Welker Jet Insert Model Control Valve

Model
WJ-1N, WJ-2N, WJ-4N,
WJ-6N, & WJ-8N

The information in this manual has been carefully checked for accuracy and is intended to be used as a
guide for the installation, operation, and maintenance of the Welker equipment described above. Correct
operating and/or installation techniques, however, are the responsibility of the end user. Welker reserves
the right to make changes to this and all products in order to improve performance and reliability.

13839 West Bellfort

Sugar Land, TX 77498-1671
(281) 491-2331 - Office
(800) 776-7267 - USA Only
(281) 491-8344 - Fax
http://www.welkereng.com

© Copyright 2009, Welker, Inc.

TABLE OF CONTENTS

1. GENERAL 3

1.1 INTRODUCTION 3
1.2 DESCRIPTION OF PRODUCT 3
1.3 SPECIFICATIONS 4

2. INSTALLATION & OPERATIONS 5

2.1 GENERAL 5
2.2 INSTALLATION INSTRUCTION 5
2.3 FILLING THE HYDRAULIC SYSTEM 6
2.4 PLACING THE WELKER JET VALVE IN SERVICE 9
2.5 SETTING THE CORRECT INSTRUMENT
SUPPLY FOR OPERATION 11

3. MAINTENANCE 13
3.1 GENERAL 13
3.2 WELKER JET CONTROL VALVE
INSPECTION & DISASSEMBLY 14
3.3 WELKER JET CONTROL VALVE REASSEMBLY 15
3.4 MOTOR INSPECTION & DISASSEMBLY 17
3.5 MOTOR REASSEMBLY 18

Welker, Welker Jet, and WelkerScope® are Registered Trademarks owned by Welker, Inc.

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Welker Jet® Insert Control Valve
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SPECIFICATIONS

1. GENERAL
1.1 INTRODUCTION
We appreciate your business and your choice of Welker products. The installation,
operation, and maintenance liability for this product becomes that of the purchaser at the
time of receipt. Reading the applicable Installation, Operation, and Maintenance (IOM)
Manual prior to installation and operation of this equipment is required for a full
understanding of its application and performance prior to use.*
If you have any questions, please call 1-800-776-7267 in the USA or 1-281-491-2331.

Notes, Warnings, and Cautions

Notes emphasize information or set it off from the surrounding text.

Caution messages appear before procedures that, if not observed, could result
in damage to equipment.

Warnings alert users to a specific procedure or practice that, if

not followed correctly, could cause personal injury.

*The following procedures have been written for use with standard Welker parts and equipment.
Assemblies that have been modified may have additional requirements and specifications that are not listed
in this manual.*

1.2 DESCRIPTION OF PRODUCT

In 1958, R.H. Welker designed the first rubber plug type control
valve to meet the demands of the gas industry for a quiet, versatile
control valve. The many refinements and improvements made since
that time have been incorporated into the current line of Welker
JetControl Valves.
The basic design consists of a rubber plug that is expanded by a
hydraulically operated piston and cylinder system. As the hydraulic
force on the plug increases, it expands radially until it seals.
Hydraulic pressure is provided by a pneumatically operated
diaphragm motor.

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Welker Jet® Insert Control Valve
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SPECIFICATIONS

1.3 SPECIFICATIONS
Table 1

Welker Jet Control Valve Specifications

Natural Gas – Typical Transmission/Distribution
Medium
Quality
Casting/Forging A350 LF2 Carbon Steel, 1045 Carbon
Materials of Construction
Steel, Aluminum 7075-T6 Bar

Size 1, 2, 4, 6, 8, 10, and 12 inch

Flange Rating 150, 300 and 600 ANSI RF

Pressure Rating 1,440 psig (100 BarG)

Temperature Range -20º F to 122º F (-29º C to 50º C)

Maximum Line Pressure 1,480 psi (102.1 bar) ANSI 600

Proprietary Nitrile (Buna Rubber) – Compatible with

Inner Valve Material Natural Gas

Hydraulic Fluid Texaco Aircraft Hydraulic Oil #5606 H or equivalent

Area Classification Can be used in hazardous areas

Table 2

Utilities Required for Diaphragm Motor

1” & 2” Valves 39 psi (2.68 bar)

4” Valve 50 psi (3.44 bar)

6” Valve 90 psi (6.21 bar)

8” Valve 70 psi (4.83 bar)

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Welker Jet® Insert Control Valve
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INSTALLATION & OPERATIONS

2. INSTALLATION & OPERATION INSTRUCTIONS

2.1 GENERAL
After unpacking the unit, check it for compliance and for any damages that may have occurred during
shipment.

Claims for damages caused during shipping must be initiated by the receiver and directed to the
shipping carrier. Welker is not responsible for any damages caused from mishandling by the
shipping company.

When sealing fittings with PTFE tape, refer to the proper sealing instructions for the tape used.

2.2 INSTALLATION INSTRUCTIONS (Refer to Figure 1 on page 5)

If you have determined that you need a capacity control spacer plate for your installation, but your
control valve is not so equipped, the needed item should be installed before proceeding.

Insert Welker Jet Control Valves are normally installed in pipe one size larger than the control
valve. Listed below are the insert models and the pipe they are normally fitted to.
WJ-1N 2” pipe or larger
WJ-2N 4” pipe or larger
WJ-4N 6” pipe or larger
WJ-6N 8” pipe or larger
WJ-8N 10" pipe or larger

Insert style control valves are also available to fit pipe larger than that listed. For example, a WJ-
4N can be ordered to fit 8” pipe, or a WJ-8NF can be ordered to fit 12” pipe.
1. To install the insert, the line into that it will be placed must have the inspection spool removed or rolled.
The insert is then positioned into the upstream pipe with the nose pointing into the line. It is important to
be certain the nose of the insert control valve points upstream, and that the correct gaskets between the
pipe flanges and the insert flange are properly installed.
2. The fitting extending from the control valve flange should be positioned vertically (pointing up). This is
to allow proper filling of the hydraulic system.
3. The inspection spool should now be replaced, with the correct gaskets in position, and the bolts should be
properly fastened. Stainless steel tubing, 3/8" or larger, rated for 3,000 psi or higher, should now be run
from the fitting on the control valve to the larger valve on the master system.
4. Mount the master system as close to the valve as possible.

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INSTALLATION & OPERATIONS

2.2 INSTALLATION INSTRUCTIONS (Continued)

5. Using small diameter stainless steel tubing, connect the large valve on the master system to the side port of
the control valve insert.

The tubing should either be sloped or level, with no vertical drops that will prevent a direct flow of
the hydraulic oil.
6. When longer runs of tubing are used, an oil fill pot is recommended in filling the hydraulic system. (See
Section 2.3 pages 6-10 for more information.)
7. Proceed to Section 2.3, filing the hydraulic system.

2.3 FILLING THE HYDRAULIC SYSTEM

Option 1

Before beginning the filling procedure, depressurize the diaphragm actuator motor.
1. Welker Jet Control Valves should be installed into the pipeline already filled with hydraulic fluid. New
control valves and motors are shipped pre-filled from the factory. When reinstalling a control valve after
maintenance, the control valve should be pre-filled according to the disassembly and reassembly
procedure outlined in the inspection procedure.
2. The hydraulic system operates best when a minimum of air is trapped within it. There are two ways to fill
the hydraulic system in a manner that traps little or no air. The first method is intended for systems with
relatively short runs of level or
downward sloping hydraulic
tubing.
OPTION 1 (See Figure 1)

 Valves “A” and “B” should

be securely closed.
 Position the indicator-locking
device on the motor
underneath the indicator rod
(Figure 10). This is to lock
the rod in the up position.
Secure indicator locking
device with hex socket cap
screws.

Figure 1

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Welker Jet® Insert Control Valve
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INSTALLATION & OPERATIONS

2.3 FILLING THE HYDRAULIC SYSTEM (Continued)

 Remove the diaphragm motor. The motor comes off the master cylinder in one piece by
turning it counterclockwise. It will be necessary to use a back-up on the master cylinder when
removing the diaphragm motor. It also might be necessary to remove the pipe plug from the
bleed valve (“B”) and slightly open the valve to relieve vacuum in the cylinder and allow the
piston to be removed.
 Remove the pipe plug from valve “C” attached to the control valve body and open valve “C”.
 Open valve “A” fully. The oil in the master cylinder will drain into the tubing.
 If the motor is positioned higher than the control valve, you will need to do the following:
• Pour hydraulic oil into the control valve master cylinder slowly, until the fluid
starts to flow out of valve “C” at the control valve body.
• Close valve “C” and replace the pipe plug securely, using PTFE tape or pipe
dope to seal the threads and fill the master cylinder to slightly below the crown
seal (approximately ¼” (6mm)).
• Tightly secure the motor assembly to the master cylinder and move the
indicator-locking device away from the indicator rod.

When replacing diaphragm motor, do not build pressure on the master cylinder.

 When screwing down the motor, crack valve “B” slightly to allow excess oil to escape. The
excess oil will escape instantly. Close valve “B” and secure with a plug. Valve “A” remains
fully open.

OPTION 2 (See Figure 2)

Before beginning the filling procedure, depressurize the diaphragm actuator motor.
3. Another method of filling the hydraulic system involves the use of an oil fill pot. This method is useful
when the run of tubing from the master cylinder to the control valve is relatively long (no more than 8-10
feet (2.5 to 3 meters)) or when it is not practical to remove the diaphragm motor assembly from the master
cylinder. With this method, the diaphragm motor assembly remains attached to the master cylinder.
 Make sure all valves are closed.
 Open the oil pot and fill two-thirds full with unused aircraft hydraulic oil.
 Remove pipe plug from valve “F” and connect pressure line, preferably pipeline pressure, to
valve “E.”
 Open valve “E” fully.
 Run high-pressure tubing from valve “D” to valve “B”, connecting the tubing only at valve
“D”. Do not connect tubing to valve “B” at this time. NOTE: Valve “B” is the smaller of the
two valves on the master cylinder.
 Purge tubing between the oil pot and master cylinder by slightly cracking open valve “D”.
When hydraulic fluid emerges from open end of tubing, close valve “D”.

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INSTALLATION & OPERATIONS

2.3 FILLING THE HYDRAULIC SYSTEM (Continued)

 Attach tubing to valve “B”.
 Remove the pipe plug from port “C” and open valve “C” then open valves “A” and “B”.
 Slightly open valve “D”. When fluid flows from port “C” with no air bubbles, close valve
“D”.
 Using instrument output, stroke the master cylinder down fully – fluid will come out of valve
“C.” Prepare to catch fluid in a pan or tube to a “catch can.” Then, depressurize the
instrument output to the diaphragm motor.
 Close valve “A”.
 Slightly open valve “D”. The pressure in the oil pot will force the master cylinder piston up.
Close valve “D” securely when the master cylinder piston reaches top of its travel.
 Reopen valve “A”.
 Repeat steps 10 through 13 several times (check oil in oil pot periodically for fluid level).
 Close valve “C” and replace pipe plug in valve “C”. Use PTFE tape or pipe dope to seal the
threads.
 Securely close valve “B”.
 Open valve “A” fully. Open valve “D”.
 Close valve “F” securely and vent pressure in the oil pot through the vent valve “E”. The oil
pot assembly may be removed if desired. Disconnect tubing from valve “B”.
 Slightly open valve “B” to allow excess oil pressure to escape. This pressure will escape
immediately when the valve is opened. Do not allow indicator rod to lower onto the
diaphragm case.
 Securely close valve “B”. A pipe plug should be installed into the outlet of valve “B” to
ensure against leaks.
 Reattach instrument supply to the top of the motor.

Figure 2

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Welker Jet® Insert Control Valve
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INSTALLATION & OPERATIONS

2.4 PLACING THE WELKER JET VALVE IN SERVICE

1. The procedure for placing the control valve in service involves interruption of the gas
flow and fluctuation of downstream pressure. All necessary precautions should be taken
before starting. Downstream piping should be protected against overpressuring. The
downstream relief should be properly adjusted before the system is brought into service.
The door on the pneumatic controller will be open while adjustments are being made. If
using gas as the supply pressure, be aware that the controller vents gas into the
enclosure.

DO NOT SMOKE. KEEP OPEN FLAMES, SPARKS AND ALL SOURCES

OF IGNITION AWAY.

Before the system can be placed in service, all sense lines and hydraulic lines must be
hooked up. Pressure sensing points should be located well downstream of the control
valve and away from reducers, tees, elbows and other sources of turbulence. The
hydraulic system should be properly filled.

Adjusting Supply Pressure

2. First- and second-stage regulators are used to regulate the supply to the controller. The
first stage should be set at 100 psig. This provides a regulated supply for output relays if
needed.
3. The second stage regulator takes the 100 psi and regulates it down to the pressure to be
supplied to the controller, up to 30 psi for the 6-30 psi output range controller or 20 psi
for the 3-15 psi output range controller
4. Pressure to the controller should be adjusted according to the pressure needed to achieve
shut-off of the control valve under maximum expected load conditions. If possible, a
test should be made to determine shut-off pressure. This would be done by supplying
pressure to the control valve motor, temporarily bringing the line into service and
adjusting the pressure to determine where shut-off occurs.
5. To determine the setting of the second-stage regulator, take the pressure required to
achieve shut-off and add 3 to 4 psig. If the setting is determined with maximum
differential pressure, add only 2 psig.
6. If the pressure required is between 30 psi and 60 psi, a 1:2 amplifying output relay
should be used and the second-stage regulator should be set to a pressure determined by
taking the initial shut-off pressure, adding 4 and dividing by 2.

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Welker Jet® Insert Control Valve
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INSTALLATION & OPERATIONS

2.4 PLACING THE WELKER JET VALVE IN SERVICE (Continued)

With a 1:2 amplifying output relay:

Initial shut-off pressure + 4 = pressure setting for second stage regulator

2

EXAMPLE:

32# Initial shut-off pressure + 4 = 18 psig pressure setting for second-stage

regulator
2

7. If the pressure required is above 60 psi, a 1:3 amplifying output relay should be used and
the second stage regulator should be set to a pressure determined by taking the initial
shut-off pressure, adding 4 and dividing by 3.

With a 1:3 amplifying output relay:

Initial shut-off pressure + 4 = pressure setting for second-stage regulator

3

EXAMPLE:

62# Initial shut-off pressure + 4 = 22 psig pressure setting for second-stage

regulator
3

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Welker Jet® Insert Control Valve
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INSTALLATION & OPERATIONS

2.5 SETTING THE CORRECT INSTRUMENT SUPPLY FOR OPERATION

1. Care should be taken when setting instrument supply gas to the controller. It is best not
to arbitrarily use a 20 or 30 psi supply because in some cases this might be twice the
pressure required for the “wide seal” positive shut-off. Therefore, it will cause higher
stresses in the inner valve and hydraulic system than is necessary for operation. The
correct method for setting instrument supply is to raise this pressure until there is an
initial shut-off with the maximum operating pressure drop. The initial shut-off is a
narrow seal as shown below (Figure 3).

2. The narrow seal (above) does not insure a positive shut-off if the inner valve must seal
off around welding slag, etc. Therefore, it is recommended that 3-4 psi be added to the
supply pressure so that the inner valve will give a “wide seal” type shut-off, as shown
below.

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INSTALLATION & OPERATIONS

2.5 SETTING THE CORRECT INSTRUMENT SUPPLY FOR OPERATION (Continued)

3. An example is shown below of what happens to the inner valve when considerably more
instrument supply is put into the instrument than necessary (for the wide seal).

• It is recommended that each Welker Jet installation be set up with that specific station’s
pressure conditions in mind.
• In some cases the Welker Jet may be put into service when the pressure drop is less than
the maximum expected. An estimated supply should be used that is capable of handling
all pressure conditions. It can be adjusted at a later date if necessary.
• 6- and 8-inch Welker Jet instruments could require instrument supplies above 30 psi
depending on the pressure drop. In these cases the Amplifying Pressure Relays are used.
When using an Amplifying Pressure Relay, adjust your instrument pressures so that you
supply the diaphragm motor with only the pressures required to insure a positive shut-off.

Example: If the control valve requires 55 psig (3.79 Barg) to achieve positive shut-off +2 psig
(.14 Barg), you will have 29 psig (1.99 Barg) from the output of the controller to a 1:2
Amplifying Relay. Limit the inlet supply to the Amplifying Relay to 57 psig (3.93 Barg) – not
the 60 psig (4.13 Barg) that one might expect with a 30 PSI (2.06 Barg) Controller. This will
eliminate the possibility of excessive supply pressure on the inner valve.

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MAINTENANCE

3. MAINTENANCE
3.1 GENERAL

Prior to maintenance or disassembly of the unit, it is advisable to have a repair kit handy
for the system in case of unexpected wear or faulty seals. All maintenance and cleaning
of the unit should be done on a smooth, clean surface.

We recommend that the unit have annual maintenance under normal operating conditions. In
the case of severe service, dirty conditions, excessive cycling usage, or other unique
applications that may subject the equipment to unpredictable circumstances, a more frequent
maintenance schedule may be appropriate.

Recommended Tools
It would be advisable to have the following tools available for installation of the unit.
However, tools used will vary depending on cylinder model and connectors used.

• (2) adjustable wrenches

• Allen® wrench
• 600-grit sandpaper
• Hammer
• 14"-16" adjustable wrench

New seals supplied in spare parts kits are not lubricated. They should be lightly coated with
lubrication grease (silicone grease or other) before they are installed into the equipment.
This helps in the installation of the seals while reducing the risk of damage when positioning
them on the parts. After the seals are installed, some additional lubrication can be applied
to shafts or cylinder inner diameters to allow smooth transition of parts.

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Welker Jet® Insert Control Valve
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MAINTENANCE

3.2 WELKER JET CONTROL VALVE INSPECTION & DISASSEMBLY

When inspecting a Welker Jet Control Valve system, both the control valve and the
motor should be disassembled.

1. Isolate and depressurize the piping in that the control valve is installed.
2. Disconnect the instrument air supply from the top of the diaphragm motor and depressurize the
control valve hydraulic system.
3. Close the connecting valve on the master
cylinder. This is the valve in the line leading
from the master cylinder to the control valve
body (valve “A” in Figure 1).
4. Disconnect the hydraulic line from the control
valve.
5. Remove the control valve from the pipeline. On
insert models, the control valve is removed by
rolling the inspection spool down or if no
inspection spool is used, removing the entire
control valve spool.
6. Using an Allen wrench, remove the nose cone.
This will expose the upstream face of the slave
piston, identifiable by flats to that a wrench can
be fitted.
7. With a wrench on the flat, turn the slave piston
counterclockwise. The inner valve and slave
cylinder should turn with the slave piston. Do not allow the cylinder and inner valve to unscrew
from each other. If they will not both turn while unscrewing the slave piston, they should both be
held stationary. The 6” and 8” models have holes drilled into the side of the cylinder to assist in
holding while turning the slave piston. Completely unscrew the slave piston from the body.
8. Remove the piston from the cylinder. Inspect the piston for wear and smoothness. If any
roughness is detected, use 600-grit sandpaper and polish the rough area. Clean the piston before
reassembly.

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MAINTENANCE

3.2 WELKER JET CONTROL VALVE INSPECTION & DISASSEMBLY

(Continued)

9. Inspect the inner valve. If replacement appears necessary, unscrew the inner valve from the slave
cylinder and screw the new inner valve along with replacing the spacer rings back onto the
cylinder.
10. Inspect O-rings/crown seals and sealing surfaces. O-ring/crown seals and back-up rings are
inexpensive parts. For this reason, replacement of these parts is recommended. Care must be
taken to place the new O-rings/crown seals and back-up rings in the proper positions. Lubricate
the new seals when replacing. Refer to the drawings in the Parts List for a cutaway drawing of
the control valve being serviced.

At this point the control valve is completely disassembled. The parts should be kept as clean as
possible. Allowing dirt into the control valve could have an adverse effect on the control valve’s
operation.

3.3 WELKER JET CONTROL VALVE REASSEMBLY

If a new inner valve is used, screw the entire inner valve

back onto the slave cylinder. (See #9 Section 3.2.)

1. Lubricate the slave piston and shaft.

2. With the large opening of the slave cylinder facing up,

carefully place the smaller threaded diameter of the slave
piston into the smaller hole of the slave cylinder until the
piston shaft makes contact with the seal in the slave
cylinder. You will have to raise the cylinder up off the
bench to do this properly. Once the piston shaft has made
contact with the slave cylinder seal, push it into the cylinder
until the shaft has made full contact with the seal (about one
inch). This process is rather easy on the 1”, 2” and 4”; it
may require a bit of force on the 6” and 8”.

3. Simply turn the whole assembly over so the slave cylinder opening is pointing down and tap it evenly until
the cylinder slides over the small end of the piston and the seal has made full contact (Figure 9).

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MAINTENANCE

3.3 WELKER JET CONTROL VALVE REASSEMBLY (Continued)

4. Before pushing the large end of the piston into the cylinder, hold the
assembly in a vertical position and fill the cylinder about one-fourth
full of aircraft grade hydraulic oil.

5. While still holding vertically, push the piston into the cylinder until
oil starts to run out of the end of the piston shaft and the threaded end
of the piston shaft extends past the inner valve. Do not push the
piston in all the way.

6. Be certain the proper O-ring or the face seal ring is in position and
well lubricated to hold it in position on the end of the slave piston as shown (Figure 9).

7. Fasten the complete assembly into the body by turning the piston clockwise (exact reversal of
disassembly). Hydraulic oil may be displaced out of the body as the slave piston is tightened.

8. When the slave system is properly tightened, it should be possible to feel a solid stopping point. Tighten
firmly and use a hammer and wrench (if necessary) to ensure that the slave piston is rigidly tightened to the
control valve body. Refer to Torque Chart below.

9. Replace the nose cone using the socket head fastener.

10. On flanged models, replace the O-ring seal on the spool flange and secure control valve into control valve
spool using the socket head cap screws.

11. Reinstall control valve in pipeline. Use new pipe flange gaskets where needed. Be certain the hydraulic
inlet is vertical and the control valve is properly oriented for correct flow direction.

12. Reconnect hydraulic line. Remove pipe plug on the fitting attached to the control valve body and carefully
top off the hydraulic system with unused aircraft hydraulic oil. Refer to Filling the Hydraulic System.

Torque Chart
The torque values for the 1”, 2”, 4” and 6” WELKER JET instruments are
as follows:
1”………… 15ft/lbs
2”………… 100ft/lbs
4”………… 150ft/lbs
6”………… 285ft/lbs
8”………… *
Additionally, it is recommended that these pistons be impacted with a small hand
sledge-hammer as shown below:
1” 1-pound hammer 2 easy raps on a 8” crescent wrench
2” 3-pound hammer 2 firm raps on a 10” crescent wrench
4” 3-pound hammer 2 firm raps on a 12” crescent wrench
6” 10-pound hammer 3 firm raps on a 18” crescent wrench
8” 10-pound hammer 3 firm raps on a 24” crescent wrench
*This size has no torque specs and will require the impacting after a metal to metal make-up is achieved
between the slave piston and regulator body.

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MAINTENANCE

3.4 MOTOR INSPECTION & DISASSEMBLY

1. Disconnect the instrument air supply from the top of the diaphragm motor.
2. Position the raised part of the indicator-locking device on the master cylinder directly under the
indicator rod. This is to lock the diaphragm motor in the raised position. For single diaphragm motor
units, proceed to step 7.
3. On tandem diaphragm motors, disconnect the instrument air
line from the lower diaphragm motor, remove all bolts that
hold the two halves of the top motor together and remove
the top half and diaphragm of the top motor.
4. Open the bleed valve to relieve any pressure.
5. On tandem diaphragm motors, lift out the diaphragm plate
and the connected drive shaft. Inspect the drive shaft for
wear and roughness. Use 600-grit sandpaper to polish the
rough areas and leave the piston clean. A set of back-up
rings and a crown seal in the midsection will be exposed.
These should be inspected and replaced if necessary. Care
must be taken to place the new crown seal and back-up rings
in the proper positions. Refer to the cutaway drawing of the
tandem diaphragm motor in the parts list. Also, care should
be taken to keep all parts clean.
6. On tandem diaphragm motors, lubricate the master piston
with silicone grease and place the diaphragm plate and drive
shaft assembly back in proper position. Reattach the
diaphragm and top cover and securely bolt the two halves
together. Reattach the instrument air supply line to the
bottom diaphragm motor.
7. Make sure the connecting valve between the master cylinder
and the control valve motor is closed, then firmly grip and
unscrew the diaphragm motor assembly from the master
cylinder (a back-up on the master cylinder will be required).
It may be necessary to remove the pipe plug from the bleed
valve and slightly open the valve to relieve the vacuum in
the cylinder and allow the piston to be removed. After the
motor is removed, close the bleed valve but do not yet
replace the pipe plug. Loosen the indicator-locking device,
allowing the master piston to drop down. Inspect the master
piston for wear and roughness. Use 600-grit sandpaper to
polish the rough areas and leave the piston clean.
8. Lift the bearing out of the master cylinder. A solid back-up
ring and O-ring or crown seal will be exposed. These
should be replaced. Refer to the drawings of control valve
motors in the Parts List for the proper placement of the
crown seal and back-up. Care should be taken to keep all
parts as clean as absolutely possible.
9. After replacing the crown seal and back-up ring, reinsert the bearing and fill the master cylinder
slightly below the crown seal with unused aircraft hydraulic oil.

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MAINTENANCE

If air has been inadvertently introduced into the hydraulic system, remove the used oil and
refer for filling the Hydraulic System.

3.5 MOTOR REASSEMBLY

1. Lubricate the piston with a film of silicone grease

and push motor piston back into diaphragm motor.
Retighten indicator-locking device. Slowly screw
the diaphragm motor assembly down firmly on the
master cylinder. Refer to Filling the Hydraulic
System.

2. Retighten the diaphragm motor assembly on the

master cylinder.

3. Move the indicator locking device out of the way of

the indicator rod.

4. Reconnect the instrument air supply to the top of the

diaphragm motor.

5. Open the valve on the bottom of the slave system.

(See Figure 1 Valve A).

The inspection and reassembly procedure is now

complete.

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Welker Jet® Insert Control Valve
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13839 West Bellfort, Sugar Land, Texas 77498-1671
Phone: (281) 491-2331
Fax: (281) 491-8344
Toll Free: (800) 776-7267
Web Page: www.welkereng.com