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Service
Air Valve Service
NOTE: Service the air valve every 3 million cycles. If
the air motor stalls, service the air valve immediately.
NOTE: Air Valve Repair Kit 222959 is available. Parts
included in the kit are marked with a symbol ({). For
the best results, use all the parts in the kit.
NOTE: Trip Rod Kit 222981 and Detent Kit 222982 are
available to replace these complete assemblies. Parts
included in Kit 222981 are marked with a symbol (})
and parts included in Kit 222982 are marked with a
checkmark (n).
Disassembly
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
1. Stop the pump at the middle of its stroke. Relieve
the pressure before performing any service.
2. Remove the air motor shroud as described under
Air Motor Shroud Disassembly, on page 11.
3. Follow steps 3 and 4 under Air Valve Replace-
ment on page 11.
4. Using a 4 mm allen wrench, remove the socket
screws (104) holding the two slide plates (124) to
the valve housing (101). Lift the slide plates off the
housing, being careful not to scratch the polished
surfaces. Clean the slide plate surfaces and edges
and inspect for damage. See Fig. 4.
5. Lift the valve carriage (111) out of the valve hous-
ing (101). The detent assemblies (J) will slide out
of the carriage; be careful not to drop them. Set
them aside.
6. Remove the screws (104) holding the top rod
fitting (103) to the valve housing (101). Turn the
fitting 90_ and remove it. Using an o-ring pick,
remove the seal (102). Repeat for the bottom rod
fitting.
7. Remove the trip rod assembly (T) from the hous-
ing (101). Set it aside.
02271
Fig. 4
104
103}
102}
101
}T
104
}107
111
124
104
Jn
104
103}
102}
1
2
Lubricate.
4
5
Torque to 2–3 NSm (20–30 in-lb)
Torque to 9 NSm (75 in-lb) and unscrew as need-
ed for plate (124) to be flush with housing (101)
6
Apply thread sealant.
Lips must face into housing (101).
3
Grease ends of trip rod (T).
24
25
3
3
2 5
1
1 6
2 5
1
1 6
} These parts are included in Trip Rod Kit
222981, which may be purchased separately.
n These parts are included in Detent Kit 222982,
which may be purchased separately.