Graco 232-504 Operation manual

308–550
Rev. H
Supersedes Rev. G
First choice when
quality counts. 

INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
POLYPROPYLENE AND KYNAR 
Husky 2150 Air-Operated
Diaphragm Pumps
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure
120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure
*Model No. DF2– Polypropylene Pumps
*Model No. DF5– KynarPumps
Model No. 232–504 Private-Label Polypropylene 2150 Pump (See page 24.)
* NOTE: Refer to the Pump Matrix on page 24 to
determine the Model No. of your pump.
US Patent No. 5,368,452.
Other US and Foreign Patents Pending.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
http://www.graco.com
COPYRIGHT
1995, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

 
Table of Contents
Safety W arnings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service
Repairing
the Air V alve 16. . . . . . . . . . . . . . . . . . . . . .
Ball Check V alve Repair 18. . . . . . . . . . . . . . . . . . . . .
Diaphragm Repair 19. . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing and Air Gasket Removal 22. . . . . . . . . . . . .
Pump Matrix 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Kit Matrix 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Chart 31. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard W arranty 32. . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 32. . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury .

This equipment is for professional use only .

Read all instruction manuals, tags, and labels before operating the equipment.
 Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor .

Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
 Check equipment daily . Repair or replace worn or damaged parts immediately .

Do not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 120 psi (0.8 MPa, 8 bar) maximum working pressure at 120 psi
(0.8 MPa, 8 bar) maximum incoming air pressure.
 Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
T echnical Data section of all equipment manuals. Read the fluid and solvent manufacturer ’s
warnings.

Do not use hoses to pull equipment.
 Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex -
pose Graco hoses to temperatures above 82  C (180  F) or below –40  C (–40 F).

Do not lift pressurized equipment.
W ear hearing protection when operating this equipment.
 Comply with all applicable local, state, and national fire, electrical, and safety regulations.
WARNING
WARNING
INSTRUCTIONS

 
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, inhaled, or swallowed.
 Know the specific hazards of the fluid you are using.
 Store hazardous fluid in an approved container . Dispose of hazardous fluid according to all local,
state and national guidelines.
 Always wear protective eyewear , gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer .
 Pipe and dispose of the exhaust air safely , away from people, animals, and food handling areas.
If the diaphragm fails, the fluid is exhausted along with the air . See Air Exhaust V entilation on
page 10.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury
.

Ground the equipment. Refer to Grounding on page 4.
 Never use a polypropylene or Kynar pump with non-conductive flammable fluids as specified by
your local fire protection code. Refer to Grounding on page 4 for additional information. Consult
your fluid supplier to determine the conductivity or resistivity of your fluid.
 If there is any static sparking or you feel an electric shock while using this equipment, stop
pumping immediately . Do not use the equipment until you identify and correct the problem.
 Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed, dispensed, or transferred.
 Pipe and dispose of the exhaust air safely , away from all sources of ignition. If the diaphragm
fails, the fluid is exhausted along with the air . See Air Exhaust V entilation on page 10.
 Keep the work area free of debris, including solvent, rags, and gasoline.
 Electrically disconnect all equipment in the work area.
 Extinguish all open flames or pilot lights in the work area.
 Do not smoke in the work area.
 Do not turn on or of f any light switch in the work area while operating or if fumes are present.
 Do not operate a gasoline engine in the work area.
WARNING
WARNING

4 308-550
Installation
General Information
The T ypical Installation shown in Fig. 2 is only a
guide for selecting and installing system compo -
nents. Contact your Graco distributor or Graco
T echnical Assistance (see back page) for assis -
tance in planning a system to suit your needs.
 Always use Genuine Graco Parts and Accessories.
Be sure all accessories are adequately sized and
pressure-rated to meet the system’s requirements.
 Reference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 27–28.
V ariations in color between the plastic components
of this pump are normal. Color variation does not
af fect the performance of the pump.
T OXIC FLUID HAZARD
Hazardous fluid or toxic fumes can
cause serious injury or death if splashed
in the eyes or on the skin, inhaled, or
swallowed.
1. Read T OXIC FLUID HAZARD on page 3.
2. Use fluids and solvents which are compatible
with the equipment wetted parts. Refer to the
T echnical Data section of all equipment manu -
als. Read the fluid and solvent manufacturer ’s
warnings.
WARNING
Tighten Screws Before First Use
After unpacking the pump and before using it for the
first time, check and retorque the manifold screws
(106, 1 12) and the cover screws (107, 108). See
pages 18, 19, and 20 for torque specifications.
After the first day of operation, check and retorque the
screws again. Repeat this process every 2 months.
Grounding
FIRE AND EXPLOSION HAZARD
This pump must be grounded. Before
operating the pump, ground the system
as explained below. Also, read the sec -
tion
FIRE AND EXPLOSION HAZARD,
on page 3.
Polypropylene and Kynar are not conductive.
Attaching the ground wire to the grounding lug will
ground only the air motor . When pumping conduc -
tive flammable fluids, always make sure the fluid
has an electrical path to a true earth ground.
Possible methods of grounding the fluid are
through the fluid containers or piping. Contact your
Graco distributor for assistance in grounding your
system. Never use a polypropylene or a Kynar
pump with non-conductive flammable fluids as
specified by your local fire protection code. US
Code (NFPA 77 Static Electricity) recommends a
conductivity greater than 50 x 10
–12
Siemans/meter
(mhos/meter) over your operating temperature
range to reduce the hazard of fire. Consult your
fluid supplier to determine the conductivity or
resistivity of your fluid. The resistivity must be less
than 2 x 10
12
ohm-centimeters.
WARNING

 
Installation
Grounding (continued)
To reduce the risk of static sparking, ground the pump
and all other equipment used or located in the pumping
area. Check your local electrical code for detailed
grounding instructions for your area and type of equip -
ment. Ground all of this equipment.
 Air Motor : Connect a ground wire and clamp as
shown in Fig. 1. Loosen the grounding lug locknut
(W) and washer (X). Insert one end of a 12 ga (1.5
mm ) minimum ground wire (Y) into the slot in the
lug (Z) and tighten the locknut securely . Connect
the clamp end of the ground wire to a true earth
ground. Order Part No. 237–569 Ground Wire and
Clamp.
NOTE:
When pumping conductive flammable fluids
with a polypropylene or a Kynar pump, always ground
the fluid system. See the WARNING on page 4.
 Air hoses : Use only electrically conductive hoses.
 Air compressor : Follow the manufacturer ’ s recom -
mendations.

All solvent pails used when flushing: Follow the
local code. Use only metal pails, which are conduc -
tive. Do not place the pail on a non-conductive
surface, such as paper or cardboard, which inter -
rupts the grounding continuity .

Fluid supply container: Follow the local code.
Fig. 1
Y
WXZ


6 308-550
Installation
Air Line
WARNING
A bleed-type master air valve (B) is required in
your system to relieve air trapped between this
valve and the pump. Trapped air can cause the
pump to cycle unexpectedly , which could result in
serious injury , including splashing in the eyes or on
the skin, injury from moving parts, or contamination
from hazardous fluids. See Fig. 2.
1. Install the air line accessories as shown in Fig. 2.
Mount these accessories on the wall or on a
bracket. Be sure the air line supplying the acces -
sories is electrically conductive.
a. Install an air regulator (C) and gauge to control
the fluid pressure. The fluid outlet pressure will
be the same as the setting of the air regulator .
b.
Locate one bleed-type master air valve (B)
close to the pump and use it to relieve trapped
air . See the WARNING at left. Locate the other
master air valve (E) upstream from all air line
accessories and use it to isolate them during
cleaning and repair .
c.
The air line filter (F) removes harmful dirt and
moisture from the compressed air supply .
2.
Install an electrically conductive, flexible air hose
(A) between the accessories and the 1/2 npt(f)
pump air inlet (N). See Fig. 2. Use a minimum 1/2”
(13 mm) ID air hose.
3. Screw an air line quick disconnect coupler (D) onto
the end of the air hose (A); be sure the coupler
porting is large enough to not restrict the air flow ,
which will af fect pump performance. Screw the
mating fitting into the pump air inlet snugly . Do not
connect the coupler (D) to the fitting until you are
ready to operate the pump.

KEY FOR FIG. 2
A Electrically conductive air supply hose
B Bleed-type master air valve
(required for pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
G Fluid suction hose
H Fluid supply
J Fluid drain valve (required)
K Fluid shutof f valve
l Fluid hose
N 1/2 npt(f) air inlet port
R 2” fluid inlet flange
S 2” fluid outlet flange
Y Ground wire (required; see page 5
for installation instructions)
Fig. 2
TYPICAL FLOOR-MOUNT INST ALLATION
YJ
FBEC
A
D
KL
G
H
R
S
N

308-550 7
Installation
Mountings
CAUTION
The pump exhaust air may contain contaminants.
V entilate to a remote area if the contaminants
could af fect your fluid supply . See Air Exhaust
Ventilation on page 10.
 Be sure the mounting surface can support the
weight of the pump, hoses, and accessories, as
well as the stress caused during operation.
 For all mountings, be sure the pump is bolted
directly to the mounting surface.
 For ease of operation and service, mount the pump
so the air valve cover (2), air inlet, and fluid inlet
and outlet ports are easily accessible.
 Rubber Foot Mounting Kit 236–452 is available to
reduce noise and vibration during operation.
Fluid Suction Line
1. The pump fluid inlet (R) is a 2” raised face flange.
Refer to Flange Connections on page 8.
2. If the fluid inlet pressure to the pump is more than
25% of the outlet working pressure, the ball check
valves will not close fast enough, resulting in
inef ficient pump operation.
3. At inlet fluid pressures greater than 15 psi
(0.1 MPa, 1 bar), diaphragm life will be shortened.
4. See the T echnical Data on page 30 for maximum
suction lift (wet and dry).
Fluid Outlet Line
WARNING
A fluid drain valve (J) is required to relieve pres -
sure in the hose if it is plugged. The drain valve
reduces the risk of serious injury , including splash -
ing in the eyes or on the skin, or contamination
from hazardous fluids when relieving pressure.
Install the valve close to the pump fluid outlet. See
Fig. 2.
1. The pump fluid outlet (S) is a 2” raised face flange.
Refer to Flange Connections on page 8.
2. Install a fluid drain valve (J) near the fluid outlet.
See the WARNING above.
3. Install a shutoff valve (K) in the fluid outlet line.

 
Installation
Flange Connections
The fluid inlet and outlet ports are 2” raised face,
standard 150 lb class pipe flanges. Connect 2” flanged
plastic pipe to the pump as follows. You will need:
T orque wrench
 Adjustable wrench
6” diameter , 1/8” thick T eflon gasket, with four 0.75”
diameter holes on a 4.75” diameter bolt circle, and
a 2.20” diameter center
 Four 5/8” x 3” bolts
 Four 5/8” spring lockwashers
 Eight 5/8” flat washers
Four 5/8” nuts.
1. Place a flat washer (E) on each bolt (C). Refer to
Fig. 3.
2. Align the holes in the gasket (B) and the pipe
flange (A) with the holes in the pump outlet
flange (S).
3. Lubricate the threads of the four bolts. Install the
bolts through the holes and secure with the wash -
ers (E), lockwashers (D), and nuts (F).
4. Hold the nuts with a wrench. Refer to the tighten -
ing sequence in Fig. 3 and torque the bolts to
20–30 ft–lb (27–41 N.m). Do not over-torque.
5. Repeat for the pump inlet flange (R).
04405
04615
Fig. 3
1
F
ES
B
A
E
D
C
R
BOL
T TIGHTENING SEQUENCE
1Lubricate
threads. T orque to 20–30 ft–lb
(27–41 N.m). Do not over-torque.
1
2
3
4
KEY FOR FIG. 3
A Flanged plastic pipe
BT eflon gasket
C Bolt
D Lockwasher
E
Flat washer
F Nut
R
2” fluid inlet flange
S 2” fluid outlet flange
1

308-550 9
Installation
Changing the Orientation of the Fluid Inlet
and Outlet Ports
The pump is shipped with the fluid inlet (R) and outlet
(S) ports facing the same direction. See Fig. 4. T o
change the orientation of the inlet and/or outlet port:
1. Remove the screws (106 and 1 12) holding the inlet
(102) and/or outlet (103) manifold to the covers
(101).
2.
Reverse the manifold and reattach. Install the
screws and torque to 80–90 in–lb (9–10 N.m).
04613
Fig. 4
1Torque
to 80–90 in-lb (9–10 N.m).
KEY
N 1/2 npt(f) air inlet port
P Muffler
Air exhaust port is 3/4
npt(f) .
R 2” fluid inlet flange
S 2” fluid outlet flange
101 Fluid covers
102 Fluid inlet manifold
103 Fluid outlet manifold
106 Fluid outlet manifold
screws (top)
112 Fluid inlet manifold
screws (bottom)
N
P
R
S
1
103
102
101
1
106
112
Fluid Pressure Relief Valve
Some systems may require installation of a pres -
sure relief valve at the pump outlet to prevent
overpressurization and rupture of the pump or
hose. See Fig. 5.
Thermal expansion of fluid in the outlet line can
cause overpressurization. This can occur when
using long fluid lines exposed to sunlight or ambi -
ent heat, or when pumping from a cool to a warm
area (for example, from an underground tank).
Overpressurization can also occur if the Husky
pump is being used to feed fluid to a piston pump,
and the intake valve of the piston pump does not
close, causing fluid to back up in the outlet line.
CAUTION
04616
Fig. 5
1
2Connect
fluid inlet line here.
KEY
R
2” fluid inlet flange
S 2” fluid outlet flange
V Pressure relief valve
Part No. 1 10–134 (aluminum)
Part No. 1 12–1 19 (stainless steel)
R
S
Connect fluid outlet line here.
1
2
3
Install valve between fluid inlet and outlet ports.
V
3

10 308-550
Installation
Air Exhaust Ventilation
FIRE AND EXPLOSION HAZARD
Be sure to read and follow the warnings
and precautions regarding TOXIC
FLUID HAZARD, and FIRE OR EXPLO -
SION HAZARD on page 3, before op -
erating this pump.
Be sure the system is properly ventilated for your
type of installation. Y ou must vent the exhaust to a
safe place, away from people, animals, food handl -
ing areas, and all sources of ignition when pumping
flammable or hazardous fluids.
Diaphragm failure will cause the fluid being
pumped to exhaust with the air . Place an appropri -
ate container at the end of the air exhaust line to
catch the fluid. See Fig. 6.
WARNING
The air exhaust port is 3/4 npt(f). Do not restrict the air
exhaust port. Excessive exhaust restriction can cause
erratic pump operation.
T o provide a remote exhaust:
1. Remove the muf fler (P) from the pump air exhaust
port.
2.
Install an electrically conductive air exhaust hose
(T) and connect the muf fler (P) to the other end of
the hose. The minimum size for the air exhaust
hose is 3/4 in. (19 mm) ID. If a hose longer than 15
ft (4.57 m) is required, use a larger diameter hose.
A void sharp bends or kinks in the hose. See Fig. 6.
3. Place a container (U) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures.
04617
Fig. 6
KEY
A Air
supply line
B Bleed-type master air valve
(required for pump)
C Air regulator
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
P Muffler
T
Electrically conductive air exhaust hose
U Container for remote air exhaust
FBEC
A
D
VENTING
EXHAUST AIR
P
TU

308-550 11
Notes

12 308-550
Operation
Pressure Relief Procedure
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until pressure is
manually relieved. To reduce the risk of serious
injury from pressurized fluid, accidental spray from
the gun or splashing fluid, follow this procedure
whenever you:
 Are instructed to relieve pressure,
 Stop pumping,
 Check, clean or service any system equipment,
 Install or clean fluid nozzles.
WARNING
1. Shut of f the air to the pump.
2. Open the dispensing valve, if used.
3. Open the fluid drain valve to relieve all fluid pres -
sure, having a container ready to catch the drain -
age.
Flush the Pump Before First Use
The pump was tested in water. If the water could
contaminate the fluid you are pumping, flush the pump
thoroughly with a compatible solvent. Follow the steps
under Starting and Adjusting the Pump.
Starting and Adjusting the Pump
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can
cause serious injury or death if splashed
in the eyes or on the skin, inhaled, or
swallowed. Do not lift a pump under pressure. If
dropped, the fluid section may rupture. Always fol -
low the Pressure Relief Procedure above before
lifting the pump.
WARNING
1. Be sure the pump is properly grounded. Refer to
Grounding on page 4.
2. Check all fittings to be sure they are tight. Be sure
to use a compatible liquid thread sealant on all
male threads. T ighten the fluid inlet and outlet
fittings securely .
3.
Place the suction tube (if used) in the fluid to be
pumped.
NOTE:
If the fluid inlet pressure to the pump is more
than 25% of the outlet working pressure, the ball check
valves will not close fast enough, resulting in inef ficient
pump operation.
4. Place the end of the fluid hose (L) into an appropri -
ate container .
5. Close the fluid drain valve (J). See Fig. 2.
6. With the pump air regulator (C) closed, open all
bleed-type master air valves (B, E).
7. If the fluid hose has a dispensing device, hold it
open while continuing with the following step.
8. Slowly open the air regulator (C) until the pump
starts to cycle. Allow the pump to cycle slowly until
all air is pushed out of the lines and the pump is
primed.
If you are flushing, run the pump long enough to
thoroughly clean the pump and hoses. Close the
air regulator . Remove the suction tube from the
solvent and place it in the fluid to be pumped.
Pump Shutdown
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
At the end of the work shift, relieve the pressure.

308-550 13
Maintenance
Lubrication
The air valve is designed to operate unlubricated.
However , if lubrication is desired, every 500 hours of
operation (or monthly) remove the hose from the pump
air inlet and add two drops of machine oil to the air
inlet.
CAUTION
Do not over-lubricate the pump. Oil is exhausted
through the muf fler , which could contaminate your
fluid supply or other equipment. Excessive lubrica -
tion can also cause the pump to malfunction.
Flushing and Storage
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
Flush the pump often enough to prevent the fluid you
are pumping from drying or freezing in the pump and
damaging it. Flush with a fluid that is compatible with
the fluid you are pumping and with the wetted parts in
your system. Check with your fluid manufacturer or
supplier for recommended flushing fluids and flushing
frequency.
Always flush the pump and relieve the pressure before
storing it for any length of time.
Tightening Threaded Connections
Before each use, check all hoses for wear or damage
and replace as necessary . Check to be sure all
threaded connections are tight and leak-free.
At least every two months, check and retorque all
threaded connections, including manifold screws,
cover screws, and air valve screws.
Preventive Maintenance Schedule
Establish a preventive maintenance schedule, based
on the pump’ s service history. This is especially impor -
tant for prevention of spills or leakage due to dia -
phragm failure.

14 308-550
Troubleshooting
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
1. Relieve the pressure before checking or servicing
the equipment.
2. Check all possible problems and causes before
disassembling the pump.
PROBLEM CAUSE SOLUTION
Pump cycles at stall or fails to hold
pressure at stall.
W orn check valve balls (301), seats
(201) or o-rings (202).
Replace. See page 18.
Pump will not cycle, or cycles once
and stops.
Air valve is stuck or dirty . Disassemble and clean air valve.
See pages 16–17. Use filtered air .
Check valve ball (301) severely
worn and wedged in seat (201) or
manifold (102 or 103).
Replace ball and seat. See page
18.
Check valve ball (301) is wedged
into seat (201), due to overpressur -
ization.
Install Pressure Relief V alve
(see page 9).
Dispensing valve clogged. Relieve pressure and clear valve.
Pump operates erratically . Clogged suction line. Inspect; clear .
Sticky or leaking balls (301). Clean or replace. See page 18.
Diaphragm ruptured. Replace. See pages 19–21.
Restricted exhaust. Remove restriction.
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm ruptured. Replace. See pages 19–21.
Loose inlet manifold (102), dam -
aged seal between manifold and
seat (201), damaged o-rings (202).
T ighten manifold bolts (1 12) or re-
place seats (201) or o-rings (202).
See page 18.
Loose fluid side diaphragm plate
(105). T
ighten or replace. See pages
19–21.

308-550 15
Troubleshooting
PROBLEM CAUSE SOLUTION
Fluid in exhaust air . Diaphragm ruptured. Replace. See pages 19–21.
Loose fluid side diaphragm plate
(105). T
ighten or replace. See pages
19–21.
Pump exhausts excessive air at
stall. W
orn air valve block (7), o-ring (6),
plate (8), pilot block (18), u-cups
(10), or pilot pin o-rings (17).
Inspect; replace. See pages 16–17.
W orn shaft seals (402). Replace. See pages 19–21.
Pump leaks air externally . Air valve cover (2) or air valve cover
screws (3) are loose.
T ighten screws. See page 17.
Air valve gasket (4) or air cover
gasket (22) is damaged.
Inspect; replace. See pages 16–17,
22–23.
Air cover screws (25) are loose. T ighten screws. See pages 22–23.
Pump leaks fluid externally from ball
check valves.
Loose manifolds (102, 103), dam -
aged seal between manifold and
seat (201), damaged o-rings (202).
T ighten manifold bolts (106 and
1 12) or replace seats (201) or
o-rings (202). See page 18.

 
Service
Repairing the Air Valve
Tools Required
T orque wrench
T orx screwdriver or 8 mm (or 5/16”) socket wrench
 Needle-nose pliers
 O-ring pick
 Lithium base grease
NOTE: Air V alve Repair Kit 236–273 is available.
Refer to page 27. Parts included in the kit are marked
with a symbol, for example (4  ). Use all the parts in
the kit for the best results.
Disassembly
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
1. Relieve the pressure.
2. With a torx screwdriver or 8 mm (or 5/16”) socket
wrench, remove the six screws (3), air valve cover
(2), and gasket (4). See Fig. 7.
3. Move the valve carriage (5) to the center position
and pull it out of the cavity . Remove the valve
block (7) and o-ring (6) from the carriage. Using a
needle-nose pliers, pull the pilot block (18) straight
up and out of the cavity . See Fig. 8.
4. Pull the two actuator pistons (1 1) out of the bear -
ings (12). Remove the u-cup packings (10) from
the pistons. Pull the pilot pins (16) out of the
bearings (15). Remove the o-rings (17) from the
pilot pins. See Fig. 9.
5. Inspect the valve plate (8) in place. If damaged,
use a torx screwdriver or 8 mm (or 5/16”) socket
wrench to remove the three screws (3). Remove
the valve plate (8) and seal (9). See Fig. 10.
6. Inspect the bearings (12, 15) in place. See Fig. 9.
The bearings are tapered and, if damaged, must
be removed from the outside. This requires disas -
sembly of the fluid section. See page 22.
7. Clean all parts and inspect for wear or damage.
Replace as needed. Reassemble as explained on
page 17.
04618
Torque to 28–33 in–lb
(3.2–3.7 N.m).
Fig. 7
3
24
2
2
04900
18
5
Fig. 8
1
2
See
Detail at right.
Grease.
3 Grease lower face.
1
7
6
5
2
3
3
11
16

 
Service
04901
Fig. 9 1716
11
10
12
15
1
2
Insert
narrow end first.
Grease.
3
Install with lips facing
narrow end of piston (1 1).
4
Insert wide end first.
1
2
3
4
2
03947
1
28
9
3
Rounded side must face down.
T ighten screws until
they bottom out on the
housing.
Fig. 10
1
2
Reassembly
1.
If you removed the bearings (12, 15), install new
ones as explained on page 22. Reassemble the
fluid section.
2. Install the valve plate seal (9  ) into the groove at
the bottom of the valve cavity . The rounded side of
the seal must face down into the groove. See
Fig. 10.
3. Install the valve plate (8) in the cavity . The plate is
reversible, so either side can face up. Install the
three screws (3), using a torx screwdriver or 8 mm
(or 5/16”) socket wrench. T ighten until the screws
bottom out on the housing. See Fig. 10.
4. Install an o-ring (17  ) on each pilot pin (16).
Grease the pins and o-rings. Insert the pins into
the bearings (15), narrow end first. See Fig. 9.
5. Install a u-cup packing (10  ) on each actuator
piston (1 1), so the lips of the packings face the
narrow end of the pistons. See Fig. 9.
6. Lubricate the u-cup packings (10  ) and actuator
pistons (1 1). Insert the actuator pistons in the
bearings (12), wide end first. Leave the narrow
end of the pistons exposed. See Fig. 9.
7. Grease the lower face of the pilot block (18 ) and
install so its tabs snap into the grooves on the
ends of the pilot pins (16). See Fig. 8.
8. Grease the o-ring (6  ) and install it in the valve
block (7  ). Push the block onto the valve carriage
(5). Grease the lower face of the valve block. See
Fig. 8.
9. Install the valve carriage (5) so its tabs slip into the
grooves on the narrow end of the actuator pistons
(1 1). See Fig. 8.
10. Align the valve gasket (4  ) and cover (2) with the
six holes in the center housing (1). Secure with six
screws (3), using a torx screwdriver or 8 mm (or
5/16”) socket wrench. T orque to 28–33 in–lb
(3.2–3.7 N.m). See Fig. 7.

18 308-550
Service
Ball Check Valve Repair
Tools Required
T orque wrench
 10 mm socket wrench
 O-ring pick
Disassembly
NOTE:
A Fluid Section Repair Kit is available. Refer to
page 25 to order the correct kit for your pump. Parts
included in the kit are marked with an asterisk, for
example (201*). Use all the parts in the kit for the best
results.
NOTE: T
o ensure proper seating of the balls (301),
always replace the seats (201) when replacing the
balls.
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
1. Relieve the pressure. Disconnect all hoses.
2. Remove the pump from its mounting.
3. Using a 10 mm socket wrench, remove the eight
bolts (106) holding the outlet manifold (103) to the
fluid covers (101). See Fig. 1 1.
4.
Remove the seats (201), balls (301), and o-rings
(202) from the manifold.
NOTE: Some models do not use o-rings (202).
5. T urn the pump over and remove the bolts (1 12)
and inlet manifold (102). Remove the seats (201),
balls (301), and o-rings (202) from the fluid covers
(101).
Reassembly
1.
Clean all parts and inspect for wear or damage.
Replace parts as needed.
2. Reassemble in the reverse order , following all
notes in Fig. 1 1. Be sure the ball checks are as -
sembled exactly as shown. The arrows (A) on the
fluid covers (101) must point toward the outlet
manifold (103).
04619
Fig. 11
1
2
Torque to 80–90 in–lb (9–10 N.m).
Arrow (A) must point toward outlet manifold (103).
106
103
101
A
201*
301*
112
102
201*
301*
2
1
1
202*
202*
3
Not used on some models.
3
3

 
Service
Diaphragm Repair
Tools Required
T orque wrench
 13 mm socket wrench
 Adjustable wrench
 19 mm socket wrench
 O-ring pick
 Lithium-base grease
Disassembly
NOTE:
A Fluid Section Repair Kit is available. Refer to
page 25 to order the correct kit for your pump. Parts
included in the kit are marked with an asterisk, for
example (401*). Use all the parts in the kit for the best
results.
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
1. Relieve the pressure.
2. Remove the manifolds and disassemble the ball
check valves as explained on page 18.
3. Using 13 mm socket wrenches, remove the
screws (107 and 108) holding the fluid covers
(101) to the air covers (23). Pull the fluid covers
(101) of f the pump. See Fig. 12.
04620
Fig. 12
1
2
23
101
A2
B
Arrow (A) must point toward air valve (B).
Y ou must torque the eight long screws (108) first, then the
short screws (107). T orque to 130–150 in–lb (15–17 N.m).
1
107
108 1

 
Service
4. Unscrew one outer plate (105) from the diaphragm
shaft (24). Remove one diaphragm (401), and the
inner plate (104). See Fig. 13.
NOTE: T eflon models include a T eflon diaphragm (403)
in addition to the backup diaphragm (401).
5. Pull the other diaphragm assembly and the dia -
phragm shaft (24) out of the center housing (1).
Hold the shaft flats with a 19 mm socket wrench,
and remove the outer plate (105) from the shaft.
Disassemble the remaining diaphragm assembly .
6.
Inspect the diaphragm shaft (24) for wear or
scratches. If it is damaged, inspect the bearings
(19) in place. If the bearings are damaged, refer to
page 22.
7. Reach into the center housing (1) with an o-ring
pick and hook the u-cup packings (402), then pull
them out of the housing. This can be done with the
bearings (19) in place.
8. Clean all parts and inspect for wear or damage.
Replace parts as needed.
Reassembly
1.
Grease the shaft u-cup packings (402*) and install
them so the lips face out of the housing (1). See
Fig. 13.
2. Grease the length and ends of the diaphragm shaft
(24) and slide it through the housing (1).
3. Assemble the inner diaphragm plates (104), dia -
phragms (401*), T eflon diaphragms (403*, if pres -
ent), and outer diaphragm plates (105) exactly as
shown in Fig. 13. These parts must be assembled
correctly.
4.
Apply medium-strength (blue) Loctite  or equiva -
lent to the threads of the fluid-side plates (105).
Hold one of the outer plates (105) with a wrench,
and torque the other outer plate to 160 to 200 in-lb
(18.1 to 22.6 N-m) at 100 rpm maximum. Do not
over-torque.
5.
Align the fluid covers (101) and the center housing
(1) so the arrows (A) on the covers face the same
direction as the air valve (B). Secure the covers
with the screws (107 and 108), handtight. Install
the longer screws (108) in the top and bottom
holes of the covers. See Fig. 12.
6. First, torque the longer screws (108) oppositely
and evenly to 130–150 in–lb (15–17 N.m), using a
13 mm socket wrench. Then torque the shorter
screws (107).
7. Reassemble the ball check valves and manifolds
as explained on page 18.