User's Manual

307909 5
Repair
Repairing the Pilot Valve
NOTE: An Air Valve and Pilot Valve Repair Kit is
available. See the back cover to order. Parts included
in the kit are marked with an asterisk, for example,
(210*). Use all the parts in the kit for the best results.
Disassembly
1. Follow the Pressure Relief Procedure on page
2.
2. Unscrew the valve cap (203) from each of the
valve housings (204) and remove the parts. Clean
and inspect the parts for damage. Refer to the
Parts Drawing on page 9.
3. To replace the rod seal (210*):
a. Cut a small slit in the tube ends and discon-
nect them from the pilot valve fittings (208)
and air valve tees.
b. Unscrew the cap screws and remove the pilot
valve housings (204). Grease the rod seals
(210*) and install one on each side of the
pump.
c. Secure the pilot valve housings (204) to the
pump with the cap screws.
d. Connect the tubing to the pilot valve fittings
(208) and air valve tees as shown in Fig. 2.
Assembly
1. Apply lithium base grease to the inside and outside
of the air valve (202) and to the o–rings and seals.
2. Install the o–ring (205), being sure to completely
seat it on the flat in the valve housing (204). Install
the long end of the valve stem (201) into the
housing.
3. Install the small spring (207) over the valve stem
(201), the air valve (202) over the spring, and the
larger spring over the air valve.
4. With the copper gasket (209*) in place on the
valve cap (203), screw the cap onto each of the
valve housings (204). Torque the cap to 7.4–12.5
ft–lb (10–17 N.m).
Repair Kit
Air Valve and Pilot Valve Repair Kit 220656
Includes:
Ref
No. Part No. Description Qty
106 181464 GASKET, polyurethane 2
107 110782 O–RING, buna–n2
108 107186 O–RING, buna–n4
109 108781 U–CUP, polyurethane 2
110 108782 U–CUP, polyurethane 2
114 179861 TUBE, polyurethane,
0.25” OD; 6 in. 3
205 159589 O–RING, buna–n2
209 156766 GASKET, copper 2
210 107161 SEAL, pilot valve rod, buna–n2
183384 TUBE, polyurethane,
0.25” OD; 9.5 in. 1
108754 SEALANT, anerobic,
medium strength, 0.5 cc tube 1