Graco 234124 Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1994, Graco Inc. is registered to I.S. EN ISO 9001
ALUMINUM AND STAINLESS STEEL
Huskyt1040 Air-Operated
Diaphragm Pumps
Aluminum Model Shown
120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure
120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure
*Model No. D73____ Aluminum Pumps
*Model No. D83____ Aluminum Pumps, Remote
*Model No. D74____ Stainless Steel Pumps
*Model No. D84____ Stainless Steel Pumps, Remote
*Model No. D7C____ Aluminum BSPT Pumps
*Model No. D8C____ Aluminum BSPT Pumps, Remote
*Model No. D7D____ Stainless Steel BSPT Pumps
*Model No. D8D____ Stainless Steel BSPT Pumps, Remote
*Model No. DR4____ Stainless Steel Plus Pumps
*Model No. DS4____ Stainless Steel Plus Pumps, Remote
*Model No. DRD____ Stainless Steel BSPT Plus Pumps
*Model No. DSD____ Stainless Steel BSPT Plus Pumps, Remote
Model No. 232501 Private–Label Aluminum 1040 Pump (See page 24.)
Model No. 234124 Private–Label Aluminum 1040 Pump (See page 24.)
*NOTE: Refer to the Pump Matrix on page 24 to determine
the Model No. of your pump.
NOTE: Plus models include stainless steel center sections.
US and Foreign Patents Pending
308479AB
Read warnings and instructions.
See page 2 for table of contents
02632C
Parts

2 308479
Table of Contents
Safety Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Matrix 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Kit Matrix 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Drawings 31. . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data and Performance Chart 32. . . . . . . . . . .
Graco Standard Warranty 34. . . . . . . . . . . . . . . . . . . . . .
Graco Information 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo 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.
DUse fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s
warnings.
DDo not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
DDo not use hoses to pull equipment.
DRoute 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).
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
WARNING
INSTRUCTIONS

308479 3
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.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
DPipe 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 Ventilation on
page 9.
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.
DGround the equipment. Refer to Grounding on page 4.
DIf 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.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
DPipe 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 Ventilation on page 9.
DKeep the work area free of debris, including solvent, rags, and gasoline.
DElectrically disconnect all equipment in the work area.
DExtinguish all open flames or pilot lights in the work area.
DDo not smoke in the work area.
DDo not turn on or off any light switch in the work area while operating or if fumes are present.
DDo not operate a gasoline engine in the work area.
WARNING

4 308479
Installation
General Information
DThe Typical Installations shown in Figs. 2–4 are
only guides for selecting and installing system
components. Contact your Graco distributor for
assistance in planning a system to suit your needs.
DAlways use Genuine Graco Parts and Accessories.
Refer to Product Data Sheet 305588.
DReference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 26–28.
DAluminum Husky 1040 Pump Model No. 239823,
with straight-thread manifolds, is available and can
be ordered separately.
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.
1. Read TOXIC FLUID HAZARD on page 3.
2. Use fluids and solvents which are compatible
with the equipment wetted parts. Refer to the
Technical Data section of all equipment manu-
als. Read the fluid and solvent manufacturer’s
warnings.
WARNING
Tightening Screws Before First Use
After you unpack the pump, and before you use it for
the first time, check and retorque external fasteners.
Retorque the fluid cover screws first, then the manifold
screws. This keeps the manifolds from interfering with
tightening the fluid covers. See the Service section for
torque specifications.
After the first day of operation, check and retorque the
fasteners again. Although the recommended fre-
quency for retorquing fasteners varies with pump
usage, a general guideline is to retorque fasteners
every two 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.
WARNING
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.
DPump: Connect a ground wire and clamp as shown
in Fig. 1. Loosen the grounding screw (W). Insert
one end of a 12 ga (1.5 mm@) minimum ground wire
(Y) behind the grounding screw and tighten the
screw securely. Connect the clamp end of the
ground wire to a true earth ground. Order Part
No. 222011 Ground Wire and Clamp.
Fig. 1
Y
W
02646B
DAir and fluid hoses: Use only grounded hoses with
a maximum of 500 ft (150 m) combined hose
length to ensure grounding continuity.
DAir compressor: Follow the manufacturer’s recom-
mendations.
DAll 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.
DFluid supply container: Follow the local code.

308479 5
Installation
Mountings
CAUTION
The pump exhaust air may contain contaminants.
Ventilate to a remote area if the contaminants
could affect your fluid supply. See Air Exhaust
Ventilation on page 9.
DBe sure the mounting surface can support the
weight of the pump, hoses, and accessories, as
well as the stress caused during operation.
DFor all mountings, be sure the pump is bolted
directly to the mounting surface.
DFor 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.
DRubber Foot Mounting Kit 236452 is available to
reduce noise and vibration during operation.
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. 3.
1. Install the air line accessories as shown in Figs.
2–4 on pages 7 and 8. Mount these accessories
on the wall or on a bracket. Be sure the air line
supplying the accessories is grounded.
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 above. 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 a grounded, flexible air hose (A) between
the accessories and the 1/2 npt(f) pump air inlet
(N). See Fig. 5. Use a minimum 3/8” (9.5 mm) ID
air hose. Screw an air line quick disconnect cou-
pler (D) onto the end of the air hose (A), and 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.
Installation of Remote Pilot Air Lines
1. Refer to Parts Drawings. Connect air line to pump
as in preceding steps.
2. Connect 1/4 in. O.D. tubing to push type connec-
tors (14) on air motor of pump.
NOTE: by replacing the push type connectors, other
sizes or types of fittings may be used. The new fittings
will require 1/8 in. npt threads.
3. Connect remaining ends of tubes to external air
signal, such as Graco’s Cycleflo (P/N 195264) or
Cycleflo II (P/N195265) controllers.
NOTE: the air pressure at the connectors must be at
least 30% of the air pressure to the air motor for the
pump to operate.
Fluid Suction Line
1. Use grounded fluid hoses. The pump fluid inlet (R)
is 1” npt(f). See Fig. 5. Screw the fluid fitting into
the pump inlet securely.
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
inefficient pump operation.
3. At inlet fluid pressures greater than 15 psi (0.1
MPa, 1 bar), diaphragm life will be shortened.
4. See the Technical Data on page 32 for maximum
suction lift (wet and dry).

6 308479
Installation
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. 3.
1. Use grounded fluid hoses (L). The pump fluid
outlet (S) is 1” npt(f). See Fig. 5. Screw the fluid
fitting into the pump outlet securely.
2. Install a fluid drain valve (J) near the fluid outlet.
See the WARNING above, and Figs. 2–4 on
pages 7 and 8.
3. Install a shutoff valve (K) in the fluid outlet line.

308479 7
Installation
02648
B
KEY FOR FIG. 2
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
G Fluid suction line
H Bung adapter
J Fluid drain valve (required)
K Fluid shutoff valve
L Fluid line
Y Ground wire (required; see page 4
for installation instructions)
Fig. 2
TYPICAL BUNG-MOUNT INSTALLATION
Y
J
FB
EC
A
D
G
H
KL
02651B
Fig. 3
TYPICAL FLOOR-MOUNT INSTALLATION
Y
J
FB
EC
A
D
KL
G
KEY FOR FIG. 3
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
G Fluid suction line
J Fluid drain valve (required)
K Fluid shutoff valve
L Fluid line
Y Ground wire (required; see page 4
for installation instructions)

8 308479
Installation
KEY FOR FIG. 4
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
G Fluid suction line
J Fluid drain valve (required)
K Fluid shutoff valve
L Fluid line
M Wall mounting bracket
Y Ground wire (required; see page 4
for installation instructions)
Fig. 4
TYPICAL WALL-MOUNT INSTALLATION
Y
J
FBEC
A
D
G
KL
M
02649B
Changing the Orientation of the Fluid Inlet
and Outlet Ports
On aluminum pumps, the fluid inlet and outlet man-
ifolds have threaded ports on both ends. The pump is
shipped with a plug installed in one end of each man-
ifold, and the opposite end open. See Fig. 5. To
change the orientation of the inlet and/or outlet port,
remove the plug from one end of a manifold and install
it in the opposite end.
On stainless steel pumps, the fluid inlet and outlet
manifolds have threaded ports on one end only. The
pump is shipped with the ports facing the same direc-
tion. To reverse the orientation of the ports:
1. Remove the screws and nuts holding the inlet
and/or outlet manifold to the covers.
2. Reverse the manifold and reattach. Install the
screws and torque to 120–150 in-lb (14–17 N.m).
02632C
KEY
N 1/2 npt(f) air inlet port
P Muffler. Air exhaust port is 3/4 npt(f)
R 1 npt(f) fluid inlet port
S 1 npt(f) fluid outlet port
106 Manifold and cover screws
3 Air valve screws
Fig. 5
1
2
Apply medium-strength
(blue) LoctiteRor equiv-
alent to the threads, and
torque to 120–150 in-lb
(14–17 N.m).
N
P
R
S
Torque to 50–60 in-lb
(5.6–6.8 NSm).
3
106 1
2
106 1

308479 9
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. You 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.
To provide a remote exhaust:
1. Remove the muffler (P) from the pump air exhaust
port.
2. Install a grounded air exhaust hose (T) and con-
nect the muffler (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. Avoid
sharp bends or kinks in the hose.
3. Place a container (U) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures.
See Fig. 6.
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 Grounded air exhaust hose
U Container for remote air exhaust
FBEC
A
D
VENTING EXHAUST AIR
P
T
U
02650

10 308479
Installation
Fluid Pressure Relief Kit
Pressure Relief Kit 235409 (V) is available for Aluminum Pumps, to prevent overpressurization and rupture of
the pump or hose. See Fig. 7. The kit includes instructions.
Thermal expansion of fluid in the outlet line can cause overpressurization. This can occur when using long fluid
lines exposed to sunlight or ambient 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
Fig. 7
1
2Connect fluid inlet line here.
KEY
R 1 npt(f) optional fluid inlet port
S 1 npt(f) optional fluid outlet port
V Pressure relief kit
R
S
Connect fluid outlet line here.
1
2
3
Install kit between fluid inlet and outlet manifolds.
V
3
02653C

308479 11
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
DAre instructed to relieve pressure
DStop pumping
DCheck, clean or service any system equipment
DInstall or clean fluid nozzles
WARNING
1. Shut off the air to the pump.
2. Open the dispensing valve, if used.
3. Open the fluid drain valve to relieve fluid pressure,
having a container ready to catch the drainage.
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
To reduce the risk of serious injury,
splashing in the eyes or on the skin, and
toxic fluid spills, never move or lift a
pump under pressure. If dropped, the fluid section
may rupture. Always follow the Pressure Relief
Procedure Warning above before lifting the pump.
WARNING
1. Be sure the pump is properly grounded. Refer to
Grounding on page 4.
2. Check fittings to be sure they are tight. Use a
compatible liquid thread sealant on male threads.
Tighten fluid inlet and outlet fittings securely.
3. Place the suction tube (if used) in fluid to be
pumped.
NOTE: If fluid inlet pressure to the pump is more than
25% of outlet working pressure, the ball check valves
will not close fast enough, resulting in inefficient pump
operation.
4. Place the end of fluid hose (L) into an appropriate
container.
5. Close the fluid drain valve (J).
6. Back out the air regulator (C) knob, and 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 increase air pressure with 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.
Operation of Remote Piloted Pumps
1. Follow preceding steps 1 through 7 of Starting
and Adjusting Pump.
2. Open air regulator (C).
WARNING
The pump may cycle once before the external sig-
nal is applied. Injury is possible. If pump cycles,
wait until end before proceeding.
3. Pump will operate when air pressure is alternately
applied and relieved to push type connectors (14).
NOTE: Leaving air pressure applied to the air motor for
extended periods when the pump is not running may
shorten the diaphragm life. Using a 3–way solenoid
valve to automatically relieve the pressure on the air
motor when the metering cycle is complete prevents
this from occurring.
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.

12 308479
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 muffler, 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 11.
Flush the pump often enough to prevent the fluid you
are pumping from drying or freezing in the pump and
damaging it. Use a compatible solvent.
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. Check
and retorque all threaded connections at least every
two months. Retorque the fluid cover screws first,
followed by the manifold screws.
The recommended frequency for retorquing of fasten-
ers varies with pump usage; a general guideline is to
retorque fasteners every two months.
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.

308479 13
Notes

14 308479
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
DRelieve the pressure before checking or servicing
the equipment.
DCheck all possible problems and causes before
disassembling the pump.
PROBLEM CAUSE SOLUTION
Pump cycles at stall or fails to hold
pressure at stall.
Worn 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 page 16. 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 Valve
(see page 10).
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).
Tighten manifold bolts (106) or re-
place seats (201) or o-rings (202).
See page 18.
Loose diaphragm shaft bolt (107). Tighten or replace (pages 19–21).
Damaged o-ring (108). Replace. See pages 19–21.

308479 15
Troubleshooting
PROBLEM CAUSE SOLUTION
Fluid in exhaust air. Diaphragm ruptured. Replace. See pages 19–21.
Loose diaphragm shaft bolt (107). Tighten or replace (pages 19–21).
Damaged o-ring (108). Replace. See pages 19–21.
Pump exhausts excessive air at
stall.
Worn air valve block (7), o-ring (6),
plate (8), pilot block (18), u-cups
(10), or pilot pin o-rings (17).
Repair or replace. See page 16.
Worn shaft seals (402). Replace. See pages 19–21.
Pump leaks air externally. Air valve cover (2) or air valve cover
screws (3) are loose.
Tighten screws. See page 16.
Air valve gasket (4) or air cover
gasket (22) is damaged.
Inspect; replace. See pages 16,
22–23.
Air cover screws (25) are loose. Tighten 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).
Tighten manifold bolts (106) or re-
place seats (201) or o-rings (202).
See page 18.

16 308479
Service
Repairing the Air Valve
Tools Required
DTorque wrench
DTorx (T20) screwdriver or 7 mm (9/32”) socket
wrench
DNeedle-nose pliers
DO-ring pick
DLithium base grease
NOTE: Air Valve Repair Kit 236273 is available. Refer
to page 25. 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
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
1. Relieve the pressure.
2. With a Torx (T20) screwdriver or 7 mm (9/32”)
socket wrench, remove the six screws (3), air
valve cover (2), and gasket (4). See Fig. 8.
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. 9.
4. Pull the two actuator pistons (11) 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
push pins. See Fig. 10.
5. Inspect the valve plate (8) in place. If damaged,
use a Torx (T20) screwdriver or 7 mm (9/32”)
socket wrench to remove the three screws (3).
Remove the valve plate (8) and seal (9). See Fig.
11.
6. Inspect the bearings (12, 15) in place. See Fig. 10.
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 16.
Reassembly
1. If you replaced the bearings (12, 15), reinstall as
explained on page 22. Reassemble the fluid sec-
tion.
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. 11.
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 (T20) screwdriver or
7 mm (9/32”) socket wrench. Tighten until the
screws bottom out on the housing. See Fig. 11.
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. 10.
5. Install a u-cup packing (10{) on each actuator
piston (11), so the lips of the packings face the
narrow end of the pistons. See Fig. 10.
6. Lubricate the u-cup packings (10{) and actuator
pistons (11). Insert the actuator pistons in the
bearings (12), wide end first. Leave the narrow
end of the pistons exposed. See Fig. 10.
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. 9.
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. 9.
9. Install the valve carriage (5) so its tabs slip into the
grooves on the narrow end of the actuator pistons
(11). See Fig. 9.
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 (T20) screwdriver or 7
mm (9/32”) socket wrench. Torque to 50–60 in-lb
(5.6–6.8 N.m). See Fig. 8.

308479 17
Service
Torque to 50–60 in-lb
(5.6–6.8 NSm).
Fig. 8
3
2
4{
22
02644B
18{5
Fig. 9
1
2
See Detail at right.
Grease.
3Grease lower face.
1
{7
{6
5
2
3
02642
3
Detail
02643
Fig. 10
17{16
11
10{
12
15
1
2
Insert narrow end first.
Grease.
3Install with lips facing
narrow end of piston (11).
4Insert wide end first.
1
2
3
4
2
02645
1
2
8
{9
3
Rounded side must face down.
Tighten screws until
they bottom out on
the housing.
Fig. 11
1
2

18 308479
Service
Ball Check Valve Repair
Tools Required
DTorque wrench
D10 mm socket wrench
DO-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: To ensure proper seating of the balls (301),
always replace the seats (201) when replacing the
balls. Also, on some models, replace the o-rings (202).
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
1. Relieve the pressure. Disconnect all hoses.
2. Remove the pump from its mounting.
3. Using a 10 mm socket wrench, remove the four
bolts (106) and nuts (114, used on stainless steel
pumps only) holding the outlet manifold (103) to
the fluid covers (101). See Fig. 12.
4. Remove the o-rings (202, not used on some
models), seats (201), and balls (301) from the
manifold (103).
5. Turn the pump over and remove the inlet manifold
(102). Remove the o-rings (202, not used on some
models), seats (201), and balls (301) 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. 12. Be sure the ball checks and
manifolds are assembled exactly as shown. The
arrows (A) on the fluid covers (101) must point
toward the outlet manifold (103).
02647C
Fig. 12
1
3
2
Apply medium-strength (blue) LoctiteRor equivalent to the
threads, and torque to 120–150 in-lb (14–17 N.m).
Beveled seating surface must face the ball (301).
Arrow (A) must point toward outlet manifold (103).
4Not used on some models.
106
103
101
A
201*
301*
106
102
201*
301*
2
1
1
202*
202*
4
4
3
3
Aluminum Model Shown

308479 19
Service
Diaphragm Repair
Tools Required
DTorque wrench
D10 mm socket wrench
D15 mm socket wrench (aluminum models) or
1” socket wrench (stainless steel models)
D19 mm socket wrench
DO-ring pick
DLithium-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
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 11.
1. Relieve the pressure.
2. Remove the manifolds and disassemble the ball
check valves as explained on page 18.
3. Using a 10 mm socket wrench, remove the screws
(106) holding the fluid covers (101) to the air
covers (23). Pull the fluid covers (101) off the
pump. See Fig. 13.
Fig. 13
1
2
23
101
106
A2
B
Arrow (A) must point toward air valve (B).
Apply medium-strength (blue) LoctiteRor equivalent to
the threads, and torque to 120–150 in-lb (14–17 N.m).
1
02635B

20 308479
Service
4. Loosen but do not remove the diaphragm shaft
bolts (107), using a 15 mm socket wrench (1” on
stainless steel models) on both bolts.
5. Unscrew one bolt from the diaphragm shaft (24)
and remove the o-ring (108), fluid side diaphragm
plate (105), Rdiaphragm (403, used on
Rmodels only), diaphragm (401), and air
side diaphragm plate (104). See Fig. 14.
6. 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 bolt (107) from the shaft. Disas-
semble the remaining diaphragm assembly.
7. 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.
8. 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.
9. Clean all parts and inspect for wear or damage.
Replace parts as needed.
Reassembly
1. Install the shaft u-cup packings (402*) so the lips
face out of the housing (1). Lubricate the pack-
ings. See Fig. 14.
2. Install the diaphragm assembly on one end of the
shaft (24) as follows:
a. Install the o-ring (108*) on the shaft bolt (107).
b. Install the fluid side diaphragm plate (105) on
the bolt so the rounded side faces the dia-
phragm (401).
NOTE: On stainless steel pumps only, the fluid side
diaphragm plate (105) is stainless steel. This plate is
not stamped with its part number. Be sure to install
this plate on the fluid side of the diaphragm.
c. On Rmodels only, install the R
diaphragm (403*). Make certain the side
marked AIR SIDE faces the center hous-
ing (1).
d. Install the diaphragm (401*) on the bolt. Make
certain the side marked AIR SIDE faces the
center housing (1).
e. Install the air side diaphragm plate (104) so
the rounded side faces the diaphragm (401).
This plate is used on all models, and is
stamped with its part number.
f. Apply medium-strength (blue) LoctiteRor
equivalent to the bolt (107) threads. Screw the
bolt into the shaft (24) hand tight.
3. Grease the length and ends of the diaphragm shaft
(24), and slide it through the housing (1).
4. Assemble the other diaphragm assembly to the
shaft as explained in step 2.
5. Hold one shaft bolt (107) with a wrench and torque
the other bolt to 20–25 ft-lb (27–34 N.m) at 100
rpm maximum.
6. 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). Apply medium-
strength (blue) LoctiteRor equivalent to the
threads of the screws (106). Secure the covers
with the screws handtight. See Fig. 13. Using a 10
mm socket wrench, torque the screws oppositely
and evenly to 120–150 in-lb (14–17 N.m).
7. Reassemble the ball check valves and manifolds
as explained on page 18.
PTFE
PTFE
PTFE
PTFE