Introduction
This instruction manual provides detailed guidance for the proper use and installation of the Ross 802K87 Valve Service Kit. This kit is designed for servicing 3/4 inch and 1 inch parallel flow 3500 double valves, ensuring optimal performance and extending the lifespan of your valve system. Please read all instructions carefully before proceeding with any service.
Safety Information
- Always ensure the electric supply to the valve is disconnected before beginning any service.
- Completely shut off and exhaust the air supply from the system to prevent accidental activation or pressure release.
- Wear appropriate personal protective equipment (PPE), such as safety glasses and gloves, during disassembly and reassembly.
- Refer to the original valve manufacturer's manual for additional safety precautions specific to your valve model.
Kit Contents
The Ross 802K87 Valve Service Kit typically includes the necessary gaskets, seals, and O-rings required for a complete valve overhaul. Please verify all components are present and undamaged upon opening the package.
Image: The Ross 802K87 Valve Service Kit in its original packaging, displaying the kit number, valve type compatibility, and initial service instructions.
Setup and Installation (Valve Servicing Procedure)
Follow these steps carefully to service your 3500 Double Valve using the 802K87 kit. This procedure is applicable for 3/4" and 1" pipe sizes.
- Prepare the Valve: Open the electric supply (if any) to the valve. Shut off and exhaust the air supply completely from the system.
- Disassembly and Cleaning: Disassemble the valve body. Thoroughly clean and dry all internal parts and the valve body itself.
- Inspect Components: Carefully inspect the piston bores, the four metal poppet seats (labeled 'A' in diagrams), and the poppet sealing portions of the piston and rod assembly (labeled 'B') and poppets (labeled 'C'). If these areas show significant blemishes or damage, it is recommended not to rebuild the valve.
- Replace Piston Seal: Remove the old piston seal (A) from the piston and rod assembly (B). Install the new seal (A) provided in the kit. Note: Ensure the seal is installed in the correct orientation as shown in any accompanying diagrams.
- Lubrication (Optional): Lightly lubricate the two piston bores, the two replacement seals, and the rod of the piston and rod assembly (B). Then, carefully insert the piston and rod assembly into the valve body.
- Install Poppets: Push the two poppets (K) onto the rods of the piston and rod assembly (B) until the poppets (K) make contact with the shoulder of the piston and rod assembly (B).
- Install Springs: Install the two springs (L).
- Install O-Ring Seals: Install the "O" ring seals (B) onto the stem guides (M) and then insert the stem guides into the valve body assembly.
Image: A detailed view of the instruction label included with the Ross 802K87 kit, outlining the step-by-step valve servicing procedure.
Operating (Post-Service Check)
After completing the service and reassembling the valve, perform the following checks:
- Slowly reintroduce air pressure to the system.
- Check for any air leaks around the valve body and connections.
- Test the valve's operation by cycling it several times to ensure smooth and correct functionality.
- If any issues are detected, immediately shut off air and power and re-inspect the assembly.
Maintenance
Regular maintenance of your valve system, including periodic inspection of seals and gaskets, can prevent unexpected failures. The Ross 802K87 kit is a single-use service kit for a complete overhaul. For ongoing maintenance, refer to your valve's specific maintenance schedule.
Troubleshooting
- Air Leaks After Service:
Possible Cause: Improperly seated seals or O-rings, damaged components not replaced.
Solution: Shut off air and power. Disassemble and carefully re-inspect all seals and O-rings for correct placement and integrity. Ensure all mating surfaces are clean and free of debris.
- Valve Not Operating Smoothly:
Possible Cause: Insufficient lubrication, incorrect assembly of internal components, or damaged parts.
Solution: Shut off air and power. Re-check assembly steps, especially lubrication. Ensure poppets and springs are correctly installed and not binding. If inspection revealed blemished areas (as per step 3), the valve may require replacement rather than just a service kit.
Specifications
| Model Number | 802K87 |
| Brand | Ross |
| Compatible Valve Type | 3500 Double Valve, Parallel Flow |
| Compatible Pipe Size | 3/4" - 1" |
| Kit Type | Valve Gasket and Seal Kit |
Image: A close-up view of the "802K87" model number label on the kit packaging, confirming the specific service kit.
Warranty and Support
For information regarding warranty, technical support, or replacement parts, please contact Ross Controls directly or refer to their official website. This service kit is intended for professional use and proper installation is crucial for its effectiveness.
Ross Controls Official Website: www.rosscontrols.com
