ITW BINKS Maple 60 User manual

Instruction Manual
For
Maple 60 - Pump
Model 104020

Instruction Manual
Page 2 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
EU Declaration of Conformity
We: ITW Automotive Finishing declare that the above product conforms with the Provisions
of Machinery Directive 98/37/EC and the ATEX Directive 94/9/EC by complying with the
following statutory documents and harmonized standards: -
Machinery Safety Standards BS EN ISO 12100 Part 1 and 2
Explosion Prevention Potentially Explosive Atmospheres BS EN 1127-1:2007
Non-electrical Equipment for Potentially Explosive Atmospheres BS EN 13463-1 2009
Constructional Safety for Potentially Explosive Atmospheres BS EN 13463-5 2005
Providing all conditions of safe use stated within the product manuals have been complied
with and that the final equipment into which this product is installed has been re-assessed
as required, in accordance with essential health and safety requirements of the above
standards, directives and statutory instruments and also installed in accordance with any
applicable local codes of practice.
H Beiersdorfer (General Manager)
8
th
March 2010
Note: Read and follow all instructions and safety precautions before using this equipment
Product Description
104020 – Maple 60 Pneumatic Pump
This equipment is designed for use with Solvent based and Waterborne materials.
Suitable for use in Zone 1 and 2, Protection Level: II 2 G X
Manufacturer: - ITW Automotive Finishing
Justus-von-Liebig-Straße 31,
63128 Dietzenbach. DE

Instruction Manual
Page 3 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Index
Section
1.1 General Description
1.2 Operating Principle
1.3 Specifications
1.4 Dimensions and Mounting Details
2.1 Important Safety Information
3.1 Installation - General
4.1 Parts Lists Main Pump
4.2 Parts Lists Air Motor
4.3 Parts Lists Fluid Section
4.4 Parts Lists Reference
5.1 Maintenance – Air Motor Assembly Procedure
5.2 Maintenance – Fluid Section Assembly
5.3 Maintenance – Final Pump Assembly
6.1 Maintenance - General
6.2 Maintenance - Fault Finding
7.1 Spare Parts Lists
7.2 Accessories

Instruction Manual
Page 4 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
General Description – Section 1.1
High Quality materials and surface treatments are used in the construction of this pump to
ensure both extended operational life and good future appearance.
The Maple pump is a horizontal piston pump for pumping Solvent / Waterborne Paints,
Solvents and other suitable materials.
An Ø230 x 60mm stroke air motor is used to drive two fluid sections giving a combined
output of 1.5 L per cycle.
The unit combines an energy efficient air motor with low shear fluid section technology from
the range of Smart Electric Pumps.
The Maple Pump achieves a reciprocating drive by using high technology ground and
lapped steel spool and sleeve air valves to control the air motor reversal, providing
reciprocating motion.
The air valve design (patent pending) ensures a positive magnetic detent for the main and
pilot air valves thus removing the possibility for a stall condition.
The air motor also utilises the Binks Low Ice quick exhaust technology to prevent air valve
freezing conditions when high cycle speeds are employed.
Equal thrust on each stroke due to the horizontal configuration incorporating the dual piston
rod design gives a balanced fluid pressure output and reduces fluid pressure fluctuations to
a minimum.
The air pump is furnished with twin exhaust mufflers to control exhaust noise emission. An
adapter kit is available to facilitate connection to a piped exhaust system if required.
A 1/8” Port is incorporated into the main air valve to facilitate an optional cycle counter.
Complies with current relevant European and US Legislation

Instruction Manual
Page 5 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Operating Principle – Section 1.2
The Assembly comprises of:-
•Central Air Piston and ‘change over’ Valves
•2 off Quick Exhaust and muffler assembly
•2 off Dynamic Chambers and Fluid Pistons
•2 off Fluid Pressure Chambers each complete with Suction
and Pressure Ball Check Valve Assemblies
•1 off Fluid Inlet Manifold
•1 off Fluid Outlet Manifold
•Support Bracket
The Pumps have horizontally opposed positive displacement pistons connected to a
common reciprocating air motor piston. The pneumatically driven piston actuates pilot air
control valves at the end of its travel producing an air logic signal to shuttle the spool valve
initiating the opposite stroke.
The air pilot valves contain no springs. They are operated by magnetic force and reset by
the main piston air supply and retained in position by a magnetic detent. The main spool
valve is air piloted and contains two exhaust ports. Both the pilot valves and the main spool
valve are easily removable.
There are no external air pilot hoses. The air logic and exhaust ports are internal. Simply
mounting the spool valve and the pilot valves assures that the logic circuits are connected
properly.
The air cylinder exhaust air is channelled through two independent quick exhaust valves to
minimises piston reversal time.
The “4-Ball” fluid section design refers to the two sets of ball checks. Each fluid chamber
has an inlet and outlet ball check, the inlet check is uniquely positioned in the piston saving
space and reducing the overall weight of the pump. The inlet and outlet ball checks are
connected by a common inlet manifold and outlet manifold respectively.
A bellows provides the fluid seal on the connecting rod within the inlet chamber, whilst a
main piston seal maintains the pump fluid pressure within the pressure chamber.
When the main piston seal starts to pass fluid due to wear, any leakage passes into the
inlet chamber.

Instruction Manual
Page 6 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Specification – Section 1.3
Specification
Pump Nominal Stroke 60 mm
2.36 ins
Pump Ratio 3:1
Nominal Flow Volume / Cycle 1.5 Litres
0.40 US Gall
Fluid Output @ 60 cycles/min
90.0 Litres / min 24.0 US Gall / min
Maximum Recommended Continuous Cycle Rate
Maximum Recommended Intermittent Cycle Rate 20 Cycles /min 40 Cycles /min
Fluid Inlet / Outlet Connections 1 1/2” Sanitary
Air Volume / cycle 0.7 SCFM (19.8 L/m) @ 45PSI (3.1 Bar)
1.4 SCFM (39.7 L/m) @ 90 PSI (6.2 Bar)
Air Flow @ 15 cycles/min 6 bar
Air Flow @ 30 cycles/min 6 bar 21 CFM (595 L/min) 42 CFM (1190 L/min)
Air Quality ISO 8573.1 Class 3.3.2
Dirt 5 microns
Water -20ºC@7bar (940ppm)
Oil 0.1mg/m³
Total Weight of Pump 65.5 Kg
144.5 Lb

Instruction Manual
Page 7 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Dimensions and Mounting Details – Section 1.4
For Piped Exhaust Air, remove mufflers and add 192803 Plug and
Hose Adapter 192779 for 1” NB Hose or 192820 for 1 ¼” NB Hose.
Note: For Pump fluid pressures above 13 bar use 1 ¼” NB
Alternate Mounting

Instruction Manual
Page 8 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Important Safety Information - Section 2.1
Directions for Working Safety
This Product has been constructed according to advanced technological standards and is operationally reliable. Damage may, however,
result if it is used incorrectly by untrained persons or used for purposes other than those for which it was constructed.
The locally current regulations for safety and prevention of accidents are valid for the operation of this product under all circumstances.
International, national and company safety regulations are to be observed for the installation and operation of this product, as well as the
procedures involved in maintenance, repairs and cleaning.
These instructions are intended to be read, understood and observed in all points by those responsible for this product. These operating
and maintenance instructions are intended to ensure trouble free operation. Therefore, it is recommended to read these instructions
carefully before start-up. ITW Automotive Finishing cannot be held responsible for damage or malfunctions resulting from the non-
observance of the operating instructions. These instructions including regulations and technical drawings may not be copied, distributed,
used for commercial purposes or given to others either in full or in part without the consent of ITW Ltd.
We reserve the right to alter drawings and specifications necessary for the technical improvement of this product without notice.
High Pressure/Electrostatic Warning
High pressure equipment can be dangerous if used incorrectly, serious bodily injury may occur if the following instructions are ignored.
Installation and maintenance should only be carried out by suitably qualified personnel.
1. Before attempting any work on a high-pressure system ensure material pump, hydraulics, compressed air motor are isolated where
relevant.
2. Relieve all pressure from the system. Note: It is possible for pressure to get locked into a system, therefore, ensure all sections of
the system are checked thoroughly for remaining pressure.
3. Take care when releasing fittings
4. Always replace worn hoses immediately
5. Never plug a leak with your finger, adhesive tape or other stop gap devices
Always ensure equipment is suitably earthed before running, to avoid any chance of electrostatic build up.
Equipment Misuse Hazard
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
•This equipment is for professional use only.
•Read all instruction manuals, tags, and labels before operating the equipment.
•Use the equipment only for its intended purpose.
•Do not alter or modify this equipment. Use only genuine ITW parts and accessories.
•Check equipment daily. Repair or replace worn or damaged parts immediately.
•Do not exceed the maximum working pressure stated on the equipment or in the Technical Data for your equipment. Do not
exceed the maximum working pressure of the lowest rated component in your system.
•Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical Data section of all
equipment manuals. Read the fluid and solvent manufacturer’s warnings.
•Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose hoses to temperatures
above 82°C (180°F) or below —40°C (—40°F).
•Wear hearing protection when operating this equipment.
•Do not lift pressurized equipment.
•Comply with all applicable local, state, and national fire, electrical, and safety regulations.

Instruction Manual
Page 9 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Important Safety Information - Section 2.1
Fire, Explosion and Electric Shock Hazard
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a fire, explosion, or electric
shock.
When installed and operated in accordance with its instructions, the pump is approved for operation in Zone 1 (Europe) & Division 1
(North America), hazardous locations. (ATEX Cat 2)
•Electrical equipment must be installed, operated, and serviced only by trained, qualified personnel who fully understand the
requirements stated in this instruction manual.
•Ground the equipment and all other electrically conductive objects in the spray area. After grounding test with ohmmeter to
ensure earth continuity is 1 ohm or less.
•Keep all covers tight while the motor is energized.
•If there is any static sparking or you feel an electric shock while using this equipment, stop spraying/dispensing immediately. Do
not use the equipment until you identify and correct the problem.
•Provide fresh air ventilation to avoid the build up of flammable fumes from solvents or the fluid being pumped.
•Keep the pumping area free of debris, including solvent, rags, and gasoline.
•Electrically disconnect all equipment in the pumping area.
•Extinguish all open flames or pilot lights in the spray/dispense area.
•Do not smoke in the spray/dispense area.
•Do not turn on or off any light switch in the spray/dispense area while operating or if fumes are present.
•Do not operate a gasoline engine in the spray/dispense area.
Hot Surface Hazard
•The electric motor becomes hot during operation, and the heat may be transferred to other connected equipment. To reduce
the risk of burning yourself, do not touch the motor surfaces while it is operating.
Before servicing, allow the motor to cool.
•Keep flammable materials and debris away from the equipment.
Pressurized Equipment Hazard
Spray from the gun/valve, hose leaks, or ruptured components can splash fluid in the eyes or on the skin and cause serious injury.
•Do not point the gun/valve at anyone or at any part of the body.
•Do not stop or deflect leaks with your hand, body, glove or rag.
•Spraying/dispensing; clean, check, or service the equipment.
•Tighten all fluid connections before operating the equipment.
•Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately. Permanently coupled hoses
cannot be repaired; replace the entire hose.
Toxic Fluid Hazard
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed.
•Know the specific hazards of the fluid you are using.
•Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.
•Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.
Moving Parts Hazard
•Keep clear of all moving parts when starting or operating the pump.
.

Instruction Manual
Page 10 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Installation – Section 3.1
Mount the pump securely and position the pump at a convenient height (below the lid
height of the paint container), to allow for maintenance, visual observation, and periodic
inspection.
The wall mount bracket are included with all pumps but can be repositioned to be foot
mounted.
Exhaust silencer kits are available for these pumps if the air exhaust is required to be piped
away from the pump rather than exhausting locally through the mufflers.
The Pump Mounting Frame must be connected to a suitable earth ground to ensure that
there is no possibility of static build up.
Attach suitable flexible hoses (20 bar working pressure) to the inlet and outlet connections.
e.g. 38 mm NB Inlet and 38 mm NB Outlet hose.
Connect a suitable 3/8 NB air hose and ½” Pressure Filter Regulator to the air motor. (Filter
rated at minimum 1000 L/min)
No additional air lubrication is required as piston o-ring lubricant is applied during assembly
or repair. If an air lubricator is used to prolong piston seal life (for example continuous duty
at high pump cycle rates) then this must be maintained as the lubricant removes the piston
seal assembly grease.
Set the pump speed to a slow cycle rate and start the pump to remove any air from the fluid
circuit. Inspect for any air or fluid leaks.
Set the pump cycle rate to achieve the required paint volume and then adjust the system
back pressure regulator and pump air pressure to achieve the desired system fluid
pressure.
A Back Pressure Regulator should be mounted in the paint system return line.
The return line ‘back pressure’ regulator responds to the changes in system fluid flow
demand, (due to variable paint usage) by dynamically adjusting the paint flow rate returning
to the system paint tank, thus maintaining the set pressure.

Instruction Manual
Page 11 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Parts List – Section 4.1
Parts List - 104020 Main Pump Assembly
ITEM PART No DESCRIPTION QTY REMARKS
1 ------ AIR MOTOR ASSEMBLY 1
2 ------ FLUID SECTION ASSEMBLY 2
90 192821 MUFFLER 2
91 192008 1.5 SANITARY GASKET PTFE 4 
92 192009 1 & 1 1/2 SANITARY CLAMP 4
93 192895 INLET MANIFOLD 1
94 192896 OUTLET MANIFOLD 1

Instruction Manual
Page 12 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Parts List - Air Motor Assembly
ITEM PART No DESCRIPTION QTY REMARKS
3 161993 20.4 X 1.78 VITON O-RING 2 
4 161994 Ø4.47 x 1.78 VITON O-RING 4 
5 162728 Ø230 PISTON SEAL 1 
6 162729 25 X 35 X 8 SHAFT SEAL 2 
7 162730 SHAFT BEARING 2

8 162731 Ø230 VITON O-RING 2 
9 165108 M8 SPRING WASHER (ST ST) 18
10 165123 M10 SPRING WASHER (ST ST) 4
11 165963 M8 HEX NUT 18
12 165965 M10 x 16 HEX HEAD SET SCREW (STST) 4
13 165975 M16 x 60 GRUBSCREW STST 1
14 165977 M8 x 90 CAP HD SCREW (ST ST) 2
15 192147 LABEL 1
16 192765 PILOT SPOOL ASSEMBLY 2 
17 192814 BELLOWS LEAK DETECTION HOSE 1 
18 192815 1/8R - 6MM PUSH IN ELBOW 2
19 192881 KNIFED BELLOWS 2

20 192882 SHAFT 2
21 192883 CYLINDER 1
22 192884 END PLATE (LH) 1
23 192885 END PLATE (RH) 1
24 192886 AIR PISTON 1
25 192887 BELLOWS NUT 2
26 192888 BELLOWS SPACER 2
27 192897 MAIN AIR VALVE ASSEMBLY 1
28 192904 EXHAUST MANIFOLD 1
29 192906 PUMP BRACKET 2
30 193094 CYLINDER STUD - SHORT 5
31 193095 CYLINDER STUD LONG 4
32 193115 EXHAUST ADAPTOR 2

Instruction Manual
Page 13 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Parts List – Section 4.2 Air Motor Assembly

Instruction Manual
Page 14 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Parts List – Section 4.2
Parts List - 192897 Main Air Valve Assembly
ITEM PART No DESCRIPTION QTY REMARKS
40 162732 Ø69 x 3 - 'O' RING 2 
41 0115-010426 Ø30 x 2 - 'O' RING 2 
42 163951 M6 x 16 SOCKET HEAD SETSCREW 12
43 191242 DIAPHRAGM 2
44 192651 1/8" BSPP PLUG 2
45 192899 MAIN VALVE BODY ASSY 1
46 192905 EXHAUST PLATE 1
47 193132 QEV CARTRIDGE ASSEMBLY 2
48 193096 1/2"BSP AIR INLET 1
49 0115-010425 VALVE BLOCK END CAP 1
50 0115-010431 SPACER 2
51 0115-010427 VALVE BUMPER 2
52 0115-010428 MAGNET 2 
53 0115-010424 SPOOL VALVE 1 

Instruction Manual
Page 15 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Parts List – Section 4.2
192897 Main Air Valve Assembly

Instruction Manual
Page 16 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Parts List – Section 4.3
Parts List – Fluid Section
ITEM PART No DESCRIPTION QTY REMARKS
60 160513 SPRING 2

61 163920 M6 x 30 CAP HD SCREW (ST ST) 5 
62 164472 M8 x 25 CAP HD SCREW (ST ST) 4
63 165077 M14 WASHER (ST ST) 8
64 165108 M8 SPRING WASHER (ST ST) 4
65 165978 M14 x 40 CAP HD SCREW (ST ST) 8
66 171784 1.750 ST ST BALL 1 
67 171788 1.375 ST ST BALL 1 
68 192551 HEXAGON PLUG - 1/4 BSP 1 
69 192595 OUTLET CHECK 1
70 192626 OUTLET CAGE 1
71 192629 INLET SPRING KEEP 2 
72 192631 INLET BALL SEAT 1 
73 192632 OUTLET BALLSEAT 1 
74 192646 Ø50.5 x 1.78 O-Ring 1 
75 192647 Ø50.5 x 2.62 O-Ring 1 
76 192648 Ø41.0 x 1.78 O-Ring 1 
77 192889 FLUID PISTON SEAL 1 
78 192891 Ø128 PISTON 1
79 192892 OUTLET CYLINDER 1
80 192893 INLET CYLINDER 1
81 192894 Ø128 PISTON KEEP PLATE 1
82 192505 Ø12.42 O-Ring 1 

Instruction Manual
Page 18 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Parts List – Section 4.4
For Reference Only
The Pilot Spool (16) is available as a completed and tested assembly; the drawing
below is for reference and identification only.
If the pilot spool is removed from the air motor for inspection it is recommended that
the 3 off O-ring seals (H) are replaced and lightly greased.
Spare Pilot Valves are fitted with the 3 off O-ring 192773.
ITEM PART No DESCRIPTION QTY REMARKS
H 192773 Ø17 O-RING 3 
When the valve is removed from
the air motor protect the magnet
from any form of contamination.
(Metallic particles are strongly
attracted to the magnet)

Instruction Manual
Page 19 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Maintenance – Section 5.1 - Assembly Procedure
Pump Assembly – Air Motor
Ensure all parts are clean and degreased.
1. Push bearings (7) into end plates (22 & 23) and insert ‘O’ rings (8) into the large
grooves, applying a light coating of grease type #.
2. Apply light coating of grease type # to the seal groove of the piston (24) and insert the
‘O’ ring portion of the piston seal (5), apply a little more grease to the top of the ‘O’ ring.
Carefully fit the seal strip into the piston groove (fit one half of the seal into the groove
and then apply pressure to the o-ring seal already in the groove, and pull the remaining
seal into the groove, being careful to avoid unduly stretching the seal strip).
3. Insert grub screw (13) into one of the piston shafts (20) use Loctite studlock 2701 and
tighten to 50Nm. Mount this through the piston (24) and screw on the other shaft (20)
again using Loctite studlock 2701 and tighten to 100Nm. Clean off any residue of
Loctite.
4. Lightly apply grease type # to the inside of the air motor cylinder (21), insert the piston
and shaft sub-assembly into the cylinder at a 45° angle and turn the piston until it is
inline with the cylinder.
5. Insert the cylinder end plate sub-assemblies over lightly greased # shafts and into the
cylinder. Press parts lightly together, making sure that the Main Valve (27) mounting
surfaces are inline.
6. Insert 5 off short tie rods(30) and 4off long tie rods(31) through the end plates. Fit 18 off
washers (9) over the ends of the tie rods. Apply Loctite 243 to the LH end of the tie rods
and add grease type # to the other end. Fit domed nuts (11) onto the LH loctited end
and screw on as far as possible, screw on the remaining domed nuts and tighten in
‘cross over’ sequence together to 22Nm.
7. Apply grease type # onto the shafts and gently push over the shaft seal (6), lips pointing
inwards (Use Tool 502679 – or use tape to cover the grooves to allow seal to be pushed
over), push the seal fully home into the end plate. Then fit the bellows retainer (26) over
the shafts, smaller hole facing inwards.
8. Screw assembly tool (502681) onto the piston shaft (20). Using tool (502682) push the
bellows (19) over the assembly tool until the bellows internal spigot locates into the shaft
groove. (Using the tool prevents damage to the convolutions)
9. Smear a film of loctite 572 over the nose of the bellows then thread the
nut (25) onto the bellows using tool (502682) to push against the nut
ensuring the thread starts squarely. Grip the bellows and turn the nut
with a 32 A/F spanner until positive resistance is felt. The distance
between the nut and the first convolution should be 0 to 1mm.
10. Remove assembly tool (502681).
11.Fit mounting brackets (29) to the end plates using 4off M10 cap head screws (12) and
washers (10) tighten to 40Nm. Use Loctite 243 on threads.
12.Install elbows (18) to the end plates, with hose (17).
13.Lightly grease # threads and o-rings of pilot valves (16) and carefully screw into the end
plates. Tighten to 8Nm (do not over tighten).

Instruction Manual
Page 20 of 28 Issue: 1.2
\\Argon\automotive_ftp\Manuals\Word Original\Pump Unit Maple 60 R1.2.docx
Maintenance – Section 5.1 - Assembly Procedure
Pump Assembly – Air Motor – Control Valve 192897
Main Valve (27) & exhaust manifold (28):-
1. Ensure all parts are free from
contamination especially the magnets
(52)
2. Lightly grease valve bore of housing (45)
and O-rings of spool assembly (53) Use
grease type #
3. Carefully insert the spool assembly into
the housing until centrally positioned.
4. Insert spacers (50) & bumpers (51) into
each end of the spool housing.
5. Insert magnets (52) into end cap (49)
then fit O-ring (41) lubricate with grease
type # and assemble into housing.
6. Position diaphragm (43) into QEV
cartridge (47) and fit into housing
(ensure transfer holes are inline &
ensure diaphragm is centrally located)
7. Fit exhaust plate (46) to manifold (28) with 6 off screws (42) using Loctite 222, tighten to
12Nm.
8. Fit 2 off O-rings (40) around QEV cartridges and fit the exhaust plate and manifold over
the QEV cartridges. Secure with 6 off screws (42) using Loctite 222, tighten to 12Nm.
9. Fit plug (44) is in position.
Assembly of Main Valve to Air Motor
1. Fit 2 off O-rings (3) and 4off O-rings (4) into air motor end plates (22)(23)
2. Lightly grease # 2 off cap head screws (14) and fit main valve assembly (27) onto the
end plates, tighten to 18Nm
3. Fit 2 off exhaust muffler (90) into 2 off exhaust adaptors (32)