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1.6.2 Assembly of the Male Docking Valve
This operation requires, the following special tools and preparations:
• A T2000-17-005 to compress the spring (two threaded rods and a
bracket with three holes).
• A flat, 7mm, fork spanner.
• Screw locking liquid - Loctite 270
• Special high temperature grease for the sealings, Uniway LIX 625.
• Torque wrench
• Two M6x35 screws
a) First place the valve needle complete (7) into the middle housing (1), together with the O-ring (17),
coated with a little grease, into its groove, and attach the retaining flange (6) with the four
countersunk screws (20). Tighten the screws crosswise, carefully and equal.
b) Insert the Stepseal® (16) in the immersion of the packing housing (2) and mount the retaining shim
(5) with the two countersunk screws (22). Check the orientation of the Stepseal (16). The step
must face the needle (see drawing).
c) Insert the Variseal (15) in the recess of middle housing (1) with the V-opening first (see drawing).
Note: Be careful not to harm the sensitive edge of the seal.
d) Put the packing housing (2) onto the middle housing (1) and keep them fixed with the two M6x35
screws mounted diagonally – temporarily.
e) Push the valve needle complete (7) in through the two seals (15) and (16) until the needle head
touches the valve seat (closed valve).
Note: One will feel a certain resistance each time the needle enters a seal.
f) The O-ring (18), lightly greased, is put onto the piston (4). The distance shim (23 and 24) is “glued“
with grease on the bottom surface of the piston (4). This shim prevents the sharp end of the spring
from wearing out the piston as the spring always turns a little when being compressed.
g) Mount the lightly greased spring (14) on top of the retaining shim (5).
h) The piston (4) is put into the spring (14).
i) Install the special (T2000-17-005-IR) tool into the two diagonally remaining holes of the middle
housing (1), for compressing the spring. The spring is compressed by spanning it until the threaded
part of the “valve needle complete” (7) reaches through the piston (4).
j) The seal lock nut (11) is screwed onto the thread with a torque wrench. Note: Always use a new
nut, and always use screw-locking-liquid (Loctite 270). Keep the needle fixed with the 7mm-
spanner, and tighten the nut to the torque 5 Nm.
k) The special tool and the two temporarily fitted M6 screws can now be removed because the spring
tension keeps the whole assembly together.
l) The inner surface of the air cylinder (3) must be greased carefully with Uniway LIX 625.