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8. Lubricate all parts before reassembling.
9. Slide the pilot valve spool (28) into the bore (S). Apply
a drop of Loctite No. 222 to the threads of the actua-
tor pin (27). Screw the pin into the spool. Use the pin
to move the spool back and forth to be sure the spool
moves freely.
CAUTION
Excessive Loctite will damage the spool and
cause premature failure.
10. Slide the valve spool (31) into the block so the flat
section faces the rectangular opening in the block.
11. Grease the spring (26) and place it in the valve spool
recess. Position the slide valve (25) over the spring,
so the spring fits into the spring recess in the bottom
of the slide valve.
12. Place a new gasket (24) on the slide valve plate (23).
Place the plate on the valve block (32), making sure
the slots on the edge of the plate face the same way
as the actuator pin (27).
13. Install the screws (22) and torque to 3.4–4.5 N.m
(2.5–3.3 ft–lb).
14. Position the air inlet gasket (38) and the plate (37) on
the valve block (32). Install the screws (39) and
torque to 6.8–7.9 N.m (5–5.8 ft–lb).
15. Install the right and left valve caps (30 and 33) on the
valve block, matching the holes in the caps and the
slide valve plate (23).
16. Look in the pump housing (2) to check the position of
the diaphragm shaft (1). Slide the actuator pin (27) so
that it will enter the pump housing toward the small
diameter of the shaft to prevent damaging the
shaft. See Fig. 5.
CAUTION
Incorrect positioning of the actuator pin can cause
serious damage to the diaphragm shaft, including
bending the shaft.
SMALL DIAMETER
OF SHAFT
27
AIR DIRECTOR VALVE
ASSEMBLY
Fig. 5
17. Lubricate the outside of the valve caps (30 and 33)
with light grease. Guide the air director valve assem-
bly (52) into the pump housing (2), so the arrow on
the inlet plate (37) faces the arrow on the pump hous-
ing.
18. Tap the air inlet plate (37) with a plastic mallet to help
align the screw holes of the plate and pump housing
(2). Install a screw (35) and washer (36) to check the
alignment; adjust as necessary . Loosely install a
screw and washer in the opposite corner. Then install
the remaining screws and washers. Using an oppo-
site and alternate pattern, torque the screws evenly
to 8.5–9.5 N.m (6.2–7 ft–lb).
T o Check the Air Director V alve Assembly
19. Be sure the air control valve (P) is turned of f, then
connect the air supply line.
20. Open the bleed–type master air valve, then open the
air control valve slowly; the pump should cycle.
21. If the pump does not start, check to be sure (a) that
the pin (27) was moved to the small diameter of the
shaft, (b) that you installed the air director valve as-
sembly correctly, and (c) that you assembled the air
valve correctly.
Replacing the Diaphragm Shaft Seals (See Fig. 6)
1. Remove the screws (35) and washers (36). Gently
tap the air inlet plate (37) from the top and bottom
with a plastic mallet to help loosen the air director
valve assembly (52). Then pull the assembly out of
the pump housing.
2. Disassemble the diaphragm covers and diaphragms
as instructed in Replacing a Diaphragm, steps 1–7.
3. Inspect the shaft (1), the bushings (51, see Figs. 5
and 6) inside the pump housing (2), and the seals (4)
for wear or damage. Replace parts as needed.
4. Install the new seal (4) so the lips of the seal face out
of the pump housing (2). Press the seal in with your
fingers; do not use any tools which could damage the
seal.
5. Reassemble the diaphragms as instructed in
placing a Diaphragm, steps 8–19.
6. Look in the pump housing (2) to check the position of
the diaphragm shaft (1). Slide the actuator pin (27) so
that it will enter the pump housing toward the small
51
diameter of the shaft to prevent damaging the
shaft. See Fig. 5.
Incorrect positioning of the actuator pin can cause
serious damage to the diaphragm shaft, including
bending the shaft.
7. Lubricate the outside of the valve caps (30 and 33)
with light grease. Guide the air director valve assem-
bly (52) into the pump housing (2), so the arrow on
the inlet plate (37) faces the arrow on the pump hous-
ing.
CAUTION
Re-
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