Graco Falcon A Series Instructions Manual page 24

Disassembly
NOTE: Pump Repair Kit 244159 is available. Also,
director valve assembly 241357 is available by itself.
For the best results, use all the new parts in the kit. Kit
parts are marked with an asterisk, for example (3*), in
the Parts Drawing and Parts List on pages 26
and 27.
1. Remove the air motor cover (69).
1. Remove the screws (25) holding the director valve
(3) to the cylinder (2). Be careful not to drop the
valve cup (7) as you remove the housing; the cup
can be easily damaged. Inspect the cup surface
for scratches. If damaged, replace the cup. See
Fig. 12.
NOTE: The surface of the valve cup (7) can be
repaired by rubbing it with 300 to 600 grit sandpa-
per on a flat surface.
NOTE: Note the position of the spool inside of the
valve housing.
2. Remove the screws (28) holding the valve plate (8)
to the cylinder (2). Be very careful not to drop or
damage the plate. Inspect the plate surface for
scratches. If damaged, replace the plate.
3. Remove the gasket (13) from the face of the
cylinder (2).
4. Clean and inspect all parts. Replace any that are
worn or damaged.
24 309224
Air Motor Service
Director Valve Service
Reassembly
1. Install the valve gasket (13) and plate (8) on the
cylinder (2). Be sure the surface of the plate facing
out is free of scratches or damage. Install the
screws (28), and torque them oppositely and
evenly to 4 to 6 in-lb (0.5 to 0.7 N.m).
2. Position the spool in the new director valve as you
noted in step 1 at left.
3. Grease the o-ring grooves in the valve housing
(3a), then install the large o-ring (3h) and two small
o-rings (3g). The grease holds the o-rings in place
during assembly.
4. Grease the valve cup (7) and the valve plate (8).
Orient the cup as shown in Fig. 12. Place the cup
on the valve plate so its position corresponds to
the position of the spool, as you noted in step 1 at
left.
5. Place the director valve housing (3a) on the cylin-
der (2). The spool (3b) must engage the valve cup
(7), or the valve housing assembly will not fit
correctly. If necessary, move the cup to engage
the spool.
6. Install the screws (25), and torque oppositely and
evenly to 14 to 17 in-lb (1.6 to 1.9 N.m). Be sure
the o-rings (3h, 3g) do not slip out of the grooves
on the housing (3a).
7. Replace the air motor cover (69).