Watts Ames Service Procedures

1
Watts / AmesService Procedures

• Models
• 007 / 2000B, 007DCDA, 009 / 4000B
• 709, 709DCDA, 909, 909RPDA
• 2000SS / 774, 3000SS / 774DCDA
• 4000SS / 994, 5000SS / 994RPDA
• C200 / 757, C300 / 757DCDA
• C400 / 957, C500 / 957RPDA
• M200, M300, M400, M500
• 719 / 200B, 919 / 400B

2
Contents

• Model
• 007 / 2000B ¾- 2
• 009 / 4000B ¾ - 2
• 007, 009 21/2- 3
• 709, 909 ¾- 2
• 709, 709DCDA 21/2- 10
• 909, 909RPDA 21/2- 10
• 774 / 2000SS, 3000SS 21/2-10
• 994 / 4000SS, 5000SS 21/2-10
• 757 / C200, C300 21/2- 10
• 957 / C400, C500 21/2- 10
• M200, M300 21/2- 10
• M400, M500 21/2- 10
• 719 / 200B ¾- 2
• 919 / 400B ¾-2

• Page
• 2
• 2
• 8
• 13
• 19
• 19
• 24
• 30
• 41
• 41
• 41
• 41
• 50
• 50

3
007(M1,M2,M3) / 2000B009 (M2,M3) / 4000B½-2
4
Modification Overview- 007 / 2000B

• ½ 007
• ¾-1 007
• ¾-1 007M1
• ¾ 007M2
• ¾ 007M3 (Current)
• 1 007M1 (Current)
• 11/2-2 007
• 11/2-2 007M1
• 11/4-11/2 007M2 (Current)
• 2 007M1 (Current)

5
Modification Overview- 009 /4000B

• ½ 009
• ¾-1 009
• ¾ 009M2
• ¾ 009M3 (Current)
• 1 009M2 (Current)
• 11/4-2 009
• 11/4-2 009M1
• 11/4-11/2 009M2 (Current)
• 2 009M2 (Current)

6
Single Access Cover Removal

• Cover is o-ring sealed.
• 007 Cover has no spring load.
• 009 Cover has spring load from the RV spring.
• Hold cover firmly while removing bolts.
• RV stem may come out with cover.
• Lift cover straight off.

7
Check Valve Removal

• Check valve modules.
• Modules sealed by o-ring and secured by a
  retainer.
• Slide retainer straight out of body.
• Modules can now be removed by hand or with a
  screwdriver flat.

8
Check Seat Removal

• Check seats are attached to the cage with a
  bayonet type locking system.
• Module is spring loaded- Hold firmly.
• Hold the cage in one hand, push the seat
  inward and rotate clockwise.
• ¾ M2 modules snap apart.

9
Check Disc Replacement

• Check disc and disc holder can be replaced as one
  piece.

10
Check Valve Reassembly Notes

• Reassemble in reverse order.
• Apply lubricant to o-rings.
• If check retainer does not slide into place
  easily, make sure checks are seated properly.

11
RV Stem Removal

• The RV stem and spring are situated between the
  check valves and are free once the single access
  cover is removed.

12
RV Seat Removal

• Unless damaged, there is no need to remove RV
  seat.
• The seat is pushed firmly into the body and is
  o-ring sealed.

13
RV Rubber Replacement

• The RV molded disc is on the lower stem. Simply
  unscrew the guide from the stem.
• The diaphragm is on the upper stem. Simply
  unscrew the stem cap from the stem.

14
RV Reassembly Notes

• Center the spring on the seat and insert the
  cover and RV assembly as a unit straight into the
  body.
• Make sure that the lower guide on the RV stem
  goes through the guide hole in the seat.
• If the cover will not press flat against the
  body, the stem is crooked and must be realigned.

15
007,007DCDA009 21/2-3
16
Single Access Cover Removal

• Cover is o-ring sealed.
• 007 cover has no spring load.
• 009 cover has spring load from the RV spring.
• Remove bolts while holding cover down.
• RV Stem may come out with cover.
• Lift cover straight off.

17
Check Valve Removal

• Check valve modules.
• Modules sealed by o-ring and secured by a
  retainer.
• Slide retainer straight out of body.
• Modules can now be removed by hand or with a
  screwdriver flat.

18
Check Seat Removal

• Check seats are part of each module.
• Check seats are attached to the cage with a
  bayonet type locking system.
• Check spring is contained.
• Hold the cage in one hand, push the seat
  inward and rotate counter-clockwise.

19
Check Disc Replacement

• Remove retaining nut from disc holder and replace
  rubber.

20
Check Valve Reassembly Notes

• Reassemble in reverse order.
• Apply lubricant to o-rings.
• If check retainer does not slide into place
  easily, make sure check valves are seated
  properly.

21
RV Stem Removal

• The RV Stem and spring are situated between the
  check valves and are free once the single access
  cover is removed.

22
RV Seat Removal

• Unless damaged, there is no need to remove RV
  seat.
• The seat is pushed firmly into the body and is
  o-ring sealed.

23
RV Rubber Replacement

• The RV molded disc is on the lower stem. Simply
  unscrew the nut from the guide.
• Replace the o-ring behind the disc.
• The diaphragm is on the upper stem. Simply
  unscrew the stem cap from the stem.

24
RV Reassembly Notes

• Center the spring on the seat and insert the
  cover and stem assembly as a unit straight into
  the body.
• Make sure that the lower guide on the RV stem
  goes through the guide hole in the seat.
• If the cover will not press flat against body,
  the stem is crooked and must be realigned.

25
709 , 909 3/4-2
26
Modification Overview

• The 909M1 (1989) in the ¾-2 sizes only.
• Change was in the body only- internal components
  are the same.
• The 709 in ¾-2 sizes only, was discontinued in
  1993.

27
Check Cover Removal

• Cover is o-ring sealed.
• Check valve assembly is attached to the cover and
  spring is contained.
• Pull cover and assembly straight out of the body.
  (Do not twist)

28
Check Valve Removal

• The check valve is attached to the cover with a
  bayonet locking system.
• Check valve assembly is spring loaded.
• Holding the assembly in both hands, rotate the
  seat (cage) ¼ turn.

29
Check Seat Removal

• Once the cover and check valve are removed the
  seat or (cage) is free.
• Seat is sealed by an o-ring.

30
Check Disc Replacement

• Check disc and disc holder can be replaced as one
  piece.

31
Check Valve Reassembly Notes

• Reassemble check valve in reverse order.
• Apply lubricant to seat o-ring and lid o-ring.

32
RV Cover Removal

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

33
RV Stem Removal

• The stem subassembly can be pulled straight out
  of the body.

34
RV Seat Removal

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

35
RV Rubber Replacement

• Replace diaphragm and RV disc assembly.
• Simply unscrew the stem cap from the stem.
• Replace stem o-rings.
• Apply lubricant to o-rings.

36
RV Reassembly Notes

• Insert RV stem assembly into body.
• Carefully guide and depress spring tension
  until the piston is completely into position.
• Insert screw driver up into vent opening to
  hold stem in place.
• Bolt cover down evenly.

37
709,709DCDA 909, 909RPDA 21/2-10
38
Modification Overview

• The 909M1 (1989) in the 8-10 sizes only.
• Change was downsizing the relief valve assembly.
• Changed RV housing from bronze to cast iron epoxy
  coated.

39
Check Cover Removal

• Cover is o-ring sealed.
• Loosen bolts ½. Spring load is now released from
  the cover and retained by the check subassembly.
• Verify spring load before removing all the bolts.

40
Check Valve Removal

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

41
Check Seat Removal

• 21/2-3 Seats removed by ¼ turn twist.
• 4-10 Seats secured by two retaining wires. Each
  wire 10 long.
• Pull one wire clockwise / one wire counter
  clockwise.
• Seats are o-ring sealed and pull straight out of
  body.

42
Check Disc Replacement

• Remove retaining nut for sizes 21/2-4.
• Remove allen head screws in retainer plate for
  sizes 6-10.

43
RV Cover Removal

• RV Cover is sealed by the diaphragm.
• Loosen cover bolts ½. Spring load is now
  released from the cover and retained by the
  bottom plug assembly.
• Verify spring load before removing all the bolts.

44
RV Stem Removal

• The piston subassembly can be lifted straight up
  and out of the body.
• The bottom plug subassembly (4-10) contains the
  spring and does not need to be removed for normal
  service.
• For removal simply unscrew from outside the
  RV body.

45
RV Seat Removal

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

46
RV Rubber Replacement

• Replace diaphragm.
• Replace wiper seal and piston o-ring. Apply
  lubricant to the o-ring.
• Replace RV disc.
• Hold upper guide fin and unscrew pressure
  plate. Replace disc assembly and stem o-ring.

47
2000SS / 7743000SS / 774DCDA21/2-12
48
Modification Overview

• Model 2000SE, 3000SE, 774X, 774XDCDA were
  produced in the 21/2,6, and 8 sizes only.
• These assemblies use check modules that are one
  size smaller than the pipe size.
• Example 8 size assembly uses 6 parts

49
Single Access Cover Removal

• Cover is secured by a grooved coupling.
• Cover has no spring load.

50
Check Valve Removal

• Check valve modules called Cam Checks.
• Checks are o-ring sealed.
• 21/2-6 Cam Checks are threaded into body.
• 1 Check must be removed before 2 can be
  removed.
• 8-10 Checks are simply bolted into body.

51
Check Valve Removal

• 21/2-6 cam checks unscrew counterclockwise by
  hand if possible.
• Do not use cam arm as a handle to unscrew.

52
Check Valve Removal

• 21/2-6 Cam Checks.
• If too tight, place a drift punch or solid rod
  (long screwdriver) in one of the holes on the
  outer edge of the check module.
• Tap with hammer in correct direction
  (counterclockwise) to loosen.

53
Check Valve Removal Notes

• 21/2-6 Cam Checks.
• There are special tools available to help
  remove check modules.

54
Check Seat Removal

• Check seats are part of each module and can not
  be removed.
• If the seat is damaged, the complete check module
  will need to be replaced.

55
Check Disc Inspection

• 21/2-6 Cam Check disc assembly is part of the
  module and can not be removed.
• For inspection and cleaning 21/2 -4, lift the
  cam arm and hold in open position.
• Raise the clapper so that the end of the cam
  arm rests between the roller and clapper.

56
Check Disc Inspection

• For inspection and cleaning of the 6size only.
• Locate the stud on the outlet flange of the
  assembly.
• Place the cam arm hole on the stud and open the
  check valve so that the cam rests between the
  roller and clapper.

57
Check Disc Inspection

• For inspection and cleaning of the 8-10 size cam
  checks.
• Using a 3/8 nut driver or a piece of small
  diameter pipe, place on the end of the torsion
  spring and move away from and around the
  retaining bracket.
• This will free the cam arm and clapper.

58
Check Valve Reassembly Notes

• Change and lubricate check o-ring.
• Install 2 check first then 1 check.
• 2 check should be tightened with a long
  screwdriver.
• Tighten 1 check firmly by hand only.
• Lubricate the outside edge of the groove couple
  gasket.

59
4000SS / 5000SS994 / 994RPDA21/2- 10
60
Single Access Cover Removal

• Cover is secured by a grooved coupling.
• Cover has no spring load.

61
Check Valve Removal

• Check valve modules called Cam Checks.
• Checks are o-ring sealed.
• 21/2-6 Cam Checks are threaded into body.
• 1 Check must be removed before 2 can be
  removed.
• 8-10 Checks are simply bolted into body.

62
Check Valve Removal

• 21/2-6 cam checks unscrew counterclockwise by
  hand if possible.
• Do not use cam arm as a handle to unscrew.

63
Check Valve Removal

• 21/2-6 Cam Checks.
• If too tight, place a drift punch or solid rod
  (long screwdriver) in one of the holes on the
  outer edge of the check module.
• Tap with hammer in correct direction
  (counterclockwise) to loosen.

64
Check Valve Removal Notes

• 21/2-6 Cam Checks.
• There are special tools available to help
  remove check modules.

65
Check Seat Removal

• Check seats are part of each module and can not
  be removed.
• If the seat is damaged, the complete check module
  will need to be replaced.

66
Check Disc Inspection 21/2- 6

• 21/2-4 first check and 6 sizes.
• Locate the stud on the outlet flange of the
  assembly.
• Place the cam arm hole on the stud and open the
  check valve so that the cam arm rests between the
  roller and clapper.

67
Check Disc Inspection 21/2-6

• 21/2 -4 second check.
• Lift the cam arm and hold in open position.
• Raise the clapper so that the end of the cam
  arm rests between the roller and clapper.

68
Check Disc Inspection 8-10

• 8-10 first check.
• Place two 3/8 X 14 all thread rod through the
  two holes of the spring retaining plate.
• Screw the rods into the disc holder about ½.
• Secure both rods with 3/8 nuts.

69
Check Disc Inspection 8-10

• 8-10 first check.
• Tighten both nuts evenly to compress spring.
• Compress the spring until the clapper has moved
  about 1 from seat and inspect.
• To remove rod, loosen nuts evenly be careful
  not to unscrew rod.

70
Check Disc Inspection 8-10

• 8-10 second check
• Using a 3/8 nut driver or a piece of small
  diameter pipe, place on the end of the torsion
  spring and move away from and around the
  retaining bracket.
• This will free the cam arm and clapper.

71
Check Valve Reassembly Notes

• Lubricate check o-ring.
• Reassemble check modules in reverse order.
• Lubricate outside edge of groove coupler gasket.

72
Relief Valve Removal

• RV assembly is threaded onto body and o-ring
  sealed.
• Disconnect RV Hose.
• Unscrew complete RV assembly from the main body.
• Do not place wrench on RV housing.
• Place wrench on flange and cover only.

73
Relief Valve Removal

• Remove cover bolts.
• Remove piston and sleeve by sliding them out
  through the flange side of the RV housing.

74
RV Seat Removal

• The RV seat is a machined part of the RV housing.
• To replace the seat, you must replace the housing.

75
Relief Valve Disassembly

• Remove sleeve from piston assembly.
• The piston assembly is spring loaded.
• Hold the piston firmly in one hand and unscrew
  the hex head bolt.

76
RV Disc Replacement

• Replace the RV disc in the disc holder.
• Replace the o-rings on the hex head bolt.

77
RV Diaphragm Replacement

• Reassemble the disc holder and spring to the
  diaphragm / piston assembly.
• Slide sleeve over diaphragm.
• Position the bead of the diaphragm over the edge
  of the sleeve.

78
RV Diaphragm Replacement

• While holding the sleeve in one hand, place the
  bolt end of the assembly on a flat surface.
• Using the other hand, cup the palm slightly over
  the diaphragm to form an air trap.

79
RV Diaphragm Replacement

• Rapidly slap the diaphragm down over the piston
  assembly and inside the sleeve.
• If the diaphragm is wrinkled, then it is not
  in the correct position.
• Repeat this step if necessary.

80
Relief Valve Reassembly Notes

• Slide the piston assembly and sleeve into the
  housing in reverse order.

81
C200,757 / C300, 757DCDAC400, 957 / C500,
957RPDAM200 / M300 M400 / M50021/2-10
82
Modification Overview

• (a) suffix after the model number indicates the
  original version that contains a bi-link check
  valve.
• The current version contains a tri-link check
  valve.
• Repair steps are the same for both models.

83
Check Cover Removal 21/2-4

• Cover slides back and is o-ring sealed.
• Remove test cock 3 from the body.
• Insert a screwdriver through the hole on top of
  the cover sleeve.
• Using both hands, rotate the cover ¼ turn
  clockwise and counter-clockwise to break o-ring
  seal.

84
Check Cover Removal 21/2-4

• Slowly slide the cover sleeve to the downstream
  side of the housing.
• Once fully pulled back, turn the sleeve 90
  degrees.

85
Check Cover Removal 6-10

• For the 6-10 sizes, remove both Victaulic
  couplers.
• Slide the downstream gasket to the downstream
  side of the housing.
• The upstream gasket can stay in place.

86
Check Valve Removal

• Check valve modules.
• Modules are o-ring sealed.
• Remove the check retainer.
• Remove check 1 first, then check 2.
• Using two flat blade screwdrivers, gently pry the
  module out of the body.

87
Check Seat Removal

• The check seat is part of the module.
• If seat is damaged, the entire module will have
  to be replaced.

88
Check Disc Replacement 21/2-4

• The check modules are spring loaded.
• Insert a screwdriver through the hole in the
  linkage and let it rest in the arbors on the
  module.
• Remove the E-clip and pin connecting the
  linkage.
• The clapper will open with no tension.

89
Check Disc Replacement 21/2-4

• Remove the screws on the disc retainer.
• Once disc is replaced, reassemble in reverse
  order.

90
Check Disc Replacement 6-10

• Locate the service hole on the side of the check
  module.
• Use a ½-13 x 5 fully threaded bolt.
• Thread the bolt until the hole in the linkage is
  aligned with the notches in the spring arbors.
• Insert a long phillips screwdriver through the
  hole and arbors.

91
Check Disc Replacement 6-10

• Back the bolt out until the spring tension is
  transferred to the screwdriver.
• Remove retaining clip and pin from linkage.
• Spring assembly can be removed from the module.
• Remove screws from disc retainer.

92
Check Valve Reassembly Notes

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

93
Relief Valve Removal

• Relief valve is threaded onto body and o-ring
  sealed.
• Disconnect sensing line hose.
• RV should be removed by hand.

94
RV Disassembly

• Remove the cover plate by removing the 4 allen
  screws.
• Remove the diaphragm.

95
RV Disassembly

• With the threaded end facing up, push up on the
  piston until the piston shaft with the attached
  E-clip is exposed.
• Remove the E-clip.

96
RV Disc Replacement

• The RV disc is molded onto the disc holder and
  must be replaced as one piece.

97
RV Diaphragm Replacement

• Form the diaphragm to fit over the disc holder.
• Reinstall the diaphragm into the body.

98
RV Reassembly Notes

• Reassemble relief valve in reverse order.
• Lubricate the RV body o-ring.

99
719 / 200B919 / 400B¾-2
100
Check Cover Removal

• Cover is threaded into body and o-ring sealed.
• Cover is spring loaded.

101
Check Valve Removal

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

102
Check Seat Removal

• The check seat or (cage) is pushed into the body
  and o-ring sealed.
• Simply pull the seat straight out of the body.

103
Check Disc Replacement

• Remove screw and disc washer from poppet.

104
Check Valve Reassembly Notes

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

105
RV Cover Removal

• Cover is spring loaded.
• RV cover is o-ring sealed.
• While holding cover firmly, remove cover bolts
  and rotate the cover ¼ turn.

106
RV Module Removal

• The RV stem and spring are free once the cover is
  removed.

107
RV Seat Removal

• The RV seat is o-ring sealed.
• Simply pull the seat straight out of the body.

108
RV Stem Disassembly

• Use a wrench to gently loosen the RV stem
  assembly.

109
RV Diaphragm Replacement

• Diaphragm is free once stem is disassembled.
• The molded step of the diaphragm should point
  towards the RV stem and disc.

110
RV Disc Replacement

• The RV disc is free once the retaining screw is
  removed.

111
RV Reassembly Notes

• Reassemble in reverse order.
• Line up the grooves on the cover with the grooves
  in the body, and turn the cover clockwise ¼ turn.