CP SWITCH VALVE SERVICE MANUAL Shop Assembly and Adjustment. IUNION SWITCH & SIGNALl[fill ANS ALDO

Transcription

1 UNON SWTCH & SGNALl[fill SERVCE MANUAL 6435 A member of the ANSALDO Group 5800 Corporate Drive, Pittsburgh, PA Shop Assembly and Adjustment CP SWTCH VALVE March, 1989 (Revised August, 1993) F B-8/ COPYRGHT 1993, UNON SWTCH & SGNAL NC. PRNTED N USA ANS ALDO Trasporti

2 REVSON NDEX Revised pages of this manual are listed below by page number and date of revision. Page Date of Revision Number Revision Number A (new) ii

3 Section CONTENTS ASSEMBLY OUTLNE a GENERAL 1. SUBASSEMBLES 1.1 MAGNET CAPS 1.2 CRCUT CONTROLLER CONTACT SPRNG BOARD 1.3 CRCUT CONTROLLER CONTACT SPRNG BLOCK 1.4 POPPET "CHECK" VALVE STEMS 1.5 PSTONS 1.6 CRCUT CONTROLLER CONTACT SPRNG BLOCK SHAFT 1.7 HAND HOLE COVER 1.8 VALVE BODY COVER 1.9 TERMNAL BLOCKS 1.10 TERMNAL BOARD CP VALVE ASSEMBLY VALVE BODY PREPARATON SEATNG AND FORMNG OF PN VALVES LAPPNG OF PN VALVE SEATS CUTTNG STEM VALVE BUSHNGS FORMNG AND LAPPNG OF STEM VALVE SEATS SEATNG OF PSTONS LAPPNG OF PSTONS NSTALLATON OF PN VALVE STEMS NSTALLATON OF CHECK VALVES NSTALLATON OF PSTONS NSTALLATON OF CRCUT CONTROLLER ADJUSTMENT OF PSTON AND CHECK VALVE NSTALLATON OF MAGNETS NSTALLATON OF PLUNGER & ASSEMBLY OF MAGNET ARMATURES 56. FNAL ADJUSTMENTS 3.1 ADJUSTMENT.PROCEDURE 58 V. FNAL ASSEMBLY 4.1 FNAL ASSEMBLY PROCEDURE 66 V. TOOLS, TEST EQUPMENT AND MATERAL REQURED 5.1 TOOLS REQURED 5.2 TEST EQUPMENT REQURED 5.3 MATERAL REQURED V. TROUBLESHOOTNG 6.1 TROUBLESHOOTNG GUDE 70 iii

4 LST OF LLUSTRATONS STYLE C.P. SWTCH VALVE MPS-1.2 Figure Title MAGNET CAP ASSEMBLY CRCUT CONTROLLER CONTACT SPRNG BOARD CRCUT CONTROLLER CONTACT SPRNG BLOCK CRCUT CONTROLLER POPPET check VALVE ASSEMBLY PSTON ASSEMBLY CRCUT CONTROLLER SPRNG SHAFT HAND HOLE COVER VALVE BODY COVER TERMNAL BLOCK TERMNAL BOARD REAMNG VALVE BODY PN VALVE SEATS PN VALVE LAPPNG CUTTNG VALVE STEM SEATS FORMNG AND LAPPNG VALVE STEM SEATS CUTTNG PSTON SEAT LAPPNG PSTON NSTALLNG PN VALVE N VALVE BODY NSTALLNG CHECK VALVES NSTALL PSTONS NSTALL CONTACT SPRNG BOARD CONTACT SPRNG BLOCK POPPET 9 CHECK 9 VALVE ADJUSTMENTS MAGNET POSTON FACNG TOOL HASP ASSEMBLY PLUNGER ASSEMBLY C.R.S. BLOCK WEGHTS USED TO OBTAN CORRECT BEND ON REL. SPRNGS CP SWTCH VALVE ASSEMBLY / / /53 54/ iv

5 OUTLNE FOR ASSEMBLY OF CP VALVES Page No. VHS No.. SUBASSEMBLES 1.1 MAGNET CAPS 1.2 CONTACT SPRNG BOARD 1.3 CONTACT SPRNG BLOCK 1.4 POPPET "CHECK" VALVE STEM 1.5 PSTON COMP 1.6 SPRNG SHAFT COMP 1.7 HAND HOLE COVER 1.8 VALVE BODY COVER 1.9 TERMNAL BLOCK 1.10 TERMNAL BOARD COMP CP VALVE ASSEMBLY VALVE BODY PREPARATON 1. Ream Bushings 2. Remove Wax Coating 3. studs to Body 4. Remove Fixture and Stud 5. Re-tap Holes Blow out Body SEATNG AND FORMNG OF PN VALVES 1. Place on Fixture Tool Guide cutting Tool Repeat cutting Clean Bushings Tool Guide Forming Operation cont'd Cont'd LAPPNG OF PN VALVE SEATS 1. Tool Guide Pin Valve Lapping compound Lapping Process Observe Results Cleaning of Pin seats Repeat for Remaining 2 Pin Valves CUTTNG STEM VALVE BUSHNGS Test Legs Preparation Tool Guide cutting Process Repeat Clean FORMNG AND LAPPNG OF STEM VALVE BUSHNGS Tool Guide Forming Tool Operation Forming Operation continued Application of Lapping compound Lapping Process Continuation of Lapping Process Clean completion of Process 32 a

6 2.6 SEATNG OF PSTONS 1. seat cutting Tool 2 Adjust cutting Tool 3. Prepare cutting Tool 4 Prepare cutting Tool 5 cutting Process 6. Repeat 2.7 LAPPNG OF PSTONS 1. Tool 2. Grease 3. Lapping compound 4. Lapping Process 5. Repeat 6. Fine Lapping compound 7. Remove and Clean 8 Repeat 9. Paint nside Body 2.8 NSTALLATON OF PN VALVE STEMS 1. clean 2. Assembly process 3. Assembly 4. Assembly cont'd. 5. Repeat for Remaining Stems 2.9 NSTALLATON OF CHECK VALVES 1. nstall Check Valve 2. nstall Spring 3. washer to Cap Plug 4. Graphite Grease Cap Plug Threads 5. Assembly to Body 6. Repeat 2.10 NSTALLATON OF PSTONS 1. nstall stud 2. Operating Arm to Valve Body 3. Shaft to Valve Body 4. Grease Chamber 5. Grease Piston 6. Pistons in Chambers 7. Repeat 8. Test caps 9. Air Strainer 10. connect Air Supply 2.11 NSTALLATON OF CRCUT CONTROLLER 1. Bracket to Valve Body 2. secure Bracket 3. Assembly Procedure 4. Guide Shaft 5. contact Sprihg Block to Valve 2.12 ADJUSTMENT OF Pr'STON AND CHECK VALVE 1. Test caps 2. Test Caps cont'd. 3. Adjustment Process 4. Air Test for Leaks 5. Repeat for Remaining Piston 6. Remove Test Caps 7. Graphite Grease 8. Assembly Process b

7 2.13 NSTALLATON OF MAGNETS 1. Preparation Process Alignment of Magnet Posts Repeat for Remaining Magnets Hasp to Valve Body Securing with Nut Lock Reinstall Center Magnet Pipe Plug or Grease Fitting NSTALLATON OF PLUNGER & ASSEMBLY OF MAGNET ARMATURES - 1. Assemble parts and grease 2. Spring and Plunger to Guide Nuts 3. Assembly to Valve Body 4. Armature to Stem Armature and Stem to Each Magnet FNAL ADJUSTMENTS 3.1 ADJUSTMENT PROCEDURE FOR CP VALVE 1. Magnets 2. Air Gap 3. Obtaining Air Gap 4. Repeat Gauge Gauge 7. Recheck Gap 8. Repeat & 4.5 oz. Weights 10. Release Springs and 8.0 oz. Weights 12. Power Supply 13. Air Pressure & P.U. Value 14. Values 15. Repeat 16. Air Leaks 17. Adj. Springs on Circuit controller 18. Minute Man Test 19. Removal From support Fixture 20. Removal of Test Legs Volt Ground Test 22. Rubber Grommet to Body 23. cover on controller 24. Magnet Caps on Magnets 25. Exhaust Plugs Assembly c

8 V. FNAL ASSEMBLY 4.1 FNAL ASSEMBLY PROCEDURE 1. (Mll0846) to nlet Air Port 2. Assemble Shut Off Valve to Union 3. Asb. Shut Off Valve to {Mll0840) 4. Assemble to Valve Body 5. {M092619) to Outlet Air Port 6. (J033581) to Nipple 7. (J033584) to outlet Air Port 8. Cable Clamps to Base 9. Valve Body to Base 10. Terminal Board to Base. 11. Hand Hole Cover to Base 12. Paint 13. Service Manual 14. nstall Cover to Base 15. Paint and Stencil 16. Hold Down for Cover ~ v. TOOLS, TEST EQUPMENT AND MATERAL REQURED 5.1 TOOLS REQURED 5.2 TEST EQUPMENT REQURED 5.3 MATERAL REQURED V. TROUBLESHOOTNG 6.1 TROUBLESHOOTNG GUDE NOTE VHS NUMBERS ARE FOR REFERENCE ONLY. THEY MAY VARY FROM ONE RECORDER TO ANOTHER. d

9 GENERAL The style cp switch Valve is used for the control of compressed air to the operating cylinder of electro-pneumatic switch machines. The Lock Valve Magnet must be energized before compressed air can reach the Pin Valve chambers of the other magnets, known as the Normal and Reverse Operating Magnets. The two plunger pistons actuate poppet valves permitting the flow of air from the main air chamber to one end or the other of a switch operating cylinder. The Walking Beam is moved by the two plunger pistons to operate the contacts of the circuit controller. ts construction prevents both pistons moving to open the poppet valves simultaneously, and the spring actuated plunger retains the beam in either extreme position. The contacts on the circuit controller indicate the position of the valve itself. The right hand magnet (facing the circuit controller) is the Normal magnet. DRAWNG NUMBER: ENGNEERNG SPEC: ENGNEERNG SPEC: QCP SPEC: REFERENCE MATERAL Sh & Sh EU-98 EU-2054 P-729 1

10 SECTON SUBASSEMBLES 1.1 MAGNET CAPS There are three Magnet caps required for each CP Valve. The following describes the procedure for assembling Magnet cap, Piece Number N075967, Drawing Cl992-Sh. 0009, as shown in Figure 1-1 (B). 1. Assemble cover Plate M (2), to Magnet cap M (3), place Beveled washer M (4) over cover Plate with bevel side of washer facing up and secure with Screw J {1) such that the Cover Plate turns easily and retains any position in which it may be set. NOTE WHEN STEP 2 S COMPLETE, COVER PLATE {M075973) MUST TURN READLY WTH THE FNGERS, BUT BE TGHT ENOUGH TO RETAN TS POSTON. 2. Turn cap over and rest head of screw on metal block. Using a rivet set, peen end of screw over to lock in place. 3. Touch up screw head and beveled washer with black paint (Spec. PP ). 4. Repeat procedure for remaining two Magnet Caps. 5. For CP Valves that utilize solid (one piece) Magnet caps M079249, Drawing Cl992 Sh. 0009, there is no assembly required. See Figure 1-l(A). 2

11 M Solid Magnet cap (A) 1 4 PEENOVER 3 N Magnet cap with cover Plate (B) Figure 1-1 MAGNET CAPS

12 1.2 CRCUT CONTROLLER CONTACT SPRNG BOARD The following is the procedure for assembling the Circuit Controller contact Spring Board, Piece Number Nl56345, Drawing C9261-Sh. 0003, as shown in Figure 1-2. NOTE WHEN ASSEMBLNG CONTACT BLOCKS ON CRCUT CONTROLLER BOARD, CONTACT BLOCKS MUST REST N THE MOLDED SLOTS OF THE BOARD AS SHOWN N D FGURE Assemble one Contact Block Nl56367 (5), in position A on one side of Molded Terminal Board J (2) and secure with Screw J (1) and Lock washer J (6). See Figure Assemble one Contact Block Nl56377 (4), in position B on same side of Molded Terminal Board J (2) and secure with Screw J (1), and Lock Washer J (6). Refer to Figure 1-2 and NOTE. J 3. nstall one screw J (1), and Flat washer J (3) in each of the remaining holes of contact Blocks Nl56367 and Nl56377 as shown in Figure 1-2 position c. 4. Repeat procedure for opposite side of Circuit Controller Contact Spring Board. 4

13 2 0 5 r- A 0,, '...,, B ~ 4 D Figure 1-2 CONTACT SPRNG BOARD 5

14 1.3 CRCUT CONTROLLER CONTACT SPRNG BLOCK The following is the procedure for assembling the Circuit controller contact Spring Block, Piece Number , Drawing C9261-Sh Assemble Contact Stop Spring Ml57743 (3), Contact Spring Ml53495 (4), and washer Ml87712 (5), to one side of Molded Block J (6) and secure with Screw Mll9318 (1), and Lock washer J (2) applied in position A as shown in Figure 1-3. Do not tighten screw at this time. 2. Repeat step 1 for other side of Molded Block J Place braided wire lead (8) of Terminal Connector N (7), between washer Ml87712 (5), and Contact Spring Ml53495 (4), on one side of contact Spring Block Nl Align hole in braided wire with holes in washer, contact spring, contact stop spring and contact block then secure to molded block with screw Mll9318 (1) and Washer J (2) applied in position "B" 'as shown in Fig Tighten screws in postions A and "B". 6. Repeat steps 3, 4, and 5 for other side of Contact Spring Block. 7. The assembly of the Circuit Controller is completed by installing the circuit controller Contact Spring Block N on the circuit controller Contact Spring Board Nl This is accomplished as follows: 6 A. Place the conta~t Spring Block assembly (7) on the contact Spring Board assembly' (1) as shown in Figure 1-4. B. Using screw J (2) and Lock washer J (3) inserted in position A", secure Terminal connector (4) to molded terminal board. c. nstall one Screw J (2) and Flat Washer J (6) in position "B of Terminal Connector (4). D. Repeat Steps 7B and 7C for remaining Terminal Connector.

15 8 7 Figure 1-3. CONTACT SPRNG BLOCK, Nl

16 7 1 0 Figure 1-4. CONTACT SPRNG BOARD P. 8/9

17

18 1.4 POPPET VALVE STEMS There are two Poppet Valve stems required for each CP Valve. The following is the procedure for assembling the Poppet Valve Stem, Piece Number Nl56363, Drawing c9261-sh. 0003, as shown in Figure Prior to assembling, coat Bolt Ml55146 (1) with graphite grease, A (Spec. M7660-1). 2. Prior to assembling, coat entire Gasket J (6), with a light coat of the same grease. 3. nstall Bolt Ml55146 (1), Washer M (7), Valve stem Ml53480 (2) and Gasket J (6) to Collar Ml53481 (3), and secure with Lock washer J (5) and Nut J (4). 4. Repeat this procedure for the remaining Poppet Valve Stem. 10

19 2 3 4 Figure 1-5. CHECK (POPPET) VALVE, N

20 1.5 PSTONS \ 2 There are two Pistons required for each CP Valve. The following is the procedure for assembling the Piston, Piece Number Nl56432, Drawing 8328-Sh. 0125, see Figure Prior to assembling, coat entire Piston Packing J (6), with a light coat of grease A (Spec. M7651-2). 2. nstall Piston Packing J (6), and Washer M (2), to Piston M (3), and secure with shakeproof Washer J (5) and Nut M (1), as shown in Figure f Piston is not immediately used, proceed as follows: A. coat the Piston Collar as well as that portion of the Piston below the collar with a light coat of rustprotector and allow coating to set. B. Press on Protector J (4), to protect Piston bevel from nicks and scratches. c. store Piston in an upright position as shown in Figure 1-6 to protect packing. 4. Repeat procedure for remaining Piston. 12

21 6 5 3 ~---4 Figure 1-6. PSTON ASSEMBLY, N

22 1.6 CRCUT CONTROLLER CONTACT SPRNG BLOCK SHAFT The following is the procedure for assembling the circuit controller Contact Spring Block Shaft, Piece Number Nl56849, Drawing 9956-Sh. 0077, see Figure Prior to assembling, check that all passages are open and able to accept grease by applying an air supply to the grease fitting end. 2. osing a small hammer, drive Plug Ml55142 (2), into shaft Ml53469 (1) until plug surface is flush or even with shaft end surface. 3. osing a file, remove all burrs on shaft, break all corners, and draw file all flat surfaces as well as the end of the shaft into which the plug was driven. NOTE WHEN APPLYNG ROSTPROTECTOR, CARE MOST BE EXERCSED TO PREVENT THE PROTECTVE MATERAL FROM CLOGGNG ANY GREASE PASSAGES. 4. Apply a light coat of rustprotector to entire shaft to protect against rust and allow to set. s. To insure grease passages are clean, apply grease (A041353), with grease gun, to shaft fitting until grease is observed exiting all holes. 14

23 1 Figure 1-7. SPRNG SHAFT, Nl

24 1.7 HAND HOLE COVER The following is the procedure for assembling the Hand Hole Cover, Piece Number Nl58816, Drawing 9261-Sh. 0002, see Figure nsert two rivets J Cl) into holes in top of cover Ml58615 (3), then place iron block against rivet heads and turn cover over so iron block rests on work bench. 2. Using the two rivets, assemble Locking Piece Ml58815 (2), to bottom of cover M (3) and peen over rivet ends, using a rivet set, until locking piece is tight against cover as shown in Figure Paint entire Cover as follows: Hand Hole cover, Nl58816, per PP Hand Hole Cover, Nl , per PP {Aluminum) 16

25 3 2 Figure 1-8. HAND HOLE COVER, Nl

26 1.8 VALVE BODY COVER The following is the procedure for assembling the valve Body Cover, Piece Number Nl89818, Drawing 9261-Sh. 0002, see Figure Assemble Clip Ml53487 (1), in position A on one side of cover Ml89817 (4) with three Rivets J (3), as shown in Figure 1-9, then place head of Rivet against metal block and turn cover over so iron block rests on workbench. 2. Using a rivet set, peen over Rivet ends until Clip is tight against top of Cover. 3. Repeat Steps 1 and 2 for opposite side of cover. 4. Using the procedure described in Steps 1 and 2, assemble Clip Ml89702 (2), to cover Ml89817 (4), in position "B", with two Rivets J (3), as shown in Figure 1-9. care must be exercised to prevent distorting curvature of Clip when peening Rivet ends over. s. Paint entire Cover per PP (Black), except for machined lip. 18

27 1 2,, /. 0 ' { 0 A op ob r , :b :P (l{) Figure 1-9. VALVE BODY COVER, Nl

28 1.9 TERMNAL BLOCK NOTE REFER TO CP VALVE BLL OF MATERAL FOR SPECFC TERMNAL BLOCK PECE NUMBER. There are four Terminal Blocks required for each CP Valve. The following is the procedure for assembling the Terminal Block, Piece Number N249059, Drawing 9968-Sh. 1350, see Figure Assemble one Flat Washer J (3), to each of six Posts (1) on Terminal Block M (4). 2. Apply one Nut J (2), to each of the six Posts of the Terminal Block M Mark nstruction Sheet M , with an x in the appropriate block, depending on piece number made. n this instance, an x is placed in the block adjacent to piece number N Place twelve washers J (5), six Nuts J (6), six nsulating Nuts J (7) and nstruction Sheet M in Plastic Bag J For other piece number Terminal Boards, the quantity of hardware to place in the plastic bag should be in accordance with drawing requirements. 5. Seal bag. 6. Attach sealed bag to Terminal Block. 7. Repeat procedure for remaining three Terminal Boards. 20

29 1 6 s 7~ - t ' ' -~ rfi1 f,u-~ rr,, ' '-\ rfn ' ~-.!...\ '?--1-\ Figure TERMNAL BLOCK, N

30 1.10 TERMNAL BOARD NOTE PROR TO ASSEMBLNG THE TERMNAL BOARD, REFER TO CP VALVE BLL OF MATERAL FOR SPECFC TERMNAL BLOCK PECE NUMBER TO BE USED. The following is the procedure for assembling the Terminal aoard, Piece Number N245971, Drawing 9261-sh. 0030, using Terminal Block N shown in Figure Assemble two Terminal Blocks N (1) to Vertical support M (2), and secure with three Screws J (3), and Lock Washers J (4) as shown in Figure Complete the assembly of the Terminal Blocks to the Vertical Support using Screw J (5) applied in position "B" as shown in Figure 1-11 and screwed into the threaded hole in the Vertical Support. 3. Repeat Steps 1 and 2 for the remaining two Terminal Blocks and Vertical Support. 4. Assemble one of the Vertical supports (2) with Terminal Blocks (1) to the Top Support M (8) by placing the end of screw (5), located in postion a, through the hole provided in the Top Support and secure with Lock Washer J (6) and Nut J (7). See Figure Repeat Step 4 for remaining Vertical support with Terminal Blocks. 22

31 d 'Cl '., \,.., 8 Q: 1 B i {) 3., 4 er 5., rr 6., 7 :-:t rr ::t_ tf ::t,, rr =i. -~- {Q,r,, ':.. (r 1 ;:t.... ',. 2 2 Figure TERMNAL BOARD, N

32 SECTON CP VALVE ASSEMBLY Now that all of the sub-assemblies have. been completed, the assembly of the CP Valve Complete can begin. 2.1 VALVE BODY PREPARATON 1. Using the special two step reamer (TilOOO), found at the work station, ream the two bushings located in the Valve Body (N155219), see A Figure Using the solvent Xylol A040226, remove the protective wax coating applied to the piston bores. CAUTON WHEN PERFORMNG STEP i3, CARE MUST BE EXERCSED NOT TO MUSHROOM THE OPPOSTE END OF STUD, Ml53467, DURNG PEENNG OPERATON. 3. Assemble studs M and Ml61756, to the Valve Body. Slide Fixture (T#lOOl), over both studs. Turn Valve Body over so Fixture is resting on table, and using a ball peen hammer, peen end of Stud M over until it is rigidly secured to the Valve Body. 4. Turn Valve Body over and remove Fixture (T#lOOl). Also remove Stud M for later use. 5. Using taps found at work station, re-tap all threaded holes.found in the Valve Body and draw file machined surface around the Poppet Valve and Plunger openings as well as the machined surface around the Piston openings. 24 WARNNG WEAR APPROPRATE EYE PROTECTON WHLE PERFORMNG THE FOLLOWNG STEP. F NOT, DAMAGE TO OR LOSS OF EYE MAY RESULT. 6. Using air nozzle, force air through all openings and passage ways in valve Body to remove all metal chips or any other foreign matter.

33 REMOVE WAX COATNG A Ream using special 2-step reamer Figure 2-1. REAMNG VALVE BODY 25

34 2.2 SEATNG AND FORMNG OF PN VALVES This section covers the process of cutting and forming the Pin valve Bushings (3). see'figure Turn Valve Body Nl55219 (2) over, resting the three Magnet Valve Bushings of the Valve Body Nl55219 (2), on the Wooden Block Ttl002, located at the work station. 2. screw Tool Guide M (4), into one of the three Pin Valve Bushings (3). CAUTON WHEN PERFORMNG STEP 13, CARE MOST BE TAKEN TO PREVENT CUTTNG SEAT TOO DEEP WHCH CAN RESULT N SCRAPPNG VALVE BODY. 3. Place Clamp TilOll (8) on Cutting Tool N (1) and insert tip of cutting Tool N (1), through hole in Tool Guide until tip rests against Pin Valve Bushing. Place a feeler gauge between Tool Guide and Clamp. Using a screwdriver, lock the set screw on the Clamp and remove the feeler gauge. Applying downward pressure with hand, turn Cutting Tool clockwise until the bottom of the Clamp comes to rest against the Tool Guide, resulting in a seat cut deep. 4. Repeat steps 12 and 13 for the two remaining Pin Valve Bushings. 5. When the last bushing has been cut, remove cutting Tool and Tool 'Guide from bushing and clean each of the three bushings, using solvent Xylol A040226, and blow dry. 6. Again screw Tool Guide M (4) into one of the Pin Valve Bushings (3} of the Valve Body. CAUTON WHEN PERFORMNG STEP 17, TAPPNG MUST BE DONE EVENLY AND WTH AN EQUAL AMOUNT OF FORCE. TAPPNG TOO HARD CAN RESULT N SCRAPPNG THE VALVE BODY. 7. nsert 60 degree Forming Tool 12, M (5), through hole in Tool Guide. With the Forming Tool resting against the bushing seat, lightly tap the top of the Forming Tool 12 several times with a small hammer while constantly rotating tool. 8. Repeat Steps 6 and 7 for remaining two bushing seats. NOTE When repairing valves, that is valves which are returned by the customer in which the seats are only slightly worn or scored, the cutting operation can often be,avoided, and sometimes the lapping also by using 60 degree punch (M098517}, and following Step t7. f the seats, by repeated reseating have become so deep that it is difficult to secure a good face, tools (Ml52452) and (M152453) may be used in the same manner as described in step f7 to force back the edges of the seat at the top and bottom. f a good seat cannot be obtained using these procedures, replace bushing and perform Steps 1 through 8. 26

35 ...,n C) ' N "".. N "" - \ < \ Figure 2-2. PN VALVE SEATS 27

36 2.3 LAPPNG OF PN VALVE SEATS This section covers the process of lapping the three Pin Valves to the Valve Body. ( See Figure 2-3) 1. screw Tool Guide (Tt1009) (3) into one of the three Pin Valve Bushings (4). 2. nsert head of Pin Valve M {2) into Tool Holder (T!1003) {1). 3. Apply a small amount of 400 grit lapping compound A to bevel of one of the three Pin Valves. 4. nsert the tip of the Pin Valve through the hole in the Tool Guide until Pin Valve rests against Pin Valve Bushing seat. Then rotate Tool Holder (1) back and forth while applying light downward pressure. Repeat several times, continually checking for an adequate amount of compound on bevel of Pin Valve. 5. Remove Tool Holder and Pin valve and wipe bevel of Pin Valve clean. Observance of a dull uniform finish on bevel of Pin Valve is an indication that a proper seat has been obtained. 6. Remove Tool Guide. Using thinner A040323, clean both Pin Valve and bushing seat, then dry thoroughly. NOTE AT THS PONT, PN VALVE MUST BE KEPT WTH TS RESPECTVE BUSHNG, SNCE PN VALVES ARE NO LONGER NTERCHANGEABLE FOLLOWNG LAPPNG PROCESS. 7. Repeat Steps 1 through 6 for remaining two Pin Valve seats using a different Pin Valve each time. 28

37 1 APPLY LAPPNG COMPOUND HERE Figure 2-3. PN VALVE LAPPNG 29

38 2.4 CUTTNG STEM VALVE BUSHNGS This section covers the process of cutting the three Stem (Exhaust) Valve Bushings (3) in the Valve Body Nl55219 (4). (See Figure 2-4). 1. screw the two test legs (Tfl004) (5), into the threaded holes provided in the bottom of the Valve Body. 2. Turn the Valve Body over and place test legs into mounting holes on bench and secure with nut. 3. screw Tool Guide M (2) into one of the three stem Valve Bushings (3). CAUTON WHEN PERFORMNG STEP #4, CUTTNG SEAT TOO DEEP CAN RESULT N SCRAPPNG VALVE BODY. 4. nsert cutting Tool N (1), Figure 2-4, through hole in clamp N (6), then insert tip of cutting Tool N (1), through hole in Tool Guide (2) until tip rests against the Stem Valve Bushing. Place a 0.025" feeler gauge between Tool Guide and Clamp. Using a screwdriver, lock the set screw on the Clamp and remove the feeler gauge. Applying light downward pressure with hand, turn Cutting Tool clockwise, cutting a bevel 0.025" deep. 5. Repeat steps 3 & 4 tor remaining two Stem Valve Bushings. 6. When cutting process has been completed, remove cutting Tool and Tool Guide from last bushing. Using thinner A040323, clean each of the three stem Valve Bushings and blow dry throughly. 30

39 Figure 2-4. CUTTNG STEM VALVE SEAT 31

40 2.5 FORMNG AND LAPPNG OF STEM VALVE SEATS This section covers the process of forming and lapping the three Stem Valve seats of che Valve Body Nl55219 (6). (See Figure 2-5). 1. screw Tool Guide M (4), into the Stem Valve Bushing (5), see Figure 2-5. CAUTON WHEN PERFORMNG STEP f2, TAPPNG MUST BE DONE EVENLY AND WTH AN EQUAL AMOUNT OF FORCE. TAPPNG TOO HARD CAN RESULT N SCRAPPNG VALVE BODY ~sert the tip of the 60 degree Forming Tool t2 M (1) through the hole in the Tool Guide until the tip rests against the bushing seat. Lightly tap the top of the Forming Tool t2 several times with a small hammer, while constantly rotating tool. 3. Repeat Steps 1 and 2 for remaining two bushing seats. NOTE When repairing valves, that is valves which are returned by the customer in which the seats are only slightly worn or scored, the cutting operation can often be avoided, and sometimes the lapping also by using 60 degree punch (M098516), and following Step #2. f the seats, by repeated reseating have become so deep that it is difficult to secure a good face, tools (Ml52450) and (Ml52451) may be used in the same manner as described in Step t2 to force back the edges of the seat at the top and bottom. f a good seat cannot be obtained using these procedures, replace bushing and perform Steps 1 through 6 of Section 2.4. and Steps 1 through 3 of Section With Tool Guide M (4) screwed into one of the three stem Valve Bushings, apply a small amount of 400 grit lapping compound A410000, to the bevel of one of the three Valve stems. 5. nsert the tip of the Valve Stem through the hole in the Tool Guide M (4) until the tip rests against the bushing seat, then rotate the Valve Stem back and forth several times while appling slight downward pressure with the hand. Remove the stem from Tool Guide and wipe clean. Observance of a dull uniform finish on the bevel of the stem is an indication that a proper seat has been obtained. 6. Repeat steps 4 and 5 until the proper finish is obtained. 7. Remove the Valve Stem and Tool Guide. Using thinner A040323, clean both the Valve Stem and bushing seat, then blow dry throughly. NOTE AT THS PONT, VALVE STEM MUST BE KEPT WTH TS RESPECTVE BUSHNG, SNCE VALVE STEMS ARE NOT NTERCHANGEABLE FOLLOWNG LAPPNG PROCESS. 8. Repeat steps 4 through 7 for remaining two Stem Valve Bushing seats, using a different Valve Stem each time.

41 - "' Cl ' r N \.. 1, " 4 Figure 2-5. FORMNG AND LAPPNG VALVE STEM SEATS 33

42 2.6 SEATNG OF PSTONS This section covers the process of cutting the Piston seats (5) in each of the two Pistbn Chambers of the CP Valve Body. 1. Screw the Base (3) of the Cutting Tool N , see Figure 2-6, completely into one of the Piston chambers. 2. Check that the cutting Tool is properly adjusted to cut a seat 1/16 inch (0.0625) deep. Proper adjustment of the cutting Tool may be checked as follows: a. Unscrew the Tension Collar (2) from the cutting Tool Base (3) and remove from the shaft of the Cutting Bit (1). b. Remove the cutting Bit (1) from the Base (3) of the cutting Tool and the Tension collar spring. c. Reinsert the cutting Bit (1) into the Base (3) of the cutting Tool so the tip of the Cutting Bit (1) makes contact with the edge of the bushing into which the seat is to be cut. d. The proper adjustment of the Cutting Tool can be verified by checking that the gap between the washer and the round bottom adjusting nut on the shaft of the Cutting Bit is 1/16 or inches. The gap should be checked using Gauge (TflOlO). e. f the cutting Tool is found to be properly adjusted, proceed to step #3. f the adjustment is found to be incorrect, proceed to Step f. f n order to change the adjustment of the cutting Tool, loosen the round top locking nut on the shaft of the cutting Bit (1) and rotate the bottom adjusting nut clockwise to reduce the gap or counterclockwise to increase the gap. g. With Gage (TflOlO) inserted between the washer and the adjusting nut, lower the adjusting nut by rotating it clockwise until the bottom of the nut comes in contact with the top of the Gauge. The adjusting nut positioned is this manner will result in cutting the seat the proper depth of 1/16 or inches deep. h. Hold the adjusting nut in this position and rotate the top or locking nut clockwise to lock the adjusting nut in this position. Once the adjustment has been locked, remove the Gauge. i. Remove the cutting Bit (1) from the Base (3) of the cutting Tool, replace the tension spring, reinsert the cutting Bit (1) into the Base (3) and screw Tension Collar (2) onto the Base. 3. Push down on the shaft of the cutting Bit (1) until the cutting Bit contacts the edge of the bushing to be cut, then rotate the Tension collar (2) clockwise until it cannot be turned any further. 4. nsert a handle in each of the holes provided in both the shaft of the cutting Bit (1) and the Tension Collar (2). 5. Rotate the cutting ~it handle clockwise while continuing to apply pressure to the cutting Bit by turning the handle on the Tension collar clockwise as well. A proper seat depth of 1/16 or inches is achieved when the cutting Bit rotates freely and the Tension collar (2) is tight against the Base (3) of the cutting Tool. 6. Repeat Steps 1 through 5 for remaining Piston Chamber. 34 NOTE WHEN BOTH SEATS HAVE BEEN CUT, REMOVE THE CUTTNG TOOL AND CLEAN BOTH SEATS, USNG THNNER A THEN BLOW DRY THROUGHLY, USNG AN AR NOZZLE.

43 1 SHAFTOF cunea cunlngbt 5 Figure 2-6. CUTTNG PSTON SEAT 35

44 2.7 LAPPNG OF PSTONS This section covers the process of lapping the two Pistons {Nl56432) {3) to the Valve Body. See Figure Screw the T Handle (Ti1006) (1), see Figure 2-7, into the end of the Nut M (2) on one of the two Pistons and lightly tighten. 2. Apply a light coat of Brake Cylinder grease Spec M , A to the wall of one of the two Piston Chambers. 3. Apply a small amount of 280 grit (coarse) lapping compound A to the bevel of Piston (4). 4. Place Piston into the lubricated chamber and apply downward pressure with hands while rotating Piston back and forth several times. A. Turn tool handle about 1/4 turn and repeat Step 14 until a complete 360 degree turn has been made. NOTE CONSTANTLY CHECK FOR AN ADEQUATE AMOUNT OF COMPOUND WHEN LAPPNG PSTON. 5. Remove Piston from Piston chamber and wipe clean. Observance of,a dull uniform finish on the bevel of the Piston will indicate the start of an air tight seat. 6. Repeat steps 3 through 5 with 400 grit (fine) lapping compound A NOTE A DULL UNFORM FNSH ON BEVEL OF PSTON WLL NDCATE THAT A PROPER SEAT HAS BEEN ACHEVED. 7. Remove Piston, clean both the bevel on Piston and Piston Seat with thinner A and blow dry throughly. NOTE AT THS PONT, PSTON MUST BE KEPT WTH TS RESPECTVE PSTON CHAMBER, SNCE PSTONS ARE NOT NTERCANGEABLE FOLLOWNG TH~ LAPPNG PROCESS. 8. Repeat Steps 1 through 7 for remaining Piston and Piston Chamber. 9. Brush inside of body cavity only, with white paint (Spec. PP ) i.e., the area in which the Circuit Controller is housed. Be careful not to get paint on newly lapped seats. 36

45 1 Figure 2-7. LAPPNG PSTON 37

46 2.8 NSTALLATON OF PN VALVE STEMS This section covers the installation of Pin Valve stem M (1), Spring J (3), and Plug Nut M (4), to the Valve Body Nl55219 (2). See Figure Thoroughly clean the three Pin Valve Bushings with thinner A040323, and using air nozzle, blow dry. 2. Assemble the Spring J (3), to the head of the Pin valve M (1) and insert Pin Valve and Spring into proper Pin Valve Bushing by inserting the tip of Pin Valve through hole in bushing. NOTE SNCE PN VALVES ARE NOT NTERCHANGEABLE, THE PN VALVE NSERTED NTO THE PN VALVE BUSHNG SHOULD BE THE PN VALVE USED DURNG THE LAPPNG PROCESS FOR EACH OF THE THREE BUSHNG SEATS. 3. Apply a light coat of Graphite Grease A041075, Spec , to the threads of the Plug Nut M (4}. 4. center coned portion of Plug Nut in opposte end of spring and screw Plug Nut into bushing. s. Repeat Steps 2 through 4 for remaining two Pin Valves. 38

47 Figure 2-8. NSTALLNG PN VALVES N VALVE BODY 39

48 2.9 NSTALLATON OF CHECK VALVES This section covers the installation of the two Check Valves in the CP Valve Body. See Figure 2-9. NOTE CHECK FACE OF BUSHNG NSDE THE TWO LARGER OPENNGS N THE BOTTOM OF VALVE BODY FOR PRESENCE OF ANY DEEP SCRATCHES OR BURRS.. Place Check Valve Nl56363 () in one of the two openings in the valve Body. Nut used in the assembly of Check Valve Stem should be facing out. 2. Next place Spring J (2) in same opening as Check Valve (1). 3. Assemble washer Ml53492 (3), to Cap Plug Ml49798 (4). 4. Apply a coat of graphite grease A041075, Spec M7660-, to the th~eads of one of the two cap Plugs (4), then place over Spring (2) and screw cap Plug into bottom of Valve Body. 5. Screw one 1/4 Pipe Plug J (5) into the threaded hole of the cap Plug (4). 6. Repeat Steps through 5 for remaining Check Valve (1), Spring (2), washer (3), Cap Plug (4) and 1/4 Pipe Plug (5). 40

49 k~=~j~ Figure 2-9. NSTALL CHECK VALVES 41

50 2.10 NSTALLATON OF PSTONS This section covers the installation of the two Pistons (4), Operating Arm (5), Shaft ' (3) and Stud (6) to the Valve Body. See Figure 2-10 (B). 1. Place threaded portion of Stud Ml61756 (6) in top hole of Valve Body cavity. 2. nstall Operating Arm Ml49673 (5) in valve body cavity as shown in Figure 2-10 (B). 3. Prior to installation, coat Shaft (3) with a light oil A (Spec. M ). With the milled surfaces of the shaft vertical, insert Shaft N (3) through square hole in operating arm and into the center hole in Valve Body cavity. See Figure 2-10 (B). NOTE OPERATNG ARM AND SHAFT MUST OPERATE FREELY WHEN NSTALLED N VALVE BODY. 4. Coat inside of both Piston chambers with a light coat of Brake Cylinder Grease A041353, Spec.M Repeat step 4 for rubber packing on one of the two Pistons (4). n addition, fill inside portion of packing cup with same lubricant. NOTE SNCE PSTONS ARE NOT NTERCHANGEABLE, THE PSTON NSERTED NTO THE PSTON CHAMBER SHOULD BE THE PSTON USED DURNG THE LAPPNG PROCESS FOR EACH OF THE TWO PSTON SEATS. 6. nstall Piston Nl56432 (4) carefully into one of the Piston chambers. 7. Repeat steps 5 & 6 for the remaining Piston. 8. Screw handle (1) out of Test Cap N (2) until bottom of handle is flush with the bottom of the cap. See Figure 2-10 (A). Screw one Test Cap (2), into top of each Piston chamber. 9. nstall Air strainer Nl55144 (3) to air inlet port of Valve Body. see Figure Plug side opposite air inlet port using a 1/2 inch pipe plug with light coat of Locktite Pipe sealant J041636, Spec. M applied to pipe plug threads. ' } 42

51 6 (A) (B) Figure NSTALL PSTONS 43

52 2.11 NSTALLATON OF CRCUT CONTROLLER This section covers the installation of the Circuit Controller to the valve body. 1. With rounded surface of Bracket Ml49672 (1) at top, slide Bracket (1) over the Shaft Nl56849 (3). See Figure Secure Bracket to the two Studs (2) with two Lock washers J (5), and two 3/8-16 std. hex nuts J (4). 3. Place Circuit Controller over Shaft and align holes in the back of the contact Spring Board of Circuit Controller with the locating pins on the ends of the two studs. 4. Using two Shakeproof Washers J (4) and two 1/4-20 Screws J (5), with fingers, start screws into threaded holes on bracket, see Figure 2-12, until the locating pins (2) on the two studs, Figure 2-il, have started into the locating holes on the reverse side of the contact Spring Board. Then tighten with screwdriver. NOTE MLLED SURFACES OF SHAFT MUST BE N A VERTCAL POSTON. 5. Pull back Contact Spring Block of Circuit controller and place Guide M153471, over shaft. 6. Reposition Contact Spring Block Nl91894 (2), Figure 2-12, on shaft and secure with Lock Nut J (1). 44

53 5 ~-- f ) -. --,J (f.. -~.. J 2 Figure

54

55 Figure CONTACT SPRNG BLOCK p. 46/47

56 2.12 ADJUSTMENT OF PSTON AND CHECK VALVE This section covers the adjustment of the Piston to proper travel distance on the Check Valve and to obtain proper travel distance of the contacts. connect air supply, regulated to 80 PS, to open air inlet port of the valve Body. 1. With air supply turned ON, turn T" handle screw on one Test Cap N246551, Figure 2-13, almost all the way out. 2. Turn T handle on the other Test Cap Screw in until air just begins to escape. 3. Continue turning T handle screw in an additional 1-1/2 to 2-1/2 turns, at which time air escape should stop. f more than 2-1/2 turns are needed to stop the air, do the following. A. Shut off air supply and back off Test Cap Screw. B. Remove the Check Valve associated with Piston being depressed with Test Cap screw. c. Evenly file the top of the bolt head on the Check valve, removing a small portion of the radius. See Figure NOTE SNCE BOLT MUST BE FLED EVENLY, CARE SHOULD BE EXERCSED WHEN FLNG TOP OF BOLT HEAD. D. Reinstall the Check Valve and repeat Steps 1 through 3, until the desired result is obtained. 4. With one of the Pistons seated using the Test Cap T handle and the air supply turned ON, apply soapy water solution to bottom of test leg pipe corresponding with the Piston seated, check for air leakage. f an air leak is detected, it will be necessary to remove the Piston and re-lap the Piston bevel and Piston seat as described in section 2.7. NOTE NO AR ESCAPE S PREFERABLE, BUT F A VERY SLOW BUBBLE S FORMED, THEN THE SEAL S CONSDERED GOOD. 5. Repeat Steps through 4 for remaining Piston. 6. With air turned OFF, check that the Front contacts make when their respective operating Pistons are from 1/32 to 1/16 from their seats. To check this: A. Turn down one T handle adjusting screw until the associated Piston is seated. B. Take up any lost motion of the Walking Beam by turning down the other T handle adjusting screw as far as possible. Front contact should be closed. c. Release the seated Piston by one half turn of the T handle screw, then tighten the other T handle screw. Front contact should be should remain closed. D. Release the seated Piston another half turn, and retighten the other screw. Front contact should be open. E. Repeat this procedure by seating the opposite Piston to check its contacts. ~ 7. With the air supply turned OFF, remove Test Caps. 8. Apply a small amount of Graphite Grease A (Spec. M7660-l}, to the threads of the two Piston Cap Nuts Ml49799 and the two Washers Ml Assemble Washer to Cap Nut and screw Cap Nut into the top of one of the Piston chambers of the Valve Body. 10. Repeat steps 8 and 9 for remaining Cap Nut and washer. 11. DO NOT insert Pipe Plug or Grease Fitting into threaded holes of Piston cap Nuts at this time. 48

57 Test Caps File bolt head evenly to obtain 1f to 2 turn adjustment on test caps Figure CHECK VALVE ADJUSTMENT

58 2.13 NSTALLATON OF MAGNETS This section covers the installation of the three Magnets to the CP Valve Body. For ' specific Magnet piece numbers, refer to CP Valve drawing and/or Bill of Material. 1. Before installing the Magnet, check the threads on the Magnet for the presence of nicks or burrs. Using the appropriate thread file, carefully remove any nicks of burrs that are found. 2. Prior to installation, remove the two Terminal Posts with washers from the Magnet. 3. Starting with the LOCK (center) position, screw Magnet into bushing. Using a pipe wrench, carefully tighten Magnet. Threaded Terminal Post holes in Magnet should be centered. See Figure f holes don't center up, take the following steps: A. Remove Magnet. B. Screw Facing Tool (Ttl008), see Figure 2-15, completely into bushing, using the top application handle of Facing Tool. c. Turn the middle or tension handle to the point where it just meets the top surface of the cutting barrel handle. D. Face bushing by carefully turning the bottom or cutting handle clockwise while continually applying little pressure with the tension handle by slowly turning it clockwise also. Remove small amounts of surface at a time. E. Remove Facing Tool. F. Reinstall Magnet and recheck Terminal Post hole alignment. G. Repeat Steps 38 through 3F until proper alignment of Terminal Post holes has been obtained. Once proper alignment has been " obtained, remove Magnet. NOTE AT THS PONT, MAGNET MUST BE KEPT WTH TS RESPECTVE BUSHNG, SNCE MAGNETS ARE NOT NTERCHANGEABLE ONCE FACNG PROCESS HAS BEEN COMPLETED. 4. Repeat Steps 1 through 3G for remaining two Magnets and Bushings. 5. once the alignment of all three Magnets has been achieved, assemble Hasp M (1) to threaded portion of Stud Ml61756 projecting from Valve Body and secure using Nut Lock, Ml56168 (4), 3/8" Jam Nut, J (5), two screws, J (3) and two Lock Washers, J (2). see Figure After Jam Nut is tightened, bend Nut Lock around nut. See (4) Figure screw each of the three Magnets into their respective bushing and tighten. 8. Re-install the Terminal Posts, with washers, in each of the three Magnets. 9. nstall either a 1/8" Grease Fitting or 1/8" Pipe Plug in the threaded hole provided in the top of the Piston cap Nuts. Refer to CP Valve drawing and/or bill of material for item to be installed in cap Nut. 50

59 Position of Terminal Posts on Magnets when tight Figure MAGNET POSTON 51

60

61 Figure FACNG TOOL p. 52/53

62

63 ~-. ) ---,1 ff... -~ =/,~-::.~4_ ~,--!,... ':"..,,.. '}-,( ~,. \rr: L ~--- l~t_t.. J...JJ;::::, J J Figure HASP ASSEMBLY p. 54/5 5

64 2.14 NSTALLATON OF PLUNGER AND ASSEMBLY OF MAGNET VALVE ARMATURE This secbion describes the installation of the Plunger in the Valve Body and the assembly of the three Magnet Valve Armatures. 1. nstallation of Plunger A. Slide Spring J (1), over shaft of Plunger Ml53473 (3) and grease liberally (Spec. M ) A B. Slide Spring and Plunger into Guide Nut Ml53474 (2). NOTE PLUNGER MUST WORK FREELY N GUDE NUT BEFORE ASSEMBLY NTO BASE OF CP VALVE. c. Place small amount of grease on tip of Plunger, then place tip of Plunger into opening in the bottom of the CP Valve Body and thread Guide Nut into CP Valve and tighten. See Figure Assembly of Magnet Valve Armatures A. Screw Armature M onto Valve Stem M001711, and secure with Jam Nut M such that the Jam Nut rests against the shoulder of the Armature. B. Carefully place the Armature into the appropriate Magnet. NOTE SNCE VALVE STEMS WERE NO LONGER NTERCHANGEABLE FOLLOWNG THE LAPPNG PROCESS DESCRBED N SECTON 2.5, THE ARMATpRE ASSEMBLY MUST BE NSERTED NTO THE MAGNET NSTALtLED N THE BUSHNG ASSOCATED WTH THE VALVE STEM LAPPNG. c. Repeat Steps 2A and 2B for the remaining two Armatures and valve Stems. 56

65 Figure PLUNGER ASSEMBLY 57

66 SECTON FNAL ADJUSTMENTS 3.1 ADJUSTMENT PROCEDURES NOTE For all following adjustments and tests, connect the CP valve assembly control box fixture (it109899). Additionally, connect the A-5 air cylinder air lines to the air outlets on each side of the CP valve assembly. The control box test leads are identified on the control box and are to be connected to the appropriate magnet with the test lead marked L connected to the center magnet. 1. Magnets must be tight on their bushings. A. Terminal Posts must be centered. See Figure 2-14 and /or Drawing D2394-sh CAUTON WHEN REQURED TO MANUALLY OPERATE ARMATURE, USE FNGERS TO APPLY DOWNWARD PRESSURE TO CENTER OF ARMATURE,.E. TO THE VALVE STEM OR JAM NUT TO PREVENT DSTORTNG AR GAP UNFORMTY. 2. The Air Gap between the Armature and the top of the projecting rings shall be (+/ ), when the Armature is operated manually. A. Adjustment is made by loosening the Jam Nut on the Armature and screwing the Armature up or down on the Valve Stem to obtain the gap. Once this adjustment has been made, tighten Jam Nut. NOTE A slight drag felt on the gauge when the amarture is held with the finger against the magnet surface is a good indication that the air gap is properly made. 3. The gap between the Armature and the Magnet surface must be uniform, that is, the bottom surface of the Armature must be parallel with the top surface of the Magnet. This can be checked by slowly turning the Armature and observing if the gap changes. f there is a non-uniformity, the correction should be made as follows: 58

67 A. Slowly turn the Armature and note when the gap decreases. This is the lower portion of the gap. B. Place C.R.S. Block under the low portion of the gap. See Figure 3-1. TAP LGHTLY ON HGHSDE BLOCK v_lel Adjustment of Armature Air Gap Figure 3-1. C.R.S. Block 58A

68

69 c. Using a small plastic or rawhide hammer, tap on the high side of the Armature. D. Repeat Steps A through c until the gap is uniform. E. Recheck the air gap. F.- f air gap requires adjustment, repeat Step 2A until a uniform air gap has been obtained. 4. Repeat Steps 1 through 3F for remaining two Magnet Armatures. 5. Place a (M279463) thick gauge between the Magnet and the bottom of the Armature. With air supply connected to the air inlet port, turn air on and manually operate the Armature of the Lock (Center) Magnet. There should be no escape of air. f air does escape, do the following: A. Carefully remove the Armature Stem Assembly. NOTE EXTREME CARE MUST BE USED WHEN DRLLNG VALVE STEM. EXCESS DRLLNG MAY RESULT N SCRAPPNG THE STEM. B. Drill out center portion of the bottom of the Stem with a i45 drill, removing small amounts of material at a time. When drilling out the Valve Stem, a fixture or device must be used that will ensure perfect alignment of the Valve stem and the drill. c. Reinstall the Armature stem Assembly in the Lock (Center) Magnet and recheck wit:h the O.033 gauge. 59

70 D. Repeat Steps Band c until, with the gauge between the Armature and the top of the Magnet, there is no air escape when the center of the Armature is manually operated. NOTE F STEP 5 S DONE PROPERLY, THERE WLL BE NO PROBLEM ATTANNG STEP Place a (M ) gauge between the Magnet and the bottom of the Armature. Again manually operate the Armature. At this time a slight hiss (escaping air) should be heard. f a slight hiss is heard, proceed to Step 7. f a hiss is not heard, perform the following: A. Loosen Jam Nut on Armature assembly. B. Back off Armature (turn counterclockwise) until with.031 gauge, a slight hiss (escaping air) is heard. c. Recheck with.033 gauge, no air shall escape. D. Once.033 and.031 adjustments have been obtained, carefully tighten Jam Nut so as not to change these adjustments. 7. With the Jam Nut tightened, recheck the gap. f the gap is correct, proceed to step 8. f the gap is not correct, perform the following: A. Remove the Armature/Stem assembly from the Magnet. B. Place the Armature/Stem assembly in the Stem Cutting Tool. c. Position the Stem cutting Tool so that the round tension knob faces operator o. Turn tension ~nob, applying slight pressure to stem. E. With the hand, rotate the Armature/Stem assembly clockwise, removing a small amount of material from the beveled portion of the stem. 60

71 F. Remove the Armature/Stem assembly from tool and clean out stem hole. G. Reinstall the Armature/Stem assembly in Magnet and recheck air gap. H. Repeat Steps 7 (A) through 7 (G) until air gap is obtained.. Recheck that Armature is parallel with Magnet surface. 8. Repeat Steps 5 through 7 for the two remaining Armature/Stem assemblies. 61

72 9. With air turned off, prior to bending the Release Spring fingers, ~heck that a weight of between 3.0 ozs. (M335538) and 4.5 ozs. (M335539), just unseats the Pin Valve. follows: This check should be made as A. Place 3.0 oz. weight over Jam Nut of Armature assembly. B. Turn air to valve on. c. Cycle air on and off. There may or may not be a vertical movement of the Armature. o. Turn air off. E. Place 4.5 oz. weight over Jam Nut of Armature Assembly. F. Turn air back on. G. Cycle air on and off. There should be a definite vertical movement of the Armature. 10. Adjust the Release Spring on the Magnet by carefully and gradually bending up each of the three spring fingers. see Figure With the air turned off, check that a weight of between 5.3 and a.o ozs. will just unseat the Pin Valve. follows: This check should be made as A. Place 5.3 oz. weight (M335540), over the Jam Nut on Armature' assembly. B. Turn air to valve on. c. cycle air on and off. There may or may not be a vertical movement of the Armature. o. Turn air off. E. Place a.o oz. weight (M335541), over Jam Nut on Armature assembly. F. Turn air to valve on. G. cycle air on and off. There should be a definite vertical movement of the Armature. 12. connect the leads from the power supply to one of the three Magnets, and connect the two air outlet ports to an AS cylinder. Turn air and power supply on. 13. Regulate air to 80' lb. psi. Charge Magnet to 3 times its' pickup voltage (for these 130 ohm Magnets, that will be 15 volts), then gradually decrease the voltage until the Armature is released by the Magnet. This will be the Release value, and it shall not be lesp than the value specified in Table 1. 62