So that others can find it more easily, here is a step-by-step
pictorial DIY showing each step in my repair today of my
1" ID Wilkins Zurn 975XL Backflow Preventer, thanks to your
help at alt.home.repair.

STEP 0: Shut inlet & outlet valves & open #2,#3 & #4 test ports
STEP 1: Repair & clean the #1 check valve on top inlet
STEP 2: Repair & clean the #2 check valve on bottom outlet
STEP 3:Repair & clean the relief valve on the side inlet

http://www2.picturepush.com/photo/a/...g/11462795.jpg
http://www3.picturepush.com/photo/a/...g/11462796.jpg
http://www4.picturepush.com/photo/a/...g/11462797.jpg
http://www1.picturepush.com/photo/a/...g/11462799.jpg
http://www2.picturepush.com/photo/a/...g/11462800.jpg
http://www3.picturepush.com/photo/a/...g/11462801.jpg
http://www4.picturepush.com/photo/a/...g/11462802.jpg
http://www5.picturepush.com/photo/a/...g/11462803.jpg
http://www1.picturepush.com/photo/a/...g/11462804.jpg
http://www2.picturepush.com/photo/a/...g/11462805.jpg
http://www4.picturepush.com/photo/a/...g/11462807.jpg
http://www5.picturepush.com/photo/a/...g/11462808.jpg
http://www1.picturepush.com/photo/a/...g/11462809.jpg
http://www2.picturepush.com/photo/a/...g/11462810.jpg
http://www3.picturepush.com/photo/a/...g/11462811.jpg

IN SUMMARY:
I found all the parts inside the three valves in excellent condition
as you had suggested it would be - but I replaced them all anyway.

The key problem I saw was the #2 check valve was stuck in place
due to light-green corrosion inside the brass cap cavity.

Also there was light-green corrosion in all cavities, which I
painstakingly wire brushed out - as that was the key issue.

On a scale of 1 to 10, this is an easy 1. No surprises. No special
tools. It took me about three hours - one hour for the #1 check
valve on the top inlet, another hour for the #2 check valve on the
bottom outlet, and another hour for the relief valve on the inlet.

It should take you about a half hour in total - maybe 45 minutes,
depending on how well you wish to clean out the green corrosion.
I took my sweet time.

Below is a quick DIY with photographs for the $755 1-inch ID
Zurn Wilkins 975XL Reduced Pressure Principle Backflow Preventer
(http://www.zurn.com/Pages/ProductDet...NodeKey=377206)
after detailing the 11-piece Wilkins Water Works RK34-975XL $43.20
repair kit (855-663-9876) and assembly instructions.

HERE ARE THE KEY REFERENCES:
Wilkins Zurn 975XL Specification Sheet
http://content.zurn.com/web_document...on/ISSM950.pdf
http://content.zurn.com/web_document...-975XL(lg).pdf

Wilkins Zurn 975XL Maintenance Sheet
http://content.zurn.com/web_document...on/ISSM950.pdf

Outstanding!



On Thu, 22 Nov 2012 04:44:32 +0000 (UTC), "Danny D."
wrote:

So that others can find it more easily, here is a step-by-step
pictorial DIY showing each step in my repair today of my
1" ID Wilkins Zurn 975XL Backflow Preventer, thanks to your
help at alt.home.repair.

STEP 0: Shut inlet & outlet valves & open #2,#3 & #4 test ports
STEP 1: Repair & clean the #1 check valve on top inlet
STEP 2: Repair & clean the #2 check valve on bottom outlet
STEP 3:Repair & clean the relief valve on the side inlet

http://www2.picturepush.com/photo/a/...g/11462795.jpg
http://www3.picturepush.com/photo/a/...g/11462796.jpg
http://www4.picturepush.com/photo/a/...g/11462797.jpg
http://www1.picturepush.com/photo/a/...g/11462799.jpg
http://www2.picturepush.com/photo/a/...g/11462800.jpg
http://www3.picturepush.com/photo/a/...g/11462801.jpg
http://www4.picturepush.com/photo/a/...g/11462802.jpg
http://www5.picturepush.com/photo/a/...g/11462803.jpg
http://www1.picturepush.com/photo/a/...g/11462804.jpg
http://www2.picturepush.com/photo/a/...g/11462805.jpg
http://www4.picturepush.com/photo/a/...g/11462807.jpg
http://www5.picturepush.com/photo/a/...g/11462808.jpg
http://www1.picturepush.com/photo/a/...g/11462809.jpg
http://www2.picturepush.com/photo/a/...g/11462810.jpg
http://www3.picturepush.com/photo/a/...g/11462811.jpg

IN SUMMARY:
I found all the parts inside the three valves in excellent condition
as you had suggested it would be - but I replaced them all anyway.

The key problem I saw was the #2 check valve was stuck in place
due to light-green corrosion inside the brass cap cavity.

Also there was light-green corrosion in all cavities, which I
painstakingly wire brushed out - as that was the key issue.

On a scale of 1 to 10, this is an easy 1. No surprises. No special
tools. It took me about three hours - one hour for the #1 check
valve on the top inlet, another hour for the #2 check valve on the
bottom outlet, and another hour for the relief valve on the inlet.

It should take you about a half hour in total - maybe 45 minutes,
depending on how well you wish to clean out the green corrosion.
I took my sweet time.

Below is a quick DIY with photographs for the $755 1-inch ID
Zurn Wilkins 975XL Reduced Pressure Principle Backflow Preventer
(http://www.zurn.com/Pages/ProductDet...NodeKey=377206)
after detailing the 11-piece Wilkins Water Works RK34-975XL $43.20
repair kit (855-663-9876) and assembly instructions.

HERE ARE THE KEY REFERENCES:
Wilkins Zurn 975XL Specification Sheet
http://content.zurn.com/web_document...on/ISSM950.pdf
http://content.zurn.com/web_document...-975XL(lg).pdf

Wilkins Zurn 975XL Maintenance Sheet
http://content.zurn.com/web_document...on/ISSM950.pdf

On Thu, 22 Nov 2012 04:52:05 -0800, Oren wrote:

Outstanding!

Thanks Oren.

Coming from you, that's a big compliment.
I didn't write all the steps because they're in the
PDF that I referenced in the end. But the PDF suffers
in that it doesn't show the pictures of the steps.

So, with the PDF & pictures combined, anyone can
perform this repair easily. I realize Smitty Two
doesn't like my OCD style - but I start knowing
nothing and, with your help plus my research, I
end up knowing 'enough' to try to teach the next
guy. That's what I live for. To learn & to teach.

Some day, I'd like to write a HOWTO DIY book that
is written how I would want it (with no step left
to the imagination). I realize 99% of the people
out there are just fine with the missing steps or
with figuring out things as they go along; but,
for me, I like to see everything before I do it.

One day I'd like to buy a house and just take
everything apart and make a book out of it. Maybe
I should start simple, as with just a car huh!

I wonder if it would sell enough to make that
DIY hobby of mine worth it?

BTW, 'm shocked at the $755 (list) price of my
$755 backflow preventer. I just don't get why it's
$600 more expensive than similar three-valve
systems at Sears.

Any idea why 'this' particular backflow preventer
is 7 times more expensive (list) than similar ones?

On Thu, 22 Nov 2012 16:06:20 +0000 (UTC), "Danny D."
wrote:

BTW, 'm shocked at the $755 (list) price of my
$755 backflow preventer. I just don't get why it's
$600 more expensive than similar three-valve
systems at Sears.

Any idea why 'this' particular backflow preventer
is 7 times more expensive (list) than similar ones?

I was shocked at the price myself. ZURN products are/were made in
Canada, at least they made PEX pipe connectors. The connectors failed
and caused major legal battles. They added to much zinc into the
brass. (IIRC) Eventually, they corroded, leaked, caused mold inside
walls of homes and such (Las Vegas).

They also gave us Justin Bieber and Shania Twain. I prefer the latter.

"Danny D." wrote in message

stuff snipped

So, with the PDF & pictures combined, anyone can
perform this repair easily. I realize Smitty Two
doesn't like my OCD style - but I start knowing
nothing and, with your help plus my research, I
end up knowing 'enough' to try to teach the next
guy. That's what I live for. To learn & to teach.

Remarkably complete and concise and what Usenet *should* be about. Even
more refreshing to stumble across after 50 messages from Sad Sacks with
nothing better to do than use Usenet like their own personal playpen.

Thanks for reminding me there are still some responsible adults left willing
to put in the effort it takes to share their knowledge and experience with
others. It's inspiring.

--
Bobby G.

On Thu, 22 Nov 2012 20:02:48 -0500, Robert Green wrote:

Remarkably complete and concise and what Usenet *should* be about.

Thanks for recognizing that effort.

I have been on USENET since the days of tin & rn and well before
Google or Netscape ever existed so I've seen the good and bad
(although my nym changes frequently for privacy reasons).

I, for one, will always be responsive to each sincere post;
I will always provide a followup update when complete; and
I'll try to stay on topic (at least per post); and, most
importantly, I'll try to provide enough detail, as I learn
the answer to the question at hand, so that the next person
who follows in our footsteps has the benefit of standing on
our shoulders.

Thanks for recognizing that effort. Kudos to all for this
wonderful alt.home.repair NNTP newsgroup - which - we might
agree - is one of the best of the net due to the people who
post on it.

Danny - your post is exceptional. This is exactly the way I approach repairs. My relief valve is spewing like crazy and (after shutting off the ball valve) while I was waiting for a call-back from some sprinkler guy I walked through your instructions. I opened mine up and found that the head of the diaphragm stem (flange that holds the o-ring that seals it at the relief port) was quite bent. As soon as I get a replacement, we'll see if that fixes it.
Anyway, thanks for taking the time to post this info.
Tom

Danny,
Struggling with same - trying to DIY repair of my 975XL. Much thanks for your efforts.

Sincerely,
Don Mabry
Nashville, TN

I have a Wilkins Zurn 975XL, but I can't tell from looking at it whether it's a model RK34 or RK114. Any ideas how to know definitively? Thanks!

The model number is on the top cap.
see http://www3.picturepush.com/photo/a/...g/11462796.jpg
If they look alike, they probably are. I think the 975XL is made with lead, and the 975XL2 is lead-free.
The other major difference is the diameter of the pipes. 3/4 1, 1.5, 2 inches.
Looking at youtube, the other Wilkins-Zurn seem to have common gasket sizes at least on the plungers.

http://www.wholesalepumpsdirect.com/...?feed=Froogle_
RK34_has_springs

http://www.wholesalepumpsdirect.com/...l?feed=Froogle
there are 2 repair_kits. RK34 has springs.the_other_one_does_not