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Disassembling Valve Block
1. Remove the two hex head screws from the front of the muffler and remove the muffler from the side of the powerhead.
2. Remove the air line from the side of the valve block.
3. Remove the valve block from the side of the powerhead by removing
the screws.
4. Remove the two end caps from the valve block.
5. Remove the pipe plug from the side of the lower valve block.
6. Rotate either the two valve pistons until the hole in the valve poppet
aligns with the pipe plug port in the lower valve block.
7. Insert a hex wrench through the pipe plug port and into the hole in the
valve poppet.
8. Unscrew the valve pistons while the hex wrench holds the poppet in
place.
9. Using an open-end wrench, remove the two hex cap screws from the
front of the lower valve block.
10. Twist and pull the upper valve block from the lower valve block.
11. Remove the valve rod assembly from the valve block.
12. Remove the two cap screws from each of the valve exhausts and pull the valve exhausts off the valve blocks.
13. Use a screwdriver to push the center riser on each diaphragm to one side then remove the diaphragm from each of the valve blocks.
14. Remove each O-ring and replace with a new one, coating each new O-ring with brown
grease.
15. Coat the diaphragm bore and both valve piston bores with brown grease.
16. Use a wire brush to clean the valve rod threads of any dry thread locking compound.


Reassembling Valve Block
1. Apply one to two drops of removable thread locking compound to
the threads of the valve poppet and reassemble.
2. Push the valve piston all the way into the lower valve block.
3. Apply a small amount of removable thread locking compound to
the threads on one end of the valve poppet and thread it into the valve piston in the lower block while holding the valve piston in place.
4. Turn the valve poppet in the lower
valve block so that the hole in the poppet body is aligned with the side port.
5. Insert a hex wrench through the side port and into the hole in
the valve poppet to hold it in place, then use a socket wrench to
tighten the valve poppet into the valve piston; do not overtighten.
6. Apply a small amount of removable thread locking compound to the threads on the other end of the valve poppet.
7. Apply some brown grease to the O-ring that goes on the upper valve block, then push the upper valve block into the lower valve block and over the valve poppet.
8. Insert the hex wrench back through the side port and into the valve poppet and hold it in place, then tighten the other piston; do
not overtighten.
9. Install the two hex bolts to hold the lower valve block to the upper valve block.
10. Use Teflon tape or pipe seal compound on the threads of the pipe plug and install it into the side port of the lower valve block.
11. Insert the diaphragms into the upper and lower valve blocks with the
outside leading edge facing out, then push them all the way down into the
valve block bore.
12. Install the valve exhausts onto the upper and lower valve blocks using
socket head cap screws.
13. Install the valve end caps into the upper and lower valve blocks and lightly snug.
14. Connect the air line on the side of the valve block.