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ADJUSTMENT
WARNING - INSTALLATION AND MOUNTING The “D” PILOTAIR Valve requires no
The user of these devices must conform to all adjustment.
applicable electrical, mechanical, piping and
other codes in the installation, operation or
repair of these devices.
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January 2002
MAINTENANCE end positions. In their end positions, three and
Periodically dismantle the “D” PILOTAIR® four-way valves have one or more passages
Valve for inspection and cleaning. Wash all open. Moving the stem to its other end position
metal parts with a non-flammable solvent. Wash closes the passages that were open and then
all seals with soap and water and examine them opens the passages that were closed. The mid-
for cracks or signs of wear. Dry all parts with a position results in one of three conditions-all
low-pressure air jet. Replace worn or defective ports lapped, supply connected to delivery, or
parts. supply connected to exhaust.
Reassemble the valve, using the exploded The valve portion of a “D” PILOTAIR Valve in
view as reference. The valve should be addition to its stem, has two end sections, a
reassembled using new rubber parts. As the body segment for each tapped port, seals
assembly proceeds, lubricate all rubber parts between sections and seal retainers. Four tie
with Dow Corning 55 M Grease and all metal-to- rods, which pass through each section, hold
metal surfaces with Number 107 Lubriplate. these parts together.
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January 2002
centering spring and without spring. A full return The ends of the “D” PILOTAIR Valve are
spring moves a valve’s stem to its position at the identified as “A” and “B”. The “A” end of the
other end of its travel with the removal of an valve is the one with the nameplate. A full return
operating force that had moved it from this spring on this end of a two-way valve or a three-
position. A centering spring returns a valve’s way valve with open exhaust makes it “normally
stem to its mid-position with the removal of an closed”. A “normally closed” valve has the
operating force that had moved it from this passage between its supply and delivery ports
position. Two-way valves never have centering closed when no operating force is acting on the
springs. Three and four-way valves have valve. A “normally open” valve has this passage
centering springs when the valve is to have the open unless an operating force closes it.
”inching” feature, that is the ability to admit or to
exhaust quantities of fluid from the delivery line With three- and four-way valves with tapped
and then close all ports to retain the fluid in the exhaust the placing of the spring is not critical
delivery line without change. since supply and exhaust ports are
interchangeable.
The stem of the valve having an operator
without spring remains in the position in which
an operating force moves it to. The use of a “D”
PILOTAIR® Valve determines the kind of
operator it has and whether it has a full return
spring, a centering spring or no springs. Lever,
button or treadle operators without springs can
be used alone on a valve as they can move a
stem in both directions. Pedal, cam, pilot,
cylinder, or solenoid operators without springs or
with centering springs cannot be used alone,
since they can only push the stem in one
direction, and the centering spring can only
return the stem to its mid-position. To be used
alone, pedal, cam, pilot cylinder and solenoid
operators must have full return springs.
However, these operators without springs or
with centering springs may be used when there
is another operator on the other end of the
valve.
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January 2002
OPERATION
(Diagrammatic Views)
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January 2002
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January 2002
See Page 8 for Major Kit and Minor Kit Information
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January 2002
See Page 8 for Major Kit and Minor Kit Information
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January 2002
MINOR REPAIR KITS FOR "D" PILOTAIR VALVE PORTIONS
KIT PT. NO. DESCRIPTION KIT PT. NO. DESCRIPTION
1/4" Valves 1/2" Valves
P -068829-00000 Kit, Minor Repair F/PD2-20, 31 Valve P -068837-00000 Kit, Minor Repair F/PD4-20, 31
Valve
P -068830-00000 Kit, Minor Rep.F/PD2-32,41,43 & 45 P -068838-00000 Kit, Minor Rep.F/PD4-32,41,43 & 45
Vlv Vlv
P -068831-00000 Kit, Minor Rep.F/PD2-42,44,& 46 P -068839-00000 Kit, Minor Rep.F/PD4-42,44,& 46
Valve Valve
The above minor kits contain seals, seal retainers, and a tube of grease for the indicated models.
With the above kits and parts, the elastomer seals and some common wear parts in the basic valve portion of the
assemblies can be repaired. On severely worn or damaged valves, additional parts may be required.
The basic valve portion kits do not contain any parts for the mechanical operator portions of the valves. The
mechanical operator portion of the valves should be repaired when necessary, with individually selected parts and
tested before being put in services. Refer to the D Pilotair Valve service literature for additional parts information
and service instructions.
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January 2002
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January 2002
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Operator Selection Codes
DESCRIPTION SEE NOTE NO. CODE NO.
Lever, No Spring Return - 01
Lever, Full Return Spring 2 02
Lever with Centering Spring 3 03
Button, No Spring Return - 04
Button, Full Return Spring 2 05
Button with Centering Spring 3 06
Cam, No Spring Return 4 07
Cam, Full Return Spring 2 08
Cam with Centering Spring 5 09
Pilot Cylinder, No Spring Return 4 10
Pilot Cylinder, Full Return Spring 2 11
Pilot Cylinder with Centering Spring 5 12
Solenoid (120V, 60 Cycle), No Return Spring 4 13
Solenoid (120V, 60 Cycle), Full Return Spring 2 14
Solenoid (120V, 60 Cycle), with Centering Spring 5 15
Solenoid (240V, 60 Cycle), No Return Spring 4 16
Solenoid (240V, 60 Cycle), Full Return Spring 2 17
Solenoid (240V, 60 Cycle), with Centering Spring 5 18
Pilot Cylinder (Low Pressure), No Spring Return 6 19
Pilot Cylinder (Low Pressure), Full Return Spring 2 20
Pilot Cylinder (Low Pressure) with Centering Spring 5&6 21
Foot Pedal, No Spring Return 4 22
Foot Pedal, Full Return Spring 2 23
Nose Mount, Spring Return 2&7 36
Nose Mount, 2-Position Detent 7 37
Nose Mount, 3-Position Detent 7 38
Foot Treadle, No Spring Return - 52
Foot Treadle with Centering Spring 3 53
End Cover with Centering Spring 4 54
End Cover with Return Spring 4 55
Solenoid (480V, 60 cycle) No Spring Return 1&4 57
Solenoid (480V, 60 cycle) Full Return Spring 1&2 58
Solenoid (480V, 60 cycle) with Centering Spring 1&5 59
Solenoid (125V DC) No Spring Return 1&4 63
Solenoid (125V DC) Full Spring Return 1&2 64
Solenoid (125V DC) with Centering Spring 1&5 65
Solenoid (150V DC) No Spring Return 1&4 66
Solenoid (150V DC) Full Spring Return 1&2 67
Solenoid (150V DC) with Centering Spring 1&5 68
Solenoid (24V DC) No Spring Return 1&4 69
Solenoid (24V DC) Full Return Spring 1&2 70
Solenoid (24V DC) with Centering Spring 1&5 71
Solenoid (12V DC) No Spring Return 1&4 72
Solenoid (12V DC) Full Return Spring 1&2 73
Solenoid (12V DC) with Centering Spring 1&5 74
Solenoid (90V DC) No Spring Return 1&4 75
Solenoid (90V DC) Full Return Spring 1&2 76
Solenoid (90V DC) with Centering Spring 1&5 77
Solenoid (40V DC) No Spring Return 1&4 78
Solenoid (40V DC) Full Return Spring 1&2 79
Solenoid (40V DC) with Centering Spring 1&5 80
Solenoid (6V DC) No Spring Return 1&4 81
Solenoid (6V DC) Full Return Spring 1&2 82
Solenoid (6V DC) with Centering Spring 1&5 83
Solenoid (12V DC Explosion Proof) No Spring Return 1&4 84
Solenoid (12V DC Explosion Proof) Full Spring Return 1&2 85
Solenoid (12V DC Explosion Proof) with Centering Spring 1&5 86
Button, Panel-Mounted, No Spring Return - 87
Button, Panel-Mounted, Full Return Spring 2 88
Button, Panel-Mounted, with Centering Spring 3 89
Detent Kit, Two-Position 4 90
Detent Kit, Three-Position 4 91
Solenoid (120V, 60 cycle) No Spring Return (Explosion Proof) 1&4 92
Solenoid (120V, 60 cycle) Full Return Spring (Explosion Proof) 1&2 93
Solenoid (120V, 60 cycle) with Centering Spring (Explosion Proof) 1&5 94
Solenoid (240V, 60 cycle) No Spring Return (Explosion Proof) 1&4 95
Solenoid (240V, 60 cycle) Full Return Spring (Explosion Proof) 1&2 96
Solenoid (240V, 60 cycle) with Centering Spring (Explosion Proof) 1&5 97
End Cover Kit - 98
Notes:
1. Molded waterproof coils standard in all valves.
2. Not normally used when valve is to have two operators. Use an operator with 4. To be used only on valve with another operator.
no spring return or one with centering spring. Installation on the "A" End of two- or 5. To be used only with another operator having
three-way valve makes normally closed valve. Installation on the "B" End makes centering spring.
normally open valve. 6. Cannot be used with low pressure pilot operator
3. When used as only operator on valve, specify Centering Spring Kit (Code 54) on opposite end.
for other end. When used with another operator, operator must have centering 7. For 1/4" valves only.
spring.
Basic Valve Solenoid Operator Conversion Kits
To Convert a Basic Valve Portion to a Piped Solenoid Operator, Select one of the following Part Numbers
1/4" 1/2"
VIEW VALVE TYPE
PART NO. PART NO.
A Two-way and Three-way, Open Exhaust PD-020100-K0000 PD-040100-K0000
E Three-way, Tapped Exhaust PD-020200-K0000 PD-040200-K0000
B Two-way and Three-way, Open Exhaust PD-020300-K0000 PD-040300-K0000
F Three-way, Tapped Exhaust PD-020400-K0000 PD-040400-K0000
C Four-way, Open Exhaust PD-020500-K0000 PD-040500-K0000
D Four-way, Open Exhaust PD-020600-K0000 PD-040600-K0000
G Four-way, Tapped Exhaust PD-020700-00000 PD-040700-K0000
H Four-way, Tapped Exhaust PD-020800-00000 PD-040800-K0000
Conversion Kits include tubing cut to length and formed, required fittings, and special tapped body
segment. Shaded areas indicate material furnished (when a different length is required, this tube is also in
the kit). Dotted lines indicate alternate piping arrangement, depending on the location of the solenoid
operator.
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January 2002
Repair Kits List
Part Number
1/4" 1/2" Description
PD-020000-00001 PD-040000-00001 LEVER OPERATING KIT, Complete, Less Spring (Includes items 1
thru 12)
PD-020000-00002 PD-040000-00002 LEVER OPERATING KIT, Complete with FULL Return Spring
(Includes items 1 thru 13)
PD-020000-00003* PD-040000-00003* LEVER OPERATING KIT, Complete with CENTERING Spring
(Includes items 1 thru 11 plus 13, 14, & 15)
*When this is the only operator on a valve, CENTERING Spring Return Kit (-00054) must be used on the other end. When used with another operator, that
operator must be one with CENTERING Spring.
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January 2002
REPAIR KITS LIST
Part Number
1/4" 1/2" Description
PD-020000-00004 PD-040000-00004 BUTTON OPERATING KIT, Complete, Less Spring (Includes
items 1 thru 5)
PD-020000-00005 PD-040000-00005 BUTTON OPERATING KIT, Complete with FULL Return Spring
(Includes items 1 thru 6)
PD-020000-00006* PD-040000-00006* BUTTON OPERATING KIT, Complete with CENTERING
Spring (Includes items 1 thru 4 plus 6, 7, & 8)
*When this is the only operator on a valve, CENTERING Spring Return Kit (-00054) must be used on the other end. When used with another
operator, that operator must be one with CENTERING Spring.
Note: Former Button was one piece. To replace old Button, order Ref. No. 1 and 1a above.
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January 2002
REPAIR KITS LIST
Part Number
1/4" 1/2" Description
PD-020000-00087 PD-040000-00087 BUTTON OPERATOR KIT, Complete, Less Spring (Includes
items 2 thru 5)
PD-020000-00088 PD-040000-00088 BUTTON OPERATOR KIT, Complete with FULL Return
Spring (Includes items 2 thru 6)
PD-020000-00089* PD-040000-00089* BUTTON OPERATOR KIT, Complete with CENTERING
Spring (Includes items 2 thru 4 plus 6, 7, & 8)
1a SHAFT 5 STOP and SPRING RETAINER
2 ROLL PIN 6 SPRING
3 BUTTON, Push (See Note) 7 RETAINER, Spring
3a MOUNTING ADAPTER 8 STOP
4 MOUNTING FLANGE 9 4 NUTS
*When this is the only operator on a valve, CENTERING Spring Return Kit (-00054) must be used on the other end. When used with another
operator, that operator must be one with CENTERING Spring.
Note: Former Button was one piece. To replace old Button, order Ref. No. 3 and 3a above.
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January 2002
REPAIR KITS LIST
Part Number
1/4" 1/2" Description
PD-020000-00007* PD-040000-00007* CAM OPERATING KIT, Complete, Less Spring (Includes
items 1 thru 14)
PD-020000-00008 PD-040000-00008 CAM OPERATING KIT, Complete with FULL Return
Spring (Includes items 1 thru 15)
PD-020000-00009** PD-040000-00009** CAM OPERATING KIT, Complete with CENTERING
Spring (Includes items 1 thru 13 plus 15, 16 & 17)
1 PIN, Cotter 10 PIN, Rod End
2 PIN, Rod End 11 ROLLER, Cam
3 NUT, Mounting Adapter (4 req'd) 12 ROLL PIN
4 ADAPTER, Mounting 13 FOLLOWER, Cam
5 PIN, Cotter 14 STOP and SPRING RETAINER
6 PIN, Rod End 15 SPRING
7 LINK (2 req'd) 16 STOP
8 SLEEVE, Retainer 17 RETAINER, Spring
9 PIN, Cotter
*This operator is to be used only on a valve with another operator.
** Use this operator only with another operator having CENTERING Spring.
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January 2002
REPAIR KITS LIST
Part Number
1/4" 1/2" Description
PD-020000-00010* PD-040000-00010* PILOT CYLINDER OPERATING KIT, Complete, Less Spring
(Includes items 1 thru 6)
PD-020000-00011 PD-040000-00011 PILOT CYLINDER OPERATING KIT, Complete with FULL
Return Spring (Includes items 1 thru 7)
PD-020000-00012** PD-040000-00012** PILOT CYLINDER OPERATING KIT, Complete with
CENTERING Spring (Includes items 1 thru 5 plus 7, 8, & 9)
1 NUT, Mounting Adapter (4 req'd) 6 STOP and SPRING RETAINER
2 CYLINDER, Pilot (Includes choke plug) 7 SPRING
3 RING, Packing 8 STOP
4 ROLL PIN 9 RETAINER
5 PISTON
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January 2002
REPAIR KITS LIST
Part Number
1/4" 1/2" Description
PD-020000-00019 PD-040000-00019 LOW PRESSURE PILOT CYLINDER OPERATOR KIT, Complete Less
Spring (Includes items 15 thru 25)
PD-020000-00020 PD-040000-00020 LOW PRESSURE PILOT CYLINDER OPERATOR KIT, Complete with
FULL Return Spring (Includes items 14 thru 26)
PD-020000-00021* PD-040000-00021* LOW PRESSURE PILOT CYLINDER OPERATOR KIT, Complete with
CENTERING Spring (Includes items 15 thru 24 plus 26, 27, & 28)
14 SPRING, Piston 22 PIN, Cotter
15 COVER, Pilot Cylinder 23 RING, 13/16" O.D. "O"
16 SCREW (4 req'd) 24 BODY, Pilot Cylinder
17 WASHER (4 req'd) 25 STOP and SPRING RETAINER
18 RING, 3-1/8" O.D. "O" 26 SPRING
19 PISTON 27 RETAINER, Spring
20 RING, 3" O.D. "O" 28 STOP, Spring
21 PIN, Rod End
* When this is the only operator on a valve, CENTERING Spring Return Kit (-00054) must be used on the other end with CENTERING Spring.
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January 2002
REPAIR KITS LIST
Part Number
1/4" 1/2" Description
PD-020000-00013* PD-040000-00013* SOLENOID OPERATING KIT (115V., 60C.) Complete,
Less Spring (Includes items 1 thru 7)
PD-020000-00014 PD-040000-00014 SOLENOID OPERATING KIT (115V., 60C.) Complete with
FULL Return Spring (Includes items 1 thru 8)
PD-020000-00015** PD-040000-00015** SOLENOID OPERATING KIT (115V., 60C.) Complete with
CENTERING Spring (Incl. items 1 thru 6 plus 8, 9 & 10)
PD-020000-00016* PD-040000-00016* SOLENOID OPERATING KIT (230V., 60C.) Complete,
Less Spring (Includes items 1 thru 7)
PD-020000-00017 PD-040000-00017 SOLENOID OPERATING KIT (230V., 60C.) Complete with
FULL Return Spring (Includes items 1 thru 8)
PD-020000-00018** PD-040000-00018** SOLENOID OPERATING KIT (230V., 60C.) Complete with
CENTERING Spring (Incl. items 1 thru 6 plus 8, 9, & 10)
1 SOLENOID (115V, 60 cycle) 6 RING, Packing
1 SOLENOID (230V, 60 cycle) 7 STOP and SPRING RETAINER
2 NUT, Mounting Adapter (4 req'd) 8 SPRING
3 BODY, Solenoid Adapter 9 STOP
4 ROLL PIN 10 RETAINER, Spring
5 PISTON
* This operator is to be used only on a valve with another operator.
** Use this operator only with another operator having CENTERING Spring.
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REPAIR KITS LIST
Part Number
1/4" 1/2" Description
PD-020000-00022 PD-040000-00022 FOOT PEDAL OPERATING KIT, Complete, Less
Spring (Includes items 1 thru 11)
PD-020000-00023 PD-040000-00023 FOOT PEDAL OPERATING KIT, Complete with
FULL Return Spring (Includes items 1 thru 12)
1 PIN, Cotter (2 req'd) 7 LINK (2 req'd)
2 PIN, Rod End 8 SLEEVE, Retainer
3 NUT, Mounting Adapter (4 req'd) 9 STOP and SPRING RETAINER
4 ADAPTER, Mounting (See Note) 10 PIN, Rod End
5 PIN, Cotter 11 PEDAL (See Note)
6 PIN, Rod End 12 SPRING
*This operator is to be used only on a valve with another operator.
Note: Pedal (11) and Adapter (4) have been redesigned. To replace old Pedal or old Adapter both Pedal (11) and Adapter (4) must be
used.
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January 2002
REPAIR KITS LIST
Part Number
1/4" 1/2" Description
PD-020000-00052 PD-040000-00052 FOOT TREADLE OPERATING KIT, Complete, Less
Spring (Includes items 1 thru 10)
PD-020000-00053* PD-040000-00053* FOOT TREADLE OPERATING KIT, Complete with
CENTERING Spring (Includes items 1 thru 13)
1 PIN, Cotter 8 SLEEVE, Retainer
2 PIN, Rod End 9 ROLL PIN
3 NUT, Mounting Adapter (4 req'd) 10 TREADLE
4 ADAPTER, Mounting 11 STOP
5 PIN, Cotter 12 RETAINER, Spring
6 PIN, Rod End 13 SPRING
7 LINK (2 req'd)
*When this is the only operator on a valve, CENTERING Spring Return Kit (-00054) must be used on the other end. When used with
another operator, that operator must be one with CENTERING Spring.
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January 2002
REPAIR KITS LIST
Part Number
1/4" 1/2" Description
PD-020000-00090 PD-040000-00090 DETENT OPERATING KIT (2 position), Complete
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January 2002
REPAIR KITS LIST
Part Number
1/4" 1/2" Description
PD-020000-00054 PD-040000-00054 SPRING RETURN KIT, Complete for CENTERING
(Includes items 1 thru 7)
PD-020000-00055 PD-040000-00055 SPRING RETURN KIT, Complete for FULL Return
(Includes items 1, 2, 3, 5, 7, and 8)
PD-020000-00098 PD-040000-00098 END COVER KIT, Complete (Includes items 1 plus 7)
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