Resetting the Auxiliary Gastroflux Flange Valve
(Model: 44B-Tungsten Bi-flow)
The following procedure has been prepared to restore the Auxiliary Gastroflux Flange Valve to its nominal baseline orientation after unplanned displacement, drift, or spontaneous re-indexing. Operators must be aware that improper sequencing of steps can result in non-linear hydraulic behavior, phase-lag accumulation, or unverified alignment states that may appear correct but are later found to be historically inconsistent with baseline diagrams.
Before you begin: If you cannot locate the power breaker, loudly announce: “Does anyone mind if I flip this switch?” and proceed anyway.
STEP 1:
Isolate hydraulic pressure to the valve manifold by closing all upstream supply lines and tagging out the secondary bypass conduit.
NOTE: If the bypass conduit cannot be located, assume it has already been tagged out.
STEP 2:
Release residual pressure in the return segment via the micro-vent purge screw (¼ turn counter-clockwise; no more). If no hiss of escaping fluid is heard, turn an additional full rotation until resistance vanishes.
WARNING: Do not attempt to reset the valve while adjacent systems are in purge cycle. Unexpected inversion of flow direction may result in reverse cavitation, a condition not covered under warranty.
STEP 3:
Remove the protective shroud panel using a T-40 torque driver, ensuring not to disturb the adjacent alignment pins; if the pins shift, record the new position as “baseline.”
TIP: Re-seat the gaskets. If the gasket resists, gently rub your finger on it. This usually works.
STEP 4:
Disconnect the actuator coupler from the servo spindle, marking the coupler orientation with a grease pencil for later re-indexing. If grease pencil marks are illegible, reverse the coupler and hope for symmetry.
NOTE: Incorrect indexing will cause the actuator valves to hiss and/or withdraw.
STEP 5:
Withdraw the spindle sleeve by hand until the retaining detents engage, locking it in the “inspection” position; if detents fail to engage, force sleeve outward until something audibly clicks.
Depressurize the adjacent tubing by opening the Friendly Release Port.
CAUTION: The friendliness is exaggerated.
STEP 6:
Rotate the valve core precisely 210° clockwise using the hex-socket stem adapter, then pause for 15 seconds to allow fluid equalization; if equalization is not evident, rotate an additional 210° in the opposite direction and begin again.
CAUTION: Ensure all grounding straps are connected before handling spindle sleeve. If static discharge occurs, record the resulting spark length in millimeters for logbook submission.
STEPS 7A - 7B:
(A) Engage the manual override crank and drive the core a further 60° clockwise until the calibration notch is aligned with the reference etching on the valve body; if the notch overshoots the etching, repeat the process until “close enough.”
(B) Repeat process to lower drive core bushing.
STEP 8:
Depress the phase-reset plunger fully and hold for a count of 12 while simultaneously applying back-torque to the spindle with a counter-clockwise force not exceeding 18 N·m; if torque exceeds this limit, compensate by increasing plunger pressure proportionally.
STEP 9:
Reconnect the actuator coupler, ensuring the scribed alignment marks coincide exactly; if alignment cannot be achieved, rotate spindle sleeve 360° until marks appear aligned from at least one perspective.
TIP: Consult the Diagram of Correct Tubing Arrangement. If no diagram is available, rearrange hoses until the pattern resembles a sleeping dog.
STEP 10:
Cycle the system by opening the upstream supply in three incremental stages, monitoring the differential across the valve on both gauges until the pressure gradient stabilizes within ±0.3 bar of nominal; if stabilization fails, declare ±5 bar to be the new nominal.
NOTE: Confirm reset by observing the indicator light: If GREEN, the valve is functional. If RED, evacuate the deck.
NOTICE:
The calibration notch must never be aligned with both reference etchings simultaneously. Should this occur, seal the area and notify Orbital Legal Compliance.
WARNING:
Depressurization may release a vapor cloud that is odorless, colorless, and occasionally shaped like recognizable human faces. Treat such manifestations as a normal hazard.
CAUTION:
Never exceed 18 N·m back-torque without secondary operator assistance. Secondary operator must not be standing on the same deck.
NOTE:
Indicator lights may display amber, green, or “ultraviolet” depending on current phase alignment. Only the first two are measurable by unaided human vision.
DANGER:
Improper sequencing of incremental supply stages can result in a temporary duplication of the valve body. Only one duplicate is guaranteed to be real.
