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  3. 3A6782G, SaniForce® Air-Operated High Sanitation Diaphragm Pumps, Models 2150, 3150, 4150, Repair/Parts

Graco 3A6782G, SaniForce® Air-Operated High Sanitation Diaphragm Pumps, Models 2150, 3150, 4150, Repair/Parts, 3A6782F, SaniForce® Air-Operated High Sanitation Diaphragm Pumps, Models 2150, 3150, 4150, Repair/Parts Owner's manual

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Repair/Parts
SaniForce® SaniForce®
SaniForce®Air Air
Air- -
-Operated Operated
OperatedHigh High
High
Sanitation Sanitation
SanitationDiaphragm Diaphragm
DiaphragmPumps, Pumps,
Pumps,Models Models
Models
2150, 2150,
2150,3150, 3150,
3150,4150 4150
4150
3A6782G
EN
For For
Fortransfer transfer
transferof of
ofuids uids
uidsin in
insanitary sanitary
sanitaryapplications. applications.
applications.Not Not
Notapproved approved
approvedfor for
foruse use
usein in
inexplosive explosive
explosiveatmospheres atmospheres
atmospheresor or
or
hazardous hazardous
hazardous(classied) (classied)
(classied)locations locations
locationsunless unless
unlessotherwise otherwise
otherwisestated. stated.
stated.See See
SeeApprovals Approvals
Approvalspage page
pagefor for
formore more
moreinformation. information.
information.For For
For
professional professional
professionaluse use
useonly. only.
only.
Important Important
ImportantSafety Safety
SafetyInstructions Instructions
Instructions
Readallwarningsandinstructionsinthismanualandrelated
manualsbeforeusingtheequipment.Save Save
Saveall all
allinstructions. instructions.
instructions.
120psi(0.8MPa,8bar)MaximumFluid
WorkingPressure
120psi(0.8MPa,8bar)MaximumAir
InputPressure
Seepage6forapprovals.
PROVENQUALITY.LEADINGTECHNOLOGY.
Contents Contents
Contents
RelatedManuals................................................2
Warnings...........................................................3
CongurationNumberMatrix...............................5
OrderingInformation...........................................6
Troubleshooting..................................................7
Repair................................................................9
PressureReliefProcedure............................9
AirValveRepair...........................................9
CheckValveRepair.....................................12
StandardDiaphragmRepair.........................14
OvermoldedDiaphragmRepair.....................16
CenterSectionRepair..................................19
LeakDetectors............................................21
Parts..................................................................22
Diaphragms.................................................29
TechnicalSpecications......................................32
GracoStandardWarranty....................................34
Related Related
RelatedManuals Manuals
Manuals
ManualNumberTitle
3A5999SaniForceHighSanitationDiaphragmPumps,Operation
3A6976LeakDetectionSystem,Instructions/Parts
2
3A6782G
Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-specic
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-specichazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING
FIRE FIRE
FIREAND AND
ANDEXPLOSION EXPLOSION
EXPLOSIONHAZARD HAZARD
HAZARD
Flammablefumes,suchassolvent,inwork work
workarea area
areacanigniteorexplode.Solventowingthrough
theequipmentcancausestaticsparking.Tohelppreventreandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhenammable
fumesarepresent.
•Useonlygroundeduidlines.
•Stop Stop
Stopoperation operation
operationimmediately immediately
immediatelyifstaticsparkingoccursoryoufeelashock.Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworkingreextinguisherintheworkarea.
•Routeexhaustawayfromallignitionsources.Ifdiaphragmruptures,uidmaybeexhausted
withair.
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT
EQUIPMENTHAZARD HAZARD
HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief
ReliefProcedure Procedure
Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenalluidconnectionsbeforeoperatingtheequipment.
•Checkuidlines,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
3A6782G3
Warnings
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE
MISUSEHAZARD HAZARD
HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorundertheinuenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalSpecications Specications
Specicationsinallequipmentmanuals.
•Useuidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
Technical
Specications Specications
Specicationsinallequipmentmanuals.Readuidandsolventmanufacturer’swarnings.
Forcompleteinformationaboutyourmaterial,requestSafetyDataSheet(SDS)from
distributororretailer.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief
ReliefProcedure Procedure
Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodicationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routeuidlinesandcablesawayfromtrafcareas,sharpedges,movingparts,andhot
surfaces.
•Donotkinkoroverbenduidlinesoruseuidlinestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
TOXIC TOXIC
TOXICFLUID FLUID
FLUIDOR OR
ORFUMES FUMES
FUMESHAZARD HAZARD
HAZARD
Toxicuidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheet(SDS)toknowthespecichazardsoftheuidsyouareusing.
•Routeexhaustawayfromworkarea.Ifdiaphragmruptures,uidmaybeexhaustedinto
theair.
•Storehazardousuidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
BURN BURN
BURNHAZARD HAZARD
HAZARD
Equipmentsurfacesanduidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhotuidorequipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE
PROTECTIVEEQUIPMENT EQUIPMENT
EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbytheuidandsolvent
manufacturer.
4
3A6782G
CongurationNumberMatrix
Conguration Conguration
CongurationNumber Number
NumberMatrix Matrix
Matrix
Checktheidenticationplate(ID)forthe
CongurationNumberofyourpump.Usethe
followingmatrixtodenethecomponentsofyour
pump.
Whenyoureceiveyourpump,recordthe9character
partnumberfoundontheshippingbox(e.g.,
SP3F.0018):_____________
AlsorecordthecongurationnumberonthepumpID
platetoassistyouwhenorderingreplacementparts:
_____________________________________
Sample Sample
SampleConguration Conguration
CongurationNumber: Number:
Number:2150HS.PSP1ASSASSPTPSEP21 2150HS.PSP1ASSASSPTPSEP21
2150HS.PSP1ASSASSPTPSEP21
2150 2150
2150HS HS
HSP P
PSP1A SP1A
SP1ASSA SSA
SSASS SS
SSPT PT
PTPS PS
PSEP EP
EP21 21
21
Pump
Model
WettedSection
Material
DriveCenterSectionandAir
ValveMaterial
ManifoldsSeatsChecksDiaphragmsSealsCertica-
tion
NOTE: NOTE:
NOTE:Somecombinationsarenotpossible.Pleasecheckwithyourlocalsupplier.
Pump Pump
PumpWetted Wetted
WettedSection Section
SectionDrive Drive
DriveType Type
TypeCenter Center
CenterSection Section
Sectionand and
andAir Air
AirValve Valve
ValveManifolds Manifolds
Manifolds
2150 2150
21503A 3A
3A3-AcompliantP P
PPneumatic
S01A S01A
S01A
StainlessSteel,for
allbut2-piecePS
diaphragms
SSA SSA
SSAStainlesssteel,TriClamp,
centerport
3150 3150
3150HS HS
HSHighSanitationS02A S02A
S02AStainlessSteel,leak
detector,3-A,forallbut
2-piecePSdiaphragms
SSB SSB
SSBStainlesssteel,DIN,center
port
4150 4150
4150PH PH
PHPharmaceuticalS03A S03A
S03AStainlessSteel,PH,
forallbut2-piecePS
diaphragms
SSC SSC
SSCStainlesssteel,TriClamp,
unloader
SP1A SP1A
SP1AStainlessSteel,PS
diaphragms,for2-piece
PSdiaphragmsonly
SSD SSD
SSDStainlesssteel,DIN,
unloader
SP2A SP2A
SP2AStainlessSteel,
leakdetector,PS
diaphragms,3-A
SSE SSE
SSEStainlesssteel,TriClamp,
horizontal,WYEmanifold
SP3A SP3A
SP3AStainlessSteel,PH,PS
diaphragms,for2-piece
PSdiaphragmsonly
SSF SSF
SSFStainlesssteel,DIN,
horizontal,WYEmanifold
SSG SSG
SSGHorizontal,nomanifolds
Seat Seat
SeatMaterial Material
MaterialChecks Checks
ChecksDiaphragm Diaphragm
DiaphragmMaterial Material
MaterialSeals Seals
SealsCertication Certication
Certication
FL FL
FL316Stainless
Steel,Flapper
— —
—StainlessSteel
FlapperBN BN
BNBuna-NBN BN
BNBuna-N21 21
21EN10204Type
2.1
SS SS
SS316Stainless
Steel,BallBN BN
BNBuna-NEO EO
EOEPDMOvermoldEP EP
EPEPDM31 31
31EN10204Type
3.1
CW CW
CWPolychloroprene
WeightedBallFK FK
FKFKM
FluoroelastomerFK FK
FKFKM
EP EP
EPEPDMPO PO
POPTFE/EPDM
Overmold
FK FK
FKFKM
Fluoroelastomer
Ball
PS PS
PSPTFE/
Santoprene
PT PT
PTPTFEBallSO SO
SOEPDMOvermold
SP SP
SPSantopreneBallSP SP
SPSantoprene
3A6782G5
OrderingInformation
Approvals Approvals
Approvals
Exceptfor3-Apumps,allpumpsareapprovedto:
II 2 GD
Ex h IIC T6...T3 Gb
Ex h IIIB T160°C Db
DiaphragmmaterialscodedEO,PO,orPS
combinedwithapperorPTballcheckscomply
with:
EC1935/2004
DiaphragmmaterialscodedEOorPScombined
withapperorPTballcheckscomplywith:
ClassVI
Allmodelsareapprovedto:
AlluidcontactmaterialsareFDAcompliant
andmeettheUnitedStatesCodeofFederal
Regulations(CFR)
ATEXT-coderatingisdependentonthetemperatureoftheuidbeingpumped.Fluidtemperatureislimited
bythematerialsofthepumpinteriorwettedparts.SeeTechnicalSpecications,page32,forthemaximum
uidoperatingtemperatureforyourspecicpumpmodel.
Ordering Ordering
OrderingInformation Information
Information
To To
ToFind Find
FindYour Your
YourNearest Nearest
NearestDistributor Distributor
Distributor
1.Visitwww.graco.com.
2.ClickonWhere Where
Whereto to
toBuy Buy
BuyanduseFind Find
Finda a
aDistributor. Distributor.
Distributor.
To To
ToSpecify Specify
Specifythe the
theConguration Conguration
Congurationof of
ofa a
aNew New
NewPump Pump
Pump
Please Please
Pleasecall call
callyour your
yourdistributor. distributor.
distributor.
OR OR
OR
UsetheOnline Online
OnlineDiaphragm Diaphragm
DiaphragmPump Pump
PumpSelector Selector
Selectorat at
atwww.graco.com www.graco.com
www.graco.com. .
.SearchforSelector Selector
Selector
To To
ToOrder Order
OrderReplacement Replacement
ReplacementParts Parts
Parts
Please Please
Pleasecall call
callyour your
yourdistributor. distributor.
distributor.
63A6782G
Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
•FollowthePressureReliefProcedure,page9,
beforecheckingorservicingtheequipment.
•Checkallpossibleproblemsandcausesbefore
disassembly.
Problem Problem
ProblemCause Cause
CauseSolution Solution
Solution
Pumpcyclesatstallor
failstoholdpressureat
stall.
Wornchecksorseats.Replace.
Airvalveisstuckordirty.Disassembleandcleanairvalve.
Uselteredair.
Checkballisseverelywornand
wedgedinseatormanifold.
Replaceballandseatcomponent.
Checkvalveballisseverelywedged
intoseatduetooverpressurization.
Follow
PressureReliefProcedure,page9.
Disassembleballcheckassembly
andinspectfordamage.
Cloggeddispensingvalve.Follow
PressureReliefProcedure,page9.
Clearvalve.
Pumpwillnotcycle,or
cyclesonceandstops.
Leakdetectorhasactivatedashut-
downsolenoid.
Investigatefailureandresetleak
detector.
Cloggedsuctionline.Inspect;clear.
Stickyorleakingcheckballsorap
valves.
Cleanorreplace.
Flapvalvesinstalledupside-down.Installtheappervalvewiththetext
sidefacingtheseat.
Ruptureddiaphragm.Replace.Seestandardor
overmoldeddiaphragmrepair
procedure.
Reducedpump
performance.
Restrictedexhaust.Removerestriction.
Loosesuctionline.Tighten.
Ruptureddiaphragm.Replace.Seestandardor
overmoldeddiaphragmrepair
procedure.
Airbubblesinuid.
Looseinletmanifold,damagedseal
betweenmanifoldanduidcover,
damagedgaskets.
Tightenmanifoldclampsorreplace
gasketsorseatingcomponents.
Loosesanitaryclamp.Tightenclamp.
Damagedorworngasket.Replacegasket.
Leakininletoroutlet
sanitarytting.
Misalignmentofinlet/outletuidline
orpipe.
Useexibleuidlinesatpumpinlet
andoutlet.
3A6782G7
Troubleshooting
Problem Problem
ProblemCause Cause
CauseSolution Solution
Solution
Manifoldsdonottfor
installationontouid
covers.
Useofincorrectaircovergaskets
resultsinmisalignment.
Installcorrectaircovergasketsfor
thetypeofdiaphragmsinuse.See
Partslistforcorrectgasket.
Diaphragmruptured.Replace.Seestandardor
overmoldeddiaphragmrepair
procedure.
Fluidinexhaustair.
Loosediaphragmplate.Tightenorreplace.Seestandard
orovermoldeddiaphragmrepair
procedure.
Wornairvalveblock,plate,pilot
block,u-cups,orpilotpino-rings.
Repairorreplace. Pumpexhaustsexcessive
airatstall.
Wornshaftseals.Replace.Seestandardor
overmoldeddiaphragmrepair
procedure.
Airvalvecoverisloose.Tightenscrews.
Airvalvegasketoraircovergasket
isdamaged.
Inspect;replace.
Pumpleaksairexternally.
AircoverclampsarelooseTightenclamps.
Pumpleaksuid
externallyfromballcheck
valves.
Loosemanifolds,damagedseal
betweenmanifoldanduidcover,or
damagedgaskets.
Tightenmanifoldclampsorreplace
seatsorclamps.
Chattering.Checkvalveballsnotseating
properly/cleanlyduetoimbalance
betweenuidinletandoutletline
sizing.Noiseisaccentuatedwith
lightviscosityuids.
Reducesize/diameterofinletline
relativetooutletline.Outletlinesize
shouldnotexceedpumpsize.
83A6782G
Repair
Repair Repair
Repair
Pressure Pressure
PressureRelief Relief
ReliefProcedure Procedure
Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressureis
manuallyrelieved.Tohelppreventseriousinjury
frompressurizeduid,suchassplashinguid,
followthePressure Pressure
PressureRelief Relief
ReliefProcedure Procedure
Procedurewhenyou
stopdispensingandbeforecleaning,checking,or
servicingtheequipment.
1.Closethemasterairvalve(A)toshutofftheair
tothepump.
2.Openoutbounduidvalvetorelieveuid
pressurefromthepump.
a.For For
Forsimple simple
simpletransfer transfer
transferapplications, applications,
applications,openeither
theuidshutoffvalve(J)ortheuiddrain
valve(K).
b.For For
Forcirculating circulating
circulatingapplications, applications,
applications,ensurethatthe
uidshutoffvalve(J)isclosedandopenthe
uiddrainvalve(K).
Air Air
AirValve Valve
ValveRepair Repair
Repair
ToolsRequired
•Torquewrench
•Torx(T20)screwdriveror7mm(9/32in.)socket
wrench
•Needle-nosepliers
•O-ringpick
•Lithiumbasegrease
Airvalverepairkit255122isavailable.Useallparts
inthekitforbestresults.
Disassemble Disassemble
DisassembleAir Air
AirValve Valve
Valve
1.FollowthePressureReliefProcedure,page9.
2.WithaTorx(T20)screwdriveror7mm(9/32in.)
socketwrench,removethesixscrews(107),air
valvecover(109),andgasket(118).
3.Movethevalvecarriage(105)tothecenter
positionandpullitoutofthecavity.Usinga
needle-nosepliers,pullthepilotblock(116)
straightupandoutofthecavity.
4.Pullthetwoactuatorpistons(114).Removethe
u-cups(106)fromthepistons.Pullthepilotpins
(112).Removetheo-rings(108)fromthepilot
pins.
3A6782G9
Repair
5.Inspectthevalveplate(110)inplace.If
damaged,useaTorx(T20)screwdriveror7mm
(9/32)in.)socketwrenchtoremovethethree
screws(107).Removethevalveplate(110).
6.Inspectthebearings(113,115)inplace.See
Parts,page22.Thebearingsaretaperedand,
ifdamaged,mustberemovedfromtheoutside.
Thisrequiresdisassemblyoftheuidsection.
SeeCenterSectionRepair,page19.
7.Cleanallpartsandinspectforwearordamage.
Replaceasneeded.
Reassemble Reassemble
ReassembleAir Air
AirValve Valve
Valve
NOTE: NOTE:
NOTE:Ifrepairsinvolveremoving
uidcovers,performthestepsin
ReassembletheOvermoldedDiaphragms,page17,
priortoreassemblyoftheairvalve.Theairvalve
congurationwillbemodiedtoaiduidcover
installation.
1.Ifthecentersectionwasdisassembledto
replacethebearings(113,115),complete
theCenterSectionRepair,page19,before
continuingwiththeairvalvereassembly.
2.Installthevalveplate(110)inthecavity,seal
down.Installthethreescrews(107),usinga
Torx(T20)screwdriveror7mm(9/32in.)socket
wrench.Tightenuntilthescrewsbottomouton
thehousing.
3.Installano-ring(108)oneachpilotpin(112).
Greasethepinsando-rings.Insertthepinsinto
thebearings,
narrow narrow
narrow
endrst.
4.Installu-cups(106)oneachactuatorpiston
(114),sothelipsofthepackingsfacethe
narrow narrow
narrow
endofthepistons.
5.Greasethelowerfaceofthepilotblock(116)and
installsoitstabssnapintothegroovesonthe
endsofthepilotpins(112).
6.Lubricatetheu-cups(106)andactuatorpistons
(114).Inserttheactuatorpistonsinthebearings
(115),
wide wide
wide
endrst.Leavethenarrowendof
thepistonsexposed.
7.Greasethelowerfaceofthevalvecarriage(119).
8.Installthevalvecarriage(105)soitstabsslipinto
thegroovesonthenarrowendoftheactuator
pistons(114).
103A6782G
Repair
9.Alignthevalvegasket(118)andcover(109)
withthesixholesinthecenterhousing(101).
Securewithsixscrews(107),usingaTorx(T20)
screwdriveror7mm(9/32in.)socketwrench.
Torqueto50-60in-lb(5.7-6.8N•m).
3A6782G11
Repair
Check Check
CheckValve Valve
ValveRepair Repair
Repair
NOTE: NOTE:
NOTE:Kitsareavailablefornewcheckvalve
appers,orcheckvalveballsinarangeofmaterials.
Gasketkitsalsoareavailable.
Disassemble Disassemble
Disassemblethe the
theCheck Check
CheckValve Valve
Valve
1.FollowthePressureReliefProcedure,page9.
Disconnectalluidandairlines.
2.Drainthepump
a.Onrotatablestand,pulltheframe
quick-releasepins(207)androtatethe
pump.
NOTE: NOTE:
NOTE:Afterdraining,rotatethepumpto
positionswhichwillaiddisassembly.
b.Onnon-rotatablestand,partiallydisassemble
theuidsectionasinstructedinthefollowing
steps.
NOTE: NOTE:
NOTE:Theverticalpumpscanbedrained
byremovingtheinletmanifoldandmanually
raisingtheinletappers.Horizontalpumps
willrequireremovaloftheuidcovers.
3.Removetheclamps(23)ontheoutletmanifold
(17)andremovethemanifold.
NOTE: NOTE:
NOTE:Usecarewhileremovingmanifoldto
avoiddamagetocheckvalvecomponents.
4.Removeremainingclamps,manifolds,gaskets
andcheckvalves.
NOTE NOTE
NOTE:Inspectallcomponentsforanydamage
andreplaceasnecessary.
5.Tocontinuewithdiaphragmdisassembly,see
DisassembletheStandardDiaphragms,page14.
Ball Ball
Ballpump pump
pumpshown shown
shown
12
3A6782G
Repair
Vertical Vertical
Verticalapper apper
apperpump pump
pumpshown shown
shown
Horizontal Horizontal
Horizontalapper apper
apperpump pump
pumpshown shown
shown
Reassemble Reassemble
Reassemblethe the
theCheck Check
CheckValves Valves
Valves
NOTE: NOTE:
NOTE:Lubricateclampsandclampingsurfaceswith
waterproof,sanitarylubricant.
1.Reassembleballorappercheckassemblyin
reverseorder.
2.Looselyattachthemanifoldstotheuidcovers.
Onceallcomponentsareproperlyaligned,
tightenclampshandtight.
NOTE: NOTE:
NOTE:Installtheappervalve(8)withthetext
sidefacingtheseat.
NOTE: NOTE:
NOTE:Flapperuidcoversarenot
interchangeableandtheirorientationis
criticalonhorizontalpumps.Horizontalpump
uidcoversmustbepositionedsothatthe
appershangdownfromthehingepinwhen
placedintheuidcover.Installtheappervalves
(8)withthetextsidefacingtheseat.
3A6782G13
Repair
Standard Standard
StandardDiaphragm Diaphragm
DiaphragmRepair Repair
Repair
NOTE: NOTE:
NOTE:Overmoldeddiaphragmsarecoveredin
OvermoldedDiaphragmRepair,page16.
Tools Tools
ToolsRequired Required
Required
•Torquewrench
•5/8in.wrench
•19mmopenendwrench
•O-ringpick
•Lithiumbasegrease
NOTE: NOTE:
NOTE:Centersectiongasketisdependenton
diaphragmmaterial.Ifchangingdiaphragmmaterial,
itmaybenecessarytoalsoreplacethecenter
sectionaircovergaskets.SeeDiaphragms,page29,
foraffectedaircovergaskets.
Disassemble Disassemble
Disassemblethe the
theStandard Standard
StandardDiaphragms Diaphragms
Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page9.
2.Removethemanifoldsanddisassemble
thecheckvalvesasexplainedin
CheckValveRepair,page12.
3.Removetheclamps(21)fromtheuidcovers(4,
15),thenpulltheuidcoversoffofthepump.
4.Withbothuidcoversremoved,usingtwo5/8in.
wrenches,holdthewrenchatsontheplates(Y)
ofeachdiaphragmassemblyandloosen.One
diaphragmassemblywillcomefreeandtheother
willremainattachedtotheshaft.
5.Disassemblethefreediaphragmassembly.
6.Removeplate(12)withbolt(14)installed,
diaphragm(10),backer(11)ifpresent,andplate
(9).
7.Pulltheotherdiaphragmassemblyandthe
diaphragmshaft(24)outofthecenterhousing
(101).Holdtheshaftatswitha19mmopenend
wrench,andremovethediaphragmassembly
fromtheshaft.Disassembletheremaining
diaphragmassembly.
8.Inspectthediaphragmshaft(24)forwearor
scratches.Ifitisdamaged,inspectthebearings
(111)inplace.Ifthebearingsaredamaged,refer
toCenterSectionRepair,page19.
9.Reachintothecenterhousing(101)withan
o-ringpickandhooktheu-cups(106),thenpull
themoutofthehousing.Thiscanbedonewith
thebearings(111)inplace.
10.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
14
3A6782G
Repair
Reassemble Reassemble
Reassemblethe the
theStandard Standard
StandardDiaphragms Diaphragms
Diaphragms
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthecenter
section,followCenterSectionRepair,page19,
beforereplacingdiaphragms.
1.Lubricateandinstalltheshaftu-cups(106)so
thelipsface
out out
out
ofthehousing(101).
2.Assemblediaphragm(10),backer(11)ifpresent,
andairsideplate(9)ontouidsideplate(12)
withscrew(14).Roundedsideofplate(9)should
facediaphragm.MakesurethesidemarkedAIR
SIDEfacesthecenterhousing.
NOTE: NOTE:
NOTE:Threadlockermustbeappliedtoscrew
(14)asshownforalldiaphragmassemblies.
1
Applyahigh-strengththreadlockerto
attachthescrewtothediaphragmplate,
ifneeded.
2
Applyamedium-strengththreadlocker
totheshaftsideofthescrew.
3.Screwassembleddiaphragmassemblyintoshaft
(24)andhandtighten.
4.Greasethelengthofthediaphragmshaft(24),
andslideitthroughthehousing(101).
5.Assembletheotherdiaphragmassemblytothe
shaftasexplainedinstep2.
6.Usinga5/8in.wrenchholdthewrenchatsof
onediaphragmassemblyandtorquetheother
diaphragmto60-70ft-lb(81-94N•m).
NOTE: NOTE:
NOTE:Applywaterproof,sanitarylubricanttothe
clamp(21)andclampingsurfaceofthecover(4,
15)toeaseassembly.
NOTE: NOTE:
NOTE:Toensureproperspacingandalignment
ofmanifolds,installclamps(21)looseenoughto
allowforuidcovermovementbeforesecuring
thecoversandclampsinplace.
7.Aligntheuidcovers(4,15)andthecenter
housing.Securethecoverswiththeclamps(21)
andhandtighten.
NOTE: NOTE:
NOTE:Applyafoodgradeanti-seizelubricanton
theclampthreadstoaidassembly.
NOTE: NOTE:
NOTE:Ballpumpuidcoversare
interchangeable.
NOTE: NOTE:
NOTE:Flapperuidcoversarenot
interchangeableandtheirorientationis
criticalonhorizontalpumps.Horizontalpump
uidcoversmustbepositionedsothatthe
appershangdownfromthehingepinwhen
placedintheuidcover.Installtheappervalves
(8)withthetextsidefacingtheseat.
8.Reassembletheballcheckvalvesandmanifolds
asexplainedinCheckValveRepair,page12.
3A6782G15
Repair
Overmolded Overmolded
OvermoldedDiaphragm Diaphragm
DiaphragmRepair Repair
Repair
Tools Tools
ToolsRequired: Required:
Required:
•Torquewrench
•19mmopenendwrench
•O-ringpick
•Lithiumbasegrease
NOTE: NOTE:
NOTE:Centersectiongasketisdependenton
diaphragmmaterial.Ifchangingdiaphragmmaterial,
itmaybenecessarytoalsoreplacethecenter
sectionaircovergaskets.SeeDiaphragms,page29,
foraffectedaircovergaskets.
Disassemble Disassemble
Disassemblethe the
theOvermolded Overmolded
OvermoldedDiaphragms Diaphragms
Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page9.
2.Removethemanifoldsanddisassemble
thecheckvalvesasexplainedin
CheckValveRepair,page12.
3.Removetheclamps(21)fromtheuidcovers(4,
15),thenpulltheuidcoversoffofthepump.
4.Oncetheuidcoversareremoved,the
diaphragmonthesideofthepumpwhichwas
lastpressurizedwithairwillbeseparatedfrom
thecentersection/aircover.Thisallowsyouto
gripthediaphragms.
5.Toloosen,gripbothdiaphragmssecurelyaround
theouteredgeandrotatecounterclockwise.One
diaphragmassemblywillcomefreeandtheother
willremainattachedtotheshaft.Removethe
freeddiaphragm(10)withscrew(14)andairside
plate(9).
6.Pulltheoppositediaphragmassemblyandshaft
(24)outofthecenterhousing(101).Holdthe
shaftatswitha19mmopenendwrenchand
removethediaphragmandairsideplatefrom
theshaft.
7.Inspectthediaphragmshaft(24)forwearor
scratches.Ifitisdamaged,inspectthebearings
(111)inplace.Ifthebearingsaredamaged,refer
toCenterSectionRepair,page19.
8.Reachintothecenterhousing(101)withan
o-ringpickandhooktheu-cups(110),thenpull
themoutofthehousing.Thiscanbedonewith
thebearings(111)inplace.
9.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
163A6782G
Repair
Reassemble Reassemble
Reassemblethe the
theOvermolded Overmolded
OvermoldedDiaphragms Diaphragms
Diaphragms
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthecenter
section,followCenterSectionRepair,page19,
beforereplacingdiaphragms.
1.Lubricateandinstalltheshaftu-cups(106)so
thelipsface
out out
out
ofthehousing(101).
2.Assembleplate(9)ontodiaphragm(10),with
screw(14).Roundedsideofplate(9)should
facediaphragm.MakesurethesidemarkedAIR
SIDEfacesthecenterhousing.
NOTE: NOTE:
NOTE:Threadlockermustbeappliedtoscrew
(14)asshownforalldiaphragmassemblies.
1
Applyahigh-strengththreadlockerto
attachthescrewtothediaphragm.
2
Applyamedium-strengththreadlocker
totheshaftsideofthescrew.
3.Screwassembleddiaphragmassemblyintoshaft
(24)andhandtighten.
4.Greasethelengthofthediaphragmshaft(24),
andslideitthroughthehousing(101).
5.Assembletheotherdiaphragmassemblytothe
shaftasexplainedinstep2.
6.Gripbothdiaphragmssecurelyaroundtheirouter
edgesandrotateclockwiseuntilbottomedonthe
shaft.
NOTE: NOTE:
NOTE:Applywaterproof,sanitarylubricanttothe
clamp(21)andclampingsurfaceofthecover(4,
15)toeaseassembly.
NOTE: NOTE:
NOTE:Toensureproperspacingandalignment
ofmanifolds,installclamps(21)looseenoughto
allowforuidcovermovementbeforesecuring
thecoversandclampsinplace.
NOTE: NOTE:
NOTE:Useafoodgradeanti-seizelubricanton
theclampthreadstoaidassembly.
3A6782G17
Repair
7.Aligntheuidcovers(4,15)andthecenter
housing.Securethecoverswiththeclamps(21)
andhandtighten.If,afterinstallingtherstuid
cover,theopposingdiaphragmprotrudesaway
fromthecenterhousing,leavingagapbetween
thecenterhousingandtheseconduidcover,
donottrytoforcethediaphragmintoposition.
Instead,completethefollowingproceduresin
steps7a–7itoattachtheseconduidcover.
NOTE: NOTE:
NOTE:Ballpumpuidcoversare
interchangeable.
NOTE: NOTE:
NOTE:Flapperuidcoversarenot
interchangeableandtheirorientationis
criticalonhorizontalpumps.Horizontalpump
uidcoversmustbepositionedsothatthe
appershangdownfromthehingepinwhen
placedintheuidcover.Installtheappervalves
(8)withthetextsidefacingtheseat.
a.Removetheairvalvecover(B),thegasket
(C),andthepilotcup(D).Seetheimagein
stepi.
b.Withinthedrive,shiftthemainairvalve
carriage(E)awayfromtheinstalleduid
cover.Thiswillexposetheairpassagethat
feedstheassembledside.
c.Reinstallthegasket(C)andtheairvalve
cover(B).Torqueallboltsaccordingto
instructionsinyourpumpmanual.
d.Supplythepumpwith10–20psi(0.07–0.14
MPa,0.7–1.4bar)airpressure,justenough
tomovethediaphragm.Thediaphragm
willshiftsotheseconduidcoverwillseat
properly.Keeptheairpressureonwhileair
owsoutoftheexhaust.
NOTE: NOTE:
NOTE:Toomuchairpressuremaycausethe
diaphragmtodeformandseatincorrectly.
e.Installtheremaininguidcover.
f.Followthe
PressureReliefProcedure,page9.
Disconnecttheairsupplyfromthepump.
g.Removetheairvalvecover(B)andthe
gasket(C).
h.Lubricateandreinstallthepilotcup(D).
i.Reinstallthegasket(C)andtheairvalve
cover(B).Torqueallboltsaccordingto
instructionsinyourpumpmanual.
8.Reassembletheballcheckvalvesandmanifolds
asexplainedinCheckValveRepair,page12.
183A6782G
Repair
Center Center
CenterSection Section
SectionRepair Repair
Repair
Tools Tools
ToolsRequired: Required:
Required:
•Torquewrench
•10mmsocketwrench
•9/16in.socketwrench
•Bearingpuller
•O-ringpick
•Press,orblockandmallet
Disassemble Disassemble
Disassemblethe the
theCenter Center
CenterSection Section
Section
NOTE: NOTE:
NOTE:Donotremoveundamagedbearings.
1.FollowthePressureReliefProcedure,page9.
Disconnectalluidandairlines.
2.Removethemanifoldsand
checkvalvepartsasdirectedin
DisassembletheCheckValve,page12.
3.Removetheuidcoversanddiaphragms
asdirectedinDisassembletheStandard
Diaphragms,page14orDisassemblethe
OvermoldedDiaphragms,page16.
NOTE:Ifyouareremovingonlythediaphragm
shaftbearing(111),skipstep4.
4.Disassembletheairvalveasexplainedin
AirValveRepair,page9.
5.Usea9/16in.socketwrenchtoremovethe
screws(3)andnuts(105)holdingtheaircovers
totheframe.
6.Usea10mmsocketwrenchtoremovethe
screws(104)holdingtheaircovers(103)tothe
centerhousing(101).
7.Removetheaircovergaskets(102).Always
replacethegasketswithnewones.
NOTE: NOTE:
NOTE:Ifremovingthediaphragmshaftbearings
(111),useano-ringpicktoremovetheu-cups
(106)rst.
8.Useabearingpullertoremovethediaphragm
shaftbearings(111),airvalvebearings(115)
orpilotpinbearings(113).Donotremove
undamagedbearings.
9.Inspecttheu-cups.Replaceasneeded.
3A6782G19
Repair
Reassemble Reassemble
Reassemblethe the
theCenter Center
CenterSection Section
Section
1.Installtheshaftu-cups(106)sothelipsface
out out
out
ofthehousing.
2.Insertnewbearings(111,113,and115)intothe
centerhousing(101),
tapered tapered
taperedend end
endrst rst
rst
.Using
apressorablockandrubbermallet,press-t
thebearingsoitisushwiththesurfaceofthe
centerhousing.
3.Reassembletheairvalveasexplainedin
ReassembleAirValve,page10
4.Alignthenewaircovergasket(102)sothepilot
pin(112)protrudingfromthecenterhousing
(101)tsthroughtheproperholeinthegasket.
5.Aligntheaircover(103)sothepilotpin(112)ts
inthemiddlehole(M)ofthethreesmallholes
nearthecenterofthecover.
6.Applyamedium-strengththreadlockertothe
threadsofthescrews(106).Installthescrews
(106),handtight.Usinga10mmsocketwrench,
torquethescrewsoppositelyandevenlyto
130-150in-lb(15-17N•m).Installthediaphragm
assembliesanduidcoversasexplainedin
Diaphragms,page29.
7.SeeReassembletheCheckValves,page13.
203A6782G
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