Condec UPC5210 - Manual (Page 22)

Maintenance & Service 19
7. Install the end bushing (12) and tighten until snug using the isolation valve needle housing socket (PN
68508) and socket wrench.
8. Tighten so that shaft rotates, but should be firm. Feel vertical motion of shaft (14). If motion exists,
retighten end bushing.
9. Install the locknut (20) into end cap (13) and using the isolation valve needle housing socket (PN 68509)
and torque wrench. Torque to approximately 325 in/lbs. (may not get to torque on all sub-assemblies).
10. Install the O-ring (32) in the piston groove and install the piston (15) into the VERNIER cavity. Ensure
that the piston keyway is facing the hole into which the self-sealing screw (36) is assembled.
11. Install the self-sealing screw (36) and tighten until snug.
12. Apply a thin coat of fluorinated Krytox grease and install the O-ring (29) and backup washer (38) on the
end cap/shaft assembly, install into manifold and tighten until snug.
4.2.6 ORION-3A Manifold, Valve Seat Installation
Tools required: needle-nose pliers
tube fluorinated Krytox grease (PN 55593)
No. 43 drill
A/R solvent (de-natured alcohol)
hex wrench (.050")
hex wrench (.061")
torque wrench
socket wrench
3/4" socket
needle housing socket (PN 65580)
isolation valve needle housing socket (PN 68509)
female socket (PN 65581)
NOTE: See Table 4-2 on page 34 and Figure 4-2 on page 35 for additional parts information.
1. Install a new seat (7) by placing it into the seat well with the needle-nose pliers. Ensure that the seat is
centered within the cavity and gently tap it with a blunt end of a drill bit to install.
2. Install the valve needle seat (9) with the smaller diameter end facing outward.
3. Install new O-rings (28, 27) inside and outside of the valve stem seat. Coat all O-rings and back-up rings
(30, 31) with fluorinated Krytox grease before installation. Make sure that the rings are installed in the
proper order.
4. Install the valve stem seat (8) by grasping the small diameter end with the needle-nose pliers and
positioning in the valve cavity, then gently pushing with the blunt end of a drill bit.
5. For COARSE (pressure) and VENT valves (two outer valves), disassemble the valve needle (11) from its
housing (10) and check for any burrs or dirt on the threads which might interfere with smooth operation.
6. Clean both the needle (11) and housing (10) in solvent, dry the parts and apply a small amount of
fluorinated Krytox grease to the needle threads before reassembly.
7. Assemble the Valve Needle (11) into the valve needle housing (10) and turn it until it stops.
8. Reinstall the needle/housing assembly into the valve cavity until finger tight.
9. Mount the manifold body (16) in a vise. For the COARSE (pressure) and VENT valves only, torque the
needle/housing assembly to 325 in-lb. using the needle housing socket (PN 65580) and torque wrench.
10. Install the housing lock nuts (1) onto the housing (10) and tighten until snug with the 3/4" socket.
11. Using the .050" hex wrench, install and tighten the lock nut (2) and set screw (34).
12. Install the knob insert (4) over the valve needle (11) shaft, align the set screws (23) with the indents and
tighten with the .061" hex wrench.
13. For the isolation valves (two inner valves), install the needle housing (19) and tighten until snug using
the isolation valve needle housing installation socket (PN 68509) and torque wrench.
NOTE: There is no specified torque, so use care when tightening so as not to break the socket nibs.
14. Install the gear (6) over the isolation valve needle (18) shaft, align the set screws (26) with the indents
and tighten with the .061" hex wrench.
15. Apply a small amount of fluorinated Krytox grease to the threads of the isolation valve needles (18) and
install into the valve by turning counter-clockwise. Rotate the gear until the needle just stops at the seat.