AMES Colt C200 Installation, Maintenance & Repair - Page 3

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AMES Colt C200 Installation, Maintenance & Repair

Maintenance Instructions 8" – 10" (200 – 250mm)

Material/Tool Requirements:

• #4 Phillips screwdriver or

to span diameter of check, see Figures A and B.

•

– 13" x 5" fully threaded hex bolt (Service bolt).

•

" open end or socket wrench.

Instructions:

WARNING

Prior to servicing any Ames valve, it is

mandatory to shut down the water sys-

tem by closing both the inlet and outlet

shutoff valves. After shutoff valves are closed, open

test cock #2, #3 & #4 to relieve pressure within the

backflow assembly.

1. After #3 test cock has been opened to relieve pressure,

remove #3 test cock from housing. When repairing an

8" or 10" (200 or 250mm) device, remove both Victaulic

couplers from body. Slide the downstream Victaulic

coupler gasket to the downstream side of the housing.

The upstream Victaulic coupler gasket stays in place.

2. Remove checks to be maintenanced.

Testing — Double Check Valve Assemblies

Test Check Valve No. 1

Step 1: Ensure shutoff #1 is open, shutoff #2 is closed.

Step 2: Connect high side hose to test cock #3, low side to test

cock #2 and open both test cock #2 and test cock #3.

Step 3: Open valve C, then open A to bleed air from the high

side. Close valve A, then open B to bleed low side.

Close valve B.

Step 4: Connect vent hose loosely to test cock# 1. Open valve

A to vent air from vent hose, Tighten vent hose at test

cock #1, open test cock #1.

Step 5: Close shutoff #1. Slowly loosen hose at test cock #2

until differential gauge rises to 2psi and retighten hose.

If the differential reading does not decrease, record

check valves as "tight".

Test Check Valve No. 2

Step 1: Move the high side hose to test cock #4, low side to test

cock #3 and open both test cock #3 and test cock #4.

Remove vent hose from test cock #1, open shutoff #1.

Step 2: Open valve C, then open valve A to bleed air from the

high side. Close valve A, then open valve B to bleed low

side. Close valve B.

Step 3: Connect vent hose loosely to test cock #1. Open valve A

to vent air from the vent hose. Tighten vent hose at test

cock #1, open test cock #1.

Step 4: Close shutoff #1, and then slowly loosen hose at

test cock #3 until differential gauge rises to 2psi and

retighten hose. If the differential reading does not

decrease, record check as tight. Remove all hoses

and restore valve to original working condition.

NOTICE

The assembly will fail both the first and second check valve tests

above, if shutoff #2 leaks excessively. To test for a leaky #2 shutoff,

use the following procedure.

" diameter rod, length sufficient

Figure A

Service Hole

3. Locate the service hole and thread in the service bolt by

hand until it contacts the linkage. (Figure A)

4. Continue to thread in service bolt with the wrench until the

service hole in the linkage is aligned with the service notches

on the spring arbors. (Figure A)

5. Insert the Phillips screwdriver through the arbors and service hole

of the linkage making sure that the tip of the screwdriver extends

past the ends of the arbors by a minimum of

6. Back out the service bolt until load is transferred to the screw-

driver. Continue to back out the service bolt until sufficient clear-

ance is achieved to remove the complete spring mechanism.

7. To disconnect linkage, remove retaining clip and pin (store

in a safe location for reinstallation).

Figure B

8. To remove spring mechanism, grasp the screwdriver at the center

and pull complete assembly straight out and store in a safe place.

9. Reinstall in reverse.

WARNING

While the spring mechanism is removed for check servicing; never

pull the screwdriver out or off the support notches on the arbors.

Doing so may cause bodily injuries.

Test for Leaky No. 2 shutoff

Step 1: Connect the high side to test cock #1, low side to test

cock #4. Open test cock #1 and test cock #4. Close

shutoffs #1 and #2.

Step 2: Close valve C. Open valve A, then open valve B

loosen hose at test cock #4 to remove air. Retighten hose.

Step 3: If the differential gauge rises above 0, there is excessive

leakage at shutoff #2 and it must be replaced to test the

assembly.

High Hose

(Yellow)

Test Cock

No. 1

" (6mm). (Figure B)

Ball Type Test Valves

Needle

Valve

Vent Hose

(Blue)

Low Hose

(White or Red)

Test Cock

No. 2

No.3

turn,

Test Cock

No.4