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Instruction Manual
D200158X012
4194S Controllers
July 2018
52
Disassembly
1. Perform steps 1 through 3 of the replacing case and cover procedure.
2. Remove the auto/manual station from the controller frame as described in steps 1 through 4 of the Replacing the
Auto/Manual Station procedure.
3. Loosen the two screws (key 288) and remove the lever cover plate (key 305).
WARNING
The lever spring (key 302) is under preload. To avoid personal injury or losing parts, carefully disassemble the auto/manual
station.
4. Using a 1.5 mm (0.0625 inch) punch, push the groove pin (key 303) out toward the surface of the lever cover plate.
5. Remove the switch lever (key 304), lever spring (key 302), and lever spring seat (key 301).
6. Remove the tubing assembly (key 309).
WARNING
The switch body springs (key 295) are under preload. To avoid personal injury or losing parts, carefully separate the switch
body assembly from the loader assembly.
7. Loosen the two screws (key 290), and separate the switch body assembly (key 291) from the loader assembly
(key 282).
8. Remove the O‐rings (keys 292, 293, and 294), switch body springs (key 295), and balls (key 296).
9. Loosen two screws (key 308), and remove the closing plate (key 307) and the closing plate gasket (key 306).
10. Pull the clip (key 300) from its engagement with the lever assembly shaft (key 297).
11. Pull the lever assembly from the switch body assembly (key 291) and rocker (key 299).
12. Remove the O‐ring (key 298).
13. Inspect the O‐rings and gaskets for damage or wear; replace if necessary.
Assembly
1. Insert the lever assembly (key 297) into the switch body assembly (key 291) and hold the rocker (key 299) with the
flats on the lever assembly shaft.
2. Insert the clip (key 300) in the groove of the lever assembly shaft to hold the lever assembly (key 297) in the switch
body assembly (key 291).
3. Position the closing plate gasket (key 306) and the closing plate (key 307). Secure with two screws (key 308).
Note
After assembly in step 3, be sure the side of the closing plate marked OUT is visible.
4. Place the balls (key 296), switch body springs (key 295), and O‐rings (keys 292, 293, and 294) in the switch body
assembly (key 291).
Note
In the following step, the ends of the springs must be in the counterbored spring seats before compression.