2. Apply new sealing compound (High-pressure,
high-temperature sealant) to the shoulder of the
seat ring (key 11). Let stand until tacky before
installing in pilot body (key 12).
3. Secure disk (key 21) to stem (key 19) with a stem
nut (key 22). Apply lapping compound to the disk
and insert this assembly into the pilot body (omit
the valve spring C).
4. Use a socket and extender to lap in the disk
(key 21) to seat joint. See Lapping Operations for
more information.
5. Screw pusher plate (key 8) onto the stem. Holding
the disk firmly against its seat, adjust the pusher
plate so that dimension C = 11/64 in. / 4.37 mm. A
gage (part number 05-02416-00) is supplied with
each repair kit. Be careful not to disturb the pusher
plate adjustment, use a prick punch to notch the
stem threads above the pusher plate so that the
pusher plate will not rotate freely. Work carefully
to avoid bending the stem. The valve travel is
now set.
6. Remove the stem nut and lift the stem assembly
(keys 19 and 8) out of the top of the pilot. Grind off
the stem Projection B flush with the upper surface
of the pusher plate. This can be done at the bench
without removing the stem from the body as long
as the grinder does not make contact with the
mating surfaces of the pilot body.
7. Reinsert the stem into the pilot body. Install disk
(key 21) and a stem nut (key 22).
8. Check that the valve travel A = 3/64 in. / 1.19 mm.
This need not be exact. Stem (key 19) should
move smoothly. Binding indicates a bent stem.
9. Remove the stem nut (key 22) and disk (key 21);
withdraw stem (key 19). Install stem with valve
spring (key 19), disk and both stem nuts.
Reassembly
1. If the seat ring (key 11), disk (key 21) and stem
(key 19) were not replaced, reinstall the seat ring
first, then slide the valve spring (key 9) over the
bushing (key 10) and slide the stem back into
place. If they were replaced, skip to step 3.
2. Install the seat ring (key 11) and stem nuts
(key 22) one at a time while holding the pusher
plate (key 8) with a socket.
3. Install the screen (key 20) and gasket (key 13).
Using the blind flange bolts (key 23), reinstall blind
flange (key 14).
Note
When replacing gaskets, be sure that
any serrated sealing surfaces are
cleaned of old gasket material.
4. Assemble the diaphragm assembly (keys 7, 16
and 17) by sandwiching the diaphragms (key 17)
between the pressure plate (key 16) (flat side
against diaphragm) and the diaphragm screw
(key 7). The number of diaphragm disks depends
on the adjusting spring range. See Table 2.
5. Apply sealing compound (High-pressure, high-
temperature sealant) to the shoulder of the
diaphragm screw. Apply sealing compound to the
diaphragm flange of the pilot body for steel body
pilots only.
6. Put the diaphragm assembly into place (pressure
plate up). Center the assembly and install the
cowl (key 6). Install four diaphragm bolts or
studs (key 18) and diaphragm nuts (key 15)
equally around the cowl to ensure the diaphragm
assembly is centered. Install the rest of the
diaphragm nuts, bolts and/or studs and tighten in
an opposing pattern.
7. Install the spring button (key 5), adjusting spring
(key 4), spring yoke (key 2) and adjusting nuts
(key 1).
Parts Ordering
When ordering parts, it is essential that the pilot type,
service and serial number be stated.
Select part by item number, but order by part number.
Specify complete part number when ordering.
Parts List
Repair Parts Kit (See Table 3)
D Series and Options Parts List (See Tables 4 to 7)
ADJUSTING SPRING RANGE
DIAPHRAGM DISK
psig bar
0 to 8 0 to 0.55 1
3 to 20 0.21 to 1.38 2
5 to 50 0.35 to 3.45 2
10 to 100 0.69 to 6.89 2
20 to 150 1.38 to 10.3 3
Table 2. Number of Diaphragm Disk
6
D Series
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