Graco 241407 Operation manual

308797S
Instructions – Parts List
ALUMINUM
HuskyTM 716 Air-operated
Diaphragm Pumps
Used to evacuate and transfer fluids.
100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Input Pressure
Part No. 241407, Series D
with two- direction manifolds
Part No. 241408, Series D
with single- direction manifolds
Patents Pending
Important Safety Instructions.
Read all warnings and instructions in this
manual. Save these instructions.
II 2 GD
Ex h IIC 66°C...135°C Gb
Ex h IIIC T135°C Db
ATEX T-code rating is dependent on the
temperature of the fluid being pumped. Fluid
temperature is limited by the materials of the
pump interior wetted parts. See Technical
Data for the maximum fluid operating tem-
perature for your specific pump model.
9246A
Model No. 241407
EN

2 308797
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
241407 and 241408 Parts Drawing . . . . . . . . . . . . . . 18
241407 and 241408 Repair Kits . . . . . . . . . . . . . . . . . 21
Husky 716 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 22
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Graco Standard Husky Pump Warranty . . . . . . . . . . . 26
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Symbols
Warning Symbol
This symbol alerts you to the possibility of serious injury or
death if you do not follow the instructions.
Caution Symbol
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the
instructions.
WARNING
CAUTION
WARNING
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 100 psi (0.7 MPa, 7 bar) maximum working pressure at 100 psi (0.7
MPa, 7 bar) maximum incoming air pressure.
•Use fluids and solvents that 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.
•Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 82°C (180°F) or below - 40°C (- 40°F).
•Wear hearing protection when operating this equipment.
•Do not lift pressurized equipment.
•Comply with all applicable local, state, and national fire, electrical, and safety regulations.
•Do 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.

308797 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.
•Know the specific hazards of the fluid you are using.
•Do not lift a pump under pressure. If dropped, the fluid section may rupture. Always follow the
Pressure Relief Procedure on page 10 before lifting the pump.
•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. Read Air Exhaust Ventilation on
page 6.
•Never use an acetal pump to pump acids. Take precautions to avoid acid or acid fumes from
contacting the pump housing exterior. Stainless steel parts will be damaged by exposure to acid
spills and fumes.
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 8.
•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 pumped.
•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. Read Air Exhaust Ventilation on page 6.
•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 off 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

4 308797
Installation
General Information
•The Typical Installations in Fig. 2 are only guides for
selecting and installing system components. Contact
your Graco distributor for assistance in planning a
system to suit your needs.
•Always use Genuine Graco Parts and Accessories.
•Use a compatible, liquid thread sealant on all male
threads. Tighten all connections firmly to avoid air or
fluid leaks.
Tightening Threaded Fasteners Before First
Use
Before using the pump for the first time, check and
retorque all external fasteners. See Torque Sequence,
page 20. After the first day of operation, retorque the
fasteners. Although pump use varies, a general guideline
is to retorque fasteners every two months.
Toxic Fluid Hazard
Read Toxic Fluid Hazard on page 3.
Use fluids and solvents that 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.
Mountings
•These pumps can be used in a variety of installations.
Be sure the mounting surface can support the weight
of the pump, hoses, and accessories, as well as the
stress caused during operation.
•Fig. 2 shows some installation examples. On all
installations, mount the pump using screws and nuts.
Pumping High-Density Fluids
High density fluids may prevent the lighter non-metallic
check valve balls from seating properly, which reduces
pump performance significantly. Stainless steel balls
should be used for such applications.
CAUTION
Safe Operating Temperatures
Minimum: 40° F (4° C)
Maximum: 225° F (107° C)
These temperatures are based upon mechanical stress only and
may be significantly altered by pumping certain chemicals.
Consult engineering guides for chemical compatibilities and
temperature limits, or contact your Graco distributor.

308797 5
Installation
Air Line
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 accessories is
electrically conductive.
a. The fluid pressure can be controlled in either of
two ways. To control it on the air side, install an
air regulator (G). To control it on the fluid side,
install a fluid regulator (J) near the pump fluid
outlet (see Fig. 2).
b. Locate one bleed-type master air valve (B) close
to the pump and use it to relieve trapped air.
Read 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 an electrically conductive, flexible air hose (C)
between the accessories and the 1/4 npt(f) pump air
inlet. Use a minimum 1/4 in. (6.3 mm) ID air hose.
Screw an air line quick disconnect coupler (D) onto
the end of the air hose (C), and screw the mating
fitting into the pump air inlet snugly. Do not connect
the coupler (D) to the fitting yet.
Fluid Suction Line
•If using a conductive (acetal) pump, use conductive
hoses. If using a non-conductive pump, ground the
fluid system. Read Grounding on page 8. The fluid
inlet port is 3/4 in.
•At inlet fluid pressures greater than 15 psi (0.1 MPa, 1
bar), diaphragm life will be shortened.
Fluid Outlet Line
1. Use electrically conductive fluid hoses (K). The pump
fluid outlet is 3/4 in. Screw the fluid fitting into the
pump outlet snugly. Do not overtighten.
2. Install a fluid regulator (J) at the pump fluid outlet to
control fluid pressure, if desired (see Fig. 2). See Air
Line, step 1a, for another method of controlling
pressure.
3. Install a fluid drain valve (H) near the fluid outlet.
Read the WARNING above.
WARNING
A bleed-type master air valve (B) is required in your
system to relieve air trapped between this valve and the
pump. See Fig. 2. 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.
CAUTION
The pump exhaust air may contain contaminants.
Ventilate to a remote area if the contaminants could
affect your fluid supply. Read Air Exhaust Ventilation
on page 6.
WARNING
A fluid drain valve (H) is required in your system to
relieve pressure in the hose if it is plugged. See Fig. 2.
The drain valve reduces the risk of serious injury,
including splashing in the eyes or on the skin, or
contamination from hazardous fluids when relieving
pressure. Install the valve close to the pump fluid outlet.

6 308797
Installation
Fluid Pressure Relief Valve
Install valve between fluid inlet and outlet ports.
Connect fluid inlet line here.
Connect fluid outlet line here.
Air Exhaust Ventilation
The air exhaust port is 3/8 npt(f). Do not restrict the air
exhaust port. Excessive exhaust restriction can cause
erratic pump operation.
See Venting Exhaust Air in Fig. 2. Exhaust to a remote
location as follows:
1. Remove the muffler (W) from the pump air exhaust
port.
2. Install an electrically conductive air exhaust hose (X)
and connect the muffler to the other end of the hose.
The minimum size for the air exhaust hose is 3/8 in.
(10 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 (Z) at the end of the air exhaust line
to catch fluid in case a diaphragm ruptures. See Fig.
2.
Fig. 1
CAUTION
Some systems may require installation of a pressure
relief valve at the pump outlet to prevent
overpresurization and rupture of the pump or hose.
See Fig. 1.
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.
1
2
3
1
2
3
9073A
Read Toxic Fluid Hazard on page 3.
Read Fire and Explosion
Hazard on page 3.
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 handling 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 appropriate container at
the end of the air exhaust line to catch the fluid. See Fig.
2.

308797 7
Installation
ABOVE-GROUND TRANSFER INSTALLATION
55-GALLON BUNG PUMP INSTALLATION
VENTING EXHAUST AIR
Fig. 2
9074A
H
J
A
CD
K
L
M
N
Y
E
F
B
G
9075A
H
A
CD
K
L
Y
W
X
Z
04054
KEY
A Pump
B Bleed-type master air valve (required for pump)
C Electrically conductive air supply line
D Air line quick disconnect
E Master air valve (for accessories)
F Air line filter
G Pump air regulator
H Fluid drain valve (required)
J Fluid regulator (optional)
K Electrically conductive fluid supply hose
L Fluid suction line
M Underground storage tank
N Wall mounting bracket
Y Ground wire (required; see page 8 for installation
instructions)
KEY
A Pump
C Electrically conductive air supply line
D Air line quick disconnect
H Fluid drain valve (required)
K Electrically conductive fluid supply hose
L Fluid suction line
Y Ground wire (required; see page 8 for
installation instructions)
KEY
W Muffler
X Electrically Conductive Air Exhaust Hose
Z Container for Remote Air Exhaust
All wetted and non-wetted pump parts must be compatible with
the fluid being pumped.

8 308797
Installation
Grounding
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 equipment.
NOTE: See the WARNING above. Fig. 3 shows a
recommended method of grounding flammable fluid
containers during filling.
Ground all of this equipment:
•Pump: The metal pump has a grounding strip in front
of the center housing. Connect the non-clamp end of
the ground wire to the grounding strip and connect
the clamp end of the ground wire to a true earth
ground. To order a ground wire and clamp, order Part
No. 222011.
•Air and fluid hoses: Use only electrically conductive
hoses.
•Air compressor: Follow the manufacturer’s
recommendations.
•Solvent pails used when flushing: Follow the local
code. Use only grounded metal pails, which are
conductive. Do not place the pail on a non-conductive
surface, such as paper or cardboard, which interrupts
the grounding continuity.
•Fluid supply container: Follow the local code.
GROUNDING A PUMP
KEY
APump
H Fluid drain valve (required)
S Dispense valve
T Fluid drain line
Y Fluid section grounding via grounding strip or grounding
screw (required for metal and acetal pumps)
Z Container ground wire (required)
Hose must be conductive.
Dispense valve nozzle must be in contact with container.
Fig. 3
WARNING
FIRE AND EXPLOSION HAZARD
This pump must be grounded. Before
operating the pump, ground the system as
explained below. Also read the section Fire
and Explosion Hazard on page 3.
The metal Husky 716 pumps have a
grounding strip connecting the vee clamps
(109). Attach a ground wire to the grounding strip with
the screw, lockwasher, and nut as shown in the
Grounding Detail on page 18.
When pumping conductive flammable fluids, always
ground the entire fluid system by making sure the fluid
system has an electrical path to a true earth ground (see
Fig. 3).
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 1012
ohm-centimeters.
1
2
9
A
H
S
T
Z
2
1
Y
Y

308797 9
Installation
Changing the Orientation of the Fluid Inlet
and Outlet Ports
Fig. 4. You can change the orientation of the fluid inlet and
outlet ports by repositioning the manifolds.
2. Remove four manifold bolts (105).
3. Turn manifold to desired position, reinstall bolts, and
torque to 80 to 90 in-lb (9 to 10 N•m). See Torque
Sequence, page 20.
NOTE: Make sure all manifold o-rings are positioned
correctly before you fasten the manifold. Manifold o-rings
(139) are shown in Fig. 6.
Fig. 4
1.
Relieve the pressure. See
Pressure Relief Procedure on
page 10.
1
1105
9071A
1105
Torque to 80 to 90 in-lb (9 to 10 N•m). See Torque
Sequence, page 20.
outlet
inlet

10 308797
Operation
Pressure Relief Procedure
1. Shut off the air to the pump.
2. Open the dispensing valve, if used.
3. Open the fluid drain valve to relieve all fluid pressure,
and have a container ready to catch the drainage.
Flush Pump Before First Use
The pump was tested with water. If water could
contaiminate the fluid you are pumping, flush the pump
thoroughly with a compatible solvent before using the
equipment. Follow the steps under Starting and
Adjusting Pump.
Starting and Adjusting Pump
4. Check all fittings to be sure they are tight. Use a
compatible liquid thread sealant on all male threads.
Tighten the fluid inlet and outlet fittings snugly. Do not
overtighten the fittings into the pump.
5. Place the suction tube (if used) in the fluid to be
pumped.
NOTE: If the inlet fluid 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.
6. Place the end of the fluid hose (K) into an appropriate
container.
7. Close the fluid drain valve (H).
8. With the pump air regulator (G) closed, open all
bleed-type master air valves (B, E).
9. If the fluid hose has a dispensing device, hold it open
while continuing with the following step. Slowly open
the air regulator (G) 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. Fig. 2 and Parts Drawings. Follow preceding steps 1
through 8 of Starting and Adjusting Pump.
2. Open air regulator (G).
3. Pump will operate when air pressure is alternately
applied to push type connectors (16).
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
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until pressure is
manually relieved. To reduce the risk of serious injury
from pressurized fluid, accidental spray, 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
1.
Read Toxic Fluid Hazard on
page 3.
2.
If lifting the pump, follow the Pressure
Relief Procedure above.
3.
If lifting the pump, follow
the Pressure Relief
Procedure above.
WARNING
The pump may cycle once before the external
signal is applied. Injury is possible. If pump
cycles, wait until end before proceeding.
At the end of the work shift, relieve the
pressure as described in Pressure Relief
Procedure at left.

308797 11
Maintenance
Lubrication
The air valve is lubricated at the factory to operate without
additional lubrication. If you want to provide additional
lubrication, remove the hose from the pump air inlet and
add two drops of machine oil to the air inlet every 500
hours of operation or every month.
Flushing and Storage
Flush the pump 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
you store 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 fasteners. Tighten or retorque as necessary.
Although pump use varies, a general guideline is to
retorque fasteners every two months. See Torque
Sequence, page 20.
Preventive Maintenance Schedule
Establish a preventive maintenance schedule, based on
the pump’s service history. This is especially important for
prevention of spills or leakage due to diaphragm failure.
CAUTION
Do not over-lubricate the pump. Oil is exhausted
through the muffler, which could contaminate your
fluid supply or other equipment. Excessive
lubrication can also cause the pump to
malfunction.
Read Pressure Relief Procedure on page
10.

12 308797
Troubleshooting
Read Pressure Relief Procedure on page 10, and relieve the pressure before you check or
service the equipment. Check all possible problems and causes before disassembling the pump.
PROBLEM CAUSE SOLUTION
Pump will not cycle, or cycles
once and stops.
Air valve is stuck or dirty. Use filtered air.
Pump cycles at stall or fails to
hold pressure at stall.
Leaky check valves or o-rings. Replace.
Worn check balls or duckbill valves
or guides.
Replace.
Check ball wedged in guide. Repair or replace.
Worn diaphragm shaft seals. Replace.
Pump operates erratically. Clogged suction line. Inspect; clear.
Sticky or leaking check valve balls. Clean or replace.
Diaphragm ruptured. Replace.
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm ruptured. Replace.
Loose manifolds or damaged
manifold o-rings.
Tighten manifold bolts or nuts;
replace o-rings.
Loose fluid side diaphragm plates. Tighten.
Fluid in exhaust air. Diaphragm ruptured. Replace.
Loose fluid side diaphragm plates. Tighten.
Worn diaphragm shaft seals. Replace.
Pump exhausts air from clamps
(metal pumps).
Loose clamps. Tighten clamp nuts.
Air valve o-ring is damaged. Inspect; replace.
Pump leaks fluid from check
valves.
Worn or damaged check valve
o-rings.
Inspect; replace.

308797 13
Service
Air Valve
NOTE: Air Valve Repair Kit 241657 is available. Parts included in the kit are marked with a dagger (†) in Fig. 5 and in
the Parts Drawings and Lists. A tube of general purpose grease 111920 is supplied in the kit. Service the air valve as
follows. See Fig. 5.
2. Remove the cover (10) and the o-ring (4).
3. Remove the carriage plungers (7), carriages (8),
carriage pins (9), and valve plate (14) from the center
housing (11).
4. Clean all the parts, and inspect them for wear or
damage.
NOTE: If you are installing the new Air Valve Repair
Kit 241657, use all the parts in the kit.
5. Grease the lapped surface of the valve plate (14), and
install the valve plate with the lapped surface facing
up.
6. Grease the bores of the center housing (11), install
the u-cup packings (2) on the carriage plungers (7),
and slide the carriage plungers into the carriage
plunger bores. See the following important installation
notes:
NOTE: Center housing (11) is shown separated
from the air covers, but it is not necessary to
remove the air covers for this service. Leave the
center housing and air covers assembled for
this service
† Included in Air Valve Repair Kit 241657
Torque to 80 to 100 in-lb (9.0 to 13.6 N-m).
Apply grease.
Apply grease to lapped face.
Apply grease to bores of center housing (11) before installing.
Seal lips face clip end (the smaller end) of carriage plunger (7).
Install with the clip ends (the smaller ends) facing toward center
of center housing (11).
NOTE:
•When you install each u-cup packing (2) on each
carriage plunger (7), make sure the lips of the u-cup
packing face toward the clip end (the smaller end) of
the carriage plunger.
•When you slide the carriage plungers (7) into the
bores, slide them in with the clip ends (the smaller
ends) facing toward the center of the center housing
(11).
7. Grease the carriage pins (9), and slide the carriage
pins into the carriage pin bores.
8. Install the carriages (8). Make sure the carriages
engage the clip ends of the carriage plungers (7) and
carriage pins (9).
9. Grease the o-ring (4), and seat it in the groove around
the cover opening of the center housing (11).
10. Screw the cover (10) into the center housing, and
torque the cover to 80 to 100 in-lb (9.0 to 13.6 N-m).
Fig. 5
1. Relieve the pressure. See Pressure
Relief Procedure on page 10.
1
2
3
4
5
6
9†
14†
†2
†8
†7
9†
8†
2†
7†
4
10
1
3
4
4
2
11
2
2
5
5
9069A
4 6
4 6

14 308797
Service
Ball Check Valves
NOTE: Fluid Section Repair Kit D05977 is available. See
page 21 to order the correct kit for your pump. Parts
included in the kit are marked with a double dagger (‡) in
Fig. 6 and in the Parts Drawings and Lists. General
purpose grease 111920 and Adhesive 113500 are
supplied in the kit.
2. Remove the top and bottom manifolds (102, 103).
3. Remove all parts shown with a dagger (‡) Fig. 6.
4. Clean all parts, and replace worn or damaged parts.
5. Reassemble the pump.
NOTE: Torque the manifold bolts (105) to 80 to 90
in-lb (9 to 10 N•m). See Torque Sequence, page 20.
1. Relieve the pressure. See Pressure
Relief Procedure on page 10.

308797 15
Service
Fig. 6
‡ 139
‡ 201
101
‡ 202
‡ 139
‡ 139
‡ 201
‡ 202
‡ 139
‡ 301
‡ 301
105
105
106
106
107
102
102
1
1
1
9081A
Torque to 80 to 90 in-lb (9 to 10 N•m). See
Torque Sequence, page 20.

16 308797
Service
Diaphragms
NOTE: Fluid Section Repair Kit D05977 is available. Parts included in the kit are marked with a double dagger (‡) in Fig.
7 and in the Parts Drawings and Lists. General purpose grease 111920 and Adhesive 113500 are supplied in the kit.
Service the diaphragms as follows. See Fig. 7.
Disassembly
2. Remove the manifolds (102) and fluid covers (101).
NOTE: Make sure all the check valve parts stay in
place. See Fig. 6 on page 15.
3. Remove the grounding strip from the vee clamps
(109), and remove the vee clamps.
4. Remove one of the fluid-side diaphragm plates (133)
(whichever one comes loose first when you use a
wrench on the hex of each), and pull the diaphragm
shaft out of the center housing (11).
5. Use a wrench on the flats of the diaphragm shaft (15)
to remove the other fluid-side diaphragm plate (133)
from the diaphragm shaft.
6. Remove the screws (141) and air covers (136), and
remove all old gasket (12) material from the ends of
the center housing (11) and the surfaces of the air
covers.
7. Remove the diaphragm shaft u-cups (16) and pilot pin
o-rings (1).
8. Inspect all parts for wear or damage, and replace as
necessary.
Reassembly
1. Insert a diaphragm shaft u-cup (16) and a pilot pin
o-ring (1) into the end of the diaphragm shaft bore of
the center housing (11).
NOTE: Make sure the lips of the u-cup face out of the
center housing.
2. Line up the holes in the gasket (12) with the holes in
the end of the center housing (11), and use six
screws (141) to fasten an air cover (136) to the end of
the center housing (11). Torque the screws to 35 to
45 in-lb (4.0 to 5.1 N-m).
3. Position the exhaust cover (13) and o-ring (4) on the
center housing (11).
4. Repeat steps 1 and 2 for the other end of the center
housing and the remaining air cover.
5. Apply medium-strength (blue) Loctite or equivalent to
the threads of the screws (140). Install on one end of
the diaphragm shaft (15) the following parts (see
proper order in Fig. 7): air-side diaphragm plate (6),
diaphragm (401), fluid-side diaphragm plate (133),
o-ring (115), and screw (140).
NOTE: The words “AIR SIDE” on the diaphragm
(401) and the flat side of the air-side diaphragm plate
(6) must face toward the diaphragm shaft (15).
6. Put grease on the diaphragm shaft (15), and carefully
(do not damage the shaft u-cups) run the diaphragm
shaft (15) through the center housing (11) bore.
7. Repeat step 5 for the other end of the diaphragm
shaft (15), and torque the diaphragm shaft screws
(140) to 80 to 90 in-lb (9 to 10 N-m) at 100 rpm
maximum.
8. Install the muffler (3).
When you install the vee clamps in step 10, orient the
center housing (11) so the air inlet is approximately 45°
above horizontal and the muffler (3) is approximately
horizontal.
9. Apply thin, even film of grease to inside of vee clamp
(109).
10. Position the fluid covers (101), install the vee clamps
(109) around the fluid and air covers, install the
grounding strip on the vee clamps, and torque the vee
clamp nuts to 80 to 90 in-lb (9 to 10 N•m). See
Torque Sequence, page 20.
11. Make sure all the check valve parts are in place. See
Fig. 6 on page 15.
12. Install the manifolds (102), and torque the manifold
bolts (105) to 80 to 90 in-lb (9 to 10 N•m). See
Torque Sequence, page 20.
1. Relieve the pressure. See Pressure
Relief Procedure on page 10.

308797 17
Service
Diaphragms
‡ Included in Fluid Section Repair Kit D05977
Install with lips facing out of center housing (11).
Torque to 35 to 45 in-lb (4.0 to 5.1 N-m).
Apply grease.
The words “AIR SIDE” on diaphragm and backup diaphragm must face toward diaphragm
shaft (15).
Flat side of the air-side diaphragm plate must face toward diaphragm shaft (15).
Apply medium-strength (blue) Loctite® or equivalent to threads, and torque to 80 to 90 in-lb
(9 to 10 N-m) at 100 rpm maximum.
Torque to 80 to 90 in-lb (9 to 10 N•m). See Torque Sequence, page 20.
9072A
Fig. 7
11
5
101
102
102
105
105
‡401
‡402 6
140
‡115 ‡16 1
3
109
141
2
4
4
6
7
7
136
12‡
4
3
16‡1
13
133
15
3
1
2
3
4
5
6
7

18 308797
241407 and 241408 Parts Drawing
† Included in Air Valve Repair Kit 241657
‡ Included in Fluid Section Repair Kit D05977
11
4
13
10
‡ 16
‡ 139
‡ 201
134
4
15
‡ 1
109
101
102
102
‡ 202
‡ 139
‡ 301
108
112
112
‡ 401
‡ 402
103
117
105
105
106
106
107
6
133
‡ 115
121
122
123
†9
8†7†2†
‡ 12
110
16 ‡
‡ 139
‡ 201
‡ 202
‡ 139
‡ 301
9070A
140
141
3
†14
Grounding Detail

308797 19
241407 and 241408 Parts List
Fluid Section Parts List
Air Motor Parts List
Guide Parts List
Ball Parts List
Diaphragm Parts List
* Item 112, 102726 used on 241408, item 125, 100896
used on 241407
† Included in Air Valve Repair Kit 241657
‡ Included in Fluid Section Repair Kit D05977
Ref.
No.
Part
No.
Description Qty
101 185622 COVER, fluid; aluminum 2
102 185624 MANIFOLD; aluminum; NPT 2
103 189220 LABEL, warning 1
105 112912 SCREW; 3/8--16; 2.25 in. (57.2
mm)
8
106 112913 NUT, hex; 3/8--16; sst 8
107 112914 WASHER, flat; 3/8 in.; sst 4
108 186207 BASE, feet 2
109 189540 CLAMP, vee 2
110 112499 NUT, clamp; 1/4--28 2
111 191079 STRIP, grounding 1
112* 102726 PLUG, steel; NPT 2
115‡ 110004 O-RING; PTFE 2
117 186205 LABEL, warning 1
121 102790 SCREW; 10--24; 0.31 in. (8 mm) 1
122 100718 LOCKWASHER; #10 1
123 100179 NUT, hex; 10--24 1
125* 100896 BUSHING, 3/4 X 1/2 npt 4
133 191837 PLATE, diaphragm, fluid side; sst 2
134 290045 PLATE, designation 1
136 194246 COVER air 2
139‡ 110636 O-RING; PTFE 8
140 113747 SCREW, flange; hex head 2
141 114882 SCREW, machine, torx 12
142 111183 RIVET (for plate 134) 2
Ref.
No.
Part
No.
Description Qty
1‡ 114866 PACKING, o-ring 2
2† 108808 PACKING, u-cup 2
3 112933 MUFFLER 1
4† 162942 PACKING, o-ring 2
6 195025 PLATE, diaphragm, air side 2
7† 15Y825 PLUNGER, carriage 2
8† 192595 CARRIAGE 2
9† 192596 PIN, carriage 2
10 192597 COVER, valve chamber 1
11 192602 HOUSING, center 1
12† 192765 GASKET 2
13 194247 COVER, exhaust 1
14† 194269 PLATE, valve 1
15 192601 SHAFT, diaphragm 1
Ref.
No.
Part
No.
Description Qty
201‡ 186776 GUIDE, polypropylene 4
202‡ 186777 STOP, polypropylene 4
Ref.
No.
Part
No.
Description Qty
301‡ 108944 BALL, buna-N 4
Ref.
No.
Part
No.
Description Qty
16‡ 108808 PACKING, u-cup 2
401‡ 190148 DIAPHRAGM, buna-N 2

20 308797
Torque Sequence
Always follow torque sequence when instructed to torque fasteners.
1. Left/Right Fluid
Covers Torque bolts to 80–90 in–lb (9–10 N•m).
2. Inlet Manifold
Torque bolts to 80–90 in–lb (9–10 N•m).
3. Outlet Manifold
Torque bolts to 80–90 in–lb (9–10 N•m).
1
2
FRONT VIEW
3
46
5
46
BOTTOM VIEW
7
9
10
8
TOP VIEW