Graco FD2 1590 Operation manual

311879F
Instructions - Parts List
Sanitary Series
FDA-Compliant
Diaphragm Pumps
For use in sanitary applications.
Model FD1___ 1040 FDA
Model FD2___ 1590 FDA
Model FD3___ 2150 FDA
120 psi (0.8 MPa, 8 bar) Maximum Air/Fluid Working Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Refer to the appropriate Pump Matrix on page 26, 34, or 42 to
determine the model number of your pump.
Model 1590 TI8926a
TI8924a
TI8928a
Model 2150
Model 1040
II 2 G

2311879F
Contents
Certificate of Conformance . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pump Matrix - 1040 . . . . . . . . . . . . . . . . . . . . . . . . 26
Available Configurations . . . . . . . . . . . . . . . . . . 26
Repair Kit Matrix - 1040 . . . . . . . . . . . . . . . . . . . . . 27
Available Configurations . . . . . . . . . . . . . . . . . . 27
Parts - 1040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Dimensional Drawing - 1040 . . . . . . . . . . . . . . . . . 31
Technical Data - 1040 . . . . . . . . . . . . . . . . . . . . . . 32
Performance Chart - 1040 . . . . . . . . . . . . . . . . . . . 33
Pump Matrix - 1590 . . . . . . . . . . . . . . . . . . . . . . . . 34
Available Configurations . . . . . . . . . . . . . . . . . . 34
Repair Kit Matrix - 1590 . . . . . . . . . . . . . . . . . . . . . 35
Available Configurations . . . . . . . . . . . . . . . . . . 35
Parts - 1590 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dimensional Drawing - 1590 . . . . . . . . . . . . . . . . . 39
Technical Data - 1590 . . . . . . . . . . . . . . . . . . . . . . . 40
Performance Chart - 1590 . . . . . . . . . . . . . . . . . . . 41
Pump Matrix - 2150 . . . . . . . . . . . . . . . . . . . . . . . . 42
Available Configurations . . . . . . . . . . . . . . . . . . 42
Repair Kit Matrix - 2150 . . . . . . . . . . . . . . . . . . . . . 43
Available Configurations . . . . . . . . . . . . . . . . . . 43
Parts - 2150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Dimensional Drawing - 2150 . . . . . . . . . . . . . . . . . 47
Technical Data - 2150 . . . . . . . . . . . . . . . . . . . . . . . 48
Performance Chart - 2150 . . . . . . . . . . . . . . . . . . . 49
Graco Warranties . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 50

Certificate of Conformance
311879F 3
Certificate of Conformance
Part Number: All FD1, FD2, FD3 models
Description: FDA-Compliant Diaphragm Pump
Materials of
Construction: All fluid contacted materials are FDA-
compliant and meet CFR Title 21,
Section 177.
Bradley A. Byron
QMS Management Representative
Graco Inc.

Warnings
4311879F
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found 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).
• Keep work 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 equipment and conductive objects in work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow Pressure Relief Procedure in this manual, when you stop operating 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.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-
ponent. 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.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco
replacement parts only.
• Do not alter or modify equipment.
• For professional use only.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not use hoses to pull equipment.
• Comply with all applicable safety regulations.
BURN HAZARD
Equipment surfaces and fluids that are heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

Warning
311879F 5
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 swal-
lowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
Warning

Installation
6311879F
Installation
General Information
• The typical installations shown in Figs. 2-4 are only
guides for selecting and installing system compo-
nents. Contact your Graco distributor for assistance
in planning a system to suit your needs.
• Always use genuine Graco parts and accessories.
• Reference numbers and letters in parentheses refer
to the callouts in the figures and the parts lists on
pages 28-30, 36-38, and 44-46.
Tightening Clamps Before First Use
After you unpack the pump, and before you use it for the
first time, check all clamps, and tighten as necessary.
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 equip-
ment.
•Pump: 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 mm²) 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
•Fluid hoses: Use only grounded hoses with a maxi-
mum of 500 ft. (150 m) combined hose length to
ensure grounding continuity.
•Air compressor: Follow the manufacturer’s recom-
mendations.
•All solvent pails used when flushing: Follow the local
code. Use only 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.
The pump is very heavy (see Technical Data on pages
32, 40, and 48 for specific weights). If the pump must
be moved, follow the pressure relief procedure on
page 11 and have two people to lift the pump by grasp-
ing the outlet manifold securely or use appropriate lift-
ing equipment.
Read the TOXIC FLUID OR FUMES HAZARD warn-
ings on page 5.
Read the BURN HAZARD warnings on page 4. To
reduce the risk of serious injury due to burns, insulate
and/or label the pump before pumping fluids above
110°F (43°C).
Read the FIRE AND EXPLOSION HAZARD warnings
on page 4.
"
Y
W

Installation
311879F 7
Mountings
• Be sure the mounting surface can support the
weight of the pump, hoses, and accessories, as well
as the stress caused during operation.
• For all mountings, be sure the pump is bolted
directly to the mounting surface.
• For ease of operation and service, mount the pump
so the air valve cover (2), air inlet, and fluid inlet and
outlet ports are easily accessible.
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 accesso-
ries 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 in. (9.5 mm) ID air
hose. Screw an air line quick disconnect coupler (D)
onto the end of the air hose (A), and screw the mat-
ing fitting into the pump air inlet snugly.
Fluid Suction Line
1. Use flexible, grounded fluid hoses.
2. For best sealing results, use a standard Tri-Clamp®
style sanitary gasket of a flexible material such as
EPDM, Buna-N, fluoroelastomer, or silicon.
3. 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 ineffi-
cient pump operation.
4. At inlet fluid pressures greater than 15 psi (0.1 MPa,
1 bar), diaphragm life will be shortened.
5. See the Technical Data on pages 32, 40, and 48 for
maximum suction lift (wet and dry).
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 10.
A bleed-type master air valve (B) is required in the sys-
tem to relieve air trapped between this valve and the
pump. Trapped air can cause the pump to cycle unex-
pectedly, which could result in serious injury, including
splashing in the eyes or on the skin, injury from moving
parts, or contamination from hazardous fluids. See FIG.
2.
In the step below, do not connect the quick-disconnect
coupler (D) on the air hose to the mating fitting on the
pump until you are ready to operate the pump. Connect-
ing the coupler too early can result in unintentional oper-
ation of the pump, leading to serious injury from moving
parts, splashing fluid in the eyes or on the skin, and con-
tact with hazardous fluids.

Installation
8311879F
Fluid Outlet Line
1. Use flexible grounded fluid hoses (L).
2. For best sealing results, use a standard Tri-Clamp®
style sanitary gasket of a flexible material such as
EPDM, Buna-N, fluoroelastomer, or silicon
3. Install a fluid drain valve (J) near the fluid outlet. See
the WARNING above, and FIG. 2.
4. Install a shutoff valve (K) in the fluid outlet line.
FIG. 2 Typical Floor-Mount Installation
A fluid drain valve (J) is required to relieve pressure in
the hose if it is plugged. 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. See FIG. 2.
TI8930a
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
G Flexible fluid suction line
J Fluid drain valve (required)
K Fluid shutoff valve
L Flexible fluid line
Y Ground wire (required; see page
6 for installation instructions)
E
F
CB
A
K
L
J
G
Y
D

Installation
311879F 9
Changing the Orientation of the Fluid Inlet
and Outlet Ports
The pump is shipped with the ports facing the same
direction. To reverse the orientation of the ports:
1. Remove the clamps holding the inlet and/or outlet
manifold to the covers.
2. Reverse the manifold and reattach. Install and
tighten clamps snugly.
FIG. 3
Key:
N 1/2 npt(f) air inlet port
P Muffler (air exhaust
port is 3/4 npt(f)
R Fluid inlet port
S Fluid outlet port
113 Manifold clamps
3 Air valve screws
Torque to
28-30 in-lb
(3.2-3.7 N•m)
1
1
N
3 113 S
R
P
106 TI8926a

Installation
10 311879F
Air Exhaust Ventilation
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 connect
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. 4.
FIG. 4 Venting Exhaust Air
Read the FIRE AND EXPLOSION HAZARD and
TOXIC FLUID OR FUMES HAZARD warnings on page
5 before operating this pump.
Be sure the system is properly ventilated for your type
of installation. When pumping flammable or hazardous
fluids, you must vent the exhaust to a safe place, away
from people, animals, food handling areas, and all
sources of ignition.
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. 4.
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
PMuffler
T Grounded air exhaust hose
U Container for remote air exhaust
P
U
TD
A
B
C
F
E
TI8931a

Operation
311879F 11
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 fluid pressure,
having a container ready to catch the drainage.
Sanitize the Pump Before First Use
It is the user’s responsibility to properly sanitize the
pump before first use. It is up to the user whether this
will include disassembling and cleaning individual parts
or simply flushing pump with a sanitizing solution. As
necessary, follow the steps under Starting and Adjust-
ing the Pump below, under the Service section on
page 16, or under Flushing on page 13.
Starting and Adjusting the Pump
1. Be sure the pump is properly grounded. Refer to
Grounding on page 4.
2. Check connections to be sure they are tight. Tighten
fluid inlet and outlet connections securely.
3. Place the suction tube (if used) in fluid to be
pumped.
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.
Pump Shutdown
At the end of the work shift, relieve pressure.
Read the PRESSURIZED EQUIPMENT HAZARD
warnings on page 4.
The equipment stays pressurized until pressure is man-
ually relieved. To reduce the risk of serious injury from
pressurized fluid or splashing fluid, follow this proce-
dure whenever you:
• are instructed to relieve pressure
• stop pumping
• check, clean or service any system equipment
Read the TOXIC FLUID OR FUMES HAZARD warn-
ings on page 5. Never move or lift a pump under pres-
sure. If dropped, the fluid section may rupture. Always
follow the Pressure Relief Procedure before lifting the
pump.
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 inef-
ficient pump operation.

Operation
12 311879F

Maintenance
311879F 13
Maintenance
Lubrication
The air valve is designed to operate unlubricated, how-
ever if lubrication is desired, every 500 hours of opera-
tion (or monthly) remove the hose from the pump air
inlet and add two drops of machine oil to the air inlet.
Flushing
Insert suction tube into cleaning solution. Open air regu-
lator to supply low pressure air to the pump. Run the
pump long enough to thoroughly clean the pump and
hoses. Close the air regulator. Remove the suction tube
from the cleaning solution and drain pump. Place suc-
tion tube in the fluid to be pumped.
Flush the pump often enough to prevent the fluid you
are pumping from drying or freezing in the pump and
damaging it. Flushing schedule will be based on what
the pump is being used for. Use a compatible cleaning
solution and always cycle the pump during the entire
flushing process.
Always flush the pump and relieve the pressure before
storing it for any length of time.
Tightening Connections
Before each use, check all hoses for wear or damage,
and replace as necessary. Check to be sure all connec-
tions are tight and leak-free.
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 fail-
ure.
CAUTION
Do not over-lubricate the pump. Oil is exhausted
through the muffler and could contaminate your fluid
supply or other equipment. Excessive lubrication can
also cause the pump to malfunction.
To reduce the risk of serious injury, whenever you are
instructed to relieve pressure, always follow the Pres-
sure Relief Procedure on page 11.

Troubleshooting
14 311879F
Troubleshooting
• Relieve the pressure before checking or servicing
the equipment.
• Check all possible problems and causes before dis-
assembling the pump.
To reduce the risk of serious injury, whenever you are
instructed to relieve pressure, always follow the Pres-
sure Relief Procedure on page 11.
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 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 clamps (113), or
replace 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.
Chattering - noisy operation. Check valve balls do not seat prop-
erly/cleanly due to imbalance
between fluid inlet and outlet line
sizing. Noise is accentuated with
light viscosity fluids.
Reduce size/diameter of inlet line rela-
tive to outline line. Outlet line size
should not exceed pump size.

Troubleshooting
311879F 15
Leak in inlet or outlet sanitary fit-
ting.
Loose sanitary clamp. Tighten clamp.
Damaged or worn gasket. Replace gasket.
Misalignment of inlet/outlet hose or
pipe.
Use flexible hoses at pump inlet and
outlet.
Gasket does not seal. Use a standard sanitary gasket of flexi-
ble material such as EPDM, Buna-N,
fluoroelastomer, or silicon.
Fluid in exhaust air. Diaphragm ruptured. Replace. See pages 19-21.
Loose diaphragm shaft bolt (107). Tighten or replace. See 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 clamps (113), or
replace seats (201) or o-rings (202).
See page 18.
PROBLEM CAUSE SOLUTION

Service
16 311879F
Service
Repairing the Air Valve
Tool Required
• Torque wrench
• Torx (T20) screwdriver or 7 mm (9/32 in.) socket
wrench
• Needle-nose pliers
• O-ring pick
• Lithium base grease
Disassembly
1. Relieve the pressure.
2. With a Torx (T20) screwdriver or 7 mm (9/32 in.)
socket wrench, remove the six screws (3), air valve
cover (2), and gasket (4). See FIG. 5.
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 nee-
dle-nose pliers, pull the pilot block (18) straight up
and out of the cavity. See FIG. 6.
4. Pull the two actuator pistons (11) out of the bearings
(12). Remove the u-cup packings (10) from the pis-
tons. Pull the pilot pins (16) out of the bearings (15).
Remove the o-rings (17) from the pilot pins. See
FIG. 7.
5. Inspect the valve plate (8) in place. If damaged, use
a Torx (T20) screwdriver or 7 mm (9/32 in.) socket
wrench to remove the three screws (3). Remove the
valve plate (8). See FIG. 8.
6. Inspect the bearings (12, 15) in place. See FIG. 7.
The bearings are tapered and, if damaged, must be
removed from the outside. This requires disassem-
bly of the fluid section. See page 24.
7. Clean all parts and inspect for wear or damage.
Replace as needed. Reassemble.
Reassembly
1. If you replaced the bearings (12, 15), reinstall as
explained on page 24. Reassemble the fluid section.
2. Install the valve plate (8) in the cavity, seal down.
Install the three screws (3), using a Torx (T20)
screwdriver or 7 mm (9/32 in.) socket wrench.
Tighten until the screws bottom out on the housing.
See FIG. 8.
3. Install an o-ring (17†) on each pilot pin (16). Grease
the pins and o-rings. Insert the pins into the bear-
ings (15), narrow end first. See FIG. 7.
4. Install a u-cup packing (10†) on each actuator pis-
ton (11), so the lips of the packings face the narrow
end of the pistons. See FIG. 7.
5. Lubricate the u-cup packings (10†) and actuator pis-
tons (11). Insert the actuator pistons in the bearings
(12), wide end first. Leave the narrow end of the pis-
tons exposed. See FIG. 7.
6. 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. 6.
7. 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. 6.
8. Install the valve carriage (5) so its tabs slip into the
grooves on the narrow end of the actuator pistons
(11). See FIG. 6.
9. 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 in.) socket wrench. Torque to 52-60 in-lb
(5.6-6.8 N•m). See FIG. 5.
Air Valve Repair Kit 255061 is available. Parts
included in the kit are marked with a symbol, for
example (4†). Use all the parts in the kit for the
best results.
To reduce the risk of serious injury, whenever you are
instructed to relieve pressure, always follow the Pres-
sure Relief Procedure on page 11.

Service
311879F 17
FIG. 5
FIG. 6
FIG. 7
FIG. 8
TI9086A
2
2
2
4†
3
Torque to 52-60 in-lb
(5.6-6.8 N•m)
TI9087A
Detail
5
†6
†7
2
1
32
3
See detail at right
Grease
Grease lower face
18† 5
31
TI9088A
TI9089A
2
1
3
4
11
12
17†
15 16
4
1
2
Insert narrow end first
Grease
Install with lips facing narrow end of piston (11)
Insert wide end first
10†
23
TI9090A
1
Tighten screws until they bottom
out on the housing
3
8†
1

Service
18 311879F
Ball Check Valve Repair
Tools Required
• O-ring pick
Disassembly
1. Relieve the pressure. Disconnect all hoses.
2. Remove the pump from its mounting.
3. Remove the clamps (106) holding the outlet mani-
fold (103) to the fluid covers (101). See FIG. 9.
4. Remove the o-rings (202), 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), 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. 9. 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 man-
ifold (103).
FIG. 9
• A Fluid Section Repair Kit is available. Refer
to the Repair Kit Matrix parts section for the
appropriate pump size so that the correct kit
for your pump is ordered. Parts included in
the kit are marked with an asterisk, for exam-
ple (202*). Use all the parts in the kit for the
best results.
• To ensure proper seating of the balls (301),
always inspect the seats (201) when replac-
ing the balls. Replace seats as necessary if
seating surface shows evidence of wear. Also,
replace the o-rings (202) as necessary. PTFE
o-rings should be replaced every time mani-
folds are removed.
To reduce the risk of serious injury, whenever you are
instructed to relieve pressure, always follow the Pres-
sure Relief Procedure on page 11.
TI8932a
2
1
Arrow (A) must point toward outlet manifold (103)
Radiused seating surface must face the ball (301).
Large chamfer on O.D. must face o-ring.
103
301*
201
202*
101
A
301*
201
202*
102
1
2
2
113
113

Service
311879F 19
Standard Diaphragm Repair
Tools Required
• Torque wrench
• 15 mm socket wrench
• 19 mm open end wrench
• O-ring pick
• Lithium-base grease
Disassembly
1. Relieve the pressure.
2. Remove the manifolds and disassemble the ball
check valves as explained on page 18.
3. Remove the clamps (106) holding the fluid covers
(101) to the air covers (23). Pull the fluid covers
(101) off the pump. See FIG. 10.
FIG. 10
If your pump uses heavy-duty diaphragms, see
page 22.
A Fluid Section Repair Kit is available. Refer to
page 27, 35, or 43 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.
To reduce the risk of serious injury, whenever you are
instructed to relieve pressure, always follow the Pres-
sure Relief Procedure on page 11.
TI9091A
1
Arrow (A) must point toward air valve.
B23
101
A
1
1
106
106

Service
20 311879F
4. Loosen but do not remove the diaphragm shaft bolts
(107), using a 15 mm socket wrench on both bolts.
See FIG. 11.
5. Unscrew one bolt from the diaphragm shaft (24) and
remove the o-ring (108), fluid side diaphragm plate
(105), diaphragm (403), backer (401) used only on
PTFE models, and air side diaphragm plate (104).
See FIG. 11.
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 open end wrench,
and remove the bolt (107) from the shaft. Disassem-
ble 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
24.
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 bear-
ings (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 packings.
See FIG. 11.
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).
c. Install the diaphragm (403*). Make certain the
side marked AIR SIDE faces the center
housing (1).
d. On PTFE models only, install the backer (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 stamped with its part number.
f. Apply medium-strength (blue) Loctite®or equiv-
alent 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 60-70 ft-lb (81-95 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). Secure covers with the
clamps. See FIG. 10.
7. Reassemble the ball check valves and manifolds as
explained on page 18.
The fluid side diaphragm plate (105) is stainless
steel. This plate is not stamped with its part num-
ber. Be sure to install this plate on the fluid side of
the diaphragm.