Conbraco Apollo Service Procedures

1
Conbraco / ApolloService Procedures

• Models
• 40-100, 40-600
• 40-200, 40-700
• 4S-100, 4S-600
• 4D-100, 4D-600
• 4D-200, 4D-700

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Contents

• Model
• 40-100, 40-200 ¾-2
• 40-100, 40-600 21/2-10
• 40-200, 40-700 21/2-10
• 4S-100, 4S-600 21/2-10
• 4D-100, 4D-600 21/2-10
• 4D-200, 4D-700 21/2-10

• Page
• 2
• 9
• 9
• 16
• 20
• 20

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40-100, 40-200¾-2
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Modification Overview

• Early models of ¾-2 40-100 and 40-200 series
  did not always have replaceable check seats. In
  1994 replaceable seats became standard.
• The ¾-2 40-100 DCA was produced in both a wye
  pattern body design and a top entry design.

5
Check Cover Removal

• Cover is threaded into body and o-ring sealed.
• Cover is spring loaded.
• Loosen cover with wrench, then remove by hand
  while holding firmly against spring pressure.

6
Check Valve Removal

• Poppet style check valve.
• The poppet and spring are free once the cover is
  removed.

7
Check Seat Removal

• Seats are threaded and o-ring sealed.
• A special tool is needed for removal.

8
Check Disc Replacement

• Remove the screw and disc washer from poppet.

9
Check Valve Reassembly Notes

• Inspect and clean the guide bore on the cover.
• The stem must move freely in the guide bore.
• Reassemble in reverse order.

10
RV Cover Removal

• RV Cover is sealed by the diaphragm.
• Spring load is contained.

11
RV Module Removal

• Remove outer diaphragm.
• Module is o-ring sealed.
• Pull module straight out of body.

12
RV Seat Removal

• RV seat is threaded and o-ring sealed.
• A special tool is needed for removal.
• Be careful not to over tighten plastic seat.

13
RV Disc Replacement

• Holding the module in one hand, remove the screw
  and retaining washer.
• Remove the seat disc.

14
Disassemble RV Module

• Module is spring loaded.
• Holding the diaphragm plate firmly, remove the
  retaining screw.

15
Disassemble RV Module

• Remove the bushing from the stem.
• Remove the stem o-ring.

16
RV Reassembly Notes

• Replace and lubricate o-rings.
• Reassemble in reverse order.
• Push module straight into body.
• Make sure diaphragm does not cover hole for
  sensing line.

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40-100, 40-60040-200, 40-70021/2-10
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Modification Overview

• The 21/2-10 40-100 series DCA was discontinued
  in 2003.

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Check Cover Removal

• Cover is o-ring sealed.
• Loosen bolts 3/8. Spring load is now released
  from the cover and retained by the check
  assembly.
• Verify spring load before removing all the
  bolts.

20
Check Valve Removal

• Center stem guided check assembly.
• Slide subassembly straight out of seat and body.

21
Check Seat Removal

• 21/2-8 sizes are threaded into the body and
  o-ring sealed.
• A special tool is required to remove the
  seat.
• 10 size is bolted into the body and o-ring
  sealed.

22
Check Disc Replacement

• 21/2-6 remove the nut and retaining plate.
• 8-10 remove the retaining plate bolts and
  retaining plate.

23
Check Valve Reassembly Notes

• Reassemble check valves in reverse order.
• Apply lubricant to o-rings.

24
RV Cover Removal

• RV cover is sealed by the diaphragm.
• No spring load on cover.
• Remove outer diaphragm.
• 8-10 the diaphragm is an integral part of the
  RV module.

25
RV Module Removal

• Module is o-ring sealed.
• Grasp the diaphragm plate and pull the module
  straight out of the body.

26
RV Seat Removal

• Unless damaged there is no need to remove the RV
  seat.
• RV seat is threaded and o-ring sealed.

27
RV Disc Replacement

• Holding the module firmly, remove the screw and
  retaining washer.
• Remove the seat disc.

28
Disassemble RV Module

• Module is spring loaded.
• Holding the diaphragm plate firmly, remove the
  screw or bolt.

29
Disassemble RV Module

• Remove the bushing from the stem.
• Remove the stem o-ring.

30
RV Reassembly Notes

• Replace and lubricate o-rings.
• Reassemble in reverse order.
• Push RV module straight into body.
• Make sure diaphragm does not cover hole for
  sensing line.

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4S-100, 4S-60021/2-10
32
Check Cover Removal

• Cover is sealed by a gasket.
• Cover has no spring load.
• For the 21/2-6 size, unscrew black plastic
  spring cap.
• Remove bolts, cover and gasket.
• 8-10 cover has spring load approximately ¼.

33
Check Valve Removal

• Check valve module.
• Module is o-ring sealed.
• 8-10- spring module is separate from the check
  module.
• Gently pry the module from the body.

34
Disassemble Check Valve

• The module is spring loaded.
• Do not remove the socket head bolt.
• Unscrew and remove the spring assembly from the
  module by placing a wrench on the flats provided.
• Do not disassemble spring assembly any further.

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Check Disc Replacement

• Once the spring assembly is removed, spring load
  is released.
• Remove the retaining screws and disc retainer.
• Remove seat disc.

36
Check Valve Reassembly Notes

• Reassemble checks in reverse order.
• Lubricate o-rings.
• A pry bar may be needed to aid in seating the
  check assembly into the body.
• Spring cap needs only to be snug.

37
Check Valve Reassembly Notes

• 8-10- Insure that the cam positioner is flipped
  down on the swing arm of the check module.
• 8-10- When replacing the spring assembly, make
  sure to place cam end of spring on both cam
  rollers of the check module.

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4D-100, 4D-600 4D-200, 4D-70021/2- 10
40
Check Cover Removal

• Check cover is secured with a grooved coupling.
• Cover has no spring load.

41
Check Valve Removal

• Check valve modules.
• Checks are bolted into the body and o-ring
  sealed.
• Either check can be removed without disturbing
  the other.

42
Disassemble Check Module

• Do not remove the large nut and lock washer on
  the retaining plate.
• Remove the socket head cap screw that holds the
  spring hub assembly.
• This will release the spring load.

43
Disassemble Check Module

• The disc holder will slide away from the front of
  the module.
• The spring hub assembly is now free.

44
Check Seat Removal

• The check seat is a machined part of the seat
  assembly.
• To replace the seat, you must replace the seat
  assembly.

45
Check Disc Replacement

• Remove the three allen screws from the disc
  retainer.
• The check disc is now free.

46
Check Valve Reassembly Notes

• Reassemble check module in reverse order.
• Make certain the module o-ring is in place and
  lubricated.
• Tighten hex nuts firmly and evenly.

47
RV Cover Removal

• Disconnect sensing hose.
• RV cover is sealed by the diaphragm.
• No spring load on cover.
• Remove outer diaphragm.

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RV Module Removal

• Module is o-ring sealed.
• Grasp the diaphragm plate and pull the module
  straight out of housing.

49
RV Seat Removal

• Unless damaged there is no need to remove the RV
  seat .
• RV seat is threaded and o-ring sealed.

50
RV Disc Replacement

• Holding the module firmly, remove the screw and
  retaining washer.
• Remove the seat disc.

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Disassemble RV Module

• Module is spring loaded.
• Holding the diaphragm plate firmly, remove the
  screw.

52
Disassemble RV Module

• Remove the bushing from the stem.
• Remove the stem o-ring.

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RV Reassembly Notes

• Replace and lubricate o-rings.
• Reassemble in reverse order.
• Push RV module straight into housing.

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