8. Reinsert stem into pilot body. Install disc and stem
nut. Check dimension C and, if correct, lock the
adjustment by prick punching the stem threads at
several points. Work carefully to avoid bending the stem.
9. Scrape away burrs raised by the prick punching.
Upper surface of pusher plate must be smooth and
flat.
10. Check that the valve travel A = 3/64" (1.2mm). This
need not be exact. Stem should move smoothly.
Binding indicates a bent stem.
11. Remove stem nut and disc; withdraw stem. Install
stem with valve spring disc and both stem nuts in
place.
Spring Pilot Assembly
1. Reassemble the pilot in the reverse order of the
disassembly procedure described above.
2. When replacing diaphragms, apply sealing compound
(Copalite or equal) sparingly to the shoulder of the
diaphragm screw (7).
3. When replacing gaskets, be sure that any serrated
sealing surfaces are cleaned of old gasket material.
AIR PRESSURE PILOT
Air Pilot Quick Test
1. Isolate the main valve from the steam line. Make sure
the internal pressure is 0 psig and allow the valve to
cool to prevent injury.
2. Disconnect the copper tubing line from the main valve
diaphragm. Point tubing in a direction to prevent
damage or burns.
3. Back off air loading pressure.
4. If used in conjunction with a temperature pilot, set
temperature setting higher than the bulb temperature.
5. Slightly open the shut off valve in the steam supply to
the main valve and allow pressure to build.
6. Increase the air loading pressure on the pilot until
steam passes from the open end of the copper tubing
line.
• When used in conjunction with a temperature pilot,
adjust pilot temperature setting to be higher than
the bulb temperature.
• The steam flow should discharge from the tubing
line. Lower air pressure and the flow should stop.
• A slight leakage is OK.
• Repeat several times.
• If the pilot does not start and stop the steam supply,
the pilot should be repaired or replaced.
7. If the pilot responds properly the problem is else-
where in the system.
Pressure
Range
Number of
Psig (bar)
Spring Color
Diaphragms
2 – 30 (0.1 – 2.0)
BLUE
2
5 – 60 (0.3 – 4.1)
RED
2
20 – 175 (1.4 – 11.9)
GOLD
3
Quick test is done using live steam. Point tubing in a
direction to prevent property damage or burns. To prevent
serious burns, wear heat resistant gloves. Failure to fol-
low this warning may result in property damage, personal
injury or death.
!
CAUTION
18
yyy
yyy
yyy
yyy
yyy
yyyy
yyyy
yyyy
yyyy
yyyy
yyyy
yyyy
yyy
yyy
yyy
yyy
yyy
8
9
11
13
14
C
Gage
A
Prick Punch
Stem Projection "B" to be
Removed as per Instructions
