REPAIR INSTRUCTIONS, PART 1
Page 285
As an alternative, two bearing press plates could
be placed side-by-side on a workbench with a
1-3/4″ (45 mm) space between the two.
5. Using a 1/8″ punch and light-to-medium
weight hammer, carefully drive the two press
pins from the valve body.
The pin body is approximately 0.155
″
(3.937 mm)
in diameter, with the ends of the pin tapered to a
flat-end diameter of 0.080
″
(2.032 mm). The tip of
the 1/8
″
punch must be in good condition so that
it seats squarely against the end of the pin, and
care must be used to ensure that the punch tip is
kept squarely against the end of the pin as it is
being driven from the valve body. If the end of the
punch is worn, or if care is not used when driving
the pins from the valve, the punch can slip and be
driven into the aluminum valve body, thus
damaging the valve.
Do not use a punch smaller than 1/8
″
. Typically, a
1/8
″
punch is long enough to drive the pins from
the valve body. Small diameter punches are not
long enough, and can bend too easily. A 5/32
″
punch is too large and will enlarge the holes in
the valve body, thus rendering the valve
unusable.
As the pins are being driven from the valve, the
typical 1/8
″
punch will bottom on its tapered
shank when the pin protrudes approximately 1/4
″
(6.35 mm) from the valve body, and before the
pin completely disengages the retaining collar of
the solenoid. At that point, remove the punch,
then turn the valve over and remove the pins.
Some pins may be loose enough to remove with
the fingers, while other pins may remain tight,
making it necessary to use pliers to grasp and
remove the pins.
6. After the pins have been driven from the
valve, separate the solenoid from the valve
body.
7. Using Permatex
®
electrical contact cleaner
(part No. 5166-24379) or equivalent, clean
the interior of the valve body by spraying the
cleaner into the solenoid opening and
through the inlet and outlet ports.
The contact cleaner must be safe for use on
plastics (Nylon
®
) and rubber (Viton
®
, etc.).
Normally, all ozone safe “green” cleaners are
acceptable.
8. Clean the solenoid mating surface of the
valve body.
9. Lubricate the O-ring on the new solenoid
with MACK O-ring lubricant (part
No. 243SX41), or equivalent.
10. Insert the solenoid into the valve body,
making sure the solenoid is completely
seated.
If the solenoid is not seated, the press pins will
cock as they are being driven into the valve body.
To determine if the solenoid is fully seated, hold
the valve up to the light, then look through the pin
holes. If the solenoid is fully seated, a clear path
will be seen all the way through the holes. If it
appears that the solenoid is not fully seated, use
a light plastic hammer to gently tap on the top of
the solenoid until seated.
11. Place the valve front side up (air inlet port
side) on a solid flat surface, then insert the
new press pins included with the kit into the
holes in the valve body.
12. Using a small hammer and 1/8″ punch,
gently tap the pins into the valve body until
they are nearly flush with the back surface of
the valve.
13. Make a mark on the punch 1/2″ (12.7 mm)
from the tip, then tap the pins further until
they are 1/2″ (12.7 mm) below the back
surface of the valve body as indicated by the
mark on the punch.
14. Reinstall the control valve.
5-111.bk Page 285 Monday, July 10, 2006 2:26 PM
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