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I-2021
3 Inch and 4 inch Indicating Relief Valve Repair
1. Open drain cocks in relief valve and piping to make sure all of the water is drained. Disconnect hose or tube
connecting relief valve to pilot valve assembly.
2. Remove bolts, nuts and washers attaching the relief valve to the pump. Discard O-rings.
3. Remove cap screws attaching switch mounting bracket and cover to body. Remove assembled valve cover
and gasket. Discard gasket.
Note: Disassembling switch housing is not necessary unless switch is known to be defective.
4. To disassemble valve cover, remove pins from both ends of switch actuating rod. Pull rod, main valve springs
and washer from cover. Remove O-rings from valve and rod. Discard O-rings.
5. Examine springs for distortion, set or other defects. Remove any nicks or burrs on outside of main valve, in
bore of body and on actuating rod. Discard any defective parts.
Note: Always use the new gaskets and O-rings supplied with the repair kit during reassembly.
6. Apply a light coating of mineral oil or other light weight oil to O-rings, and install in main valve. Lubricate O-ring,
and install in groove in actuating rod. Be sure to remove any twists from O-rings.
7. Make sure a pin is installed in inner hole in actuating rod. Insert rod in valve cover and install one pin in rod
on outside of cover. Slide washer, springs and main valve on rod, and install remaining pin behind valve.
8. Position assembled cover and gasket against flange of body with drain pointing down. Place switch mounting
bracket on cover so sealing grip is either horizontal or points down slightly. Adjust the position of the switch
so that insertion of a .015 inch feeler gauge will light amber indicator, but insertion of a .010 feeler gauge will
not.
9. Attach relief valve to pump using O-rings, bolts, nuts and lock washers. Lubricate O-ring used on connecting
pipe.
10. Connect tube or hose from pilot valve assembly to relief valve.
WARNING
If a tube or hose is used to drain the cover it should be connected to a separate drain valve and not to the manifold
drain valve.
