
1

Doc. – No. TBD 9794 8070 (EDN 061219)
NO. INSPECTION AND TEST REFERENCE DOCU. ACCEPTANCE Vendor Purchaser Third RECORDS REMARKS
DESCRIPTION SPEC/DWG./STD CRITERIA (Elwood) (Pertamina) Party
P (procedure) etc. H/W/R/O H/W/R/O
H/W/R/O
E Top Cap -- Main Valve

E1 Material Certificate R EN 10204 3.1
E2 Dimension control and visual Production drawings Drawing dimensions H
F Valve Body - By-Pass Valve

F1 Material Certificate R EN 10204 3.1
Material Standard SERVICE PROVIDER
X-Ray Emission Test certificate AT ELWOOD
F2 PMI-Test Specification R
X-Ray Fluorescent Spectrometry EN 10204 3.1 FACILITY
Optical Emission Spectrometry ASME / ASTM
Wet Chemical Analysis
ASME SECTION VIII
ASME SECTION VIII DIV 2 DIV 2 Test certificate
F3 UT R EN 10204 3.1
AM-203, 2004 Edition Add 2 AM-203, 2004 Edition
Add 2
F4 Dimension control and visual Production drawings Drawing dimensions H
1

Doc. – No. TBD 9794 8070 (EDN 061219)
G Gland Flange – By-Pass Valve
G1 Material Certificate R EN 10204 3.1
G2 Dimension control and visual Production drawings Drawing dimensions H
H Spindle – By-Pass Valve
H1 Material Certificate R EN 10204 3.1
TEST METHODS
PREFORMED
X-Ray Emission Material Standard BY SERVICE
Test certificate
H2 PMI-Test X-Ray Fluorescent Specification R PROVIDER AT
Spectrometry Optical EN 10204 3.1 ELWOOD
ASME / ASTM
Emission Spectrometry FACILITY
H3 examination of machined parts
I Seat -- By-Pass Valve
I1 Material Certificate R EN 10204 3.1
TEST METHODS
PREFORMED
X-Ray Emission Material Standard BY SERVICE
Test certificate
I2 PMI-Test X-Ray Fluorescent Specification R PROVIDER AT
Spectrometry Optical EN 10204 3.1 ELWOOD
ASME / ASTM
Emission Spectrometry FACILITY
I3 examination of machined parts
1

Doc. – No. TBD 9794 8070 (EDN 061219)
NO. INSPECTION AND TEST REFERENCE DOCU. ACCEPTANCE Vendor Purchaser Third RECORDS REMARKS
H/W/R/O
J Top Cap -- By-Pass Valve
J1 Material Certificate R EN 10204 3.1
J2 Dimension control and visual Production drawings Drawing dimensions H
K Cap Orifice -- By-Pass Valve

K1 Material Certificate R EN 10204 3.1
K2 Dimension control and visual Production drawings Drawing dimensions H
L Motor
L1 Material and test certificates motor spec Reliance/Baldor R certificates according to be supplied by
EN 10204 3.1 motor vendor
1

Doc. – No. TBD 9794 8070 (EDN 061219)
NO. INSPECTION AND TEST REFERENCE DOCU. ACCEPTANCE Vendor. Purchaser Third RECORDS REMARKS
H/W/R/O
M Testing
Material Certificate for Pressure Mill test certificate
M1 Retaining Components R R EN 10204 3.1
M2 Preliminary Functional Test Test Procedure H O Test Report
M3 Functional Test H O Test Report
Hydrostatic Test Test certificate

M4 Hydrostatic Test Test Procedure H O EN 10204 3.1
Spécification
N Final Inspection
check of completeness /
N1 visual examination H R REPORT
check of name plates, labels, tags

N2 or signs
Basic Unit Drawing H R REPORT
N3 control of main dimensions Basic Unit Drawing drawing dimensions H R REPORT
Quality Control Manufacturing Dossier

N4 of The Complete Supply H R Report (Job Book)
N5 Inspection Release Certificate SEE REF. DOC. H R REPORT
N6 Paint Inspection H R REPORT
N7 Spare Parts Verification PURCHASE ORDER H R REPORT
1
OPE
ERATIO
ON & MAINT
M TENAN
NCE IN
NSTRUCTION
N
Elwo
ood Decoki
D ing Coontroll Valvve
TABLE OF CONTENT
TS PAGE
SPECIFICA
ATIONS…… …………………………
……………… ………………
………………
…….. 2
SAFTEY SE
ECTION…… ………………
………………………… ………………
…………………. 3
INTRODUC
CTION………………… ………………
……………… …………………………
……… 4
INSTALLA
ATION………
…………………………
………………
………………
…………………. 6
APPROVED
D LUBRICA …………………………
ANTS ……… ………………
………………
……... 7
START-UP
P……………
……………… …………… ……………
……………… ………………
……… 8
DECOKING
G CYCLE ………………
… …………………………
………………
………………
………9
TROUBLE SHOOTING
G GUIDE………………
………………
………………
…………………. 10
DECOKING
G CONTROOL VALVE SERVICE
S STRUCTURE
E
A. REMOVAL
R OF VALVEES………… ……………… …………………………………….. 12
B. REPAIR
R MA
AIN VALVEE ……………………… ……………………………………... 14
C. REPAIR
R BY
Y-PASS VAL
LVE…………………… …………………………………….. 23
D. REPLACEM
R MENT OF VALVES…… ……………… …………………………………. 34
STORAGE PROCEDUURE
A. SHORT TERM STORA
AGE…………
……………
………………
………………
……… 37
B. LONG
L TERM
M STORAG
GE…………
………………
……………… ……... 39
………………
INSTALLA
ATION AND
D MAINTEN
NANCE MA
ANUAL……
………………
………………
……... 43
9796 0260
0608552 REV B
1
Speciification
ns Elwo
ood Deccoking Controol
Maximum Allowable
A Working
W Prressure: 429.9 bars @ 200° C
Maximum Allowable
A Flow
F Main Valve:
V M
2000 GPM
Maximum Allowable
A Flow
F By-Passs Valve: 680 GPM
Water temp
perature
Normal:
N 190° F
Maximum:
M 210° F
Internal Wetted
W Parts:: Stainless Steel
Main Valvee Sealing Material:

M Stainless Steel
aling Materrial:
By-Pass Sea Stainless Steel
Body Material: Forged Staainless Steell
Main Valvee Flange Co

onnection: ASA 2500## Ring Jointt
By-Pass Va
alve Flange Connection
n: ASA 300# R
Raised Facee
Maximum Stainless Stteel mum Pa

article Size: 5.0 mm
2
SA
AFETYPRECAUTIONS
SAFETY PR
RECAUTTIONS
Before usingg this equipm

ment, read thhis manual completely
c aand thoroughhly, understaand its operatting
procedures, safety warnnings and maaintenance reequirements.. Only qualiified personnnel trained oon the
construction
n and operatiion of this eq
quipment annd the hazardds involved sshould installl, adjust, opperate
and/or service this equip
pment.
3
INTRO
ODUCTIO
ON
The Elwood d Decoking Control

C Valvve is designeed and built ffor use in a hhydraulic deecoking systeem
found in pettrochemical refineries.
Hydraulic decoking
d uses high pressuure, high volume water jjets to removve coke from m a given cooke
chamber. During
D a typical decoking g operation, it is necessaary to stop thhe flow of water to the jeets
and divert th
his water to a by-pass lin
ne back to a tank. This iis done to avvoid frequentt starting andd
stopping of the pumps, while
w providding a recircu w through thee pumps, thuus removing heat.
ulating flow
The purposee of the Elwo

ood Decokinng Valve is to
t control thee water flow
w from the deecoking jet
pumps while providing these featurees:
 Wheen in the by-p

pass mode, there
t is a verry tight shutt-off of waterr to the decooking nozzlees,
whille providing a predeterm
mined flow raate through ththe valve to bbe diverted bback to the ttank,
thus removing heat build-up for pump prrotection.
 At thhe start of a decoking cy

ycle, a time delay
d allows for a throttlling action thhrough the vvalve
befoore full flow is achieved. This throttlling action ppermits the w
water columnn to the jets tto
fill up
u gradually and virtually eliminatess water hamm mer in the puumps and pipping.
 Duriing full flow

w through thee valve for maximum
m deccoking, theree is a minim
mum pressuree
drop
p through thee valve.
The Elwood d Decoking unit

u consists of a Main anda By-Pass valve whichh are synchroonized 180°
apart. It is operated
o by a motor-driv
ven cam mecchanism. W When one valvve is open, tthe other valvve is
closed. Vallve open or closed
c status is monitoreed by externaally mountedd sensors whhich are actuuated
by the valvee spindle assemblies. Thhe unit is sup
pplied with oor without thhe complete electrical coontrol
system, depending on th he user’s app
plication. Caam position is monitoredd 360° usingg an encoderr.
The present standard connection sizzes available are 8ʺ x 3ʺ aand 6ʺ x 3ʺ.
4
Design Feeatures
Valve spinddle acceleratiion and deceeleration is positively,

p mechanically controlled. This helps
m
eliminate pipe line shock and limits the periods of high fluidd velocity inn the seat areea during inittial
opening andd closing, extending the life
l of the in nternal compponents.
No upstreamm strainer is required, beecause the vaalves are nonn-clogging ddesign. How wever, it is allways
desirable to limit the sizze of coke finnes in the syystem to maxximize the coomponent liffe of the valvves.
Depending ono what valv ve is used, itt is possible to
t pass cokee fines up to 10mm diam
meter at full oopen.
However, th his is not recommended at a any time.
A by-pass orifice
o assem
mbly is offereed as a stand
dard feature. The purposse of the oriffice is to
“breakdown n” the pump recirculating g system preessure beforee dischargingg to atmosphhere pressuree.
This orifice is sized to th
he user’s req
quirements. The orifice assembly is a “throw-aw way” cartridgge
design and is
i mounted inside the by y-pass valve.
All valves use

u stainless steel discs and
a hardened d stainless stteel seats to pprovide a
drop-tight seeal. The discs are symm
metrical and can
c be “reveersed” and used again beefore needingg
replacementt.
The Main annd By-Pass valves

v can be
b completely
y disassembbled and rebuuilt without rremoving eitther
valve body from
f the pip
ping system.
The drivetraain, which in

ncludes the cams,
c gears, shafts and bbushing, runss immersed iin an oil bathh and
is virtually maintenance
m e-free.
n be supplied
The unit can d with, or wiithout, limit switches an d rotary encoder for monnitoring the
valve positio
on.
5
INSTA
ALLATIO
ON
As shipped from the facctory, the Elw

wood Decok
king Control Valve is com
mpletely tessted and readdy for
installation in the Decok
king system..
It is recomm
mended the unit
u be installled accordin
ng to the folllowing proceedures.
Foundation n Requiremeents
The unit shoould be mounted on a sm mooth flat su
urface, and seecured usingg the mounting hole provvided
in the lowerr base plate (refer
( to Elw
wood Foundaation Drawinngs 9794 79770 or 9794 77732).
Piping Requuirements
Connect thee Main pipe lines
l to the Main
M valve using
u ASA Ring JJoint flanges or ASA Raiised
either A
Face flangess. Flanges are
a not includ ded.
Connect thee By-Pass pip

pe line to thee By-Pass vaalve using ann ASA Raiseed Face flange. Flanges are
not included
d.
Lubricant Requirement
R ts
The Elwood d Decoking Valve
V drive system conssists of two ddifferent drivve systems. The first is a
right angle reducer.
r Thee second is an
a integrated d drive syste m manufacttured by Elwwood. Both
systems requuire proper maintenance
m e of the lubriicant system
m.
Right Anglee Reducer

Check the oil
o level in th
he right anglee reducer. Remove
R the pplug locatedd on the side of the reduccer
jjust below th
he motor flaange. If the oil
o level is lo
ow, add lubrricant as requuired. Refer to Table 1 ffor
recommended lubricant and capacities.
Elwood Drivve System

i visible in tthe sight gauuge, located on the side oof
Fill the loweer Gear casee with oil unttil the level is
the Gear casse. The oil filler
f is locatted on the topp deck platee near Main vvalve by the reducer. Reefer
to Table 1 for
fo recommen nded lubricaants and capaacities.
Electrical Requirement
R ts
Refer to mootor nameplaate or manufaacturer’s sch
hematic provvided with thhe unit.
Ensure all wiring

w compllies with all national, staate and local electrical coodes.
After wiring
g, use the maaintenance mode
m to jog the
t electric m
motor to ensuure proper rootation
according to
o rotation decal located on
o lower Gear case.
6
TABLE 1
App
proved Lubriccants
Riight Anglle Reduccer
Ambient
A AGMA ISO Viscossity Oil M
Maintenance
Tempe
erature °C (°F) Lu
ubricant No. Grade Capaccities Intervals
‐40 to ‐10 (‐25 tto 125) 7S ISO 460SS 7.9 L (8
8.4 Qts) ①
NOTE:
Pour p
poi nt of l ubri ca nt s houl d b
be a t l ea s t 5°C
C (9°F) l ower t ha n the expe cted
mi ni mum a mbi en t s ta rti ng tem
mpera ture.
di ca tes s ynth eti c ba s e fl ui ds

S ‐ Ind
① ‐ F
Fi rs t oi l cha ng ea rs ; then a t l ea s t every th
ge a fter two ye hree yea rs the
erea fter.
Recommen
nded Synthe
etic Productss
Mobil Gear S
SHC 634
Elwood G
E Gear Case
e
Ambient
A AGMA ISO Viscossity Oil M
Maintenance
Tempe
erature °C (°F) Lu
ubricant No. Grade Capaccities Intervals
‐40 to ‐10 (‐40 tto +14) 3S ISO 15S 129 L (3
34 Gal) ②
‐10 to 10 (14 to
o 50) 4 ISO 150 130 L (3
34 Gal) ②
10 to 35 (50 to
o 95) 6 ISO 320 131 L (3
34 Gal) ②
35 to 55 (95 to
o 131) 7 ISO 460 132 L (3
34 Gal) ②
‐30 to 60 (‐22 tto 140) 6S ISO 320SS 133 L (3
34 Gal) ②
NOTE:
AGMA
A l ubri ca nt nu mbers l i s ted a bove a re fo r hi gh qua l i tyy Rus t a nd Oxi da ti on i nhi bii ted gea r oi l s
Pour p
poi nt of l ubri ca nt s houl d b C (9°F) l ower t ha n the expe cted
be a t l ea s t 5°C
mi ni mum a mbi en t s ta rti ng tem
mpera ture.
di ca tes s ynth eti c ba s e fl ui ds
S ‐ Ind
② ‐ F
Fi rs t oi l cha ng yea rs ; then a t l ea s t every th
ge a fter one y hree yea rs the
erea fter.
Recommen
nded Synthe
etic Productss
Mobil Gear S
SHC 632
Castrol Tribo
ol 1510
Shell Omala
Viscosity
y Ranges ffor AGMA
A Lubrican
nts
Viscosity R
Range AGMA ISO Viscossity
mm2/s (cS St) @ 40°C Lu
ubricant No. Grade
135 to 165
1 4 ISO 150
198 to 242
1 5 ISO 220
288 to 352
2 6 ISO 320
414 to 506
4 7 ISO 460
Note: Per IS
SO 3448, Induss tri a l Li qui d Lubri ca nts ‐ ISO
O Vi s cos i ty Cl a s s i fi ca ti on
7
STA
ART UP
1. Befoore starting the jet pumpss, make suree that the Maain Valve is closed, and the By-Pass
Valvve is opened. The limit switches
s sho
ould be interl rlocked with the pump sttart circuitryy so
that the pumps will
w not start unless the valves
v are in the correct pposition.
2. With
h the pumps running, iniitiate a decok
king cycle too check the ooperation of each valve.
3. Mak ke sure that as

a the fluid media
m is intro
oduced, the vvalve spindlles move freely downwaard,
follo
owing the cam profile.
t no excessive noises are present during a cyccle.

4. Checck for smootthness of opeeration and that
Note: A slig
ght click ma
ay be heard just
j after thee Main Valvve is open alll the way an
nd begins too
close. This is normal – due to load
d reversal in the gear traain.
5. Checck for any fluid leaks aro

ound the top
p caps and thhe spindles bbelow each vvalve.
8
TYPIC
CAL DEC
COKING
G CYCL
LE
The Decokin
ng process begins
b with the
t By-Pass Valve open,, the Main V
Valve closed and the pum
mp or
pumps on.
Typiical Steps in
n the Decoki
king Cycle
Operator depresses the Decoker

D starrt button.
The drive motor

m starts and
a the cam shaft
s starts to rotate.
By-Pass starrts to close and

a the Main
n valve startss to open.
Valve drive motor stopss when the main

m valve reeaches the prrefill positioon for a predeetermined tim
me.
The valve motor

m starts and
a continuees to closes th
he By-Pass V
Valve. The Main Valvee continues to
opening unttil it reaches full open po
osition.
The full flow

w of the pum
mp at the rateed working pressure
p in nnow availablle for Decokking operatioon.
After complleting the Deecoking cyclle, the valve motor startss and the cam
m shaft rotattes back to thhe
start position
n. The Mainn spindle clo
oses and the By-Pass Vaalve opens. A All of the floow is directeed
through the By-Pass vallve and Breaakdown orifice assemblyy.
9
TROU
UBLESHO
OOTING GUIDE
SYM
MPTOM POSSIBLE CAUSES REM
MEDY
Fluid leaks att Spindle Cap 1. Worrn cup seal in Spindle
S Cap 11. Replace
2. Worrn cup seal Upper Guide Beaaring 22. Replace
3. Hex
x Plug not tightt 33. Check and ttighten
Fluid leaks frrom Lower Flaange Worn Lower
L Cup Seaal R
Replace
Fluid leaks att Flange Joint 1. Ring
gs not seated properly
p 11. Check and / or replace
2. Loo
ose hex nuts onn flanges 22. Check and / or replace
Fluid leaks att Cutting Jets
during By-Paass Mode 1. Worrn Disc in Main Valve 11. Check and / or replace
2. Worrn Valve Seat in
i Main Valve 22. Check and / or replace
Fluid leaks back to Sump
during Decok king Mode 1. Worrn Disc in By-P
Pass Valve 11. Check and / or replace
22. Tighten nuts on By-Pass
2. Worrn Valve Seat in
i By-Pass Vallve VValve
Fluid leaking
g between the Main
M 1. Valvves not seated correctly; boltts are not 11. Check and /oor replace
and By-Pass Valve tight en
nough
2. Worrn O-Ring in groove
g on Mainn Valve 22. Check and / or replace
Excessive waater hammer on
n Worn Upper Choke Ring
R C
Check and /or rreplace
Valve openin
ng
Excessive waater hammer on
n Worn Upper
U Choke Ring
R C
Check and /or rreplace
Valve closing
g
Valve Spindlle hangs up 1. Spin
ndle Assembly
y bent 11. Remove andd check
22. Disassemblyy and check
2. High friction betw
ween packing annd spindle bbearing
bbearing surfacees for
ssmoothness
3. Inteernal clearance between compponents 33. Remove andd check

too tighht
4. Obsstruction on Vaalve Seat preveenting Disc 44. Disassemblee and check
from seeating properlyy
5. Hyd draulic fluid do
oes not reach thhe Upper 55a. Check Spinndle bore
Cap cyylinder 55b. Check Fluiid leakage out of
uupper cavity
Excessive No
oise in gear traiin 1. Worrn gears, bushiings, cams, tapppet rollers DDisassemble annd check all
or moto
or coupling ccomponents
11. Check motoor coupling
Valves timing
g incorrect 1. Geaar motor rotatio
on reversed rrotation
2. Enccoder not set properly 2. Check encooder setting at

ttop dead centerr 200°-205°
Jet pumps wiill not start 1. Lim
mit Switch signaal not present CCheck and adjuust all limit
sswitches for prroper actuation
10
VALVE SERVIC
CING
The Elwood d Decoking valve
v is designed to inco
orporate threee major asseemblies: Thhe Main valvve
assembly, By-Pass
B Valvve assembly and lower unit.
u Becaus e the valve cconsists of a number of ssub-
assemblies, the manual is designed to
t present th
he overall vaalve in an outtline format including thhe
following:
 Writtten service procedures

p for
f valve rem moval and seeal replacem ment
 Asseembly drawings for all su ub-assemblies
 Partss list outlinin
ng all the serrviceable parrts required for repair.
A lifting kit 9920-7185 is available from the maanufacturer. The kit inclludes the toools required tto
assist in the lifting and removal
r of in
nternal valvee component
nts, except foor the seat replacement.
WARNING
WAR
RNING
Refer to the safety sectio
on of this manual beforee proceedingg with any mmaintenance oor repair of tthis
equipment. Carefully reead and follo ow all instru
uctions in this manual. Faailure to com
mply may ressult
in personal injury
i and /o
or property damage.
d
BASIC
DECOKER
A
ASSEMBLY Y
ELECTTRIC
LOOWER MAIN BY‐PA
ASS MOTO OR
U
UNIT VALVE VALV
VE
ASSSEMBLY A
ASSEMBLY ASSEMBBLY
TAPPET TAPPPET SPINDLE SPINDLE

ASSEMBLYY ASSEM
MBLY A
ASSEMBLY ASSEMBBLY BY‐‐PASS
MAIN BY‐PA
ASS GEA ARBOX MAIN BY‐PA
ASS OR
RIFICE
VALVE VALV
VE ASSSEMBLY VALVE VALV
VE ASSEEMBLY
11
Repairr Procedure – Rem
moval oof Valvves
The followin
ng maintena
ance proced
dures outlinee the steps reequired to reemove the B
By-Pass andd
Main valve assembly.
Valve Removal
R l: By-Pa
ass and Main
M Vaalves
Disconnectiing the Valvve Spindles from
f Tappett Assembly
Refer to Deecoker Basicc Valve Assembly draw
wing (Figuree 2).
Manually rootate the vallve using thee hex drive located
l on th
he end of thhe electric motor. Positiion
the By-Passs valve so thee connectingg pin is loca
ated in the ceenter of the access holee on the side of
the riser.
Decoker Valv
ve Basic Asssembly
Figure 2
Remove scrrews (9), wasshers (10), and

a access co over panel (117).
Remove scrrews (16) andd washers (113).
Remove thee pin connectting the mainn valve spindle to tappett assembly (15).
Remove hexx head cap sccrews (14) and
a washers (13).
12
By-Passs Valve Remova
al
The followin
ng maintenaance proceddures outlinee the steps reequired to reemove the B
By-Pass valvve
ffrom the low
wer unit and
d main valvee assembly.

wing (Figuree 2).

l on th
he end of th
he electric motor. Rotatee the
By-Pass vallve to the clo
osed position onnecting ppin (12) has been removved. There
n after the co
should be about a ¼ incch of clearance between n the tappet and the botttom of the sppindle.
Remove hex x nut (8), and

d studs (7), located
l on th
he side of thee By-Pass vaalve.
Remove soccket head cap p screws (5), located on the inside annd outside oof the riser. T
There are a ttotal
of six sockeet head cap screws.
Always use the lifting lu

A ugs located on the top of the valve. Use extremme caution wwhen lifting tthe
By-Pass vallve off the lo
ower unit to prevent
p dam
mage to the ssealing surfface betweenn the Main aand
By-Pass vallves. Protect sealing areeas on the va
alve body annd spindle af
after the valvve is removeed.
Lift the By-Pass valve assembly

a (3), off the low
wer unit (1).
Main Valve
V Reemoval
The followin
ng maintena
ance proced
dures outlinee the steps reequired to reemove the M
Main valve fr
from
the lower.

wing (Figuree 2).

l on th
he end of th
he electric motor. Rotatee the
Main valve to the closed necting pin (15) has beeen removed. There should
d position affter the conn
be about a ¼ inch of cleearance betw ween the tapppet and thee bottom of tthe spindle.
Remove soccket head cap p screws (5), located on the inside annd outside oof the riser. T
There are a ttotal
of eight sock
ket head cap
p screws.
A
Always use the lifting lu
ugs located on the top of the valve. Use extrem me caution w when lifting tthe
Main valve off the loweer unit to preevent damagge to the seaaling surfacee between th
he Main andd
By-Pass vallves. Protect sealing areeas on the va
alve body an nd spindle af
after the valvve is removeed.
Lift the Maiin valve asseembly (4), offf the lower unit (1).
13
Repairr Procedure - Main
n Decooker Vaalve
Valve Disassem
D mbly
Disconnectiing the Valvve Spindle frrom Tappet Assembly
A

wing (Figuree 3).
The spindlee must be dissconnected from

f the tapp
ppet assembly ly before serrvicing the vvalve.
The followinng maintena ance proceddures outlinee the steps reequired to ddisconnect thhe Main valvve
spindle from
m the tappett assembly.
Decoker Valv
ve Basic Asssembly
Figure 3

Remove scrrews (16) andd washers (113).
14
Disassemblly of Main Valve
V - Upper Section
Refer to Ma
ain Valve Assembly
A drrawing (Figu
ure 4).
The followinng maintenaance proced dures outlinee the properr disassemblyy of the uppper valve secction,
including reemoval of sp
pindle, seat, seat seals, upper
u cup seeals, o-ring sseals and uppper guide
bearing.
Main Va
alve Assemb
bly
Figure 4
Remove #4 SAE plug (2 23), installedd into valve cap (21), andd install liftiing eye.
Remove soccket head cap p screws, rettaining the valve
v cap (222).
Use the lifting eye and hoist,
h lift vallve cap (21),, straight upwward.
Remove sprring (18), sprring cap (17)).
Remove upp per spindle seal
s (16), wh hich is installled in valve cap, (21).
Remove o-rring seal (19)) and (20).
Install #6 SA
AE lifting ey
ye into the en nd of the spiindle (13).
15
Use the lifting eye and hoist
h to lift spindle
s assem
mbly straightt upward rem
moving the sspindle assem
mbly
(13) and upp per guide beearing (15).
Use extrem
me caution when
w lifting the
t spindle out
o of the vaalve to preveent damage tto the sealin
ng
surfaces of the spindle. Protect alll sealing areas on the vaalve body an
nd spindle affter the spinddle is
removed froom the valvee.
Install lifting eyes into seat

s (12).
h to lift seat
s straight upward.
u
Note: Itemss 10, 11, 3, 4,

4 5, 19, 20, and
a 16, shou
uld always bbe replaced w
when the uppper section of
the valve asssembly is seerviced.
Disassemblly of Main Valve

V Lowerr Section
Refer to Ma
ain Valve Assembly
A drrawing (Figu
ure 4).
The followinng maintenaance proceddures outlinee the properr disassemblyy of the loweer valve secttion,
including reemoval of lo
ower cup sea
al, lower guiide bearing, lower seal rretaining rin
ng, lower flaange
and lower flange
fl wiper..
Note: Acceess cover pan

nel must be removed.
r
Remove soccket head cap p screw (9).

Remove botttom flange (8).
(
Remove low
wer guide bearing (6).
Remove low
wer seal retaiining ring (2
2).
Remove cupp seal (3).
Remove o-rring (4).
Remove bacck-up washeer (5).
Remove wipper seal (7).
Note: Itemss 3, 4, 5, and

d 7 should always
a be rep
placed when
n the lower bbearing is reemoved.
16
Disassemblly of Spindlee - Main Va
alve
pindle Assem
Refer to Sp mbly drawin
ng (Figure 5).
The followinng maintenaance proceddures outlinee the properr disassemblyy of the maiin valve spin
ndle,
including reemoval of th
he spindle nu
ut, guide, o--rings, disc, and choke rring.
In order to properly serrvice the spiindle assemb bly, it must bbe secured tto prevent th
he spindle frrom
rotating or moving
m wheen force is ap pplied to thee spindle nu
ut. Use extreeme caution when securring
the spindle assembly, to
o prevent damage to thee sealing surf rfaces of thee spindle.
Note: Item 7, spindle nut

n is assemb
bled using a thread lockking compou
und and may
ay require
heating to remove.
r
Sp
pindle Assem
mbly – Main
n Valve
Figure 5
Remove spindle nut (7)..

Remove spindle guide (6).
Remove o-rrings (5).
Remove disc (4).
Remove o-rrings (5).
Remove chooke ring (3).
Remove o-rring (2).
Note: Item 4, disc and o-rings, Item

ms 2 and 5 should
s be rep
eplaced every
ry time the vaalve is
disassembleed. Inspect Item
I 3, chokke ring, for excess
e wearr and replacee as requiredd.
17
Main Valve
V Assembly
Spindle Asssembly Maiin Valve
Refer to Sp
pindle Assem
mbly drawin
ng (Figure 5).
The followin
ng procedurres outline th
he proper asssembly andd replacemen
nt of parts fo
for the Main
n
Valve spind
dle assembly..
Note: The valve

v spindlee should be securely
s mo
ounted in a ddevice to preevent damagge to the sealling
areas during g assembly and
a tighteniing operatio ons. Inspectt all parts to be assembleed to make ssure
they are clean and free of defects. Inspect
I the internally
i drrilled passagge that comm municates
hydraulic flluid through h the spindlee to the top of
o the spindlle, to ensuree it is not bloocked and iss free
of contamin nation. The outer sealin ng diameter of the spinddle and spinddle spacer m must be free of
corrosion, nicks,
n cuts, sharp
s edges,, or depressiions. The suurface finishh at the sealling area mu ust be
a minimum of 16 micro o inches. Beefore assemb bling, apply a thin coat of lithium ggrease to thee
spindle areaa from the thhreads down n to the seat area for thee choke ringg. Do not appply grease tto
the threads.. Also applyy a thin coat of lithium grease to th he o-ring seaaling areas oof the chokee
ring, disc an
nd spindle sp pacer.
Install o-ring (2).

Install choke ring (3).
Install o-ring (5).
Install disc (4).
(
Install o-ring (5).
Install spind
dle spacer (6).
A
Apply a threead locking compound to
t the spindlle threads (L
Loctite® 2422) or equivallent.
Install lock nut (7).
Torque to 1100 lb-ft.
18
Assembly of
o Main Valv
ve Lower Section
alve Assemb
Refer to Va bly drawing
g (Figure 4).
The followinng procedurres outline th

he proper asssembly andd replacemen nt of parts fo
for the lowerr
section of th
he main valvve, including
g replacemeent of lower cup seal, low
wer guide beearing, and
lower flangee wiper.
Inspect loweer sealing ch

hamber of valve
v body to
o make sure the sealing areas are cllean and freee of
corrosion, nicks,
n cuts, sharp
s edges,, or depressiions. The su
urface finish
h at the sealling areas m
must
be a minimuum of 63 miicro inches.
A
Apply a thin hium grease to the innerr bores of th
n coat of lith he lower guidde bearing.
Install cup seal

s (3) into lower guide bearing (6)..
Install back--up washer (5)
( into outerr groove in lower
l guide bearing (6).
Install o-ring (4) into ou
uter groove in lower guid
de bearing (66).
A
Apply a thin
n coat of lith
hium grease to the innerr bore of thee valve bodyy (sealing surface for o-rring
and back-upp washer).
Install lowerr seal retainiing ring (2) into

i valve bo
ody.
Install lowerr bearing (6)) into valve body.
b
Install wiperr (7) into thee groove locaated on the lower
l flangee (8).
Install lowerr flange (8) onto
o lower guide
g and vaalve body.
Note: Vent hole should g toward the By-Pass vaalve mountin

d be pointing ng face and pperpendicullar to
the flow patth.
Install sockeet head cap screws

s (9). Do not fullyy tighten soccket cap screews. The soccket caps scrrews
should be tigght enough to
t secure thee flange in pllace, but alloow the flangge to move innto position
when the sppindle assemb bly is installled.
Note: Item
ms 3, 4, 5, an
nd 7 should always
a be reeplaced when
n the lower bearing is rremoved.
19
Assembly of
o Main Valv
ve Upper Seection
alve Assemb
Refer to Va bly drawing
g (Figure 4).

for the upperr
section of th
he main valvve, including
g replacemeent of spindlle assembly, seat and seaal, upper cup
up
seals, o-ring
gs and upper guide bearring.
Inspect the inner bore areas

a of the valve body in
i the sealin
ng areas for the seat andd upper guidde
bearing. It is important that all sea
aling areas are harp edges, or
a free of ccorrosion, niicks, cuts, sh
depressionss. The surfa
ace finish at the sealing areas must be a minimu um of 63 miicro inches.
1, should be replaced eveery time thee valve is serrviced.

Note: Itemss 10, and 11
Install back--up washers (11) and o-rring (10) into

o the first o--ring grooves located onn the small ouuter
diameter of the seat (12)).
Install back--up washers (11) and o-rring (10) into
o the secondd o-ring groooves located on the smalll
outer diameter of the seaat (12).
A
Apply a thin
n coat of lith ng areas of the valve boody, o-rings (10), and baack-
hium grease to the sealin
up washers (11), on thee outer diam
meter of the seat
s (2).
Install seat (12),

( into valve body. Make
M sure thee seat is propperly locatedd into the low
wer valve boody
bore and is perpendicula
p ar to the boree.
Note: To co omplete the seat installa

ation, the folllowing partts are requirred to assist with the
installation:: Upper gu
uide bearing (15), withou ut seals insta
talled, and vvalve cap (211) without seeal
installed.
Install the up
pper guide bearing
b (15),, without o-rrings and bacck-up washeers, into the vvalve body bbore.
The upper guide
g bearing
g should be sitting
s on top p of the parttially installeed seat (12).
Note: Use th
he lifting eye and hoist to lift valve cap.
Install valvee cap (21) on

nto upper guide bearing (15).
( Slowlyy lower valvve cap (21) oonto the uppeer
guide bearinng, using thee weight of thhe cap to preess the seat ((12), into plaace. Removve valve cap (21)
and upper guide bearing g (15) after th
he seat is completely insstalled.
AApply a thin
n coat of lith
hium grease to the uppeer sealing arrea, the loweer guide bearing bore an
nd
gguide diameeters of the spindle
s asseembly and diisc.
Note: Use extreme

e cauttion when liffting the spiindle into thhe valve to prrevent damaage to the
sealing surffaces of the spindle. Onnce the spind dle starts to enter the lowwer seal, it m
may be
necessary to
o apply a forrce to the top
p of the spinndle using a dead blow h hammer. D Do not discon
nnect
spindle from
m hoist.
20
Install #6 SA
AE lifting eyye into the en nd of the spiindle (13).
h to lift and
a position the valve sppindle over thhe valve boddy. Carefullly
lower the sppindle into th
he valve bod dy, making su ure the spinddle remains pproperly aliggned with thhe
valve bores.. Lower the spindle asseembly into th he valve boddy until the sspindle disc contacts the
valve seat.
A
Apply a thin
n coat of lith
hium grease to the innerr bores of th
he upper guiide bearing.
Note: Itemss 3, 4 and 5 should be reeplaced everry time the vvalve is serviiced.
Install cup seal

s (3) into upper
u guide bearing (15).
Install retain
ning ring (14
4) into upperr guide beariing (15).
( into outerr groove in upper
u guide bearing (15)).
uter groove in upper guidde bearing (115).
A
Apply a thinn coat of lith
ng areas of the valve boody, upper gguide bearingg,
o-rings (4), and back-up p washers (5
5).
Note: To co omplete the upper guidee bearing insstallation, thhe followingg parts are rrequired to aassist
with the insstallation: Valve
V cap (21
1) without seeal installedd.
Install upperr guide bearing (15), into

o the valve body
b bore. T The upper guuide bearingg (15) shouldd
slide partially into the valve body boore, until thee o-ring (4) ccontacts the valve body bbore.
Note: Use th

guide bearinng, using thee weight of th
he cap to preess the upperr guide bearring (15) intoo place. Rem
move
valve cap (221) after the upper guide bearing is completely
c innstalled.
A
hium grease to upper sp
pindle diameeter and uppper seal boree located on the
inside of thee valve cap (21).
(
Install upperr cup seal (16) into the valve

v cap (21
1).
Install sprin
ng cap (17) on
o top of the spindle asseembly.
Install o-ring (20) onto upper
u guide bearing (15)).
Install o-ring (19) onto valve
v cap (21).
Note: Use th
Lift valve caap (21) into position. Lo

ower the cap
p over the uppper guide beearing (15); insert returnn
spring (18) into
i the valv
ve cap (21) when
w the cap
p is about 122 inches abovve the upper guide bearinng,
and continue to lower vaalve cap on to
t upper guiide bearing.
21
Note: Makee sure the sp pring is corrrectly located d in the cap bore and onn top of the spindle, as tthe
cap is lowerred into posiition. Lowerr the cap slo owly makingg sure the caap remains pperpendiculaar to
the valve bo
ody and doess not bind on n the guide .
When the ca ap is in posiition correcttly, there willl be a gap bbetween the vvalve body aand the cap of
about .020 of
o an inch.

s (22) to
t secure thee valve cap ((21).
Note: The socket

s cap screw
s must be
b tightened evenly and in a symmeetrical patterrn, alternatin ng
o side; tighteen each bolt one quarterr of a turn aat a time. Th
ffrom side to he socket heead cap screw ws
must be torq
qued in the same
s manneer. A .020 strip
s gauge sshould be in nserted betweeen the cap and
the valve bo
ody during th he torque op
peration, to ensure the ccap is tightenned correctlly and is nott
binding or crushing
c thee upper guid
de bearing.
Tighten and d torque sock

ket head cap screws on thhe valve capp (21) to 6000 lb-ft.
Install #4 SA
AE plug (23) into the vaalve cap (21) and tightenn.
Note: Tighten lower fla

ange socket head cap sccrew (9), on the lower fllange (8).
The lower flange

f sockeet head cap screws
s shoulld be tighten
ned and then
n torqued
to 600 lb-ft.
Caution: Once the vaalve is re-asssembled; the cam shaft shhould be rottated four coomplete cycles
using the maanual hand operated
o driv
ve system on n the back off the electricc motor, to ennsure the vaalve
spindle movves freely up
p and down. If the spind dle does not m
move freely up and dow wn; stop
immediatelyy, operating the valve in this conditio
on could res ult in damagged to the vaalve or drive
system.
22
Repairr Procedure - Decok
ker By-P
Pass V
Valve
Valve Disassem
D mbly
Disconnectiing Spindle from Tapp
pet Assembly
y

wing (Figuree 6).
The spindlee must be dissconnected from

f the tapp
ppet assembly ly before sevvering the vaalves.
The followinng maintena ance proceddures outlinee the steps reequired to ddisconnect th
he By-Pass valve
spindle from
m the tappett assembly.
Decoker Basiic Valve Asssembly
Figure 6

Remove hexx head cap sccrews (14) and
a washers (13).
23
Disassemblly of By-Passs Valve - Upper Section
Refer to By
y-Pass Valvee Assembly drawing (F
Figure 7).
The followinng maintenaance proced dures outlinee the properr disassemblyy of the uppper valve secction,
including reemoval of sp
pindle, seat, seat seals, upper
u cup seeals, upper oo-rings sealss, center guiide
bearing andd upper guidde bearing.
By-Pass Valve
V Assemb ly
Figure 7
Remove #4 SAE plug (2 21) and instaall lifting eyee.

Remove soccket head cap p screws (22 2).
h to lift valve
v cap (20
0), straight uupward.
24
Remove sprring (19) and d upper spind dle seal (18).
Remove o-rring seal (16)) and (17).
Install lifting eyes into spindle
s (12).
h to lift spindle
s straig
ght upward, removing thhe spindle (12), upper guuide
bearing (15)) and center guide bearin ng (13).
When liftingg the spindlle out of the valve, use extreme

ex cauttion to preveent damage to the sealin ng
surfaces of the spindle. After spind dle is removed from the valve, all seealing areass on the valvve
should be protected.
Install lifting eyes into seat

s (11).
h to lift seat
s straight upward.
u
Note: Itemss 3, 4, 9, 10, 14, 16, 17 and

a 18 shoulld always bee replaced wh
when the uppper section of the
valve assem
mbly is servicced.
Disassemblly of By-Passs Valve Low

wer Section
n
Refer to By
Figure 7).
The followinng maintenaance proceddures outlinee the properr disassemblyy of the loweer valve secttion,
including reemoval of lo
ower cup sea
al, lower guiide bearing aand lower fl
flange, and lolower flangee
wiper.
Note: Acceess cover pan

nel must be removed.
r
Remove soccket head cap p screw (8).

Remove botttom flange (7).
(
Remove low
wer guide bearing (5).
Remove low
wer cup seal (2).
Remove o-rring (3).
Remove bacck-up washeer (4).
Remove wipper seal (6).
Note: Itemss 2, 3, 4, and

d 6 should always
a be rep
placed when
n the lower bbearing is reemoved.
25
Disassemblly of Spindlee
Refer to Sp
pindle Assem
mbly drawin
ng (Figure 8)
8
The followin
ng maintena
ance proced
dures outlinee the properr disassemblyy of the spin
ndle, includiing
removal of the
t spindle nut,
n guide, o-rings,
o discc, and chokee ring.
Note: Item 7 spindle nu

ut is assemb
bled using a thread lockking compou
und and mayy require heaating
to remove.
pindle Assem
By-Pass Sp mbly
Figure 8
Remove spindle nut (7)..

Remove spindle guide (6).
Remove o-rring (5).
Remove disc (4).
Remove o-rring (5).
Remove chooke ring (3).
Remove o-rring (2).
Note: Item 4, disc and o-rings, (2) and (5) sho

ould be replaaced every tiime the valve is
disassembleed. Inspect (3),
( choke riing, for exceess wear andd replace as required.
26
Disassemblly of Breakd
down Orificce
Refer to Va
alve Assemb
bly drawing
g (Figure 7).
The followinng maintena ance proced

dures outlinee the properr disassemblyy of the breaakdown oriffice,
including reemoval of brreakdown orrifice, orificce seals, orifi
fice sleeve, aand cap seal..
Remove soccket head cap p screws (25

5).
Remove orifice cap (24)).
Remove o-rring (23), and d crush wash
her (37).
Insert pull ro
od into break
kdown orificce assembly; the pull toool should enggage the holles in the last
orifice stagee.
Remove breeakdown oriffice assemblly.
Refer to Brreakdown Orifice

O Assem
mbly drawing (Figure 99).
Note: Item 5, socket seet screws aree assembled using a threead locking compound aand may reqquire
heating to remove.
r
A
After disasssembling, insspect inner bore
b sealingg area of vallve body to mmake sure th he sealing arrea
is clean andd free of corrrosion, nick
ks, cuts, sharrp edges, or depressionss. The surfaace finish att the
sealing areaa must be a minimum
m off 63 micro innches. If thhe sealing arrea in the vaalve body is
damaged, itt must be rep paired or repplaced. Insp spect the breeakdown orif ifice assembly for damagge,
missing discc, loose disc,, excessive erosion
e to th
he disc, or slleeves. Item
ms (23) o-ringg, crush wassher
(37), breakddown orificee seal (35), and
a back-up washer (36) 6), should alwways be repllaced when the
breakdown orifice assem mbly is servviced. It is possible to rep
eplace only ssections of thhe breakdow wn
orifice assemmbly; howevver, it is reco
ommended that t the breaakdown oriffice assembly ly be servicedd as
a complete unit.
u Components that have been in i service wiill reduce the overall serrvice life of the
breakdown orifice, and d could possiibly cause da amage to thee new compponents that are installedd.
Breakdown
B Orifice Asseembly
Figure 9
27
By-Passs Valve Assemb
bly
Spindle Asssembly
Refer to Sp
pindle Assem
mbly drawin
ng (Figure 8)
8
The followin
ng procedurres outline th
he proper asssembly andd replacemen
nt of parts fo
for the spinddle
assembly.
Note: The valve

v spindlee should be securely
s mo
ounted in a ddevice to preevent damagge to the sealling
areas during g assembly and
a tighteniing operatio ons. Inspectt all parts to be assembleed to make ssure
they are clean and free of defects. Inspect
I the internally
i drrilled passagge that comm municates
hydraulic flluid throughh the spindlee to the top of
o the spindlle, to ensuree it is not bloocked and iss free
of contamin nation. The outer sealinng diameter of the spinddle spacer m must be free oof corrosionn,
nicks, cuts, sharp edgess, or depresssions. The surface
s finissh at the seaaling area must be a
minimum off 16 micro inches.
i Befoore assembliing, apply a thin coat off lithium greease to the
spindle areaa from the thhreads down n to the seat area for thee choke ringg. Do not appply grease tto
the threads.. Also applyy a thin coat of lithium grease to th he o-ring seaaling areas oof the chokee
ring, disc an
nd spindle sp pacer.
Install o-ring (2).

Install choke ring (3).
Install o-ring (5).
Install disc (4).
(
Install o-ring (5).
Install spind
dle spacer (6).
A
t the spindlle threads (L
Loctite® 2422) or equivallent.
Install lock nut (7).
Torque to 450
4 lb-ft.
28
Assembly of
o By-Pass Valve
V Lowerr Section
Refer to By
Figure 7).

for the lowerr
section of th
he By-Pass valve,
v includ
ding replaceement of low
wer cup seal,, lower guidde bearing, loower
fflange wipeer, and lowerr flange.
Inspect loweer sealing ch

hamber of valve
v body to
o make sure the sealing areas are cllean and freee of
corrosion, nicks,
n cuts, sharp
s edges,, or depressiions. The su
urface finish
h at the sealling areas m
must
be a minimuum of 63 miicro inches.
A
Apply a thin hium grease to the innerr bores of th
n coat of lith he lower guidde bearing.
Install lowerr cup seal (2

2) into lowerr guide bearin
ng (5).
( into outerr groove in lower
l guide bearing (5).
uter groove in lower guidde bearing (55).
A
Apply a thin
n coat of lith
hium grease to the innerr bore of thee valve bodyy (sealing surface for o-rring
and back-upp washer).
Install lowerr bearing (5)) into valve body.

b
Install wiperr (6) into thee groove locaated on the lower
l flangee (7).
Install lowerr flange (7) onto
o lower guide
g and vaalve body.
Note: Vent hole should

d be pointing
g toward the surface thee mates to th
he Main valvve body and
pparallel to the
t flow path
h.

s (8). Do not fully
y tighten soccket cap screews. The soccket cap screews
should be tigghtened enough to securre the flangee in place, buut allow the fflange to moove into posiition
when the sppindle assemb bly is installled.
Note: Item
ms 2, 3, 4, an
nd 6 should always
a be reeplaced when
n the lower bearing is rremoved.
29
Assembly of
o Breakdow
wn Orifice
Refer to Va
alve Assemb
bly drawing
g (Figure 7)
The followin ng maintena ance proced dures outlinee the properr assembly an
nd replacemment
of parts for the breakdo own orifice, including reeplacement of breakdow wn orifice asssemblies,
orifice sealss, orifice sleeeve seals an
nd cap seals.
Note: Itemss (23) o-ring g, crush wash her (23), breeakdown orif ifice o-ring sseal (35), an
nd orifice baack-
up washer (36),
( should always be replaced
r wheen the breakkdown orificce assembly is serviced.
It is possiblee to replace only section
ns of the breeakdown orif ifice assemblly; however, r, it is
recommend ded that the breakdown
b orifice
o assem
mbly be servviced as a coomplete unitt. Components
that have beeen in servicce will reducce the overalll service life
fe of the breaakdown oriffice, and cou uld
ppossibly dammage the neew componen nts that are installed.
Refer to Brreakdown Orifice

O Assem
mbly drawing (Figure 88).
Assemble orrifice sleevee together as shown in th

he drawing, m
making sure all of the o--rings and baack-
up rings are in place.
A
t socket head set screw
ws (5), as reqquired (Locttite® 242).
Install o-ring (35) and back-up

b wash
her (36) into
o o-ring grooove.
A
Apply a thin
n coat of lith
hium grease to o-ring (3
35) and backk-up washerr (36).
Inspect loweer sealing chhamber of valve

v body too make sure the sealing areas are cllean and aree
ffree of corro
osion, nickss, cuts, sharp
p edges, or depressions.
d The surfacce finish at tthe sealing aareas
must be a minimum
m of 63 micro inches.
Apply a thiin coat of lith

hium greasee to the inneer sealing boore of the vaalve body wh
here the
breakdown orifice is sea aled.
Install break
kdown orificce assembly into valve bo
ody.
A
Apply a thin
n coat of lith
hium grease to the innerr bore of thee orifice capp, (24) wheree the crush
washer is ho
oused (37), and
a the inneer bore for the
t o-ring seeal (23).
Install the crrush washer (37) into thee orifice cap

p (24).
Install the o-ring (23) innto the o-ring
g groove in the
t orifice caap (24).
Install orificce cap (24) over
o breakdoown orifice assembly.
a
s (25) through
t oriffice cap (24),, and thread into the valvve body.
Note: Makee sure that both

b the crussh washer and
a o-ring arre positioneed correctly bbefore
tightening.
Tighten and
d torque the socket
s head cap screws (25)
( to 650 llb-ft.
30
Assembly of
o By-Pass Valve
V Upperr Section
Refer to By
Figure 7).
The followinng procedurres outline thhe proper asssembly andd replacemen nt of parts fo
for the upperr
section of th
he valve, rep
placement off spindle asssembly, seatt and seal, ceenter guide bbearing andd
seals, upperr guide bearring and sealls.
Inspect the inner bore areas

a of the valve body in
i the sealin
ng areas for the seat andd center guiide
bearing. It is important that all sea
aling areas are harp edges, or
a free of ccorrosion, niicks, cuts, sh
depressionss. The surfa
ace finish at the sealing areas must be a minimu um of 63 miicro inches.
Note: Itemss 9 and 10 should be rep

placed everyy time the vaalve is servicced.
Install back--up washers (9) and o-rin

ng (10) into the first o-riing grooves located on tthe small outter
Install back--up washers (9) and o-rin
ng (10) into the second oo-ring groovves located oon the small outer
A
Apply a thin hium grease to the o-rin
n coat of lith ngs (10), andd back-up waasher (9), on
n the outer
diameter off the seat (11
1).
Install seat 11,

1 into valv
ve body. Maake sure the seat
s is propeerly located iinto the loweer valve boddy
bore and is perpendicula
p ar to the boree.
Note: To co omplete the seat installa

ation, the folllowing partts are requirred to assist with the
installation:: Center gu uide bearing
g, (13), witho
out seals insstalled, uppeer guide beaaring, (15),
without sealls installed and
a valve ca ap, (20) with
hout seal insstalled.
Install centeer guide bearring (13), wiithout o-ring

gs and back-uup washers iinto the valvve body bore.
Install upperr guide bearing (15), witthout o-ringss and back-uup washers innto the valvee body bore.. The
upper and ceenter guide bearings
b sho
ould be sittin
ng on top of tthe partiallyy installed seat (11).
Note: Use th

Install valvee cap (20) on ( Slowlyy lower valvve cap (20) oonto the uppeer
guide bearinng, using thee weight of thhe cap to preess the seat ((11), into plaace. Removve valve cap (20),
upper guide bearing (15 5) and centerr guide bearinng (13), afteer the seat is completely installed.
AApply a thin
n coat of lith
hium grease to the uppeer sealing arrea, the loweer guide bearing bore an
nd
gguide diameeters of the spindle
s asseembly and diisc.
Note: Use extreme

e cauttion when liffting the spiindle into th
he valve to prrevent damaage to the
sealing surffaces of the spindle.
31
Once the sppindle starts to enter thee lower seal, it may be neecessary to aapply a forcce to the top of
the spindle using a deadd blow hamm mer. Do no ot disconnectt spindle froom hoist.
Install #6 SA
AE lifting eyye into the en nd of the spiindle (12).
h to lift and
a position the valve sppindle over thhe valve boddy. Carefullly
lower the sppindle into th
he valve bod dy, making su ure the spinddle remains pproperly aliggned with thhe
valve bores.. Lower the spindle asseembly into th he valve boddy until the sspindle disc contacts the
valve seat.
A
Apply a thin
n coat of lith
hium grease to the innerr bores of th
he center guiide bearing and upper gguide
bearing.
Note: Itemss 3, 4 and 14

4 should be replaced eveery time thee valve is serrviced.
Install lowerr cup seal (14) into centeer guide beaaring (13).
( into outerr groove in center
c guide bearing (133).
uter groove in center guid de bearing ( 13).
A
Apply a thinn coat of lith ng areas of the valve boody, upper gguide bearingg, o-
rings (3), an
nd back-up washers
w (4)..
Note: To co omplete the upper guidee bearing insstallation, thhe followingg parts are rrequired to aassist
with the insstallation: Valve
V cap (20
0) without seeal installedd.
Assembly th he center guiide bearing (13)

( and the upper guidee bearing (155) together.
Install the bearing assem
mbly, into the valve body y. The centeer guide bearring (13) shoould slide
partially into
o the valve body
b bore, until
u the o-rin
ng (3) contaccts the valvee body bore.
Note: Use th

guide bearinng, using thee weight of th
he cap to preess the upperr guide bearring (15) intoo place. Rem
move
valve cap (220) after the upper guide bearing is completely
c innstalled.
A
hium grease to upper sp
pindle diameeter and uppper seal boree located on the
inside of thee valve cap (20).
(
Install upperr cup seal (18) into the valve

v cap (20
0).
v cap (20).
v cap (20).
32
Note: Use th
Lift valve caap (20) into position. Lo

ower the cap
p over the uppper guide beearing (15); insert returnn
spring (19) into
i the valv
ve cap (20) when
w the cap
p is about 122 inches abovve the upper guide bearinng,
and continue to lower vaalve cap on to
t upper guiide bearing.
Note: Makee sure the sp pring is corrrectly located

d in the cap bore and on
n top of the spindle, as tthe
cap is lowerred into posiition. Lowerr the cap slo
owly makingg sure the caap remains pperpendiculaar to
the valve bo
ody and doess not bind on n the guidess.
When the caap is in posiition correcttly, there willl be a gap bbetween the vvalve body aand the cap of
about .030 of
o an inch.

s (22) to
t secure thee valve cap ((20).
Note: The socket

s cap screw
s must be
b tightened evenly and in a symmeetrical patterrn, alternatin ng
ffrom side to
o side; tighteen each bolt one quarterr of a turn aat a time. Th
he socket heead cap screw ws
must be torq
qued in the same
s manneer. A .030 strip
s gauge sshould be in nserted betweeen the cap and
the valve bo
ody during th he torque op
peration, to ensure the ccap is tightenned correctlly and is nott
binding or crushing
c thee upper guid
de bearing.
Tighten and d torque sock

ket head cap screws on thhe valve capp (20) to 3500 lb-ft.
Install #4 SA
AE plug (21) into the vaalve cap (20) and tightenn.
Note: Tighten lower fla

ange socket head cap sccrew (8), on the lower fllange (7).
The lower flange

f sockeet head cap screws
s shoulld be tighten
ned and then
n torqued
to 275 lb-ft.
Caution: Once the vaalve is re-asssembled; the cam shaft shhould be rottated four coomplete cycles
using the maanual hand operated
o driv
ve system on n the back off the electricc motor, to ennsure the vaalve
spindle movves freely up
p and down. If the spind dle does not m
move freely up and dow wn; stop
immediatelyy, operating the valve in this conditio
on could res ult in damagged to the vaalve or drive
system.
33
Repairr Procedure – Repllacemeent of V
Valvess
The followin
ng maintenaance proceddures outlinee the steps reequired to ree-install thee Main and B
By-
Pass valve assembly
a onto the lowerr unit.
Main Valve
V Reeplacemeent
wing (Figuree 10).
Note: Alwa
ays use the liifting lugs lo
ocated on th
he top of the valve.
Decoker Valv
ve Basic Asssembly
Figure 10
Manually ro otate the cam

m shaft usinng the hex drive
dr locatedd on the end of the electrric motor to
pposition thee Main valvee tappet asseembly to the lowest posittion. Beforee lifting the MMain valve
assembly innto place, ma ake sure thee spindle con
nnecting pinn hole is lineed up correctly. The
connecting pin
p hole mu ust be perpenndicular to inlet
i and ou
utlet flanges,, and the tappped hole for the
limit switch target mustt be facing thhe outlet port.
Lift valve Main

M valve asssembly (4),, over the low
wer unit (1).
Slowly loweer the Main valve
v assem
mbly (4), onto
o the lower uunit (1).
34
Stop at apprroximately four
f inches above
a the lo
ower unit to make sure tthe spindle ccounter boree is
lined up witth the tappett assembly loocator. Oncce aligned, ccontinue to llower the unnit down to
approximattely ¾ of inch from the lower
l unit annd stop. Thhere are two locator pinss installed in
nto
the lower unnit to assist with the location of the valve. Oncce the valve iis aligned with the locattor
nue to lower the Main va
ppins, contin alve assemblly onto the llower unit.

s (5). The
T socket head
h cap screew should bee threaded alll the way inn and
then backedd off one or two
t turns.
Manually ro otate the camm shaft to po

osition the valve
v spindlee in the cut oout located oon the side oof
the riser. Make
M sure th
he spindle is raised up offf the seat appproximatelly ½ inches. To install tthe
connecting pin
p (15), it may
m be neceessary to rota ate the spinddle to line upp the hole inn the spindlee
with the holle in the tapp
pet assemblyy. Once thee pin is instaalled into spiindle tappet assembly, itt
should movve freely back k and forth by hand.
Install the pin connectin

ng the main valve
v spindlee to tappet aassembly (155).
35
By-Passs Valve Replaceement
The followin
ng maintenaance proced
dures outlinee the steps reequired to ree-install thee By-Pass vaalve
assembly on
nto the lower unit.

wing (Figuree 10).
Note: Alwa
ays use the liifting lugs lo
ocated on th
he top of the valve.
Manually ro otate the cam

m shaft usinng the hex drive
dr locatedd on the end of the electrric motor to
pposition thee By-Pass vaalve tappet asssembly to the
t lowest poosition. Beffore lifting th
he By-Pass vvalve
assembly innto place, ma ake sure thee spindle con
nnecting pin
n hole is lineed up correctly. The
connecting pin
p hole mu ust be perpenndicular to the
t outlet flaange.
A
hium grease to the O-Riing groove loocated on thhe Main valvve body. Aft
fter
installing O-Ring
O (6) innto groove, apply
a a thin coat of lithiium grease tto the surfacce.
Install O-Ring (6) into groove

g locateed on the Maain valve boody.
Lift valve By-Pass
B valvee assembly (3),
( over the lower unit ((1).
Slowly loweer the By-Paass valve assembly (4), onto
o the loweer unit (1).
Stop at apprroximately four

f inches above
a the lo
ower unit to make sure tthe spindle ccounter boree is
lined up witth the tappett assembly lo
ocator. Oncce aligned, ccontinue to llower valve onto the lowwer
unit. Use exxtreme cauttion not to daamage the O-Ring
O seal (6) or misallign the valvve as it is
lowered.
Install studss (7), hex nutt (8) and tigh

hten.
s (5). The
T socket head
h cap screew should bbe threaded aall the way inn and
then backed d off one or two
t turns.
Manually ro otate the camm shaft to po osition the valve

v spindlee in the cut oout located oon the side oof
the riser. Make
M sure thhe spindle is raised up offf the seat appproximatelly ½ inches. To install tthe
connecting pinp (12), it may
m be neceessary to lift the valve asssemblies ussing just thee center liftin ng
lug, approxximately .03 inches
i to heelp in the aliignment of tthe valve. TThis could bee required too
assist with the
t installatiion of the soocket head cap
c screws (55) or the insstallation off the connectting
ppin (12). It may also bee necessary to t rotate thee spindle to lline up the h
hole in the sp
spindle with the
hole in the tappet
t assemmbly. Once the pin is in nstalled into the spindle tappet assem mbly, it shou uld
move freelyy back and fo orth by hand d.
Install the pin connectin

ng the main valve
v spindlee to tappet aassembly (122).
Install washher (13) and hex
h head cap p screws (144), onto connnecting pin ((15) and tighhten.
Install washher (13) and hex
h head cap p screws (144), onto connnecting pin ((15) and tighhten.
Install accesss cover panel (17), wash
hers (10) and
d screws (9)).
Manually ro otate the vallve two comp

plete cycles using the heex drive locaated on the eend of the
electric mottor, to make sure the vallves are operating propeerly.
36
Sttorage Procedure
Decokiing Valvees
In order to ensure
e propeer operation and
a a maxim mum productt life, it is crritical to takee special
precautions whenever th he valve is non-operation
n nal for an exxtended periood of time.
Note: Do noot allow the valve to rem

main non-op perational fillled with waater for moree then 15 daays;
the water will become stagnate
s and
d corrosive.
Short Term
T Sto
orage
Whenever th he valve is non-operatio
n nal for moree than 15 dayys, the valvee should be ddrained and ffilled
with a waterr-based vapoor corrosion inhibitor.
Water Reemoval
In the mainttenance mod de, manually
y position thee Main and BBy-Pass valvve spindles, so both valvves
are in the op
pen position..
Remove plu ugs located on
o the end off spindle top caps for botth Main andd By-Pass vaalves.
Remove draain plugs on the Main an nd By-Pass valve
v bodies..
Note: Remo
oving the pllugs will allo
ow excess wa
ater to drain
n from the vvalve.
Figure 11
37
Treatmen
nt Procedu
ure
After drainin
ng the valvee of excess water,
w add co
oncentrated w
water-based vapor corrosion inhibitoor
into the valv
ve, accordingg to the follo
owing proced
dure:
Add ¼ liter of water-bassed vapor co

orrosion inhiibitor into poort located on the top capp of the Maiin
valve.

orrosion inhiibitor into poort located on the side off the By-Pass
valve into th
he orifice chamber.

orrosion inhiibitor into poort located on the top capp of the By-P
Pass
valve.
Re-install th
he drain plug d By-Pass vallve bodies (F
gs in the Maiin valve and Figure 11).
Add 2 liters of water-baased vapor co

orrosion inhiibitor into poort located oon the side of the By-Passs
valve into th
he orifice chamber.
Re-install drrain plug forr By-Pass vaalve orifice chamber

c (Figgure 11).

orrosion inhiibitor into poort located oon the top caap of the Maiin
valve.

orrosion inhiibitor into poort located oon the top caap of the By--Pass
valve.
Re-install th
he plugs locaated on the end
e of spindlle top caps fo
for both Mainn and By-Paass valves
(Figure 1).
38
Long Term Sto
orage
Long term storage

s is deffined by a vaalve that is non-operatio
n onal for moree than 60 dayys. Whenevver
the valve is non-operatioonal for morre than 60 daays, the valvve should be drained andd filled with aan
oil-based vaapor corrosio
on inhibitor.
Water Reemoval
The valve shhould be disconnected frrom all pipin

ng system. UUse the mainntenance moode to manuaally
position the Main and By-Pass
B valve spindles, so
s both valvees are in the open positioon.
Remove plu ug on the end
d of spindle top
t cap for Main
M valve.
Remove plu ug on the end
d of spindle top
t cap for By-Pass
B valvve.
Remove draain plugs located on the side
s of the Main
M and Byy-Pass valvess.
Remove thee orifice cap on the By-PPass valve boody.
Remove thee breakdown orifice assembly.
Figure 12
39
Treatmen
nt Procedu
ure Vent Areas
A
Use the maiintenance mo ode to manuually position
n the Main an
and By-Pass valve spindlles, as requirred.
There are tw
wo vent areass within the Main and By-Pass valvees that require treatmentt; the upper vvent
area and low
wer vent areaa (Figures 13
3 and 14).
By-Pass Va alve Lower Vent

V Area
Use the maiintenance mo ode to positiion the By-PPass valve sppindle so the valve is fullly closed. Fill or
inject water-based vapor corrosion inhibitor
i into
o lower ventt port (Figuree 14). Use tthe maintenaance
mode to mo ove the valvee to the open
n position. As the valve i s opening, ccontinue to fi
fill or inject
water-basedd vapor corroosion inhibitor. The ven nt must remaain open to attmosphere aat all times.
Never plug the vent linee. The next time
t the valv
ve is operateed some of thhe water-bassed vapor
corrosion in
nhibitor will exhaust out the vent porrt.
Main Valvee Lower Ven nt Area

Use the maiintenance mo ode to positiion the Mainn valve spinddle so the vallve is fully cclosed. Fill oor
i into
o lower ventt port (Figuree 13). Use tthe maintenaance
mode to mo ove the valvee to the open
n position. As the valve i s opening, ccontinue to fi
fill or inject
water-basedd vapor corroosion inhibitor. The ven nt must remaain open to attmosphere aat all times.
Never plug the vent linee. The next time
t the valv
ve is operateed some of thhe water-bassed vapor
corrosion in
nhibitor will exhaust out the vent porrt.
By-Pass Va alve Upper Vent

V Area
Rotate the vent
v elbow lo ocated on thee spindle top
p cap so the oopen end is facing upwaard (Figure 114).
Use the maiintenance mo ode to positiion the By-P
Pass valve sppindle so the valve is fullly open. Filll or
i into
o elbow portt. Use the m maintenance m mode to movve
the valve to the closed position.
p As the valve is closing, conntinue to fill or inject waater-based vaapor
nhibitor. Oncce the valve reaches the closed posittion, stop thee filling proccess and rotaate
corrosion in
the elbow doownward. TheT vent musst remain op pen to atmospphere at all ttimes. Neveer plug the vent
line. The neext time the valve is operated some ofo the water--based vaporr corrosion iinhibitor willl
exhaust out the vent porrt.
Main Valvee Upper Ven nt Area

Rotate the vent
v elbow lo ocated on thee spindle top
p cap so the oopen end is facing upwaard (Figure 113).
Use the maiintenance mo ode to positiion the Mainn valve spinddle so the vallve is fully oopen. Fill orr
i into
o elbow portt. Use the m maintenance m mode to movve
the valve to the closed position.
p As the valve is closing, conntinue to fill or inject waater-based vaapor
nhibitor. Oncce the valve reaches the closed posittion, stop thee filling proccess and rotaate
corrosion in
the elbow doownward. TheT vent musst remain op pen to atmospphere at all ttimes. Neveer plug the vent
line. The neext time the valve is operated some ofo the water--based vaporr corrosion iinhibitor willl
exhaust out the vent porrt.
40
MAIN VALVE
UPPER
CUC VENT
PPER VENT C CHAMBER
UPPER
UPPER VENT
BERCHAMBER
OUTLET
OU INLET
LOWER VENT CHAMBER

LOWE
FIGURE 13.
BY-PASS VALVE
UPPER VENT
CHAMBER
LOWER
LOWE VENT CHAMBER
BREAKDOWN ORIFICE
LOWER VENT CHAMBER
NT CHAMBER
FIGURE 14.
41
Treatmen
nt Procedu
ure
After drainin
ng the valvee of excess water,
w add co
oncentrated w
water-based vapor corrosion inhibitoor
into the valv
ve, accordingg to the follo
owing proced
dure:

orrosion inhiibitor into poort located on the top capp of the Maiin
valve.
Re-install brreakdown orrifice assembbly and orifiice cap (Figuure 12). Thee breakdownn orifice
assembly shhould be treaated using a suitable
s rust inhibitor sppray (LPS 3®
®), to coat alll metallic
surfaces.

orrosion inhiibitor into poort located on the side off the By-Pass
valve into th
he orifice chamber.

orrosion inhiibitor into poort located on the top capp of the By-P
Pass
valve.
Re-install th
he drain plug d By-Pass vallve bodies (F
gs in the Maiin valve and Figure 12).

orrosion inhiibitor into poort located oon the side of the By-Passs
he orifice chamber.
valve into th
Re-install drrain plug forr By-Pass vaalve orifice chamber

c (Figgure 12).

orrosion inhiibitor into poort located oon the top caap of the Maiin
valve.

orrosion inhiibitor into poort located oon the top caap of the By--Pass
valve.
Re-install th
he plugs locaated on the end
e of spindlle top caps fo
for both Mainn and By-Paass valves
(Figure 12).
Add oil-based vapor corrrosion inhib bitor into thee inlet and ouutlet port on the Main vaalve, makingg sure
nternal areass of the seat,, spindle and
to coat the in d flow ports.
Apply metallic sealing tape
t over thee Main valvee inlet and ouutlet ports, ssealing off poorts from
atmosphere..
Apply metallic sealing tape
t over thee By-Pass ou utlet port, seaaling off porrt from atmoosphere.
Remove riseer cover to provide
p accesss to the botttom of the MMain and Byy-Pass valve spindles. U Use a
suitable rustt inhibitor sp
pray (LPS 3® ®), to coat alll exposed mmetallic surfaaces, and repplace cover.
Coat all expposed threadss on the studds with oil-baased vapor ccorrosion inhhibitor and ccover with
cardboard or plastic tube.
If the lower unit does no ot contain an
ny oil, the acccess covers should be reemoved and all metallic parts
should be spprayed with rust inhibito or. After all internal partts are properrly treated, reeplaced the
covers.
Coat all unppainted surfaaces with a ru ust inhibitor.
Refer to Vallve Servicing Section D.. for Gear Reeducer long term storagee proceduress.
42

Elwood Parts and Service Manual

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PARTS AND SERVICE MANUAL

(EDN 064752 – Rev. A)

PART NUMBER 9794 8070

Decoking Control Valve, Basic Unit, 6"x 3"

Item Qty EPN EDN Description

Item Qty EPN EDN Description

Item Qty EPN EON Description

Item Qty EPN EDN Description

Item Qty EPN EDN Description

2 1 2215 0262 049568 Bushing Roller 3" Dia.

4 2 539 9353 051442 Thrust Bearing 1.0 inch dia.

5 2 541 4198 057460 Snap Ring 1.75 Dia. Housing, VH-175

ELWOOD CORP. - FLUID POWER GROUP

Item Qty EPN EDN Description

8477 3295 1 3391.39 Seat, 3" Decoker

8477 3316 1 5068.00 Seat, 6"/ 8", Decoker, HP ***OBSOLETE***

8610 8608 2 3.46 Ring, Back-Up (8 226 H1750)

8610 8608 1 3.46 Ring, Back-Up (8- 226 H1750)

8610 8613 6 3.39 Ring, Back-Up (8- 137 H1750)

8610 9715 2 5.08 Ring, Back-Up (8- 152 H1750)

8610 9754 3 5.77 Ring, Back-Up (8 243 H1750)

8610 9882 2 ·8.81 Ring, Back-Up (8 259 H1750)

8610 9961 2 12.85 Ring, Back-Up (8- 263 H1750)

9784 6594 1 340.00 Seal Kit, Gearbox Asm, 6 X 3 Decoker Valve

9784 7458 1 200.00 Seal Kit, 3" Spindle Asm.,Decoker Valve, SS

9784 7830 1 60.00 Seal Kit, Orifice Pack Asm.

9794 6592 1 691.00 Roller Asm, 3 in. Dia.

9794 6593 1 632.00 Roller Asm. 2 1/2" Dia.

9794 7457 1 13120.00 Spindle Assembly, 6" Decoker, Chrome Plated

9794 7458 1 6880.00 Spindle Assembly, 3" Decoker Valve, Chrome

Decoker Control Valve VENDOR NAME Elwood Corporation DATE 7/15/13

A Valve Body -- Main Valve

Mill test certificate

ASME SECTION VIII

Decoker Control Valve VENDOR NAME Elwood Corporation DATE 7/15/13

A4 Dimension control and visual Production drawings Drawing dimensions H

B Gland Flange -- Main

D Spindle -- Main Valve

TEST METHODS PREFORMED BY

Decoker Control Valve VENDOR NAME Elwood Corporation DATE 7/15/13

Mill test certificate

F Valve Body - By-Pass Valve

Decoker Control Valve VENDOR NAME Elwood Corporation DATE 7/15/13

Decoker Control Valve VENDOR NAME Elwood Corporation DATE 7/15/13

K Cap Orifice -- By-Pass Valve

Decoker Control Valve VENDOR NAME Elwood Corporation DATE 7/15/13

M2 Preliminary Functional Test Test Procedure H O Test Report

M3 Functional Test H O Test Report

Hydrostatic Test Test certificate

check of name plates, labels, tags

N3 control of main dimensions Basic Unit Drawing drawing dimensions H R REPORT

Quality Control Manufacturing Dossier

N5 Inspection Release Certificate SEE REF. DOC. H R REPORT

N6 Paint Inspection H R REPORT

N7 Spare Parts Verification PURCHASE ORDER H R REPORT

Main Valvee Sealing Material:

Body Material: Forged Staainless Steell

Main Valvee Flange Co

Maximum Stainless Stteel mum Pa

8477 3316 1 5068.00 Seat, 6"/ 8", Decoker, HP OBSOLETE