Emerson Anderson Greenwood 727 Series User manual

ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Before installation these instructions must be read fully and understood
© 2017 Emerson. All Rights Reserved.valves.emerson.com VCIOM-03376-EN 17/05
Engineering doc. #05.9040.257 Rev. C
SAFETY PRECAUTIONS
∙When the safety valve is under pressure never
place any part of your body near the outlet of
thevalve.
∙The valve outlet and any separate drains
shouldbe piped or vented to a safe location.
∙Always wear proper safety gear to protect
hands, head, eyes, ears etc. any time you are
near pressurized valves.
∙Never attempt to remove the safety valve
fromasystem that is pressurized.
∙Never make adjustments to or perform
maintenance on the safety valve while in service
unless the valve is isolated from the system
pressure. If not isolated properly from the
system pressure, the safety valve may open
inadvertently resulting in serious injury.
∙Remove the safety valve prior to performing
anypressure testing of the system.
∙The safety of lives and property often depends
on the proper operation of the safety valve.
The valve must be maintained according
to appropriate instructions and must be
tested periodically and reconditioned to
ensurecorrectfunction.
CONTENTS
1. General description....................................... 2
2. Main valve maintenance ............................... 3
3. Unloader maintenance ............................... 11
4. Hand valve maintenance............................. 13
5. Pilot maintenance ....................................... 16
6. Pilot minimum lift adjustment and
pressuresetting preparation ..................... 19
7. Pilot set and reseating pressure
adjustment................................................... 21
8. Pilot installation .......................................... 24
9. Valve assembly leak tests........................... 26
10. Pilot set pressure test................................. 28
11. Pilot and manifold leak test........................ 29
12. Repair kits and parts philosophy................ 31
13. Repair tools.................................................. 32
14. Piston disk and nozzle sealing facerepair 34

2
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
1 GENERAL DESCRIPTION
Operation
The Type 727 pilot operated safety valve uses
the principle of loading the larger area of a
differential area piston with line pressure to
hold the piston closed up to set pressure.
Service configurations (see Figure 1)
The 727 assembly is shipped in one of two main
valve configurations depending on whether it
is to be applied to steam or air/gas service.
Thepilot assembly is identical for both services.
1. Steam service configuration
Valves for steam service are identified
externally by the presence of tubing
connecting the unloader valve in the
manifold assembly to the main valve
outlet. When the pilot actuates, it vents the
small volume of steam in the dome of the
unloader causing the unloader to open.
The unloader is connected directly to the
main valve dome chamber and allows the
pressure in the dome chamber to vent
intothe outlet of the main valve.
2. Air/gas service configuration
Valves for air/gas service are identified
externally by the lack of tubing from the
manifold to the main valve outlet. The
unloader piston has been removed and a
cap is installed in the unloader cavity in
the manifold. The pilot vents main valve
dome pressure directly to the atmosphere.
An NPT plug is installed in the unloader
discharge port in the main valve outlet.
Internally, the main valve piston radial hole
used for steam service either is eliminated
or plugged permanently for air/gas service.
Installed in the top groove of the air/gas
piston is a special piston ring with a low
leakage end joint design. Installed in
the pressure sense port in the cap is a
pressurespike snubber.
WARNING
The protection and safety of equipment, property
and personnel depends on the proper operation
of the safety valves described in this manual. All
Emerson Flow Control safety valves should be
kept in proper working condition in accordance
with the manufacturer’s written instructions.
Periodic testing and maintenance by the user of
this equipment is essential for reliable and safe
valveoperation.
All installation, maintenance, adjustment, repair
and testing performed on safety valves should
be done by qualified technicians having the
necessary skills and training adequate to perform
such work. All applicable codes and standards,
governing regulations and authorities should be
adhered to when performing safety valve repair.
No repair, assembly, adjustment or testing
performed by other than Emerson Flow Control
or its authorized assemblers and representatives
shall be covered by the warranty extended by
Emerson Flow Control to its customers. The
user should use only original, factory supplied
OEM parts in any maintenance or repair activity
involving this product.
This maintenance manual is provided as a general
guide for the repair and maintenance of the
safety valves described herein. It is not possible
to describe all configurations or variations
with such equipment. The user is advised to
contact Emerson Flow Control or its authorized
assemblers and representatives for assistance
in situations that are not covered adequately or
described in this manual.
Before removing a safety valve for maintenance,
ensure that the system pressure has been fully
depressurized. If an isolation block valve is used,
ensure that any trapped fluid between the block
valve and the safety valve is vented safely.
Before disassembling the safety valve ensure
that the valve has been decontaminated from
any harmful gasses or fluids and that it is at a
safe temperature range for handling. Fluids can
be trapped in the dome space of pilot operated
safetyvalves.
Before installation, the Installation and
Operational Safety Instructions should be read
fully and understood. These Instructions may
be requested from the factory or are available
atvalves.emerson.com.
Onrising system pressure, the pilot actuates at
set pressure, venting pressure from the main
valve dome chamber. When the main valve
dome pressure is reduced to 40% of system
pressure, the main valve disk lifts off the nozzle
seat, thereby venting system pressure through
the outlet.
When system pressure drops by 5 to 7% of set,
the pilot closes, allowing system pressure to
recharge the main valve dome causing the disk
to reseat on the nozzle.
When operating below set pressure, the inlet
and main valve dome pressures are equal so
that the seating force on the main valve seat is
equal to the system pressure times the seating
area. Since the seat load increases with system
pressure, the main valve maintains premium
seat tightness up to set pressure.

3
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
2 MAIN VALVE MAINTENANCE
Depending on the vintage of the main valve,
the cap may be equipped with drain plunger
assembly (refer to Figure 2A, items 16, 17,
and 18). This arrangement is found typically
in earlier production models. In more recent
production, this feature has been eliminated
as shown in Figure 2B. Please refer to
the appropriate section below for detailed
disassembly and assembly instructions.
Disassembly – Main valve with drain plunger
in cap
(Refer to Figures 2 and 3)
1. Note: for ease of repair, the tools and repair
kits specified in Section 12 and Section 13
should be used.
2. Disconnect tubing from unloader to outlet
flange.
4. Remove piston assembly. For sizes 6 x 8 and
8 x 10, a ½-13 UNC eye bolt can be threaded
into back of piston to aid in removal. The
weight of 6” and 8” pistons may require use
of a lift assist device. Protect disk seat face
from damage.
5. Before removing liner (5), remove and
discard compacted liner seal (13) being
careful not to damage metal surfaces.
Remove liner (5).
6. Use only a 12 point socket to remove
nozzle retaining screws (9) and spring
washers(23). To remove nozzle (3), reinstall
two screws 180 degrees apart without the
spring washers. Tap lightly on screws and
drive nozzle (3) free of seal (15). Remove
screws, nozzle (3), nozzle seal (15) and
extrusion ring (14). Discard screws (9),
washers (23) and nozzle seal (15). Under
nocondition re-use items 9, 23 and 15.
3. Reposition main valve with the cap (2)up.
Remove the cap nuts (7). If the cap is
stuck to the valve body, free it by tapping
around the cap edge with a brass hammer.
Carefully raise the cap about 1 inch from the
body and determine whether the damper(8)
has moved upward while remaining in
contact with the underside of the cap.
If the damper did not rise freely, proceed
with extreme caution in removing the cap.
The dome spring (10) is under compression
and the spring loaded damper may be stuck
in the piston. The damper could suddenly
release after the cap is removed possibly
causing personal injury. Remove the cap
and manifold assembly. Eyebolt holes are
located on the cap diameter for handling
purposes.
Remove damper (8), dome spring (10) and
filter assembly (19). Filter may be removed
by grabbing sleeve with pliers. Set filter
assembly aside for cleaning and inspection.
Re-use if not damaged. Remove and discard
seal (20) at filter port on both cap and body.
Remove plug (18) in cap (2) and remove
drain plunger (17) and spring (16). For valves
in vapor service with a pressure snubber
(93C) (see detail C in Figure 2), remove
and inspect pressure snubber visually
for blockage. Clean snubber if blocked.
For valves in vapor service with remote
sense options, (see detail D in Figure 2)
inspect remote sense fitting (93D) visually
for blockage. Remove and clean fitting if
blocked.
Repair – Main valve with drain plunger in cap
Refer to Section 12 'Repair kits' and
Section13'Repair tools'.
1. Inspect the nozzle (3) and disk (29) seat
surfaces for nicks or scratches. Restoration
of disk and nozzle seat surfaces should only
require lapping and polishing. If the seat
surfaces are damaged more extensively,
machining may be required. Refer to
Section14.
2. Inspect piston rings (11 and 12) for
scratches or galling. If replacement
is required refer to ring kits listed in
Section12. To replace rings, remove rings
and centralizer springs (21 and 22). Discard
rings and springs. Assemble new rings
and centralizers on piston following the
instructions supplied in each kit. If piston
ring expanders described in Section 13
are not available, both rings can be hand
installed on the piston. Carefully expand
correct ring over piston OD. Place brass
shim stock under ring gap end to prevent
scratching piston. Slide ring into groove.
3. Inspect liner (5) interior for damage or
foreign deposits. Replace liner if damaged.
Chemical and/or oxide deposits may be
removed by polishing with 600 grit paper.

4
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
2 x 3, 3 x 4
Steam service
4 x 6, 6 x 8, 8 x 10
Steam service
All sizes
Air/gas service
FIGURE 1

5
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Assembly – Main valve with drain plunger
incap
1. Note: before assembly, clean all valve parts
thoroughly with oil-free solvent and dry,
paying particular attention to all sealing
surfaces. Do not bead or sandblast. Check
both damper and nozzle for matching orifice
'letter' designators before assembling.
2. Install extrusion ring (14) with radius edge
into flange corner, fit nozzle seal (15)
around bottom of nozzle (3) (see detail E
inFigure2). Install nozzle in valve body and
lightly secure nozzle with new retaining
screws (9) and new belleville washers (23)
(see detail G in Figure 2 for washer stack
orientation). Note that all valve sizes use six
washers per screw except the 4 x 6 valve
size which uses seven washers per screw.
Use a 12 point socket to tighten screws
in a clockwise pattern, one revolution
per screw, until all screws are seated
fully. Thisprocedure will ensure proper
compression of new nozzle seal. Do not
tighten screws alternately as this method
could cause seal failure.
3. Stand valve on its outlet flange; install
liner(5) in valve body. Lubricate 45° step
inliner with silicone grease.
6. Insert filter (19) into port in valve body and
slide a new dipper tube seal (20) over the
filter sleeve (see Figure 2, detail F).
Note: the manifolded valve requires an ⅛”
thick dipper tube seal Part no. 06.0553.002.
Do not use the
1
/
16” thick dipper tube seal
Part no. 06.0553.001 in this assembly.
Seesection 12 for repair kit information.
7. Position mating hole in cap assembly over
the filter assembly sleeve and lower onto
studs, checking that damper is centered
into cap recess before cap seats against
valve body. A
1
/
16” to ⅛” gap must be visible
between cap and body. This indicates cap
is in proper contact with the liner seal.
Alternately tighten opposite cap nuts to
maintain parallelism between cap and body
until cap is solid against body face. Torque
nuts to values in Table 1.
8. For valves in steam service, reconnect
tubing from unloader to outlet flange.
Iftubing fittings have been removed, coat
fitting NPT threads with Never-Seez before
reinstalling. Refer to Section 13 for thread
seal information.
4. If a piston installation sleeve is used, (see
Section 13.7 for details) place sleeve on top
of liner. Lubricate ID of sleeve with silicone
grease. Wipe both piston and nozzle sealing
surfaces with a clean, lint free, cloth or rag
wetted with clean degreasing fluid. Insert
piston into sleeve to compress rings with
radial hole in piston toward valve inlet (refer
to Figure 2). Insert and center a wooden
or plastic dowel into piston and lightly tap
piston into liner approximately half way.
Remove installation sleeve and press
piston down to nozzle. Install spring (10),
damper(8) and liner seal (13).
If an installation sleeve is not used, lubricate
the ID of liner at both top and mid point with
silicone grease. Carefully insert piston with
the radial hole toward valve inlet (refer to
Figure 2). Insert and center a wooden or
plastic dowel into piston. Push in top ring
with screw driver. Lightly tap piston into
liner. Press piston down to nozzle. Install
spring (10), damper (8) and liner seal (13).
5. Reassemble drain plunger (17) and spring
(16) into cap (2) and check for freedom of
movement. Apply Never-Seez to the threads
and the sealing edge of the drain plug (18)
and screw into the cap by hand and tighten
to 35-40 ft·lb torque using a calibrated
torque wrench. For valves in steam
service with standard internal sense, apply
Never-Seez to the threads and the sealing
edge of the port plug (93A) and screw into
the cap by hand and tighten to 35-40 ft·lb
torque using a calibrated torque wrench.
For valves with remote sense or snubber
options, install remote sense/snubber fitting
(93,B,C,D) by lightly lubricating the cap bore,
the insert’s extension barb end, sealing
edge and mounting thread. Screw the insert
into the cap port as far as possible by hand.
Using a wrench, screw the connector into
the cap slowly until it is fully seated. Finally,
using a calibrated torque wrench, tighten
the connector to 65-70 ft·lb torque to seat it
in the cap body.

6
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Disassembly – Main valve without drain
plunger in cap
(Refer to Figures 2B and 3)
1. Note: for ease of repair, the tools and repair
kits specified in Section 12 and Section 13
should be used.
2. Disconnect tubing from unloader to outlet
flange.
3. Reposition main valve with the cap (2)up.
Remove the cap nuts (7). If the cap is
stuck to the valve body, free it by tapping
around the cap edge with a brass hammer.
Carefully raise the cap about 1 inch from the
body and determine whether the damper(8)
has moved upward while remaining in
contact with the underside of the cap. If the
damper did not rise freely, proceed with
extreme caution in removing the cap. The
dome spring (10) is under compression and
the spring loaded damper may be stuck
in the piston. The damper could release
suddenly after the cap is removed, possibly
causing personal injury. Remove the cap
and manifold assembly. Eyebolt holes are
located on the cap diameter for handling
purposes.
Remove damper (8), dome spring (10) and
filter assembly (19). Filter may be removed
by grabbing sleeve with pliers. Set filter
assembly aside for cleaning and inspection.
Re-use if not damaged. Remove and discard
seal (20) at filter port on both cap and body.
Remove plug (18) in cap (2) and remove
drain plunger (17) and spring (16). For valves
in vapor service with a pressure snubber
(93C) (see detail C in Figure 2), remove
and inspect pressure snubber visually
for blockage. Clean snubber if blocked.
For valves in vapor service with remote
sense options, (see detail D in Figure 2)
inspect remote sense fitting (93D) visually
for blockage. Remove and clean fitting if
blocked.
Repair – Main valve without drain plunger
incap
Refer to Section 12 'Repair kits' and
Section13'Repair tools'.
1. Inspect the nozzle (3) and disk (29) seat
surfaces for nicks or scratches. Restoration
of disk and nozzle seat surfaces should only
require lapping and polishing. If the seat
surfaces are damaged more extensively,
machining may be required. Refer to
Section14.
2. Inspect piston rings (11 and 12) for
scratches or galling. If replacement
is required refer to ring kits listed in
Section12. To replace rings, remove rings
and centralizer springs (21 and 22). Discard
rings and springs. Assemble new rings
and centralizers on piston following the
instructions supplied in each kit. If piston
ring expanders described in Section 13
are not available, both rings can be hand
installed on the piston. Carefully expand
correct ring over piston OD. Place brass
shim stock under ring gap end to prevent
scratching piston. Slide ring into groove.
3. Inspect liner (5) interior for damage or
foreign deposits. Replace liner if damaged.
Chemical and/or oxide deposits may be
removed by polishing with 600 grit paper.4. Remove piston assembly. For sizes 6 x 8 and
8 x 10, a ½-13 UNC eye bolt can be threaded
into back of piston to aid in removal. The
weight of 6” and 8” pistons may require use
of a lift assist device. Protect disk seat face
from damage.
5. Before removing liner (5), remove and
discard compacted liner seal (13) being
careful not to damage metal surfaces.
Remove liner (5).
6. Use only a 12 point socket to remove
nozzle retaining screws (9) and spring
washers(23). To remove nozzle (3), reinstall
two screws 180 degrees apart without the
spring washers. Tap lightly on screws and
drive nozzle (3) free of seal (15). Remove
screws, nozzle (3), nozzle seal (15) and
extrusion ring (14). Discard screws (9),
washers (23) and nozzle seal (15). Under
nocondition re-use items 9, 23 and 15.

7
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Assembly – Main valve with drain plunger
incap
1. Note: before assembly, clean all valve parts
thoroughly with oil-free solvent and dry,
paying particular attention to all sealing
surfaces. Do not bead or sand blast. Check
both damper and nozzle for matching orifice
'letter' designators before assembling.
2. Install extrusion ring (14) with radius edge
into flange corner, fit nozzle seal (15)
around bottom of nozzle (3) (see detail E
inFigure2). Install nozzle in valve body and
secure nozzle lightly with new retaining
screws (9) and new Belleville washers (23)
(see detail G in Figure 2 for washer stack
orientation). Note that all valve sizes use six
washers per screw except the 4 x 6 valve
size which uses seven washers per screw.
Use a 12 point socket to tighten screws
in a clockwise pattern, one revolution
per screw, until all screws are fully
seated. Thisprocedure will ensure proper
compression of new nozzle seal. Do not
tighten screws alternately as this method
could cause seal failure.
3. Stand valve on its outlet flange; install liner
(5) in valve body. Lubricate 45° step in liner
with silicone grease.
4. If a piston installation sleeve is used, (see
Section 13.7 for details) place sleeve on top
of liner. Lubricate ID of sleeve with silicone
grease. Wipe both piston and nozzle sealing
surfaces with a clean, lint free, cloth or rag
wetted with clean degreasing fluid. Insert
piston into sleeve to compress rings with
radial hole in piston toward valve inlet (refer
to Figure 2). Insert and center a wooden
or plastic dowel into piston and lightly tap
piston into liner approximately half way.
Remove installation sleeve and press
piston down to nozzle. Install spring (10),
damper(8) and liner seal (13).
If an installation sleeve is not used, lubricate
the ID of liner at both top and mid point with
silicone grease. Insert piston carefully with
the radial hole toward valve inlet (refer to
Figure 2). Insert and center a wooden or
plastic dowel into piston. Push in top ring
with screwdriver. Tap piston lightly into
liner. Press piston down to nozzle. Install
spring (10), damper (8) and liner seal (13).
5. For valves in steam service with standard
internal sense, apply Never-Seez to the
threads and the sealing edge of the port
plug (93A) and screw into the cap by hand
and tighten to 35-40 ft·lb torque using a
calibrated torque wrench. For valves with
remote sense or snubber options, install
remote sense/snubber fitting (93,B,C,D) by
lightly lubricating the cap bore, the insert’s
extension barb end, sealing edge and
mounting thread. Screw the insert into the
cap port as far as possible by hand. Using
a wrench, screw the connector slowly into
the cap until it is fully seated. Finally, using
a calibrated torque wrench, tighten the
connector to 65-70 ft·lb torque to seat it
inthe cap body.
6. Insert filter (19) into port in valve body and
slide a new dipper tube seal (20) over the
filter sleeve (see Figure 2, detail F).
Note: the manifolded valve requires an ⅛”
thick dipper tube seal Part no. 06.0553.002.
Do not use the
1
/
16” thick dipper tube seal
Part no. 06.0553.001 in this assembly.
Seesection 12 for repair kit information.
7. Position mating hole in cap assembly over
the filter assembly sleeve and lower onto
studs, checking that damper is centered
into cap recess before cap seats against
valve body. A
1
/
16” to ⅛” gap must be visible
between cap and body. This indicates cap is
in proper contact with the liner seal. Tighten
opposite cap nuts alternately to maintain
parallelism between cap and body until cap
is solid against body face. Torque nuts to
values in Table 1.
8. Reconnect tubing from unloader to outlet
flange. If tubing fittings have been removed,
coat fitting NPT threads with Never-Seez
before reinstalling. Refer to Section 13 for
thread seal information.

8
16
17
14
15
329
923 3 4 18 5 8 12
8
13
2221
3029
93D
93A
93B
18
93C
19
13
7 6
2
19
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Internal sense option
Remote sense option Snubber option
Remote sense and
snubber option DETAIL E
DETAIL B
DETAIL A
DETAIL D
DETAIL F
DETAIL C
Belleville stack
orientation before
installation
(4 x 6 requires
7washers)
See Detail G
See
DetailE
See Detail F
Radial hole
Inlet
Outlet
See Detail
A, B, C, D
MAIN VALVE ASSEMBLY (4” SHOWN)
FIGURE 2A PARTS LIST
Item Description
1Body
2Cap
3Nozzle
4Piston
5Liner
6Stud
7Nut
8Piston damper
9Retainer screw
10 Dome spring
11 Damper ring
12 Piston seal ring
13 Liner seal
14 Seal extrusion ring
15 Nozzle seal
16 Drain spring
17 Drain plunger
18 Pipe plug, drain
19 Filter assembly
20 Seal, upper tube
21 Centralizer spring
22 Centralizer spring
23 Belleville washer
29 Disk
30 Bolt, case retainer
31 Screw, disk retainer
93A Pipe plug, remote sense
93B Remote sense, fitting
93C Pipe plug, snubber
93D Remote sense fitting/snubber
DETAIL G

9
14
15
3
29
923 3 4 18 5 8 12
8
13
2221
3029
93D
93A
93B 93C
19
13
7 6
2
19
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Internal sense option
Remote sense option Snubber option
Remote sense and
snubber option DETAIL E
DETAIL B
DETAIL A
DETAIL D
DETAIL F
DETAIL C
Belleville stack
orientation before
installation
(4 x 6 requires
7washers)
See Detail G
See
DetailE
See Detail F
Radial hole
Inlet
Outlet
See Detail
A, B, C, D
MAIN VALVE ASSEMBLY (4” SHOWN)
FIGURE 2B PARTS LIST
Item Description
1Body
2Cap
3Nozzle
4Piston
5Liner
6Stud
7Nut
8Piston damper
9Retainer screw
10 Dome spring
11 Damper ring
12 Piston seal ring
13 Liner seal
14 Seal extrusion ring
15 Nozzle seal
16 Drain spring
17 Drain plunger
18 Pipe plug, drain
19 Filter assembly
20 Seal, upper tube
21 Centralizer spring
22 Centralizer spring
23 Belleville washer
29 Disk
30 Bolt, case retainer
31 Screw, disk retainer
93A Pipe plug, remote sense
93B Remote sense, fitting
93C Pipe plug, snubber
93D Remote sense fitting/snubber
DETAIL G

10
29* 21
11 12
22 4
30
11 12
29 21 22 4
31
31
¼ 9
5
/
16 18
⅜31
7
/
16 50
½75
9
/
16 110
⅝150
¾250
⅞378
1 (8” 150/300 CL) 405
1 (8” 600 CL) 450
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
TABLE 1 - TORQUE VALUES FOR VALVE ASSEMBLY (foot-pounds)
Bolt size Carbon steel
6” AND 8” PISTON
8” PISTON
2”, 3” AND 4” PISTON
* Non-removable
FIGURE 3

11
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
3 UNLOADER MAINTENANCE
(STEAMSERVICE ONLY)
Unloader disassembly (see Figure 4)
For size 4 x 6 and larger main valves, the
unloader piston fits directly into the unloader
cavity in the manifold. For 3 x 4 and smaller
main valves, a reduced size unloader piston
andadapter sleeve fit into the unloader cavity.
1. Disconnect tubing and remove unloader
nozzle bushing (60) and bushing seal (61).
2. Remove unloader piston (59 or 63) and
adapter sleeve (62) if present.
Unloader repair
Inspect the bushing and piston seat surfaces
for nicks or scratches. Restoration of bushing
and piston seat surfaces should only require
lapping and polishing. If the seat surfaces are
damaged more extensively, a new bushing and
piston will have to be installed. If replacement
is required, refer to kits in Section 13.
Unloader assembly - 2 x 3 and 3 x 4 main
valves (see Figure 4)
The unloader assembly used for these valve
sizes is basically an assembly for adapting the
standard larger main valve unloader cavity in
the manifold to operate with the reduced size
unloader piston and nozzle required for proper
operation of the two small valve sizes. This
assembly consists of an adapter sleeve (62),
small unloader piston (63), nozzle bushing (60)
and bushing seal (61). Install this assembly as
follows:
1. Clean and degrease all of the unloader
components taking special care to protect
the unloader piston and nozzle seat faces
from contact with any surface.
Note: these lapped and polished surfaces
should not be touched at any point in
handling except for careful wiping with a
soft clean lint free rag wetted with clean
degreasing fluid.
2. Insert the unloader piston (63) into the
adapter sleeve (62) as shown in Figure
4 andcheck the piston movement in the
adapter bore. The piston should fit closely
inthe bore but move freely without binding
at any point.
Unloader assembly – 4 x 6, 6 x 8 and 8 x 10
main valves (see Figure 4)
The unloader piston for these main valve sizes
fits directly into the unloader socket bore in
the manifold body. This assembly consists
of an unloader piston assembly (59), nozzle
bushing(60) and bushing seal (61). Install
theseitems as follows:
1. Clean and degrease all of the unloader
components taking special care to protect
the unloader piston face and nozzle seat
from contact with any surface.
Note: these lapped and polished surfaces
should not be touched at any point in
handling except for careful wiping with a
soft clean lint free rag wetted with clean
degreasing fluid.
2. Insert the unloader piston assembly (59)
into the manifold unloader socket until it
seats against the back face of the piston
bore as shown in Figure 4. During insertion
the piston ring (59A) may have a tendency
to hang on the front edge of the piston bore
section of the unloader socket; if so, a slight
wobbling of the piston while lightly pushing
on the depressed center of the piston disc
should compress the ring into the bore.
Once the piston ring is in the piston bore
thepiston should move freely without
binding at any point.
3. Place the bushing seal (61) on to the
unloader nozzle bushing (60), lubricate the
bushing thread lightly with Never-Seez
and screw the bushing into the manifold
socket until the bushing seal is seated in
the manifold counterbore. Using a wrench,
tighten the unloader nozzle bushing into the
manifold until the bushing’s back face seats
metal-to-metal against the manifold face.
4. Install and align tubing adapter fitting on
unloader bushing and reinstall unloader
discharge tubing section. Lightly lubricate
fitting NPT threads with Never-Seez.
Vapor service valves (see Figure 4)
Valves for vapor service have no unloader
internals and have a blind bushing (65) installed
in place of an unloader nozzle. While no routine
maintenance is required, it may be necessary to
remove the blind bushing if the manifold hand
valve seats must be resurfaced (see Section 4).
3. Lightly lubricate adapter sleeve’s end
face that engages the unloader nozzle
bushing with Never-Seez and insert the
adapter sleeve, with the piston in place,
into the manifold unloader socket until
it seats against the back face of the bore
asshownin Figure 4.
4. Place the bushing seal (61) on to the
unloader nozzle bushing and lubricate the
bushing thread lightly with Never-Seez.
Screw the bushing into the manifold
socket until a quick rise in bushing turning
resistance is felt indicating that the bushing
has seated against the adapter sleeve.
5. Continue tightening the unloader nozzle
bushing into the manifold until the bushing’s
back face seats metal-to-metal against the
manifold face.
6. Install and align tubing adapter fitting on
unloader bushing and reinstall unloader
discharge tubing section. Lightly lubricate
fitting NPT threads with Never-Seez.

12
60 61 59 59A
60 61
65 61
63 62
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Large valve unloader (Steam service)
Assembly (4 x 6, 6 x 8 and 8 x 10)
Small valve unloader (Steam service)
Assembly (2 x 3 and 3 x 4)
Valve unloader (Vapor service)
FIGURE 4

13
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Hand valve seat resurfacing (see Figure 5)
1. Examine the hand valve seating surface
in the manifold block cavity for signs of
mechanical damage or excessive wear.
2. Recondition the seating surface, if required,
with the special Seat Resurfacing Tool
(Anderson Greenwood Part no. 02.2543.001)
per the included instructions.
WARNING!
Failure to follow these instructions closely may
result in further damage to the seating surface
requiring costly replacement of the entire
manifold block.
3. Remove all chips and debris from the
manifold cavity carefully after reconditioning
the valve seat. Clean, dry compressed air
should be used for this purpose to prevent
debris migration into the manifold’s internal
flow passages. The inlet isolation valve
cavity may be cleared by removing fitting
93A, B, C, or D located on the main valve cap
(see Figure 2) and applying a compressed
air jet to the opening. The dome isolation
and vent valve cavities may be cleared by
removing the unloader bushing and piston
assembly (see Section 3 and Figure 4) and
applying compressed air to the opening
located at the bottom of the unloader cavity.
WARNING!
Failure to remove debris thoroughly from the
valve cavities in the manifold block may result
inpilot/main valve damage or malfunction.
4. Replace fitting or reassemble unloader
parts removed in step 3.
4 HAND VALVE MAINTENANCE
The manifold block hand valves are intended
to function for the life of the valve with no
maintenance. If there is evidence of hand valve
seat leakage, the valve should be removed and
checked for abnormal wear/damage. Damaged
valves should be replaced with new assemblies.
The associated valve seating surface inside the
manifold block should also be examined closely
and resurfaced if required. See Section 12 for
hand valve kits and Section 13 for the special
hand valve seat resurfacing tool.
Hand valve removal (see Figure 5)
1. Remove the lock wire from the hand valve
handle.
2. Loosen the handle bolt (76) and remove
the hand valve handle (75) and hand valve
collar(78) from the valve stem.
3. Remove the latch plates (85) from the
manifold by removing the mounting
bolts(81).
4. Loosen the bushing locknut (72B) on
thetopof the hand valve bonnet.
5. Loosen the hand valve bushing (72) to
thetop of the valve bonnet.
6. Loosen and unscrew the locking collar
retaining nut (72A) as far as possible and
raise the locking collar (73) above the hex
for the hand valve bonnet. If the locking
collar is difficult to raise, lightly tap the
collar to free it from the manifold. Do not
strike it heavily or grip it with pliers as it
maycrush down on the bonnet threads
andbe extremely difficult to remove.
7. Loosen and remove the hand valve
assembly from the manifold block.

14
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
6. Install the hand valve handle (75) on to the
valve stem and screw handle bolt (76) into
handle end until it is engaged with the flat
on the valve stem. Tighten the handle bolt to
secure the handle.
Note: two of the handles have a hole drilled
across one end. These handles should be
installed on the two pilot vent hand valves on
the front face of the manifold.
7. Tighten the hand valve bushing (72C), using
a calibrated torque wrench with a crows
foot attachment, to 5-10 ft·lbs to compress
the valve stem packing. Turn the hand
valve handle (75) a few turns to close and
open the valve and check the torque on the
bushing again. Do this several times; the
hand valve should require some effort to
open and close but should not be extremely
difficult to operate.
8. Tighten the hand valve bushing
locknut(72B) onto the top of the hand
valve bonnet to prevent the bushing from
loosening.
9. Reattach the latch plates (85) to the
manifold. Be careful when tightening the
mounting bolts to center the spring washer
under its washer.
10. Remove the hand valve handles (75) from
the valve stems; insert the valve handle into
the cross drilled bore on the hand valve
lockout collar (78) and align the handle
mounting hole with the small ID of the
collar bore. Slip each handle/collar set
onto its hand valve stem until the handle
is engaged with the stem. Align the handle
bolt carefully with the flat on the valve stem
and tighten the bolt to secure the handle
and lockout collar. The lockout collar
should be free to move against the hand
valve. If the collar is immobile or pressed
against the hand valve, the handle bolt may
be misaligned with the stem. Loosen the
handle bolt and realign the bolt with the
stem before tightening.
11. Reinstall the lock wire on the four main
isolation valves on the sides of the manifold.
Hand valve installation (see Figure 5)
WARNING!
Correct installation torques are important for both
of the following tightening operations to ensure
sealing and locking of the hand valve body to the
manifold block.
1. Turn the hand valve stem to its full up (ccw)
position.
2. Loosen the bushing locknut (72B) and collar
retaining nut (72C) to the top of the valve
bonnet, leaving as much room as possible
for the bonnet locking collar (73) and place
the locking collar, slotted end down, up
ontothe bottom of the bonnet.
3. Lubricate the hand valve bonnet bottom
threads and sealing edge with a light
coating of Never-Seez, screw the hand
valve assembly into the manifold body by
hand and using a calibrated torque wrench
equipped with a crowfoot wrench tighten the
hand valve body to 35-40 ft·lbs torque. Take
care during final tightening not to allow the
locking collar to slip down and engage the
locking pin (74).
4. Hold the locking collar (73) above the hand
valve bonnet hex and rotate it until the
closest mating location between the locking
pin in the manifold and one of three slots
in the locking collar that will not require
loosening of the bonnet is found. If there
is an exact match, slip the locking collar
down around hand valve bonnet hex until
the locking pin is engaged with the collar
slot and the collar is seated against the
manifold counterbore face. If the closest
matching slot found does not fully align
with the locking pin then, using an open end
wrench, tighten the valve bonnet slowly until
collar slot and pin are fully aligned and then
installlocking collar as described.
5. Screw the locking collar nut (72A) down
onto the top of the collar by hand and,
using a calibrated torque wrench equipped
with a crows foot adapter, tighten the nut
to 10-15 ft·lb torque. Do not over tighten
thisnut.

15
74 73 72 76
75
78
66
72B 72C
72A
85
81 3
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Vent valve
(Type 2)
Inlet ISO valve
(Type 2)
Dome ISO valve
(Type 2)
Hand valve
seatingsurface
DETAIL A
FIGURE 5
Detail A

16
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
5 PILOT MAINTENANCE
Pilot disassembly (see Figure 6)
While disassembling the pilot valve, place all
parts in an orderly arrangement to facilitate
reassembly in the proper sequence. Before
beginning disassembly, have the correct tools
and repair kits specified in Sections 12 and 13
available.
1. Use a 2” open end wrench to loosen the pilot
valve bushing (501) and remove the pilot
valve from the manifold.
2. Use a 1⅛” wrench to hold bonnet (509)
and remove bonnet cap (512). Loosen
locknut(510) and back out adjusting screw
(511) to relieve pilot spring compression.
3. Remove bonnet (509), being careful to catch
spring (507) and spring washers (506 and
508) when they disengage. Turn pilot upside
down on a soft surface to remove remaining
internal parts from upper half of body.
Discard disk (520). Remove nozzle (515) and
seal (504) with a pair of needle nosed pliers
and discard.
4. Loosen and remove locknut (525). Place
blowdown adjustment bushing (523) in a soft
jaw vise. Using a
15
/
16” wrench on the flats
provided on the pilot body (500), loosen and
remove the blowdown assembly. Loosen
and remove the blowdown adjustment
screw (522) from the bushing. Remove
shims (527) from adjustment screw.
5. Place reseat seat (521) in a vise. Using an
allen wrench on the blowdown adjustment
screw (522), loosen and remove seat.
Remove reseat piston (524) located inside.
Discard both reseat seat (521) and reseat
piston (524).
Pilot repair
Replace discarded parts with new nozzle
(515), seal (504), reseat seat (521) and reseat
piston(524). Refer to repair kits in Section 13.
Upper pilot assembly (see Figure 7)
Before assembly, clean all parts thoroughly
with solvent and dry. In particular, the nozzle
seal counterbore in the pilot body must be
inspected and cleaned of any residual graphite
flakes. The lapped and polished metal seats are
the key to proper pilot operation and care must
be taken in handling these components. This
is particularly important for the pilot main seat
disc and nozzle.
Note: these lapped and polished surfaces
should not be touched at any point in handling
except for careful wiping with a soft clean lint
free towel wetted with clean degreasing fluid.
1. Assemble pilot nozzle, disc, disc spring
washer, disc ball, spindle and guide shown
in Figure 7 by the following steps:
A. Remove pilot nozzle (515) from protective
wrapping and, using a lint free cloth and
clean degreasing fluid, clean oil from
nozzle seat gently and set nozzle on its
base on a flat clean surface.
B. Remove pilot disc (520) from its
wrapping, clean as above and place it
face down gently on nozzle seat.
C. Insert Belleville spring washer (519)
with cone upward into recess in top of
disc and place ball (518) into center of
washeras shown.
D. Place spindle (516) on top of disc and
nozzle assembly.
Note: if all components are in place
correctly the spindle will sit in this
position without support.
E. Center guide (517) over spindle/nozzle
assembly and slide it down over spindle
and nozzle until it seats on nozzle step.

17
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Assembly and installation of blowdown
assembly (Figures 6 and 7)
1. Clean polished seat surface of reseat
piston (524) and insert it into the blowdown
adjustment screw (522) with lapped face
turned toward internally threaded opening.
2. Clean polished seat surface of reseat
seat (521), lubricate threads lightly with
Fluorolube to prevent galling and screw it
into the blowdown adjustment screw.
2. While gripping both nozzle and guide,
pick up guide/nozzle subassembly, flip
subassembly upside down and install nozzle
seal (504) onto bottom step of nozzle.
3. While holding guide/nozzle subassembly
upside down in one hand and pilot body (500)
upside down in the other, insert the guide/
nozzle subassembly into the pilot body
until the nozzle seats in the body’s nozzle
seal counterbore and flip the completed
assembly right side up.
4. Install the special lift test dial indicator
housing as shown in Figure 8, flip assembly
upside down, clamp indicator housing hex
in soft jaw vise and, using the
15
/
16” wrench
flats provided on pilot body, tighten body to
indicator housing sufficiently to compress
pilot nozzle seal.
Note: failure to tighten housing may result
in a change of pilot lift setting when the pilot
spring bonnet is installed during final pilot
assembly.
5. Compressing the nozzle seal during step
4 sometimes will result in extrusion of
particles of grafoil seal material between
the bottom projection on the nozzle and
the pilot body. Check for this condition by
turning the pilot body upside down and
inspecting the joint visually between the
bottom of the pilot nozzle and the pilot body
bore. If any loose seal material is seen,
remove it with a jet of compressed air.
3. Turn blowdown screw assembly upside
down, clamp reseat seat hex in vise and
tighten seat securely into adjustment
screwwith a
5
/
16” allen wrench.
Note: do not insert allen wrench so far into
socket that it presses the reseat piston
against the reseat seat during tightening as
this could cause scoring of the piston’s and
reseat seat’s polished surfaces.
4. Lubricate external threads of blowdown
adjustment screw (522) with Fluorolube
and screw it into blowdown adjustment
bushing(523).
5. Install a shim stack (527) of
approximately.100 inches height onto the
blowdown adjustment screw. This initial
shim stack height may require adjustment
later to set the minimum pilot lift as
explained in Figure 8. Multiple C-washer
shims of .012, .025, and .063inches
thickness are supplied to be used as
required.
6. Hand tighten the blowdown adjustment
screw into the blowdown adjustment
bushing until the shim stack seats against
top of the bushing. Lubricate blowdown
bushing mounting threads lightly.
7. Insert spacer rod (503), round conical end
first, into the blowdown assembly; install
the blowdown assembly into the lower end
of the pilot body (500) and, using the wrench
flats on the pilot body, lightly tighten the
bushing. Do not over tighten bushing since
it may have to be removed for shim height
adjustment (see page 20).

18
514
513
512
511
509
508
507
506
516
518
519
520
515
504
500
521
503
526
525
510
517
502
501
505
529
527
528
523
524
522
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
PARTS LIST
Item Description
500 Body
501 Mounting bushing
502 Retaining ring
503 Spacer rod
504 Seal - nozzle
505 Washer - bonnet spring
506 Washer - spring bottom
507 Spring
508 Washer - spring top
509 Bonnet
510 Nut - lock
511 Screw - adjustment
512 Cap
513 Seal - gag hole
514 Bolt - gag hole
515 Nozzle
516 Spindle
517 Guide
518 Ball
519 Washer - disk spring
520 Disk
521 Seat - reseat
522 Screw - BD locking
523 Bushing - BD locking
524 Piston - reseat
525 Nut - BD locking
526 Seal - BD locking
527 Shim stack
528 Seal - dome isolation
529 Seal - metal wedge
FIGURE 6

19
516
518
519
520
515
504
521
526
525
522
517
527
523
524
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
FIGURE 7
GUIDE NOZZLE SUBASSEMBLY BLOWDOWN ADJUSTMENT
SUBASSEMBLY
6 PILOT MINIMUM LIFT ADJUSTMENT AND
PRESSURE SETTING PREPARATION
1. Install dial gauge in top of indicator housing.
2. The pilot assembly is now ready for setting
of the minimum pilot lift as described
in Figure 8. This procedure will require
Anderson Greenwood pilot setting fixture
assembly Part no. 06.3036.002 and test
tankinstallation (see Figures 8 and 9).
3. After installing shims to set minimum
pilot lift to the specified range, clamp the
blowdown bushing hex in a soft jawed vise
and, using the
15
/
16” wrench flats provided
on the pilot body, tighten the blowdown
bushing.
4. Using the pilot test fixture, verify the
minimum lift setting and adjust the
blowdown adjustment screw in until pilot
lift is approximately .050”. This will put the
blowdown near the normal range for final
adjustment.
5. Install blowdown locking seal (526) around
shoulder ring on bottom of blowdown
bushing (523). Install blowdown lock
nut(525) hand tight (see Figures 6 and 7).
6. Remove the special housing and dial
indicator.
7. Insert top spring washer w/hole (508),
spring (507) and bottom spring washer (506)
into bonnet. Place bonnet spring washer
(505) over guide (517) and screw bonnet
assembly into pilot body. Install adjustment
screw (511) with locknut (510) (see Figures 6
and 7).
Note: apply a very light coat of Fluorolube
to adjustment screw and bonnet mounting
threads before assembly.
8. Turn pilot assembly upside down, clamp
bonnet hex in soft jaw vise and, using
the
15
/
16” wrench flats provided on pilot
body, tighten body to bonnet securely to
completely seat the nozzle gasket.
9. The pilot is now ready to be adjusted for
setpressure and reseat pressure.

20
05.1050.207
06.3037.001
06.3036.001
06.1330.001
06.2819.003 .063
06.2819.002 .025
06.2819.001 .012
.005 - .015 .010 - .025
ANDERSON GREENWOOD TYPE 727 DUAL PILOT MANIFOLD
INSTALLATION AND MAINTENANCE INSTRUCTIONS
1. Install pilot on test stand.
2. With pilot assembled as shown, without
spring, spring washer and adjusting
screw, back blowdown adjustment screw
all the way out (downward position) full
counterclockwise position.
Shim Thickness
FIGURE 8
Moveable stem
2” Dial indicator
.100 Stem travel
1.00 Stem extension
.375 ø shank
¼” Set screw
Housing for lift
testpartnumber
Spindle
Test fixture for
cartridgepilot
PTFE seal
Add shims here to
obtainproper lift
O-ring
Reseat assembly
Locknut
Blowdown screw
Supply port (air in)
Lift
Air Steam
3. Pressurize inlet to 25 psig and measure lift
of spindle. Lift must be as shown in table.
Cycle dial indicator up and down physically
to measure pilotlift.
4. Add shims between bushing and blowdown
screw to obtain correct lift. To add shims,
the reseat assembly must be removed from
body. Shims are 'C' washers, therefore
disassembly of lower unit is not required.
Snap shims on or off and combine as
required to meet lift requirements. Measure
shim thickness before removal so thickness
adjustments can be made as required.