Type 99

disk or O-ring seat are referenced in Figure 9, part key numbers unique to the 1000 psig (69,0 bar) maximum inlet regulator are referenced in Figure 11, and part key numbers for a Type 61HP (extra high pressure) pilot is referenced in Figure 12.

 1.  Access to all internal actuator parts can be gained without removing the main valve body from the line. Disconnect the loading tubing from the upper casing.

caution

If the regulator has an indicator assembly, perform the following step carefully to avoid bending the travel indicator stem (key 103, Figure 6).

Note

The O-rings and gaskets (keys 111 and 108, Figure 6) in the indicator assembly are static seals and need not be disturbed, unless they are leaking.

 2.  Remove the four cap screws (key 58, Figure 9) and lift off the spring case (key 1, Figure 9). Remove the travel indicator stem, if any, by unscrewing the indicator stem adapter (key 101, Figure 6).

 3.  Remove the main spring seat (key 2, Figure 9) and main spring (key 3, Figure 9).

 4.  Remove the 12 cap screws (key 12, Figure 9)

and hex nuts (key 13, Figure 9), and lift off the upper casing.

 5.  Remove the diaphragm (key 11, Figure 9) and diaphragm plate (key 10, Figure 9) by tipping it so that the lever (key 9, Figure 9) slips out of the pusher post (key 8, Figure 9).

 6.  Separate the diaphragm and diaphragm plate by unscrewing the diaphragm rod (key 4, Figure 9) from the pusher post. Inspect the diaphragm

(key 11, Figure 9) and pusher post gasket (key 7,

Figure 9). Either part must be replaced if it is damaged or no longer pliable.

 7.  If the unit has a stem seal O-ring (key 64,

Figure 7 or 11), this O-ring may be replaced by

     removing the retaining ring or cotter pin (key 28,

     Figure 9) and disconnecting the lever from the

     valve carrier (key 26, Figure 9 or 11), removing

     the union nut (key 14, Figure 9 or 11),

     disconnecting the pilot supply tubing (key 24,

     Figure 9 or 11), and sliding the lower casing

     (key 29, Figure 9) away from the valve body

     (key 17, Figure 9), with a disk or O-ring seat, the

     valve carrier must be pulled out of the lower

     casing to gain access to the O-ring. Another

     O-ring, held captive by the pressed-in bushing, is

     part of the lower casing assembly on a stem seal

     unit and normally does not require replacement.

 8.  If clogging is suspected in the upstream regulator

     passages, disconnect the pilot supply tubing

     (key 24, Figure 9 or 11), remove the filter assembly

     (key 75, Figure 9), and blow through it to check

     for filter clogging. If necessary, to clean or replace

     filter parts in a standard P590 Series filter

     assembly, remove the following as shown in

     Figure 10: filter body (key 1), machine screw

     (key 4), spring washer (key 6), gasket (key 7),

     washer (key 5), and filter element (key 2). Upon

     reassembly, one of the flat washers must go

     between the filter element and filter head (key 3)

     and the other must go between the filter element

     and gasket.

 9.  If the lower casing was removed, install a new body

     gasket (key 16, Figure 9) and, with a disk or O-ring

     seat, slide the valve carrier into the casing. Then

     slide the entire assembly into the valve body (disk

     or O-ring seat) and secure with the union nut.

     Secure the lever to the valve carrier with the

     retaining ring or cotter pin.

 10. Loosely reassemble the diaphragm and diaphragm plate so that the bolt holes and

       loading connection hole in the diaphragm can

       be properly aligned with the corresponding

       holes in the casing when the lever is fitted

       properly into the pusher post. When this

       orientation is made, install the collar (key 6,

       Figure 9) and tighten the diaphragm rod into the

       pusher post (key 8, Figure 9).

 11.  In order for the regulator to operate properly, the

       assembled collar, diaphragm, diaphragm plate,

       pusher post, and diaphragm rod must be

       mounted on the ball of the lever so that the

       pusher post (key 8, Figure 9) orientation is as

       shown in Figure 9.

 12.  Install the upper casing and secure it to the

    lower casing with the twelve cap screws torque

    580 to 920 inch-pounds (65,5 to 104 N•m) and hex

    nuts. Put lower casing back on body and install

    union nut.

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