fti AIR FT025C User manual

1
FTI AIR AODD MODELS FT20P & FT20V
Assembly, Installation, & Operation Manual
Record your Model and Serial Number here.
MODEL NUMBER
SERIAL NUMBER
P/N 109690 R4

2
EU Declaration of Conformity
FTI Air hereby declares that the following machine(s) fully comply with the applicable health and
safety requirements as specified by the EU Directives listed. The complete product complies with
the provisions of the EU Directive on machinery safety.
This declaration is valid provided that the devices are fully assembled and no modifications are
made to these devices.
Type of Device:
Air Operated Double Diaphragm Pumps
Models:
FT025P, FT025V, FT025C, FT05P, FT05V, FT05C, FT05A, FT05S, FT10P, FT10V, FT10A, FT10S
FT15P, FT15V, FT15A, FT15S, FT20P, FT20V, FT20A, FT20S FT30A & FT30S
EU Directives:
Machinery Safety (2006/42/EC)
Applied Harmonized Standards:
EN ISO 12100
Manufacturer:
FTI Air A Division of Finish Thompson, Inc.
921 Greengarden Road
Erie, Pennsylvania 16501-1591 U.S.A
Signed,
President
19 May 2016
Person(s) Authorized to Compile Technical File: FTI Air GmbH
Otto-Hahn-Strasse 16
Maintal, D-63477 DEU
Telephone: [phone]

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Table of Contents
Important Information - READ ME FIRST
Export Regulation Notice ........................................................................................................................ 4
Chemical Reaction Disclaimer ................................................................................................................ 4
Safety Precautions ................................................................................................................................. 4-5
Pump Specifications
Materials Profiles.................................................................................................................................... 5
ModelNumberExplanation & Example Part Numbers................................................................................... 6
Dimensional Drawing.............................................................................................................................. 6
Performance Curve................................................................................................................................. 7
Specifications......................................................................................................................................... 7
Installation/Operation
Installation Drawing................................................................................................................................ 8
Precautions............................................................................................................................................. 8
Troubleshooting...................................................................................................................................... 9
Maintenance
Recommended Tools ............................................................................................................................. 9
Wet End Servicing .................................................................................................................................. 9
Disassembly ................................................................................................................................... 10-11
Reassembly .................................................................................................................................... 12-16
Air End Servicing ................................................................................................................................... 16
Shaft Bushing & O-ring Replacement.............................................................................................. 16-18
Air Valve O-ring Replacement.......................................................................................................... 18-19
Valve & Muffler Gasket Replacement............................................................................................... 19-20
Air Valve Slide, Plate, & Gasket Orientation..................................................................................... 20
Replacement Air Valve Kit Installation.............................................................................................. 21
Exploded View ....................................................................................................................................... 21
Spare Parts List...................................................................................................................................... 21-23
Warranty ....................................................................................................................................................... 24

4
Important Information- Read Me first
IMPORTANT NOTICE
U.S. Export Administration Regulations, pursuant to ECCN 2B350, prohibit the export or re-export to certain enumerated
countries of air operated double diaphragm pumps in which all wetted materials are constructed from fluoropolymers without first apply-
ing for and obtaining a license from the U.S. Bureau of Industry and Security(BIS). This affects all FTI AIR pumps constructed from PVDF
with PTFE balls and diaphragms. Please contact the BIS (www.bis.doc.gov) or FTI Air with questions regarding the Regulations or a list
of the countries to which they apply.
Chemical Reaction Disclaimer
The user must exercise primary responsibility in selecting the product’s materials of construction which are compatible with the fluid(s)
that come(s) in contact with the product. The user may consult FTI Air (manufacturer) and a manufacturer’s representative/distributor
agent to seek a recommendation of the product’s material of construction that offers the optimum available chemical compatibility.
However neither manufacturer nor agent shall be liable for product damage or failure, injuries, or any other damage or loss arising out
of a reaction, interaction or any chemical effect that occurs between the materials of the product’s construction and fluids that come into
contact with the product’s components.
Unpacking & Inspection
Unpack the pump and examine for any signs of shipping damage. If damage is detected, save the packaging and notify the carrier imme-
diately.
To install the pump, follow the installation instructions provided
Safety Precautions
WARNING: Never use a natural polypropylene or natural PVDF pump with flammable or combustible fluids/materials.
WARNING: FTI Air maximum temperature limits are based upon the material’s mechanical stress only. Maximum temperature is
application dependent. Consult a chemical resistance guide or the chemical manufacturer for chemical compatibility and temperature
limits.
WARNING: Chemical Hazard. This pump is used for transferring many types of potentially dangerous chemicals. Always wear
protective clothing, eye protection and follow standard safety procedures when handling corrosive or personally harmful materials. Proper
procedures should be followed for draining and decontaminating the pump before disassembly and inspection of the pump. There may be
small quantities of chemicals present during inspection.
WARNING: Hot surfaces. FTI Air pumps are capable of handling liquids with temperatures as high as 220ºF (104ºC). This may cause
the outer areas of the pump to become hot as well and could cause burns.
WARNING: If a diaphragm rupture occurs, material being pumped may be forced out of the air exhaust. Proper care should be
taken, always wear protective clothing, eye protection & follow standard safety procedures.
WARNING: When pumping hazardous liquids, or operating the pump in an enclosed room, it is important to pipe the exhaust air to
a safe area.
WARNING: For polypropylene or PVDF pumps do not exceed 100 psig (6.9 bar) air supply & 120 psig (8.3 bar) for
aluminum and stainless steel.
CAUTION: Before attaching air supply to pump to make sure all airline debris is clear. It is recommended to use a minimum 5µ
(micron) air filter before the air valve.
CAUTION: Before maintenance or repair, close the compressed air line supply valve, bleed the pressure and disconnect air line from
the pump. Discharge line may also be pressurized. Any pressure must be relieved prior to servicing. Remove suction / discharge lines &
drain the pump.
CAUTION: If pump is used with materials that tend to solidify or settle, the pump should be flushed after each use to prevent
damage.
WARNING: Pump exhaust may be loud and contain particles. Wear appropriate ear and eye protection. In the event of a diaphragm
rupture material can be forced out of the air exhaust muffler. If product is hazardous or toxic, pipe exhaust to appropriate safe area.
CAUTION: Do not over-tighten the air inlet fitting or muffler. Too much torque could damage the air valve or muffler plate.
CAUTION: Use only genuine FTI Air replacement parts to assure compatibility & longest service life.

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Material Chemical
Composition Description Operating Temperature Relative Cost
Minimum Maximum
Polypropylene Pure Polypropylene Thermoplastic that is resistant to alkali and strong
acids.
32°F
(0°C)
158°F
(70°C) $
PVDF Pure Polyvinylidene Fluoride Strong fluoropolymer with excellent chemical
resistance.
10°F
(-12°C)
220°F
(104°C) $$$
Stainless Steel 316 Stainless Steel Excellent chemical resistance, high tensile and
impact strength, abrasion resistant. Limited by other materials used $$
Aluminum ADC 12, LM24, LM25 Moderate chemical resistance with good impact
strength and abrasion resistance. Limited by other materials used $
Buna Acrylonitrile-butadiene
Rubber
General purpose elastomer.Resistant to oil, water,
solvent, and hydraulic fluid.
10°F
(-12°C)
190°F
(88°C) $
EPDM Ethylene Propylene Diene
Rubber
Good resistance to mild acids, detergents, alkalis,
ketones, and alcohols.
-40°F
(-40°C)
250°F
(121°C) $
FKM Fluorocarbon Rubber
Good chemical resistance and high temperature
properties. Resistant to most acids, aliphatic,
aromatic, and halogenated hydrocarbons, oils,
grease, and fuels.
-40°F
(-40°C)
350°F
(177°C) $$
Neoprene Chloroprene Rubber
General purpose elastomer with good resistance
to moderate chemicals, oils, grease, solvents, and
some refrigerants.
0°F
(-18°C)
212°F
(100°C) $
SantopreneTM
Fully cured EPDM rubber
particles encapsulated in a
polypropylene (PP) matrix
Thermoplastic elastomer with good abrasion resis-
tance with chemical resistance to a wide range of
solvents and chemicals. Injection
molded with no fabric layer.
-40°F
(-40°C)
225°F
(107°C) $
Hytrel®Thermoplastic polyester
elastomer
Combines resistance and flexibility of elastomers
with the strength of plastics. Resistant to acids,
bases, amines, and glycols. Injection molded with
no fabric layer.
-20°F
(-29°C)
220°F
(104°C) $
Polyurethane Polyester Urethane Thermoplastic that exhibits excellent abrasion
resistance.Injection molded with no fabric layer.
32°F
(0°C)
150°F
(66°C) $
PTFE Polytetrafluoroethylene Chemically inert. Resistant to a wide range of
chemicals.
40°F
(4°C)
225°F
(107°C) $$
FEP Fluorinated Ethylene
Propylene
Similar to PTFE in composition and chemical
resistance. Used to encapsulate FKM o-rings for
superior chemical resistance.
40°F
(4°C)
225°F
(107°C) $$
SantopreneTM is a registered tradename of Exxon Mobil Corp.
Hytrel®is a registered tradename of DupontTM
Material Profiles
CAUTION: Check the temperature limits for all wetted components when choosing pump materials. See table below.
EXPLOSION HAZARD! FTI Air pumps with standard materials of construction should not be used with halogenated hydrocarbons.
Halogenated hydrocarbon solvents can cause explosion when used with aluminum components in a closed (pressurized) system. FTI Air
pumps with standard materials of construction contain aluminum components and will be affected by halogenated hydrocarbon solvents.
1-1-1 Trichloroethane and Methylene Chloride are the most common halogenated hydrocarbons. However, other
halogenated hydrocarbon solvents are suspect if used either as part of paint or adhesive formulation, or for clean-up flushing.
For applications that may involve halogenated hydrocarbons, contact FTI Air to discuss the availability of alternative pump materials of
construction.

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Series*
FT - Pump End
FW - Wet End
Pump Size*
20 - 2”
Wetted Materials*
P- Polypropylene, FDA
V- PVDF
Non-wetted Materials
P- GFRPP
Air Valve Materials
A - Aluminum P- GFRPP
*Required for wet end
Example Pump P/N’s: FT20P-PP-RRPR-F1, FT20P-PA-BBPB-F1, FT20V-PP-1TVC-F1 & FT20V-PA-FFVF-F1
Example Wet End P/N’s: FW20P-RRPR, FW20P-BBPB, FW20V-1TVC & FW20V-FFVF
Dimensional Drawing
PART # XX XX X - X X - X X X X - X X - X
Non-
wetted
Material
Air Valve
Material
Diaphragm
Material
Check
Valve
Ball
Check
Valve
Seat
Seat
O-ring
Series Pump
Size
Wetted
Material Connection Porting Location
Model Number Explanation & Example Part Numbers
Specials
Diaphragm Materials*
N- Neoprene 1 - PTFE/Neoprene
B- Buna-N, FDA 2- PTFE/Santoprene
E- EPDM 3- PTFE/BUNA, FDA
F - FKM 4 - PTFE/Santoprene, FDA
R- Santoprene 5 - Santoprene, FDA
H- Hytrel 6 - Hytrel, FDA
U- Polyurethane
Check Valve Ball Materials*
N- Neoprene F- FKM
B- Buna-N R- Santoprene
E- EPDM T- PTFE, FDA
S- 316SS, FDA 5- Santoprene, FDA
W - Weighted
PTFE, FDA
Check Valve Seat Materials*
P- Polypropylene, FDA V- PVDF
Check Valve Seat O-Ring Materials*
B- Buna-N U- Polyurethane
F - FKM C - FEP/FKM, FDA
R - Santoprene
Connection
F - ANSI/DIN/ISO Flange
Porting location
1- End (standard)
Specials
M1 - Metal mufer M2 - Oversized
P1 - Halogenated hydro- metal mufer
carbon compatible

7
0100 200 300 400 500 600
0
1
2
3
4
5
6
0
20
40
60
80
100
020 40 60 80 100 120 140 160
FLOWRATE - LPM
DISCHARGE PRESSURE - BAR
DISCHARGE PRESSURE - PSIG (FT)
FLOWRATE - US GPM
20 (34)
40 (68)
60 (102)
80 (136)
100 (170)
AIR CONSUMPTION
SCFM (Nm
3
/hr)
(46)
(92)
(138)
(185)
(231)
FT20P & FT20V Performance
Specifications
Pump Type: Non-Metallic Air Operated Double Diaphragm
Weight: PP - 67.0 lbs (30.4 kgs)
PVDF - 97.5 lbs (44.2 kgs)
Air Inlet/Exhaust Size: 3/4” FNPT
Max Air Inlet Pressure: 100 psig (6.9 bar)
Max Material Inlet Pressure: 10 psig (0.7 bar)
Air Consumption @ 100 psi: 100 scfm (170 Nm3/hr)
Noise Level: 77 dB(A)
Max Suction Lift:
Wet -28 ft H20 (8.5 m H2O)
Dry - Rubber: 13 ft H20 (4.0 m H2O)
PTFE: 9.3 ft H20 (2.8 m H2O)
Max Flow Rate: 154 gpm (583 lpm)
Suction/Discharge Size: 2” ANSI/DIN/ISO 150# flange
Max Particle Size: 0.35” (8.9 mm)
Max Outlet Pressure: 100 psig (6.9 bar)
Displacement Per Stroke: 0.31 gal (1.2 liter)

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Installation Drawing
Installation and Start up
Install the pump in a vertical position or it may not prime properly. Pump should be located as close to the product being
pumped as possible. Suction line length should be as short as possible and limit the number of fittings. Suction line di-
ameter should not be reduced smaller than the suction diameter of the pump. When using rigid pipe run short sections of
flexible hose or flexible connections between the pump & piping. Secure the pump to a suitable surface.
Air Supply
Connect the pump air inlet to an air supply with sufficient capacity to achieve desired performance. A pressure regulating
valve should be installed to insure air supply pressure does not exceed recommended limits.
Air Valve Lubrication
No lubrication is required for the air distribution system.
Fasteners
Re-torque all fasteners before operation. Creep of housing and gasket materials may cause fasteners to loosen. Re-torque
all fasteners to the torque specifications listed on the exploded view drawing in this manual.
Air Inlet & Priming
Pump will start to operate as soon as the shut-off valve is opened. It is recommended to open the shut-off valve slowly at
first. Once the pump primes; the shut-off valve can be opened additionally to increase the pump’s flow. If the pump is oper-
ating but not pumping any liquid see the troubleshooting section for tips & suggestions.
Installation / Operation Precautions

9
PUMP WILL NOT START OR CYCLE:
• Blocked liquid pipe or hose - Clean out or replace
• Clogged liquid chamber - Remove debris
• Diaphragm shaft bushing / o-ring leak - Replace o-rings
• Air valve carrier not shifting - Inspect, clean, re-oil with 10 wt. air tool oil. (aluminum air valve)
• Air valve carrier not shifting - Inspect, replace seals (polypropylene air valve)
ERRATIC CYCLING:
• Diaphragm failure - Replace diaphragm
• Valve ball not seating properly, worn or damaged – Inspect, remove debris or replace
• Leak in suction line - Inspect, repair or replace
• Diaphragm shaft bushing / o-ring leak - Replace o-rings
• Air valve carrier not shifting - Inspect, clean, re-oil with 10 wt. air tool oil. (aluminum air valve)
• Air valve carrier not shifting - Inspect, replace seals (polypropylene air valve)
• Over lubrication in air valve - Inspect, degrease, reuse. Adjust lubrication
• Excess moisture in air valve – Inspect, dry, reuse. Consider installing an air dryer
• For aluminum air valves, worn carrier or valve bore – measure carrier and valve bore, diametrical clearance should be
between .0020” - .0035”. Replace worn components as needed
• For plastic air valves, worn carrier seals – replace carrier seals if there is no longer interference between seals and valve
bore
PUMP CYCLES BUT WILL NOT PUMP:
• Too much suction lift - Reduce suction lift or fill liquid chambers with liquid
• Leak in suction line - Inspect, repair or replace
• Valve ball not seating properly, worn or damaged - Inspect, remove debris or replace
• Clogged suction pipe or hose - Inspect & clear
• Clogged strainer if used - Inspect & clear
• Diaphragm failure - Replace diaphragm
PUMPED LIQUID RELEASED FROM AIR EXHAUST
• Diaphragm failure - Replace diaphragm
• Outer plate unthreading - Tighten & re-torque
Troubleshooting Tips & Suggestions
Maintenance
Recommended tools for Servicing Pump
• 13 mm, 15 mm, & 17 mm box wrenches; (2) 30mm socket wrenches, snap ring pliers; 5, 6, & 8 mm hex wrenches,
o-ring pick, & torque wrench.
Wet End Servicing (Installing Wet End Kit)
• Relieve airline pressure and fluid line pressures before conducting maintenance.
• The pump can be drained by turning it upside down and allowing fluid to drain into an appropriate container. Use proper
safety equipment when conducting maintenance as internal components may still contain the pumped media.
• Lubricate all stainless steel to stainless steel fasteners to prevent galling. Torque values listed in the back of this manual
are for lubricated fasteners.
Accessories
Surge suppressors, spill stops & filter regulators are available and should be used with FTI Air pumps.

10
Remove the (8) discharge manifold bolts &
washers (items 11 & 12) from the discharge mani-
fold (item 39) using a 17 mm wrench.
Wet End Disassembly
5To remove the diaphragms (items
21/22), begin by loosening the (2)
outer plates (item 20) using two 30
mm wrenches. Use 6-sided sockets
or wrenches to prevent damage to the
hex portion of the outer plate.
4Remove both liquid chambers by
removing the (12) bolts, washers &
nuts (items 11, 12, 18 & 27) on each
liquid chamber using a 17mm wrench
and nuts can be removed using a
15mm wrench. Inspect and replace
diaphragms if needed.
3Repeat the above steps for the suc-
tion manifold (item13). The seat o-rings,
valve seats and valve balls (items 14,
15, 16, & 17) are located in the liquid
chambers (item 19).
2The discharge seat o-rings, valve seats, and
valve balls (items 14, 15, 16, & 17) can now be
accessed and replaced if needed.
1
3
2
5
4
1

11
7To remove the remaining diaphragm(s) (items
21/22) and plates (items 20 & 23) from the shaft
(item 32), place the shaft in a vise. Using a 6-sided
30 mm wrench, remove the remaining diaphragm(s)
and plates.
6Remove the outer plate, diaphragm(s), and inner plate (items 20, 21/22 & 23) from the side that is
loosened. Pull or push the shaft (item 32) and remaining plates and diaphragms out of the center section. If
pulling, it may be easier to grip the diaphragm if it is inverted.
After performing required maintenance, the pump can be reassembled. The pump can also be reassembled using the disas-
sembly instructions in the reverse order as listed above. For detailed assembly instructions, follow the steps in the Wet End
Reassembly section beginning on page 12.
7
6 6

12
Wet End Reassembly
Slide the center hole of one diaphragm (item
22) over the molded-in bolt of an outer plate (item
20). The air side of the diaphragm is labeled and
should face away from the plastic portion of the
outer plate.
If the pump is fitted with PTFE diaphragms (item
21), first place a PTFE diaphragm over the molded
in bolt of the outer plate (item 20). Then place the
backup diaphragm (item 22) on the outer plate. The
shape of the PTFE diaphragm and back up dia-
phragm should roughly conform to one another. See
the exploded view drawing for proper orientation.
Place the inner plate (item 23) over the molded-in
bolt. Ensure the round recess in the plate faces the
diaphragm (item 22).
Place the bump stop (item 31) onto one end of
the shaft (item 32).
3
2
1
1
32

13
The shaft (item 32) and shaft o-rings (item 30)
should retain the lubricant that was factory applied.
If they appear dry, apply a light coat of lithium thick-
ened grease. Avoid over lubrication as it can cause
decreased performance of the air distribution system.
5
5
Apply a couple drops of a medium strength
thread locker, such as Loctite® 246, to the molded
in outer plate bolt (item 20). Thread the shaft (item
32) onto the molded in bolt until it is snug to the flat
back side of the inner plate (item 22).
4
4
Push the shaft (item 32) through the center of
the shaft bushing (item 29). It is normal for this to
be a tight fit, especially if the shaft and shaft o-rings
(item 30) are in good condition.
6
6Place the remaining bump stop (item 31) on the
other end of the shaft.
7
7

14
Install the liquid chambers (item 19) by placing
one side over the diaphragm. Start all bolts, washers
& nuts (items 11, 12, 18 & 27) before tightening
and torqueing. Torque all fasteners in a star pattern.
Repeat to install the second liquid chamber. Ensure
both chambers are orientated the same and that the
inlet and outlet ports are vertical when facing the
front of the pump as shown.
11
Tighten and torque the outer plates (item 20). If
the pump is fitted with PTFE diaphragms (item 21),
it is necessary to restrict their ability to rotate when
tightening the outer plates. This can be done by
inserting all the liquid chamber bolts (items 12 & 18)
through the PTFE diaphragm holes and into the cen-
ter section (item 35) on each side. This will ensure
that the PTFE diaphragm does not obstruct the bolts
ability to thread into the center section when the
liquid chambers are installed. Remove these bolts
once the outer plates are torqued.
10
10
It may be easier to thread the molded in bolt into
the shaft if the diaphragm(s) is inverted on one or
both sides. This can be done by hand.
8
8
Note: When installing polytetrafluoroethylene (PTFE) diaphragms, it is important to tighten outer plates simultaneously (turning in opposite direc-
tions) to ensure tight fit.
The other diaphragm(s) (items 21/22) and inner/
outer plates (items 20 & 23) can be installed onto the
opposite end of the shaft (item 32).
9
9
11

15
12 Flip the pump upside down and drop the
suction valve balls (item 17) into the liquid chamber
(item 19) ball cages.
13 Place the valve seats (item 16) into the seat
counter bores of the liquid chambers (item 19). The
o-ring (item 14) gland in the valve seat should be
facing away from the valve ball.
14 Place the manifold o-rings (item 15) into the
o-ring gland on the suction manifold (item 39). Place
the suction manifold atop the pump and install,
tighten and torque the (8) manifold bolts & washers
(items 11 & 12).
14
12 13
15 Stand the pump upright onto the suction
manifold feet (item 13). Place the large o-rings
(item 15) into the glands in the face of the liquid
chambers (item 19) followed by the small o-ring
(item 14) in the gland of the valve seats (item
16). Place the valve seats on the liquid chambers
with the o-ring down against the liquid chamber.
15

16
Air End Servicing (Installing Air End Kit)
1Remove both air chambers by removing the (4)
bolts and (4) nuts using a 13mm (or ½”) wrench.
2Remove and set aside the air valve (item 3)
using a 6 mm hex wrench (see “Valve & Muffler
Gasket Replacement” section for more details). The
shaft bushings (item 29) can be removed by placing
a large socket between the two bushings. Place an
extension into the socket from one side of the center
section. Tap with a rubber mallet to remove the
bushing. Repeat for the remaining bushing.
21
Shaft, Bushing, & O-ring Replacement
• Follow steps 1 – 7 in the Wet End Servicing disassembly section to access the shaft bushing (item 29) and o-rings (items
28 & 30).
16 Place the valve balls (item 17) on the valve
seats and discharge manifold (item 39) atop the
components that are stacked on top of the liquid
chambers. Install, tighten and torque the (8)
manifold bots & washers (items 11 & 12).
16

17
3Use the supplied grease packets to lightly grease
the OD and ID o-rings (items 28 & 30) that come
preinstalled in the new shaft bushings supplied in air
end kits.
3
4Insert both bushings into the center section.
Ensure the bushing is fully installed and the large
rib on the outside of the bushing is flat against the
center section.
4
5Inspect the shaft (item 32) for damage. It is
common for shafts to become grooved during
service. Grooving is normally caused by carbonized
oil and/or abrasive foreign material getting trapped
between the seal and the shaft. Over time, deep
grooves can form in the shaft. When that occurs, it
is recommended that the shaft be replaced.
5
6After determining if the condition of the shaft
is acceptable, ensure both center section o-rings
(items 33 & 34) are in place on both sides of the
center section.
6

18
7Install both air chambers (item 26) by placing
one side on top of the center section (item 35).
Ensure the air path hole of the center section lines
up with the through hole in the air chamber. Insert
the bolts & washers (items 24 & 25) through the air
chamber and center section.
7
1Plastic Air Valve - To replace the valve cap
o-ring remove the retaining ring (item 8), than
unthread the valve cap (item 6) using an 8mm hex
wrench.
1Aluminum Air Valve - To replace the valve cap
o-rings (item 5), remove the (3) button head cap
screws (item 7) using a 5mm hex wrench. Repeat
for the remaining cap.
1
• To rebuild the rest of the pump, follow steps 5 – 16 in the Wet End Servicing – Wet End Reassembly section.
Air Valve O-Ring Replacement
1
8Flip the components over and place the remain-
ing air chamber on the center section. Thread the
nuts & washers onto the bolts (items 24, 25 & 40).
Tighten and torque the fasteners.
8

19
2Plastic Air Valve - Remove and replace o-ring
(item 5). Install cap (item 6) and tighten until groove
for the retaining ring is visible. Install retaining ring
(item 8).
2Aluminum Air Valve - Remove and replace
o-ring (item 5). Install cap (item 6), tighten, and
torque the valve cap screws (item 7). Repeat for the
remaining cap.
22
Valve and Muffler Gasket Replacement
1Remove the valve body (item 3) by removing the
(4) socket head cap screws & lock washers (items
1 & 2) that attach the valve body to the muffler plate
(item 38) with a 6mm hex wrench.
2Pull the valve body and gasket (items 3 & 36)
off the front of the center section (item 35) and the
muffler plate gasket, muffler plate and muffler (items
37, 38 & 41) off the back.
2
1

20
3Place the new gasket (item 36) on the air valve (item 3) and ensure the slots in the gasket align with the slots in the air
valve and valve plate (item 10).
Air Valve Slide, Plate & Gasket Orientation: If the valve plate (item 10) and slide valve (item 9) are removed, ensure they
are installed in the proper orientation. The flat face of the slide valve sits in the pocket of the valve carrier (item 4) so that the
square cut out on the slide valve faces the smooth polished side of the valve plate.
3 33
6Tighten and torque the (4) cap
screws into the muffler plate.
5Place the muffler gasket (item 37)
over the (4) cap screws & lock wash-
ers (items 1 & 2) on the back side of
the center section (item 35) followed
by the muffler plate and muffler (items
38 & 41).
4Insert the (4) cap screws (item
1) through the valve body and gasket
(items 3 & 36) and place onto the center
section (item 35). Ensure the slide valve
and valve plate (items 9 & 10) are in
place and the valve sits flat on the center
section.
5
46