XVII. Disassembly of Pilot Valve
A. 39PV07/37 Disassembly
Figures 41 and 42
1 Remove and discard the aluminum seals and
sealing wire.
2. Remove Cap (Compression Screw) by turning
counterclockwise.
3. If a lifting lever is installed, also use Figure 42 to
remove the Lifting Lever assembly. Then return to
Figure 41 to continue disassembly.
a. The Lifting Lever Assembly consists of:
1 – Lever
1 – Drive Pin
1 – Cam Shaft
1 – Bushing
b. Remove Lifting Lever Assembly by turning
Bushing counterclockwise.
c. Turn Cap (Compression Screw)
counterclockwise.
d. Measure distance from Release Lock Nut to the
top of the Lifting Stem for reassembly later.
e. Remove the Release Lock Nut and Release Nut
by turning counterclockwise.
4. Measure and record Compression Screw height for
later use when resetting.
5. Turn Compression Screw Lock Nut
counterclockwise to loosen.
6. Turn Compression Screw counterclockwise to
remove the load on the Spring.
7. Turn Set Screw counterclockwise to loosen.
8. Bonnet can now be removed by turning
counterclockwise.
9. Spring and Spring Washers can now be removed.
Note: If Lifting Lever option is equipped, there is
no need to remove Drive Pin from Bottom Spring
Washer assembly.
10. Remove the four Cap Screws (Top Plate) holding the
Top Plate to the Pilot Base. Remove and discard the
Spring Seal (Main Piston) and O-Ring (Top Plate).
11. Remove Main Piston from Pilot Base.
Note: For Dirty Service Option, please refer to
“Dirty Service Option” (Section XXII.B) for
disassembly instructions.
12. Removing the Insert Assembly.
The Insert Assembly consists of:
1 - Insert Top
1 - Insert Bottom
1 - Spring Seal (Insert)
1 - O-Ring (Insert)
Remove Insert Assembly from the top of the Pilot
Base with tool #4995401 as shown in Figure 81.
Remove and discard the O-Ring (Insert) on the
bottom of the Insert Assembly. Disassemble Insert
Assembly by removing the Insert Bottom from the
Insert Top. Discard Spring Seal (Insert).
13. Remove Adjuster Cap from the bottom of the Pilot
Base by turning counterclockwise.
14. Loosen Adjuster Lock Nut by turning
counterclockwise.
15. Removing the Adjuster Assembly.
The Adjuster Assembly consists of:
1 – Adjuster Top
1 – Adjuster Bottom
1 – O-Ring (Adjuster Top)
1 – O-Ring (Adjuster Bottom)
1 – Spring Seal (Adjuster Top)
16. Turn Adjuster Assembly clockwise counting the
number of flats until assembly stops. Record
number of flats for reassembly.
17. Remove Adjuster Assembly from the Pilot Base by
turning counterclockwise. Remove O-Ring (Adjuster
Top) and O-Ring (Adjuster Bottom) from adjuster
assembly and discard. Disassemble Adjuster Top
from the Adjuster Bottom by turning Adjuster Top
counterclockwise. Remove Spring Seal (Adjuster
Top) from Adjuster Top and discard.
18. Refer to Field Test Connection / Backflow Preventer
Option (Section XXII.A) for disassembly of Field
Test Connection
Consolidated 2900 Series POSRV Maintenance Manual
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