Warren rupp HDB1, Service And Operating Manual

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hdb15dl6sm-REV0208 Models HDB1½-A, HDB40-A Page 5
To re-install the sleeve and spool set, lightly lubricate the o-rings on the sleeve
with an o-ring assembly lubricant or lightweight oil (such as 10 wt. air line lubricant).
Re-install one end cap, gasket and bumper on the valve body. Using the arbor press
or bench vise that was used in disassembly, carefully press the sleeve back into the
valve body, without shearing the o-rings. You may have to clean the surfaces of the
valve body where the end caps mount. Material may remain from the old gasket. Old
material not cleaned from this area may cause air leakage after reassembly. Take care
that the bumper stays in place allowing the sleeve to press in all the way. Re-install
the spool, the opposite end cap, gasket and bumper on the valve body. After inspect-
ing and cleaning the gasket surfaces on the valve body and intermediate, re-install
the valve body on the pump using new gaskets. Tighten the four hex head capscrews
evenly and in an alternating cross pattern.
PILOT VALVE
The pilot valve assembly is accessed by removing the main air distribution valve
body from the pump and lifting the pilot valve body out of the intermediate housing.
Most problems with the pilot valve can be corrected by replacing the o-rings.
Always grease the spool prior to inserting it into the sleeve. If the sleeve is removed
from the body, reinsertion must be at the chamfered side. Grease the o-rings to slide
the sleeve into the valve body. Securely insert the retaining ring around the sleeve.
When reinserting the pilot valve, push both plungers (see #40 on drawing), located
inside the intermediate bracket, out of the path of the pilot valve spool ends to avoid
damage.
PILOT VALVE ACTUATOR
The bushings (no. 37) for the pilot valve actuators threaded into the intermediate
bracket (no. 17) from the outside. The plunger (no. 40) may be removed for inspection
or replacement from the inside by removing the air distribution valve body (no. 5) and
the pilot valve body (no. 34) from the pump. The plungers (no. 40) should be visible
as you look down into the intermediate from the top. Depending on their position, you
may find it necessary to use a fine piece of wire to pull them out.
Under rare circumstances, it may become necessary to replace the o-ring seal
(no. 41). If it cannot be removed in much the same manner as the plunger (no. 40), the
bushing (no. 37) can be turned out through the inner chamber (no. 12) by removing
the manifold assembly (no. 31) and the outer chamber (no. 22) to reach the bushing
(no. 37).