User's Manual

4 307909
Repair
Repairing the Air Control Valve
NOTE: An Air Valve and Pilot Valve Repair Kit is
available, page 5. Parts included in the kit are marked
with an asterisk, for example, (106*). Use all the parts
in the kit for the best results.
Disassembly
1. Follow the Pressure Relief Procedure on page
2.
2. Cut a small slit in the tube ends and disconnect
them from the pilot valve fittings, air valve tees
(113), and barb fittings (117).
3. Remove the valve end housings (102) by unscrew-
ing the screws (111) and nuts (112). Refer to the
Parts Drawing on page 8.
4. Center the valve spools (103) in the housing (101).
Remove the spools and stem (104) by applying
opposing force with wrenches on the spool (103)
flats.
5. If the air filter (115) needs cleaning or replacement,
unscrew the filter housing (116) and remove the
filter. To clean them, soak the filter housing and the
filter in solvent until they are clean. Blow them dry
with low pressure air [under 30 psi (2.1 bar)].
Press fit the filter into the housing, using 40–60
lbs. of force. Apply sealant to the filter housing
threads and screw it into the center housing (101).
Assembly
1. Apply lithium base grease to all o–rings, u–cups,
gaskets and to the complete spool assembly
before installing them.
2. Remove the seal retainers (105) from each side of
the center housing (101). Replace the u–cup
(110*), with the lips facing into the housing. Install
the retainers with the flat side facing into the
housing.
3. Replace the spools (103) if damaged. Replace the
o–ring (108*) and u–cup (109*) on each spool,
being sure to seat them in the grooves. Install the
u–cup with the lips facing towards the housing
(101).
4. Apply medium strength thread sealant to the spool
stem (104) threads. Remove the excess sealant.
CAUTION
Do not overtighten the spools (103) as this can
shear the spool threads.
5. Thread one spool (103) onto the stem (104) and
insert it into the center housing (101); be careful
not to dislodge the u–cups (110) and retainers
(105). Thread the other spool onto the stem. With
wrenches on the flats of the spools, apply oppos-
ing force and tighten until snug; 7–13 in–lb
(0.79–1.47 N.m).
6. Replace the gasket (106*) in each end housing
(102) and the o–ring (107*) on each end housing
shoulder.
7. Install the end housings (102) onto the center
housing (101); be careful not to move the spool
and dislodge the u–cups (110) and retainers (105).
Secure the end housings with the four screws
(111) and nuts (112), torquing them to 27–45
in–lb (3–5 N.m).
CAUTION
If the mufflers are replaced, they must be installed
with the lock rings to avoid damage to the spool
and o–rings during operation.
8. Replace the two o–rings (108*) in the center
housing (101).
9. Install the air valve on the pump and connect the
tubing as shown in Fig. 1.