To service an Imperial® Diaphragm Manifold you will need the following tools:

• Imperial Overhaul Hit 600R
• Adjustable Wrench
• Clean Crease (Optional)
• Torque Wrench
• Long Nose Pliers
• Clean Rags
• Methylated Spirits or Rubbing Alcohol

Safety is important

• Ensure work area is clean and well lit
• Ensure there are no hazards or obstructions
• Ensure you have safety glasses and put them on NOW
• Check the manifold is not damaged
• Check gauges are tight
• Ensure the sightless (if fitted) has no damage.

Step 1 – Remove the handles

• Using long-nose pliers gently prise off the knobs and place them in a safe convenient location
• Check for any damage and replace if cracked

Step 2 – Remove Piston Assemblies

• Remove all large brass nuts from the manifold
• Gently pierce the large white diaphragm and remove it
• Remove the spring and piston which is now removed

Step 3 – Remove All Components from Manifold

• Your manifold should now be looking like this.
• Check inside the cutout for the diaphragm seals, ensure there are not scratches or damage inside where the valve seats

Step 4 – Clean Valve Seat

• Using a lint-free rag soaked in methylated spirits (or rubbing alcohol) clean the valve seat assembly
• Leave to dry and ensure all alcohol has evaporated

Step 5 – Clean Brass Components

• Next, disassemble the piston assembly and seal
• Using a lint-free cloth soaked in a little alcohol clean all the brass components
• Do this for all remaining piston assemblies
• Using light crease lubricate the thread of the piston. Do this for all remaining pistons
• You should end up with all pistons cleaned, brass nuts clean and all parts ready for assembly

Step 6 – Open the Repair Kit

• Open the 600R kit and remove the components
• Divide into 2, each kit does 2 valves
• You should have
  – 2 Diaphragms (1 Thick 1 Thin)
  – A Brass Spacer
  – A Spring
  – A Small Nylon Spring Cap

Step 7 – Start Re-Assembly

• Place the Spring (Large End Down) into the receptacle in the valve seat
• Place spring cap on top

Step 8 – Valve Assembly

• (Optional) Place a small amount of grease onto the edge of 1 face of the thick seal. Place Grease side down into the housing.

Step 9 – Valve Re-assembly

• Place the thin seal into the receptacle
• Place the spacer on top of this

• Next, lightly grease screw thread of piston and insert into large brass nut

• Ensure piston is fully restricted into the brass nut
• Place assembly into valve seat and gently hand tighten the large nut

• Tighten brass nut to 125 inch-pounds with a torque wrench
• Repeat seal and piston installation and torque all remaining valve port assemblies
• Check torque again after 24 hours

Last Step – Complete Re-Assembly

• Finally, replace all knobs back onto piston shafts
• Gently tighten fully and then loosen pistons
• Perform cleanup of any excess grease