4. MAINTENANCE (Fig. 6)
Before carrying out any maintenance on the system ensure:
➢You are wearing appropriate PPE, including eye and skin protection.
➢The Vacuum Tap (I) is closed.
➢System pressure is released by depressing an Applicator Trigger (Fig. 5 U) until flow slows to a
minimum.
➢The Outlet Plug (W) on the Outlet Tee (C) is removed (catch any chemical which flows from the port
in a suitable container).
DIRECTIONAL VALVE / DV (ATS/425 –Fig. 8) is located at the top left of the power unit
(Fig. 2, 7).
REMOVAL/INSTALLATION (Fig. 7):Most maintenance can be carried out with the valve in place. If
complete removal is required, grasp the 3-port rubber valve manifold, and gently pull away from the valve.
Remove the two screws on the back of the power unit. To refit, reverse the operation.
VALVE FILTER (ATS/444): Replace every 1000 hours or sooner if heavily contaminated. Manually release
the valve filter cover clips by levering with fingers (Fig. 8). Carefully remove valve filter taking care not to
drop dust into the working parts. Fit new valve filter by reversing the process.
BLEED VALVE INSERT (ATS/447): Clean every 1000 hours, or sooner if heavily contaminated. Pull insert
out of main body taking care not to dislodge the 4 ‘O’ rings in the two small holes near the end (Fig. 8).
Inspect the holes to make sure that they are clear and use the strand of wire attached to the bleed insert to
remove any debris.
DIAPHRAGM ASSEMBLY (ATS/443): Replace every 3000 hours. First remove the valve filter (see
above). Remove the spring (ATS/442) and pull the drive box in the direction of the arrow (Fig. 8) using
pliers on the lug. Unscrew the large black ring nut and gently prise off the black cap, using a screwdriver in
the slot provided. Pull out the rubber diaphragm by grasping the outer rim. Re-fit the diaphragm assembly
(ATS/443), taking care not to remove the lubricant on the shaft. If the spring (ATS/442) shows any signs of
corrosion, replace it. Fit a new diaphragm assembly by reversing the operation, ensuring that the semi-
circular extrusion engages in the recess of the main body. When replacing the drive box, push hard until a
click is heard, indicating proper engagement. Prior to fitting the filter and cover, push the drive box from one
end of the directional valve to the other and back. An audible click should be heard, indicating that the drive
box has been fitted correctly and that it is functioning properly.
DIAPHRAGM PUMP (AOFL/2004-V –Fig. 9) is located on the right of the power unit (Fig. 2, 7).
REMOVAL/INSTALLATION (Fig. 7):Unscrew the Inlet Elbow (B) and the Outlet Tee (C). Remove the
four screws on the back of the power unit. Disconnect the fittings from both Manifolds (X). To refit, reverse
the process ensuring the directional arrows on the Manifolds (X) are in the position as shown.
NON-RETURN VALVES (AOFL/4446 –Fig. 9): Regular inspection of the Intake Filter (K–Fig. 1), and
ensuring that both your chemical and the container are kept free of debris, should ensure the valves remain
operational without maintenance. If debris does block the valve(s), the flow rate will be reduced or stop
completely. As a first port of call, remove the Outlet Plug (W–Fig. 6) and try to pump some warm, mild
detergent through the pump. The pump should dispense an equal amount of liquid per click from the DV.
If necessary, the valves can be disassembled as shown in Figure 9. Pay attention to the orientation of the
valves and the Manifold (X) directional arrows. Any debris can then be removed and/or the valves replaced
using the valve kit AOFL/4446.
PUMP HEAD DIAPHRAGM (ATS/456-V –Fig. 9): Ensuring that you follow the manufacturer’s instructions
for the chemical being used carefully (especially those that require dilution), the pump head diaphragms
remain maintenance free. In the rare event of failure, they can be replaced as shown in Figure 9; there is
no need to remove the manifold/non-return valves. Note the position of the Pump Heads (Y) relative to the
Pump Housing (Z) then carefully unscrew them anti-clockwise. To remove the diaphragm(s) hold the
rubber tightly by hand and unscrew anti-clockwise. To refit, reverse the process. If one diaphragm fails,
then we recommend changing both diaphragms at the same time as part of the general service.
