Graco ChemSafe 515 Parts list manual

Instructions-Parts
ChemSafe™ 515
Air-Operated Diaphragm Pump 334794E
EN
1/2–inch high purity pump for industrial applications. For professional use only.
Not approved for use in European explosive atmosphere locations.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these
instructions.
100 psi (0.7 MPa, 7.0 bar) Maximum Air
Supply Pressure
100 psi (0.7 MPa, 7.0 bar) Maximum
Fluid Working Pressure
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Warnings ........................................................... 3
Configuration Number Matrix............................... 6
Installation.......................................................... 8
General Information ..................................... 8
Tighten Bolts ............................................... 8
Tips to Reduce Cavitation............................. 8
Mount The Pump ......................................... 9
Ground The System..................................... 10
Air Lines...................................................... 10
Air Exhaust Ventilation ................................. 11
Fluid Supply Line ......................................... 12
Fluid Outlet Line........................................... 12
Operation........................................................... 13
Tighten Bolts ............................................... 13
Flush the Pump Before First Use .................. 13
Start and Adjust the Pump............................ 13
Pressure Relief Procedure............................ 14
Pump Shutdown .......................................... 14
Maintenance ...................................................... 15
Maintenance Schedule................................. 15
Lubrication................................................... 15
Tighten Threaded Connections ..................... 15
Flushing and Storage ................................... 15
Troubleshooting.................................................. 16
Repair................................................................ 18
Disassemble the Fluid Section ...................... 18
Disassemble the Center Section ................... 19
Replace the Air Motor................................... 19
Reassemble the Center Section.................... 20
Reassemble the Fluid Section....................... 21
Torque Instructions ............................................. 23
Parts.................................................................. 24
Kits.................................................................... 27
Dimensions ........................................................ 28
Performance Charts............................................ 29
Technical Data ................................................... 31
2334794E

Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific
risks. When these symbols appear in the body of this manual or on warning labels, refer back to these
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
plastic drop cloths (potential static arc).
•Keepwork
area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable
fumes are present.
• Ground all equipment in the work area. See Grounding instructions.
•Useonly
grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are antistatic or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use
equipment until you identify and correct the problem.
• Keepaw
orking fire extinguisher in the work area.
• Route exhaust away from all ignition sources. If diaphragm ruptures, fluid may be exhausted
with air.
Static charge may build up on plastic parts during cleaning and could discharge and ignite
flammable vapors. To help prevent fire and explosion:
• Clean plastic parts only in well ventilated area.
• Do not cleanwithadrycloth.
• Do not operate electrostatic guns in equipment work area.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin
and cause serious injury.
•Fol
low the Pressure Relief Procedure when you stop spraying/dispensing and before
cleaning, checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
334794E 3

Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
•Turnoffall
equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.
•Makesure
all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure
due to the thermal expansion. Over-pressurization can result in equipment rupture and serious
injury.
• Open a valve to relieve the fluid expansion during heating.
• Replace hoses proactively at regular intervals based on your operating conditions.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Many solvents can degrade plastic parts and cause them to fail, which could cause serious
injury or property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing
parts.
•SeeTechnical Data in this and all other equipment instruction manuals. Read fluid and
solvent manufacturer’s MSDSs and recommendations.
4334794E

Warnings
WARNING
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Route exhaust away from work area. If diaphragm ruptures, fluid may be exhausted into
the air.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid
severe burns:
• Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective
equipment includes but is not limited to:
•Protect
ive eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
334794E 5

Configuration Number Matrix
Configuration Number
Matrix
Check the identification plate (ID) for the
Configuration Number of your pump. Use the
following matrix to define the components of your
pump.
Sample Configuration Number: 515PT-P01APT3PTPTPOPT
515PT P01A PT3 PT PT PO PT
Pump
Model
Center
Section
and Air
Valve
Fluid
Covers
and
Manifolds
Seats Balls Diaphragms Manifold and Seat Seals
Pump Center Section and Air
Valve Material
Fluid Covers and Manifolds
515 PT
1/2 in. PTFE
P01A Polypropylene
center with npt
air inlet
PT3 PTFE, npt
515 UH
1/2 in. UHMWPE
P03A Polypropylene
center with
bspt air inlet
PT4 PTFE, bspt
UH3 UHMW, npt
UH4 UHMW,bspt
Seat Material Ball Material Diaphragm Material Manifold and Seat
Seal Material
PT PTFE PT PTFE BN Buna N PT PTFE
UH UHMWPE EP EPDM
PO PTFE/EPDM Overmolded
6334794E

Configuration Number Matrix
Models
Model Pump Air & Fluid
Connection
Threads
Fluid Covers,
Seats, &
Manifolds
Balls Diaphragm Manifold Seal
24X426 bspt
24X425 1/2 in. PTFE npt PTFE
24X498 bspt
24X497 npt
PTFE/EPDM
Overmolded
24X540 bspt
24X541 npt EPDM
24X496 bspt
24X495
1/2 in.
UHMWPE
npt
UHMW
PTFE
Buna N
PTFE
334794E 7

Installation
Installation
General Information
The Typical Installation shown is only a guide 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. Be sure all accessories
are adequately sized and pressure rated to meet the
system’s requirements.
Reference letters in the text, for example (A), refer to
the callouts in the figures.
Variations in color between the plastic components
of this pump are normal. Color variation does not
affect the performance of the pump.
Storage: Pumps that are not put into operation
upon delivery must be stored appropriately. See
Flushing and Storage, page 15.
Tighten Bolts
Before mounting and using the pump for the
first time, check and retorque all external bolts.
Remove all protective bolt covers (37). Follow
Torque Instructions, page 23, to tighten all bolts.
Replace the bolt covers (37). After the first day of
operation, retorque the bolts. Retorque the bolts if the
pump has been idle for an extended time, been used
in thermal cycling applications, been disassembled,
or if there is a large difference between environmental
temperatures and fluid temperatures.
Tips to Reduce Cavitation
Cavitation in an AODD pump is the formation and
collapse of bubbles in the pumped liquid. Frequent
or excessive cavitation can cause serious damage,
including pitting and early wear of fluid chambers,
balls, and seats. It may result in reduced efficiency of
the pump. Cavitation damage and reduced efficiency
both result in increased operating costs.
Cavitation depends on the vapor pressure of the
pumped liquid, the system suction pressure, and the
velocity pressure. It can be reduced by changing any
of these factors.
1. Reduce vapor pressure: Decrease the
temperature of the pumped liquid.
2. Increase suction pressure:
a. Lower the installed position of the pump
relative to the liquid level in the supply.
b. Reduce the friction length of the suction
piping. Remember that fittings add friction
length to the piping. Reduce the number of
fittings to reduce the friction length.
c. Increase the size of the suction piping.
3. Reduce liquid velocity: Slow the cyclic rate of
the pump.
Pumped liquid viscosity is also very important but
normally is controlled by factors that are process
dependent and cannot be changed to reduce
cavitation. Viscous liquids are more difficult to pump
and more prone to cavitation.
Graco recommends taking all the above factors
into account in system design. To maintain pump
efficiency, supply only enough air pressure to the
pump to achieve the required flow.
Graco distributors can supply site specific
suggestions to improve pump performance and
reduce operating costs.
8334794E

Installation
Mount The Pump
To avoid serious injury from toxic fluid or fumes:
• Ventilate to a remote area. The pump
exhaust air may contain contaminants. See
Air Exhaust Ventilation, page 11.
• Never move or lift a pump under pressure. If
dropped, the fluid section may rupture. Always
follow the Pressure Relief Procedure, page 14,
before moving or lifting the pump.
1. Be sure the mounting surface can support the
weight of the pump, hoses, and accessories, as
well as the stress caused during operation.
2. For all mountings, be sure the pump is secured
with screws through the mounting feet. Always
mount the pump upright.
3. Make sure the surface is flat and that the pump
doesn’t wobble.
4. For ease of operation and service, mount the
pump so air valve, air inlet, fluid inlet and fluid
outlet ports are easily accessible.
Accessories/Components Not Supplied System Components
A Air supply line J Air inlet port (not visible)
BBleed-type master air valve (required
for your pump)
KExhaust port and muffler
C Air filter/regulator assembly L Fluid inlet port
DMaster air valve (to isolate the
filter/regulator for service)
M Fluid outlet port
EGrounded flexible fluid supply line NMounting feet
FFluid drain valve (required for your
pump)
G Fluid shutoff valve
HGrounded, flexible fluid outlet line
334794E 9

Installation
Ground The System
The equipment must be grounded to reduce the
risk of static sparking. Static sparking can cause
fumes to ignite or explode. Grounding provides an
escape wire for the electrical current.
•Always ground the entire fluid system as
described below.
• The pumps are not conductive. Any system
used to pump flammable fluids must be properly
grounded.
• Follow your local fire codes.
Before operating the pump, ground the system as
explained below.
•Pump: Always ground the entire fluid system by
making sure the fluid has an electrical path to a
true earth ground.
•Air and fluid hoses: Use only flexible grounded
hoses with a maximum of 500 ft. (150 m) combined
hose length to ensure grounding continuity.
•Air compressor: Follow manufacturer’s
recommendations.
•Fluid supply container: Follow local code.
•Solvent pails used when flushing: Follow local
code. Use only conductive metal pails, placed
on a grounded surface. Do not place the pail
on a nonconductive surface, such as paper or
cardboard, which interrupts grounding continuity.
Check your system electrical continuity after the
initial installation, and then set up a regular schedule
for checking continuity to be sure proper grounding
is maintained.
Air Lines
1. Install an air regulator and gauge (C) to control
the fluid pressure. The fluid stall pressure will be
thesameasthesetting of the air regulator.
2. Locate a bleed-typemasterairvalve(B)closeto
the pump and use it to relieve trapped air. Be
sure the valve is easily accessible from the pump
and located downstream from the regulator.
Trapped air can cause the pump to cycle
unexpectedly, which could result in serious
injury from splashing.
3. Locate another master air valve (D) upstream
from all air line accessories and use it to isolate
them during cleaning and repair.
4. An air line filter (C) removes harmful dirt and
moisture from the compressed air supply.
5. Install a grounded, flexible air hose (A) between
the accessories and the 1/4 npt(f) or 1/4 bspt
pump air inlet. Use a hose with a minimum 1/4 in.
ID.Ifah
ose longer than 10 ft. (3 m) is required,
use a larger diameter hose.
10 334794E

Installation
Air Exhaust Ventilation
If pumping toxic fluids, you must vent the exhaust
away from people, animals, food handling areas,
and all sources of ignition. Follow all applicable
codes.
NOTE: Do not restrict the air exhaust port. Excessive
exhaust restriction can cause erratic pump operation.
To provide a remote exhaust:
1. Use Kit 17F612 (NPT) or 17F613 (BSPT), sold
separately.
2. Remove the muffler (U) from the pump air
exhaust port (K).
3. Install the adaptor from the kit.
4. Install a grounded air exhaust hose (S). If a hose
longer than 10 ft. (3 m) is required, use a larger
diameter hose. Avoid sharp bends or kinks in
the hose.
5. Place a container (T) at the end of the air exhaust
linetocatc
h fluid in case a diaphragm ruptures.
If the diaphragm ruptures, the fluid being pumped
will exhaust with the air.
JAir inlet port (not visible) TContainer for remote air exhaust
K Exhaust port U Muffler
S Grounded air exhaust hose
334794E 11

Installation
Fluid Supply Line
1. Use grounded, flexible fluid hoses (E). See
Ground The System, page 10.
2. 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. Excessive
inlet fluid pressure also will shorten diaphragm
life. Approximately 3–5 psi (0.02–0.03 MPa,
0.21–0.34 bar) should be adequate for most
materials.
3. For maximum suction lift (wet and dry), see
Technical Data, page 31. For best results, always
install the pump as close as possible to the
material source. Minimize suction requirements
to maximize pump performance.
Fluid Outlet Line
1. Use grounded, flexible fluid hoses. See
Ground The System, page 10,
2. Install a fluid drain valve (F) near the fluid outlet.
3. Install a shutoff valve (G) in the fluid outlet line.
12334794E

Operation
Operation
Tighten Bolts
Before mounting and using the pump for the
first time, check and retorque all external bolts.
Remove all protective bolt covers (37). Follow
Torque Instructions, page 23, to tighten all bolts.
Replace the bolt covers (37). After the first day of
operation, retorque the bolts. Retorque the bolts if the
pump has been idle for an extended time, been used
in thermal cycling applications, been disassembled,
or if there is a large difference between environmental
temperatures and fluid temperatures.
Flush the Pump Before First Use
The pump was tested in water. If water could
contaminate the fluid you are pumping, flush the
pump thoroughly with a compatible solvent. See
Flushing and Storage, page 15.
Start and Adjust the Pump
NOTICE
To avoid damage to your pump, be certain that all
pumped fluids arecompatiblewithwettedparts.
See Technical Data, page 31.
1. Be sure the pump is properly grounded. See
Ground The System, page 10.
2. Check fittings to be sure they are tight. Use a
compatible liquid thread sealant on male threads.
NOTICE
Do not overtighten fluid inlet and outlet fittings.
Soft plastic threads can be stripped easily.
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.
NOTICE
Excessive fluid inlet pressure can reduce
diaphragm life.
4. Place the end of the fluid hose into an appropriate
container.
5. Close the fluid drain valve.
6. Back out the air regulator knob and open all
bleed-type master air valves.
7. If the fluid hose has a dispensing device, hold
it open.
8. Slowly increase air pressure with the air regulator
until the pump just starts to cycle. Allow the
pump to cycle slowly until all air is pushed out of
the lines and the pump is primed.
NOTE: Use lowest possible air pressure to prime,
just enough to cycle the pump. If the pump does
not prime as expected, turn air pressure DOWN.
9. If you are flushing, run the pump long enough to
thoroughly clean the pump and hoses.
10. Close the bleed-type master air valve.
334794E 13

Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure
whenever you see this symbol.
This equipment stays pressurized until pressure
is relieved manually. To help prevent serious
injury from pressurized fluid, such as splashing
in the eyes or on skin, follow the Pressure Relief
Procedure when you stop pumping and before you
clean, check, or service the equipment.
1. Shut off the air supply to the pump.
2. Open the dispensing valve, if used.
3. Open the fluid drain valve to relieve fluid
pressure. Have a container ready to catch the
drainage.
Pump Shutdown
At the end of the work shift and before you check,
adjust, clean, or repair the system, follow the
Pressure Relief Procedure, page 14.
14334794E

Maintenance
Maintenance
Maintenance Schedule
Establish a preventive maintenance schedule
based on the pump’s service history. Scheduled
maintenance is especially important to prevent spills
or leakage due to diaphragm failure. A clogged
muffler may restrict pump performance. Inspect
air lines and muffler media regularly to maintain
performance.
Lubrication
Thepumpislubricated at the factory. It is designed
to require no further lubrication for the life of the
packings. There is no need to add an inline lubricator
under normal operating conditions.
Tighten 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
mounting bolts. Check bolts. Tighten or retorque as
necessary. Although pump use varies, a general
guideline is to retorque bolts every two months. See
Torque Instructions, page 23.
Flushing and Storage
•Flushbefor
e fluid can dry in the equipment, at the
end of the day, before storing, and before repairing
equipment.
•Flushatth
e lowest pressure possible. Check
connectors for leaks and tighten as necessary.
• Use solvent that is compatible with the equipment
wetted parts and the material being dispensed.
•Alwaysflu
shthepumpandrelievethepressure
before storing it for any length of time.
NOTICE
Flush the pump often enough to prevent the fluid
you are pumping from drying or freezing in the
pump and damaging it.
Storage: Pumpsmustbestoredinanenvironment
where they are clean, dry, and protected from
extreme temperatures, UV radiation, and vibration.
Graco recommends an ambient temperature range of
60°F-80°F (15°C-25°C), with a humidity level below
65%.
334794E 15

Troubleshooting
Troubleshooting
Problem Cause Solution
Pump is running too fast, causing
cavitation before prime.
Lower inlet pressure.
Check valve ball is severely warn
or wedged in seat or manifold.
Replace ball and seat.
Seat is severely worn. Replace ball and seat.
Outlet or inlet is clogged. Unclog.
Inlet or outlet valve is closed. Open.
Inlet fittings or manifolds are loose. Tighten.
Pump cycles but will not prime.
Manifold o-rings are damaged. Replace o-rings.
Pump cycles at stall or fails to hold
pressure at stall.
Check valve balls, seats or o-rings
are worn .
Replace.
Spool valve is stuck or dirty. Disassemble and clean air
valve. Use clean dry air.
Air supply pressure too low. Increase air supply pressure.
Spool valve is worn or damaged. Replace spool valve.
Check valve ball is severely worn
or wedged in seat or manifold.
Replace ball and seat.
Dispensing valve is clogged. Relieve pressure and clear valve.
Pump will not cycle, or cycles once
and stops.
Diaphragm is ruptured. Replace.
Suction line is clogged. Inspect; clear.
Check valve balls are sticky or
leaking.
Clean or replace.
Diaphragm is ruptured. Replace.
Exhaust is restricted. Remove restriction.
Spool valve is damaged or worn. Replace spool valve.
Air supply is erratic. Repair air supply.
Pump operates erratically.
Exhaust muffler is icing. Use drier air supply.
Suction line is loose. Tighten.
Diaphragm is ruptured. Replace.
Manifolds are loose, or seats or
manifold o-rings are damaged.
Tighten manifold bolts or replace
seats and/or o-rings.
Diaphragm glide seals or o-rings
are damaged.
Replace.
Air bubbles in fluid.
Pump is cavitating. Reduce pump speed, increase
suction hose diameter, or increase
inlet head.
Exhaust air contains fluid being
pumped.
Diaphragm is ruptured. Replace.
Moisture in exhaust air. Inlet air has high humidity. Use drier air supply.
16 334794E

Troubleshooting
Problem Cause Solution
Pump exhausts excessive air at
stall.
Spool valve seals are worn or
damaged.
Replace.
Fluid covers are loose. Retorque.
Diaphragm is damaged. Replace.
Pump leaks air externally.
Manifold fittings are loose Retorque.
Fluid covers are loose. Retorque.
Pump leaks fluid externally.
Diaphragms are damaged. Replace.
334794E 17

Repair
Repair
NOTE: Before repairing the pump, follow the
Pressure Relief Procedure, page 14.
Disassemble the Fluid Section
1. Carefully remove all cap plugs (37). Turn the
pump upside-down.
2. Usea10mms
ocket to remove the base plates
(12) and the inlet manifold (10).
3. Remove the o-ring seals (17), d-rings (21), and
check balls (22) from inlet side of each fluid cover
(6).
4. Inspect the inlet ball retainers (20). If necessary
to replace, use a hook to remove without
scratching the inner bore.
5. Turn over the pump and use a 10 mm socket to
remove the manifold retainer (11) and the outlet
manifold(8).
6. Inspect both manifolds’ (8 & 10) wearable seats
(35 & 36), and replace if worn or damaged.
NOTE: Use a small hammer and PVC tool (44)
to tap new wearable seats (35 & 36) into the
manifolds (8 & 10).
7. Remove the o-ring seal (17) from the outlet side
of each fluid cover (6).
8. Without scratching the inner bore, use a hook to
remove the two outlet ball retainers (20).
18 334794E

Repair
9. Remove the check balls (22), d-rings (21), and
wearable seats (19) from the outlet side of each
fluid cover (6).
10. Remove the nuts (28) and bolts (24) by using two
10 mm wrenches, to hold on one side and to turn
the other. The nuts (28) will come off of one side
only. Remove the bolts (24).
NOTE: The nuts are permanently affixed to one
end of the bolts.
11. Remove the fluid cover retainers (9) and the fluid
covers (6) from the body (1).
Disassemble the Center Section
1. One diaphragm (25) and strike plate (4) should
screw off by hand. Slide the second diaphragm
and strike plate out with the shaft (5).
2. Inspect the o-ring seals (32) and glide shaft seals
(39). Replace as needed.
3. Carefully remove the cap plugs (37) from both
muffler locations.
4. Usea4mmAllenwrenchtoremovethescrews
(16) and muffler caps (14).
5. Inspect the mesh baffle spacers (38) and felt
mufflers (15). Replace as needed.
6. Use a 19 mm socket and the supplied tool (42) to
remove the spool assembly (3).
7. Inspect each spool assembly (3) for worn or
damaged parts. Replace each assembly as
needed.
Replace the Air Motor
1. Use pin wrench (43) to remove the air motor
assembly (2) from the body (1).
2. Inspect o-rings (33) & (34), and replace if
necessary.
334794E 19

Repair
3. Apply a thin film of lubricant (46) to air motor
o-rings (34) & (33), and to the outside of the air
motor assembly (2), and screw back into the
body (1), small end first.
NOTE: Be careful not to clog air holes with
lubricant.
NOTE: Use only the lubricant (46) supplied with
the rebuild kits.
Reassemble the Center Section
1. Carefully lubricate the spool assembly o-rings
with a thin film of the appropriate lubricant (46).
NOTE: Be careful not to clog air holes with
lubricant.
2. Verify the o-rings on the first spool assembly (3)
are properly seated and carefully insert it into
one of the ports of the air motor assembly (2) in
the body (1). The o-ring at the end of the spool
assembly (3) fits into a groove at the bottom of
the port. It may be necessary to separately insert
thiso-ringinthegroovefirsttoensureproper
seating.
3. Use a 19 mm socket and the supplied tool (42) to
tighten the spool assembly (3) until it is flush with
surface of the air motor assembly.
NOTE: Do not overtighten the spool assembly.
4. Repeat Step 3 for the spool assembly (3) on the
other side of the air motor assembly.
5. Perform a quick field test to verify the o-rings
were not nicked or broken when the spool
assemblies (3) were inserted.
a. Attach an air hose to the port on the body (1).
b. Set the air pressure to 30 psi. This will cause
one or both spools (3) to pop or shift.
c. Press each spool (3) individually to verify that
the other spool (3) has a corresponding shift.
d. Plug the air holes on the air motor (2) to
verify no air is escaping from either of the
spools (3).
6. Install the muffler media (alternating felt mufflers
(15) and mesh baffle spacers (38)) into the
muffler. Use the new felt mufflers (15) supplied
in the rebuild kit. Muffler parts must be placed in
exactly the order shown in the illustration.
7. Position the muffler cap (14) over the installed
muffler media, and use a 4 mm Allen wrench to
tighten the screws (16). Torque the screws to
16 in-lbs (1.8 N∙m).
8. Repeat Step 6 for the muffler on the other side of
the body (1).
9. Lubricate an o–ring seal (32) and place into
the ID of the air motor assembly’s central hole.
Lubricate and install a glide shaft seal (39) in the
same hole.
NOTE: To avoid damage to the central hole or
o-ring grooves, use rubber-tipped needle-nose
pliers to form a kidney shape with the glide shaft
seal (39) before inserting the seal into the central
hole.
10. Repeat Step 8 on the other side of the air motor
assembly.
20 334794E