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Kimray GEN II Repair Manual
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Kimray GEN II Repair Manual

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Repair Manual
GEN II

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Summary of Contents for Kimray GEN II

  • Page 1 Repair Manual GEN II...

  • Page 2: Table Of Contents

    GEN II REPAIR MANUAL INDEX Introduction ....................1 Elastomer Materials ..................2 Terminal Arm Disassembly ................3 Terminal Arm Assembly ................7 Pilot Disassembly ..................9 Pilot Assembly ..................... 13 Pilot Installation ................... 15 Settings ....................... 17 NOTE: We reserve the right to modify or change, without prior notice, any statement or information contained herein.

  • Page 3: Introduction

    • Use repair kit RMD GENUINE KIMRAY To get the long service you have come to expect from Kimray products, always use PARTS when doing repairs. Remember, parts made to less than Kimray specifications don’t save you money!!! ENG-002.6 Rev.

  • Page 4: Elastomer Materials

    GEN II REPAIR MANUAL ELASTOMER MATERIALS AFLAS VITON is a trade mark of Asahi Glass Co is a trade mark of Dupont ® ® TEMPERATURE: TEMPERATURE: -25° to +500° F -10° to +350° F -30° to +260° C -23° to +177° C...

  • Page 5: Terminal Arm Disassembly

    Open case and inspect Gasket between cases for rips or tears (Fig 1.2). If the Gen II is not able to be put on a stand now is a good time to separate case by removing Hinge Screw (Fig 1.3).
  • Page 6 GEN II REPAIR MANUAL Terminal Arm DISASSEMBLY STEP 3 Pry here Pull out on Variable Link Knob and slide Knob off of Tangent Arm (Fig 1.4). Using a flat blade screwdriver pry off lower end of Variable Link Knobs yoke.
  • Page 7 GEN II REPAIR MANUAL Terminal Arm DISASSEMBLY STEP 8 Remove terminal Retainer Nut, make sure to use a wrench around housing. (Fig 1.13). Pull Terminal Arm out from mounting housing (Fig 1.14). Figure 1.13 Figure 1.14 STEP 9 Remove Retaining Nut from Arm and dis- card O ring and seal (Fig 1.15).
  • Page 8 GEN II REPAIR MANUAL NOTES Page 6 www.kimray.com...

  • Page 9: Terminal Arm Assembly

    GEN II REPAIR MANUAL Terminal Arm ASSEMBLY STEP 1 Install retaining nut, seal and O ring on terminal arm. Do not push O ring over threads or it may be cut by threads. Roll O ring over threads (Fig 1.1).
  • Page 10 GEN II REPAIR MANUAL Terminal Arm ASSEMBLY STEP 5 Install Spring Clip. Insert back first then use needle nose pliers to finish (Fig 1.9). Figure 1.9 STEP 6 Loctite Insert Pivot Rod (Fig 1.10). Make sure Pivot Rod moves freely & does not bind Terminal Arm Assy.

  • Page 11: Pilot Disassembly

    GEN II REPAIR MANUAL PILOT DISASSEMBLY Upper Cap 5449 * Spring 585 Screw 7189, 6 Req’d. * Throttle Spring 5469 Diaphragm Assy 7102AS * Switch Plate 6799 Screw 4918, 2 Req’d. Lock Washer 4543 Pilot Block 7346 Thumb Screw 6780 O Ring 647V, 2 Req’d.
  • Page 12 GEN II REPAIR MANUAL PILOT DISASSEMBLY STEP 3 Pull here Remove 3 screws from Upper Cap on Pilot, be careful of Spring when removing Cap (Fig 1.3 and 1.4). Figure 1.3 Figure 1.4 STEP 4 Pilot Plug Remove Diaphragm Plate being careful of Spring (Fig 1.5).
  • Page 13 GEN II REPAIR MANUAL PILOT DISASSEMBLY STEP 8 Remove Lock Nut from switch and pull up on Selector Knob (Fig 1.10 and 1.11). Figure 1.10 Figure 1.11 STEP 9 On Selector Knob make sure holes are clear. These holes connect to one another so blow air in to them in order so see if pathway is clear (Fig 1.12).
  • Page 14 GEN II REPAIR MANUAL NOTES Page 12 www.kimray.com...

  • Page 15: Pilot Assembly

    GEN II REPAIR MANUAL PILOT ASSEMBLY STEP 1 Clean Pilot Block and replace 4 O-rings under Selector Knob. Clear holes of any obstructions (Fig 1.1). Apply grease between Selector Knob and Pilot body before installing (Fig 1.2). Figure 1.1 Figure 1.2 STEP 2 Tighten Lock Nut (Fig 1.3).
  • Page 16 GEN II REPAIR MANUAL PILOT ASSEMBLY STEP 5 Install Pilot Plug small ball first (Fig 1.9). Place Spring #5469 on Upper Diaphragm Assembly. Apply grease to Assembly were Spring rests (Fig 1.10). Figure 1.9 Figure 1.10 STEP 6 Place Spring #585 in Upper Cap. Use grease in Cap were Spring sets (Fig 1.11).

  • Page 17: Pilot Installation

    GEN II REPAIR MANUAL PILOT INSTALLATION STEP 1 Replace 3 O-rings on back of Pilot Body (Fig 1.1). O Rings Secure Pilot Body to Case with 2 screws (Fig 1.2 and 1.3) do not use loctite on Figure 1.1 Figure 1.2 these screws.
  • Page 18 GEN II REPAIR MANUAL NOTES Page 16 www.kimray.com...

  • Page 19: Settings

    GEN II REPAIR MANUAL SETTINGS PRE-SETTING LEVEL FOR THROTTLE STEP 1 Attach Float at Coupling (Fig 1.1). Regulate Supply Pressure to 20 pounds Supply Line and connect to side of GennII (Fig 1.1). Figure 1.1 STEP 2 Switch Selector Knob on Pilot to throttle and move Variable Link Arm to throttle side (Fig 1.2).
  • Page 20 GEN II REPAIR MANUAL PILOT SETTINGS PRE-SETTING LEVEL FOR SNAP STEP 1 Move Selector Knob from T to S for Snap and move Variable Link Arm over to Snap side (Fig 1.5). Figure 1.5 STEP 2 Perform same test as for Throttle mode...
  • Page 21 GEN II REPAIR MANUAL NOTES www.kimray.com...