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This kit replaces the Pilot Check Valve that mounts on the lower part of the knife cylinder. The original is no longer available, so this kit contains the valve, manifold, and a new pilot tube that replaces the original tube.
Contents of the Kit:
1-Cartridge Valve and Manifold
1-New Pilot Tube
1-2-1/2" Pipe Nipple (for some cylinders with a screw-on top; Gold models mostly; not always used)
1-45 degree adapter
1-Roll of Teflon tape
It is recommended that a technician install this kit.
Instructions To Install:
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Remove knife if possible.
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Lower blade carrier to table if possible. This device is the only thing besides the snubber* keeping the blade carrier up. The snubber is not enough to trust alone. If you can not get the blade carrier down, build up a stable support under the blade carrier with wooden blocks, that could support the carrier if it were to drop. *The snubber is a pin that is pushed by an adjustable spring behind the blade carrier. It is mounted on the outside, left side of the machine as viewed from behind, near the top of the blade cylinder, and all that you see from the outside is a setscrew with a locking nut. It is for supporting the blade when your blade cylinder seals start to leak a little, to keep the blade from drifting down when the power is off.
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Remove pilot tube, and old Check Valve, but leave the old pipe nipple that comes out of the cylinder. Remove old fittings from the check valve, for they will be used in the new installation.
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Install 90 degree fitting into Port 3, aligned in direction in picture. Be sure to use teflon tape only on the side that screws into the manifold, being careful not to cover the end with tape. Do not use tape on pilot tube fitting!
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Screw manifold onto cylinder into Port 1, aligning as in picture. Use teflon tape on nipple.
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Aim old upper 90 degree fitting away from cylinder as shown in photo. Avoid turning fitting counter-clockwise, but if you get too much resistance going clockwise, you may need to replace the fitting.
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Install Pilot Tube as in picture. Do not tighten first fitting until you have successfully started the second on the threads. Some re-aiming of fittings, and even the manifold is necessary to get the tube to screw on. Even a very gentle re-bending of tube is possible. Note: some cylinders may need the extra nipple supplied with kit to mount properly.
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Clean hose threads and put on teflon tape. Install hose.
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Remove all blocks, or simply turn on machine and test. Make sure that hoses do not rub on anything when the cylinder rocks while activating. Adjust as needed.
Not all installations and hardware are the same.
Different hardware was used over the years by Challenge that has different dimensions so some adjustments and possibly different hardware may be needed.
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